AMARAVATI DEVELOPMENT CORPORATION LIMITED

Name of Assignment: Selection of Authority Engineer Consultant for Detailed Design

Review, Construction Monitoring & Supervision, Quality Assurance & Technical Auditing
(QA&TA) for “Water Treatment Plant and water supply network consisting head-works like
Intake well, Raw water pumping main, Cushion tanks, semi-underground Reservoirs, SCADA
Operated and Monitored water Transfer and Transmission system” being implemented on EPC
mode in ‘Amaravati’ the New Capital City of Andhra Pradesh state, India.
RFP No: 19/CE/ADC/ENGG/2018-19. ADDENDUM-1 dated 06-08-2018

1. The following Special Conditions of Contract shall constitute part of Section 8:

Conditions of Contract and Contract Forms (Time Based)

Number
Amendments of, and Supplements to, Clauses in the General Conditions
of GC
of Contract
Clause

1.1(a) The Contract shall be construed in accordance with the law of: Government of
India & Government of Andhra Pradesh.

1.1 (b) The date of the “Applicable Regulations” is: AP eProcurement Regulations
(Current Version)

4.1 The language is: English.

6.1 and 6.2 The addresses are:

Client : Amaravati Development Corporation Limited
#20-4-15, Plot-1G, Anand Heights, Kedareswarapet,
Vijayawada – 520003. Andhra Pradesh State. INDIA.
Attention : Chairperson & Managing Director (CMD)

Consultant :
Attention :
Telephone:

8.1 Consultant / Lead member on behalf of JV:

9.1 The Authorized Representatives are:

For the Client: CE / SE @ ADCL

For the Consultant:

 AMARAVATI DEVELOPMENT CORPORATION LIMITED
Name of Assignment: Selection of Authority Engineer Consultant for Detailed Design
Review, Construction Monitoring & Supervision, Quality Assurance & Technical Auditing
(QA&TA) for “Water Treatment Plant and water supply network consisting head-works like
Intake well, Raw water pumping main, Cushion tanks, semi-underground Reservoirs, SCADA
Operated and Monitored water Transfer and Transmission system” being implemented on EPC
mode in ‘Amaravati’ the New Capital City of Andhra Pradesh state, India.
RFP No: 19/CE/ADC/ENGG/2018-19. ADDENDUM-1 dated 06-08-2018

11.1 The effectiveness conditions are the following :

1. Approval of the Contract by the GOAP.
2. Receipt by Client from the successful consulting firm a Performance Security
in the form of Bank Guarantee (BG) in the format specified in Appendix-H for
an amount of 2.50% of the Contract Value and valid for a period up to 2(two)
months beyond the expiry of the contract period.

12.1 Termination of Contract for Failure to Become Effective:

The time period shall be: one (1) month

13.1 Commencement of Services:

The number of days shall be: Ten (10) days from Signing the Contract
Agreement and the issuance of Work-Order.
Submittal of Confirmation of Key Experts’ availability to start the Assignment
shall be submitted to the Client in writing as a written statement signed by each
Key Expert: Yes.

14.1 Expiration of Contract:

The time period shall be: Eighteen (18) months plus DLP 24 months.

23.1 The following limitation of the Consultant’s Liability towards the Client can
be subject to the Contract’s negotiations:

“Limitation of the Consultant’s Liability towards the Client:

a) Except in the case of gross negligence or willful misconduct on the
part of the Consultant or on the part of any person or a firm acting on
behalf of the Consultant in carrying out the Services, the Consultant,
with respect to damage caused by the Consultant to the Client’s
property, shall not be liable to the Client:
(i) for any indirect or consequential loss or damage; and
(ii) for any direct loss or damage that exceeds one time the total
value of the Contract;
 AMARAVATI DEVELOPMENT CORPORATION LIMITED
Name of Assignment: Selection of Authority Engineer Consultant for Detailed Design
Review, Construction Monitoring & Supervision, Quality Assurance & Technical Auditing
(QA&TA) for “Water Treatment Plant and water supply network consisting head-works like
Intake well, Raw water pumping main, Cushion tanks, semi-underground Reservoirs, SCADA
Operated and Monitored water Transfer and Transmission system” being implemented on EPC
mode in ‘Amaravati’ the New Capital City of Andhra Pradesh state, India.
RFP No: 19/CE/ADC/ENGG/2018-19. ADDENDUM-1 dated 06-08-2018

(b) This limitation of liability shall not

(i) affect the Consultant’s liability, if any, for damage to Third Parties
caused by the Consultant or any person or firm acting on behalf of the
Consultant in carrying out the Services;
(ii) be construed as providing the Consultant with any limitation or
exclusion from liability which is prohibited by the “applicable law in
the Client’s country”.

Imp. Note: Any suggestions made by the Consultant in the Proposal to

introduce exclusions/ limitations of the Consultant’s liability under the
Contract should be carefully scrutinized by the Client and discussed with the
CMD, ADCL prior to accepting any changes to what was included in the
issued RFP. In this regard, the Parties should be aware of the GOI/GOAP’s
policy on this matter which is as follows:

To be acceptable to the CMD, ADCL any limitation of the Consultant’s

liability should at the very least be reasonably related to (a) the damage the
Consultant might potentially cause to the Client, and (b) the Consultant’s
ability to pay compensation using its own assets and reasonably obtainable
insurance coverage. The Consultant’s liability shall not be limited to less than
a multiplier of the total payments to the Consultant under the Contract for
remuneration and reimbursable expenses. A statement to the effect that the
Consultant is liable only for the re-performance of faulty Services is not
acceptable to the CMD,ADCL. Also, the Consultant’s liability should never
be limited for loss or damage caused by the Consultant’s gross negligence or
willful misconduct.

The CMD,ADCL does not accept a provision to the effect that the Client shall
indemnify and hold harmless the Consultant against Third Party claims,
except, of course, if a claim is based on loss or damage caused by a default or
wrongful act of the Client to the extent permissible by the law applicable in
the Client’s country.

24.1 The insurance coverage against the risks shall be as follows:

(a) Professional liability insurance, with a minimum coverage of
Consultancy Contract Value;
(b) Third Party motor vehicle liability insurance in respect of motor vehicles
operated in the Client’s country by the Consultant or its Experts or Sub-
 AMARAVATI DEVELOPMENT CORPORATION LIMITED
Name of Assignment: Selection of Authority Engineer Consultant for Detailed Design
Review, Construction Monitoring & Supervision, Quality Assurance & Technical Auditing
(QA&TA) for “Water Treatment Plant and water supply network consisting head-works like
Intake well, Raw water pumping main, Cushion tanks, semi-underground Reservoirs, SCADA
Operated and Monitored water Transfer and Transmission system” being implemented on EPC
mode in ‘Amaravati’ the New Capital City of Andhra Pradesh state, India.
RFP No: 19/CE/ADC/ENGG/2018-19. ADDENDUM-1 dated 06-08-2018

consultants, with a minimum coverage of: “in accordance with the

applicable law in the Client’s country”;
(c) Third Party liability insurance, with a minimum coverage of state “in
accordance with the applicable law in the Client’s country”;
(d) employer’s liability and workers’ compensation insurance in respect of
the experts and Sub-consultants in accordance with the relevant
provisions of the applicable law in the Client’s country, as well as, with
respect to such Experts, any such life, health, accident, travel or other
insurance as may be appropriate; and
(e) insurance against loss of or damage to (i) equipment purchased in whole
or in part with funds provided under this Contract, (ii) the Consultant’s
property used in the performance of the Services, and (iii) any documents
prepared by the Consultant in the performance of the Services.

27.1 No exceptions.

27.2 The Consultant shall not use these documents and software for purposes
unrelated to this Contract without the prior written approval of the Client.

32.1 Key Experts, Non-Key Experts or Sub consultants who are found to be in breach
Removal of the Consultant’s Code of Conduct (ESHS) shall be replaced by the
of Experts Consultant, or at the Client’s written request.
or Sub-
consultants

32.2 Key Experts, Non-Key Experts or Sub consultants, who are found to be
incompetent or incapable in discharging assigned duties, shall be replaced by the
Consultant, or at the Client’s written request.

32.3 The time period shall be: Five (5) days

41.2 Contract Ceiling Value (Only GST will be Reimbursable):

 AMARAVATI DEVELOPMENT CORPORATION LIMITED
Name of Assignment: Selection of Authority Engineer Consultant for Detailed Design
Review, Construction Monitoring & Supervision, Quality Assurance & Technical Auditing
(QA&TA) for “Water Treatment Plant and water supply network consisting head-works like
Intake well, Raw water pumping main, Cushion tanks, semi-underground Reservoirs, SCADA
Operated and Monitored water Transfer and Transmission system” being implemented on EPC
mode in ‘Amaravati’ the New Capital City of Andhra Pradesh state, India.
RFP No: 19/CE/ADC/ENGG/2018-19. ADDENDUM-1 dated 06-08-2018

42.3 Beginning 19th month from commencement of services, Price adjustment

/price escalation “does apply” to remuneration rates and local costs during
Contract period (both Construction + Defects Liability periods) and /or during
contract extension period applies to remuneration rates and local costs @ 5%
for every 12 months.

43.1 and The Consultant has to pay, include the following:

43.2
(a) any indirect taxes, duties, fees, levies and other impositions imposed,
under the applicable law in the Client’s country, on the Consultant, the
Sub-consultants and the Experts in respect of:
(b) any payments whatsoever made to the Consultant, Sub-consultants and
the Experts (other than nationals or permanent residents of the Client’s
country), in connection with the carrying out of the Services;
(c) any equipment, materials and supplies brought into the Client’s country
by the Consultant or Sub-consultants for the purpose of carrying out the
Services and which, after having been brought into such territories, will
be subsequently withdrawn by them;
(d) any equipment imported for the purpose of carrying out the Services and
paid for out of funds provided by the Client and which is treated as
property of the Client;
(e) any property brought into the Client’s country by the Consultant, any
Sub-consultants or the Experts (other than nationals or permanent
residents of the Client’s country), or the eligible dependents of such
experts for their personal use and which will subsequently be withdrawn
by them upon their respective departure from the Client’s country,
provided that:
(i) the Consultant, Sub-consultants and experts shall follow the usual
customs procedures of the Client’s country in importing property into
the Client’s country; and
(ii) if the Consultant, Sub-consultants or Experts do not withdraw but
dispose of any property in the Client’s country upon which customs
duties and taxes have been exempted, the Consultant, Sub-consultants
or Experts, as the case may be, (a) shall bear such customs duties and
taxes in conformity with the regulations of the Client’s country, or (b)
shall reimburse them to the Client if they were paid by the Client at
the time the property in question was brought into the Client’s
country.

44.1 The currency of payment shall be the following: Indian Rupees.

 AMARAVATI DEVELOPMENT CORPORATION LIMITED
Name of Assignment: Selection of Authority Engineer Consultant for Detailed Design
Review, Construction Monitoring & Supervision, Quality Assurance & Technical Auditing
(QA&TA) for “Water Treatment Plant and water supply network consisting head-works like
Intake well, Raw water pumping main, Cushion tanks, semi-underground Reservoirs, SCADA
Operated and Monitored water Transfer and Transmission system” being implemented on EPC
mode in ‘Amaravati’ the New Capital City of Andhra Pradesh state, India.
RFP No: 19/CE/ADC/ENGG/2018-19. ADDENDUM-1 dated 06-08-2018

45.1(a) “DELETED”

45.1(c) The Client shall pay the Consultant’s invoices within forty-five (45) days after
the receipt by the Client of such itemized invoices with supporting documents.

45.1(e) The Consultant’s Accounts are:

for foreign currency: “Not Applicable”
for local currency:
Name of the Account
holder
Account Number
Name of Bank
Address of Branch / Fax
No.
Bank IFSC No. / Swift
Code

46.1 “DELETED”

49. Disputes shall be settled by arbitration in accordance with the following

provisions:
1. Selection of Arbitrators. Each dispute submitted by a Party to arbitration
shall be heard by a sole arbitrator or an arbitration panel composed of
three (3) arbitrators, in accordance with the following provisions:
(a) Where the Parties agree that the dispute concerns a technical matter,
they may agree to appoint a sole arbitrator or, failing agreement on
the identity of such sole arbitrator within thirty (30) days after
receipt by the other Party of the proposal of a name for such an
appointment by the Party who initiated the proceedings, either Party
may apply to Indian Road Congress for a list of not fewer than five
(5) nominees and, on receipt of such list, the Parties shall alternately
strike names therefrom, and the last remaining nominee on the list
shall be the sole arbitrator for the matter in dispute. If the last
remaining nominee has not been determined in this manner within
sixty (60) days of the date of the list, Indian Road Congress shall
 AMARAVATI DEVELOPMENT CORPORATION LIMITED
Name of Assignment: Selection of Authority Engineer Consultant for Detailed Design
Review, Construction Monitoring & Supervision, Quality Assurance & Technical Auditing
(QA&TA) for “Water Treatment Plant and water supply network consisting head-works like
Intake well, Raw water pumping main, Cushion tanks, semi-underground Reservoirs, SCADA
Operated and Monitored water Transfer and Transmission system” being implemented on EPC
mode in ‘Amaravati’ the New Capital City of Andhra Pradesh state, India.
RFP No: 19/CE/ADC/ENGG/2018-19. ADDENDUM-1 dated 06-08-2018

appoint, upon the request of either Party and from such list or
otherwise, a sole arbitrator for the matter in dispute.
(b) Where the Parties do not agree that the dispute concerns a technical
matter, the Client and the Consultant shall each appoint one (1)
arbitrator, and these two arbitrators shall jointly appoint a third
arbitrator, who shall chair the arbitration panel. If the arbitrators
named by the Parties do not succeed in appointing a third arbitrator
within thirty (30) days after the latter of the two (2) arbitrators
named by the Parties has been appointed, the third arbitrator shall,
at the request of either Party, be appointed by Indian Council of
Arbitration.
(c) If, in a dispute subject to paragraph (b) above, one Party fails to
appoint its arbitrator within thirty (30) days after the other Party has
appointed its arbitrator, the Party which has named an arbitrator
may apply to the Indian Council of Arbitration to appoint a sole
arbitrator for the matter in dispute, and the arbitrator appointed
pursuant to such application shall be the sole arbitrator for that
dispute.

2. Rules of Procedure. Arbitration proceedings shall be conducted in

accordance with procedure of the Arbitration & Conciliation Act 1996,
of India.
3. Substitute Arbitrators. If for any reason an arbitrator is unable to perform
his/her function, a substitute shall be appointed in the same manner as the
original arbitrator.
4. Nationality and Qualifications of Arbitrators. The sole arbitrator or the
third arbitrator appointed pursuant to paragraphs 1(a) through 1(c) above
shall be an internationally recognized legal or technical expert with
extensive experience in relation to the matter in dispute and shall not be
a national of the Consultant’s home country [Note: If the Consultant
consists of more than one entity, add: or of the home country of any of
their members or Parties] or of the Government’s country. For the
purposes of this Clause, “home country” means any of:
 AMARAVATI DEVELOPMENT CORPORATION LIMITED
Name of Assignment: Selection of Authority Engineer Consultant for Detailed Design
Review, Construction Monitoring & Supervision, Quality Assurance & Technical Auditing
(QA&TA) for “Water Treatment Plant and water supply network consisting head-works like
Intake well, Raw water pumping main, Cushion tanks, semi-underground Reservoirs, SCADA
Operated and Monitored water Transfer and Transmission system” being implemented on EPC
mode in ‘Amaravati’ the New Capital City of Andhra Pradesh state, India.
RFP No: 19/CE/ADC/ENGG/2018-19. ADDENDUM-1 dated 06-08-2018

(a) the country of incorporation of the Consultant [Note: If the

Consultant consists of more than one entity, add: or of any of their
members or Parties]; or
(b) the country in which the Consultant’s [or any of their members’ or
Parties’] principal place of business is located; or
(c) the country of nationality of a majority of the Consultant’s [or of
any members’ or Parties’] shareholders; or
(d) the country of nationality of the Sub-consultants concerned, where
the dispute involves a subcontract.

5. Miscellaneous. In any arbitration proceeding hereunder:

(a) proceedings shall, unless otherwise agreed by the Parties, be held in
Vijayawada, INDIA;
(b) the English language shall be the official language for all purposes;
and
(c) the decision of the sole arbitrator or of a majority of the
arbitrators (or of the third arbitrator if there is no such majority)
shall be final and binding and shall be enforceable in any court of
competent jurisdiction, and the Parties hereby waive any objections
to or claims of immunity in respect of such enforcement.

2. The following Qualification of Key Personnel: Hydraulic Engineer / Water supply

network Expert shall constitute part of Section 7: Terms of Reference (TOR)
Enclosure-B:
He will be responsible for Design and oversee construction of projects involving
provision of potable water, perform hydraulic modelling and pipeline design, identify
design alternatives, design water storage tanks or other water storage facilities, water
supply networks, perform hydrological analyses using three dimensional software, to
model the movement of water, perform hydraulic analyses of water supply systems or
water distribution networks to model flow characteristics, test for pressure losses, or to
identify opportunities to mitigate risks and improve operation efficiency. Conduct cost
benefit analysis for water supply systems, analyse the efficiency of water delivery
 AMARAVATI DEVELOPMENT CORPORATION LIMITED
Name of Assignment: Selection of Authority Engineer Consultant for Detailed Design
Review, Construction Monitoring & Supervision, Quality Assurance & Technical Auditing
(QA&TA) for “Water Treatment Plant and water supply network consisting head-works like
Intake well, Raw water pumping main, Cushion tanks, semi-underground Reservoirs, SCADA
Operated and Monitored water Transfer and Transmission system” being implemented on EPC
mode in ‘Amaravati’ the New Capital City of Andhra Pradesh state, India.
RFP No: 19/CE/ADC/ENGG/2018-19. ADDENDUM-1 dated 06-08-2018

structures, Design pumping systems, pumping stations, pipelines force mains, conduct
environmental impact studies related to water distribution.
He should have the following qualification / experience.
(i) Essential Qualifications.
(a) Graduate in Civil Engineering/ Chemical Engineering/Environmental Engineering
or Post Graduation in Environment science from a recognized University.
(b) Professional Experience of 15 years in handling Water treatment and water
supply network projects.
(c) 10 years’ experience in Design of water supply network projects.
(d) Must be familiar with modern trends in design and construction of water supply
networks and pumping stations etc.
(ii) Preferential Qualifications.
(a) Post Graduate Degree in Public Health Engineering/ /Chemical engineering/
Environmental Engineering.
3. The attached Schedule-K, Schedule E, Annexure I(c) of Schedule –D shall
constitute part of Clients input in terms of documents related to this project
Amaravati Development Corporation Limited

SCHEDULES

1
Amaravati Development Corporation Limited

Schedule-A Site of the Project…………………………………………………...

Schedule-B Development of the Project …….………………………………….

Schedule-C Project facilities…………………………………………………….

Schedule D Specifications and Standards……………………………………….

Schedule-E Maintenance Requirements…………………………………….…...

Schedule-F Applicable Permits………………………………………………….

Schedule-G Form of Bank Guarantee……………………………………………

Schedule-H Contract Price Weightages…………………………………….…….

Schedule-I Drawings………………….………………………………………....

Schedule-J Project Completion Schedule……………………….………………

Schedule-K Tests on Completion…………………………………...……….…...

Schedule-L Provisional/ Completion Certificate………………….…………….

Schedule-M Payment reduction for non-compliance…………………………….

Schedule-N Selection of Employer’s Engineer/ Authority Engineer……………

Schedule-O Insurance……………………………………….…………………....

Schedule-P CAD Requirements..............................................................................

Schedule-Q Guideline for Health, Safety, and Environment Plan............................

Schedule-R Project Management Requirements.......................................................

Schedule-S Quality Assurance..................................................................................

Schedule-T Reports…………………………………………………………………

2
Amaravati Development Corporation Limited

Schedule A - Site of the project

(See Clause 2.1 and 8.1)

Contents
The Site ..........................................................................................................................3

Annexure I - Site............................................................................................................ 4
Annexure II – Land Details..............................................................................................5
Appendix A-I – Map showing total trunk road network and Package XV roads............. 6

3
Amaravati Development Corporation Limited

The Site of the Project

1.1 The Site of E3 road of Amaravati Trunk road network is as described in

Annexure-I of this Schedule-A.

1.2 The dates of handing over the Land to the Contractor are specified in Annexure-
II of this Schedule-A.

1.3 An inventory of the Site including trees and any other immovable property
on, or attached to, the Site shall be prepared jointly by the Employer’s
Representative and the Contractor, and such inventory shall form part of the
Agreement.

4
Amaravati Development Corporation Limited

Schedule-A
Annexure - I
1.0 Site

E3 – Seed Access Road is the road considered under package-XV.

This road is designed as 6-lane carriageway along with 3-lane BRT.
Details of this road are furnished in the following table.

Length Start of Project End of Project

S. No. Road Name Type of Road
(Km) Stretch Stretch

16°32'41.75"N 16°29'53.52"N
1 E3 Seed Access 18.270
80°26'10.90"E 80°35'43.45"E

2.0 Existing Features

Existing carriageway details:

The project road is having existing carriageway of 7.25 m on both sides including the
shyness. A median of 16.3 m width is present for the total length of 18.27 km. Existing
carriageway details for the project road is given in the below table.
S. No. Road Name Existing carrigeway Existing median width
width (m)
(m)
1 E3 7.25 + 7.25 16.3

2.1 Electric Line / Electric Pole/ Utilities

2.1.1 Since the alignment is a green-field, no existing features are identified along this road
of the trunk network. Additional site surveys shall be conducted with contractor to confirm
and finalise relocation of utilities.

2.2 Religious Structures

No existing religious structures are identified along the package XV roads.

5
Amaravati Development Corporation Limited

(Schedule-A)
Annexure - II
Land Details
1.0 Existing Land

Total project area of 217 sq.km is distributed in the capital area with main trunk road
network and internal roads network. Seed Access road in this package has been designed for
a length of 18.270 km.
2.0 Handing over of Site to Contractor

Details of Site Handing over are as follows:

A. At the time of Appointed Date

Table 1: Handing over of site for Road and Other Infrastructures to Contractor

Chainage
S. No. Road Name Road Type ROW Length(Km)
From (Km) To (Km)
1 E3 Seed Access 60 m 0.000 18.270 18.270

B. Within 90 days of Appointed date – NIL

6
Amaravati Development Corporation Limited

Appendix-A1

Map showing the total trunk road network within the capital region

Map showing the package XV (E3) road within the total trunk road network

7
Amaravati Development Corporation Limited

Schedule B - Development of the Project Roads and Utilities/Services

(See Clause 2.1)

Contents

Development of the Project Roads and Utilities/Services

Appendix B I: Design and Construction of Roads

Appendix B I (a): Typical Cross Sections.

Appendix B I (b): Geometric Design and Other Features.

Appendix B I (c): Junctions.

Appendix B I (d): Embankment and Pavement Design

Appendix B II: Storm water Network

Appendix B II(a): Storm water crossings

Appendix B III: Potable Water Supply Network

Appendix B IV: Recycled Water Supply Network

Appendix B V: Domestic Sewage Collection Network

Appendix B VI: Power and ICT conduits and Concrete duct for power cables.

Appendix B VII: Illumination System

Appendix B VIII: ITS

Appendix B IX: Pipe Conduits for ICT cables

Appendix B X: Utility Corridor/Clash Analysis

Appendix B XI: Drawings

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Amaravati Development Corporation Limited

General

A Special purpose vehicle viz “Amaravati Development Corporation Limited” is

formed with the equity participation of State Government for procurement and con-
struction of trunk Infrastructure in Amaravati Capital City Area in Andhra Pradesh.

The Amaravati Development Corporation Limited (ADCL) represented by Chairperson

& Managing Director, now invites BIDs from eligible Contractors for the following
Project:

Survey, Investigation, Design, Construction, Testing, Commissioning of smart in-

frastructure works of Additional lanes of Roads, Storm water Drains, Culverts,
minor/major Bridges ,Water Supply including Headworks (Intake well, Raw wa-
ter pumping main, Water treatment Plant, Cushion tanks , semi underground res-
ervoirs, Integration with entire water supply and other Ancillary works), Sewer-
age Network, Power & ICT conduits, RCC duct for Power cables, Reuse water
network ,Gas lines crossings, Cycle track, Street furniture and Avenue Plantation
& 10 years O&M for Water supply including Headworks for Road E3 on EPC
basis under Package-XV in Amaravati, the new Capital City of Andhra Pradesh
state, India.
This project involves the following:
- Construction of Road section for approx. 18.270 km length of 50 mts ROW (Sub-
Arterial) as stated in the relevant section along with bridges and/or cross over Pala
vagu and Kondaveeti vaagu channels.
- The contactor has to design and plan for construction, the design principles of Road
and Utilities matching the end conditions of the backward and forward reaches
including all connectors without compromising the objectives of the project as
specified by the Authority.
- Construction of Storm water collection network and Disposal
- Construction of Intake-well-cum-raw water pump house of capacity 17050 m3/hr
- Construction of Water treatment plant capacity of 8261 m3/hr (190 MLD) with
ZLD concept, the proven technology installations are to be demonstrated to the
Authority/Authority engineers for approval
- Construction of 64 ML capacity underground clear water reservoir-cum- pumping
station
- Construction of 7 Nos of cushion tanks (ELSRs) as given in
- Construction of 8 SUGRs cum Pump houses
- Construction of water supply network on continuous pressurized supply system
9
Amaravati Development Corporation Limited

- Construction of approach road to Intake site complete with all civil, electrical &
mechanical works, instrumentation & controls including SCADA through optical
fibre cable and wireless redundant system, including erection, testing and commis-
sioning of pumps, motors, VFDs, valves, flow meters, RMS, BMS, integration of
full water supply system, trail run for 3 months, DLP for two years and O&M for
8 years
- Construction of Domestic Sewage Collection Network
- Under-ground Power Transmission and Distribution Network using RCC ducts and
HPPE pipe conduits for power cables up to 220KV, 33 KV & 415 V.
- ICT Distribution Network for OFC cables using HDPE pipe conduits
- Street Lighting all along the road network
- Laying of HDPE pipe conduits for ITS systems.
- Completeness of the Offer as per complete scope of works
- Any other work required for the above but not mentioned elsewhere.

The scope under this contract comprises of Data collection and studies, Design, Engi-
neering, Manufacture, Supply, Transportation to site, Storage, Construction, Installa-
tion/Erection, Testing, Commissioning and putting into successful operation of the
complete Facility on EPC basis including all Civil, Structural Mechanical, Electrical,
Control & Instrumentation and all Infrastructural work covering lighting, drains, all
preparatory & temporary works for the purpose of meeting the entire scope of works.

The Contractor shall be fully responsible to ensure that the whole of the Works, includ-
ing each individual component, is designed and constructed in a manner so that the
System as a whole operates as a fully integrated system capable of achieving the re-
quired output in an efficient and economical manner, and to include all plants, equip-
ment and accessories required for the safe and satisfactory operation of the facilities.
To achieve this, the Contractor shall ensure that each individual component performs
in a manner which is complimentary to that of all other components. Any accessories
which are not specifically mentioned in the specifications, but which are essential or
necessary for completion of the Works and successful performance of the System and
facilities shall be provided by the successful Bidder within the tendered cost. The Con-
tractor shall endeavor to standardize on the manufacture and supply of plant and equip-
ment so as to minimize the operation and maintenance requirements. The Contractor

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Amaravati Development Corporation Limited

shall ensure that his designs are "maintenance-friendly" and that all items of plant and
equipment are designed and installed in a manner which will facilitate routine and pe-
riodic maintenance and operations.
Scope of Project
The scope of works covers:
- The Bidder shall be responsible for the design, engineering, manufacturing, fabri-
cation, assembly, testing and inspection at supplier’s works, packing, dispatch,
shipping, delivery at Indian port/unloading at Indian port/delivery from Indian
port to site in case of imported equipment and delivery/unloading at site for
indigenous equipment, unloading and storing at site, insurance up to time of
take -over/hand over by Employer, handling at site, complete erection, start-up,
commissioning, successful performance testing and handing over of the full
Package, warranty, and defect liability period on EPC basis .

- Upon completion of the Performance Test and issue of Completion Certificate,

- Site clearance

- The contractor before start of any works, as a first task overlap the master plan for
the given road on the ground by importing the coordinates through Total Station
only. After setting the coordinates, shall demark the site area for the road with pre
cast M-20 cement concrete including reinforcement permanent boundary stone of
size 150 mm x 150 mm at top and 300 mm x 300 mm at bottom, total height 1.20
m at turnings/corners, fixing in ground in all types of stratas, 0.45 m above GL and
0.75 m below GL including excavation having pit size 60 cm x 60 cm x 75cm
depth including fixing, firmly with hard murum, metal obtained from excavation,
including engraving “ADCL” letters on two sides and painting with two coats of
blue colour cement paint, two coats of white wash to exposed sides with all labour,
material including transportation etc. complete. All works shall only begin once
the demarcation of the boundary is duly approved by Employers Engineer.

- The Bidder shall include in its scope all the equipment, works and services neces-
sary for complete, safe and reliable operation and maintenance of the facility in
accordance with the terms of the Contract, even if certain works are not expressly
stated in any part of the Tender Documents.

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- Throughout these Tender Documents, the terms "Bid" and "Tender" and their de-
rivatives ("Bidder/Tenderer", "Bidding/ Tendering", etc.) are synonymous, and
Day means calendar day of twenty-four (24) hours. Singular also means plural.
"Bidder" or "Applicant" and "Bid" or "Application" for the purpose of interpreta-
tion of Instructions to Bidders shall mean the same. Any other term not defined
herein should be interpreted in a manner as defined in General Condition of Con-
tract as defined in the EPC Agreement.

- All pressure containing equipment and components shall be designed, fabricated,

tested, and inspected in accordance with project specification and ASME Section
VIII, Div 1. Material certification to BS-EN-10204:2004 shall be supplied for all
items.

- Inspection and Quality Control of all equipment and civil work, Erection, Com-
missioning, trial run, along with all consumables and manpower, project manage-
ment and monitoring for timely submission of design documents and drawings and
timely execution of the project with demonstration of performance guarantee pa-
rameters including supply of all measuring instruments and manpower.

- Training of ADCL Operating and Maintenance personnel.

- The Bidder’s proposal shall include details and references of the recorded opera-
tional reliability of the key equipment and systems to be provided.

The Contractor shall ensure that all designs and equipment for which he is responsible
are safe. Nothing in this requirement shall remove the Contractors obligation from
drawing the attention of the Employers Representative to any feature of the Works
which is not consistent with safety, or to prevent him making proposals for incorporat-
ing equipment or designs which would increase the safety of the site and plant.

The installation layout and system design shall not allow any item of plant to be so
positioned that danger to operating personnel could arise during normal operation and
maintenance. Particular attention shall be paid to the positioning of pipes, air vents and
rotating machinery.

Prior to commencement of the work, the Contractor shall submit the following:

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1. Layouts, general arrangements, dimensional elevations and cross-sectional

drawing for all the project components, equipment, structures and facilities of
the works.
2. Piping isometric, composite layout and fabrication drawings, Piping engineer-
ing Diagrams, pipe and fittings schedules, valve schedules, pipe support sched-
ules.
3. Technical data sheets and calculations for all bought out and manufactured item
4. Hydraulic & Mechanical design calculations
5. List, type, data sheets and valve schedule of motors and actuators, Alarm and
annunciation/Sequence of Event (SOE) list and alarms & trip set points.
6. Sequence and protection interlock schemes
7. Type test reports
8. Foundation Plan and Loading Data for Civil Design and drawings.
9. Model study reports wherever applicable
10. Functional & guarantee test procedures and test reports
11. Documentation in respect of Quality Assurance System as listed out elsewhere
in this Specification
Geotechnical Investigations

Site-specific geotechnical investigations were carried out by the client for the
existing site and are enclosed as Schedule U.

This is for reference only and a detailed geotechnical investigation shall be performed
at the Site for given road area before starting works by the Bidder.

The Bidder is required to verify the sub-soil strata including the CBR value by perform-
ing its own site investigation prior to developing the civil/structural design.

The geotechnical parameters necessary for the detailed foundation designs would de-
pend on the findings of site specific ground investigation.

Geotechnical Investigation Report:

For structural design purposes, Geotechnical investigation shall be conducted and SBC
shall be found out at required depths at locations of Intake well, Each unit of WTP,
SUGRs, Cushion Tanks, Pump houses, Bridge structures and other important structures
by the contractor confirming to relevant IS Code, through the Government approved
agencies. The soil test shall include bore log, SPT, UDS test, Tri-axial test, Vane shear

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test, core sample test, plate load test depending upon requirement of the structural de-
sign of the structures. Before detailed engineering & design of the structures the con-
tractor shall submit detailed soil test report along with calculation of SBC to the Engi-
neer-in-Charge’s for approval of SBC to be adopted for structural design. On approval
of the SBC the contractor shall design the structure considering the recommended SBC.
In case further data would be necessary before or after submission of tender / during
execution of the work, the tenderer / contractor shall collect the same of his own & at
his cost.
Ignorance of any data shall not relieve the contractor of his obligation to complete &
commission the work as per the provisions of the Agreement. For detail structural de-
sign of the intake well and bridges, the contractor has to collect all the required hydrau-
lic & flow parameters of the river/water way where the intake well and bridge structures
are to be constructed, from the Water Resources Department, and other data as will be
required from the concerned departments, at his own cost and risk & shall submit to the
Engineer-in-Charge’s for approval. Then based on the approved data the agency has to
prepare detail design & drawing of Intake well and bridge structures.
While designing of the structures, it shall be ensured that the weight of the structure
including foundation, water, over burden earth on foundation / slab / raft etc. as appli-
cable shall be within the permissible limit of S.B.C. allowed by the Engineer-in-Charge.

Topographical and other relevant Survey:

The Contractor is required to reconfirm the topographical surveys and soil investiga-
tions enclosed with the bid. The Employer does not warrant either the sufficiency or
accuracy of site data provided in the Bid Documents or elsewhere. Any Site data in
Employer’s possession that is not included in the Bid Documents will be available for
inspection at the Employer’s addresses provided in Conditions of Contract.

He should be ready with the qualified agencies he intends to use for the purpose and
ensure that the work starts within a fortnight of the Letter to Proceed. He shall conduct
investigations as are normally necessary to ensure full and satisfactory designs and
safety.

Field laboratories

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The Contractor will be required to establish a field laboratory as approved by Employ-

ers Representative, suitably equipped to carry out tests as stipulated in the QA/QC Man-
ual, including all specialized equipment which will be required for testing the material
and equipment being supplied under the Contract. Suitable trained laboratory staff will
have to be posted with full facility of computerized record keeping. The minimum
equipment to be provided in the laboratory shall be as listed below in the Table 1. Ad-
ditional equipment as may be deemed necessary may be added to the same in due course
on requirement of the Employer/Contractor. The Contractor shall provide a laboratory
as approved by Employer’s Representative for the testing of materials.

In addition to the equipment in the laboratory, the Contractor will also provide field
testing equipment as directed by the Employer’s Representative on sites where work is
in progress.

The contractor shall put a concrete batching plant of required capacity within the site
area for efficient working.

The laboratory shall have the following facilities required for sampling and testing ma-
terials and concrete in the field. All such facilities shall be provided by the Contractor
at no extra cost to the Employer. The following equipment with operators shall be made
available at Employers /Employers Representative request (all must be in serviceable
condition):

Table-1 List of Equipment to be provided for Laboratory by the Contractor

1. Concrete cube testing machine suitable for 15 cm cubes of 1 No.

100 tonnes capacity with proving calibration ring
2. Cast Iron Cube moulds 15 cm size 50 Nos.
(Minimum)
3. Slump cone complete with tamping rod (as required to suit 5 sets
concrete plan)
4. Laboratory balance to weigh upto 5 Kg. with sensitivity of 1 No.
10 gm.
5. I S. Sieves for coarse and fine aggregates 1 Set
6. Set of measures from 5 litres to 0.1 litre 1 Set
7. Electric oven with thermostat upto 120oC 1 No.
8. Flakiness gauge 1 No.
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9. Schmidt Hammer 2 Nos.

10. Elongation index gauge 1 No.
11. Sedimentation pipette 1 No.
12. Pycnometer 1 No.
13. Calibrated glass jar (1 litre capacity) 1 Nos.
14. Glass flasks and metal containers As required
15. Chemical reagents like sodium hydroxide, tannic acid, litmus As required
papers, etc.
16. Laboratory balance of 2 Kg capacity and sensitivity of 1 gm 1 No.
17. Total Station 1 nos.
18 Staff and associate equipment’s for total station 2 nos.
19. SS Std. Measuring Tap 15 nos.

Arrangement can be made by the Contractor to have the cubes tested in an approved
laboratory in lieu of a testing machine at site at his expense, with the prior consent of
the employer.

The outside laboratory shall also be used for routine testing of cement, reinforcement,
coarse and fine aggregate and other items.

Temporary Works

Not less than 14 days before commencing any portion of the Works, the Contractor shall
submit to the Employer’s Representative for his approval comprehensive drawings and
calculations for all Temporary Works which the Contractor proposes for the construc-
tion of that part of the Works.

Notwithstanding approval by the Employer’s Representative of any design for the Tem-
porary Works, the Contractor shall be entirely responsible for their safety, efficiency,
security and maintenance and for all obligations and risks in regard to such Temporary
Works specified or implied in the Contract.

Workability and maintenance

Facilities and equipment shall be arranged and spaced sufficiently to enable sat-
isfactory operation and maintenance of the Plant. Access around all equipment shall be
provided, in accordance with Good Utility Practices, to allow effective inspection,
maintenance and removal of equipment.
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All automatic valves and major equipment should be at ground level or accessible by
permanent platforms. The marking and test specification of safe working load values
on lifting equipment shall be in SI units.

Sufficient space should be provided to ensure easy inspections and maintenance of all
the equipment.

Development of the project roads and utilities/services

Development of the Project Roads and Utilities/Services shall include detailed design
and Construction of the following as described in this Schedule-B and in Schedule-C.

Standards and specifications

The Project Roads and Utilities/Services shall be designed and constructed in conform-
ity with the Standards and Specifications given in Schedule-B and D respectively.

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Appendix B-I

Development of the Project Roads

Development of the Project Roads shall include detailed design and construction of the
following as described in this Schedule-B and in Schedule-C.

1.0 Project Roads and Utilities / Services

 Design and Construction of Roads, Carriageway details are given in

Appendix B I (a)
i) Typical Cross Section details are given in Appendix B I (b)
ii) Geometric design and other features are given in Appendix B I (c)
iii) Embankment and Pavement design details are given in Appendix B I (d)
iv) Longitudinal storm water drains details are given in Appendix B II (a)
v) Storm water crossings details are given in Appendix B II (b)
vii) Drawings are given in Appendix B IX
2.0 Standards and Specifications
The Project Roads shall be designed and constructed in conformity with the
Standards and Specifications given in Schedule-D.

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Appendix B-I (a)

1.0 Design and Construction of Roads

1.1 The Design and Construction of Roads for package XV roads as specified in
Appendix B I (a) of Schedule-B. Notwithstanding anything to the contrary
contained in the Schedules, the Finished Road Level (FRL) provided in the Plan &
Profile Drawings shall be followed. (Appendix B IX).

1.2 Width of Carriageway

Width of carriageway is as given in typical cross sections drawings in Appendix B I (b).

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Appendix B-I (b)

1.0 Typical Cross Sections

Typical Cross Sections details are as given below in Table -1

Table -1

S. No. Road Name Applicable TCS PROW

1 E3 Provided as per drawing 60 m

1.1 Cross Section along the project road

Package XV road (E3) has to be constructed with a 3 lane (BRT) in the middle, single lane
main carriageway of 3.5 m on both the sides, cycle track of 3 m, green belt of 3 m and side
walk of 3 m at both the ends of the carriageway for the present contract package.
Configuration of main carriageway, BRT lanes, cycle track, green belt and side walk has to
be followed from the typical cross section drawing attached.
Proposed cross section for the package XV roads has been furnished in the below figure.

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Proposed cross sections for this package E3 road is furnished in below figure.

PROPOSED CROSS SECTION OF E3 ROAD

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Appendix B-I (c)

1.0 Package XV road (E3) has to be constructed with a 3 lane (BRT) in the middle, single lane
main carriageway of 3.5 m on both the sides, cycle track of 3 m, green belt of 3 m and side
walk of 3 m at both the ends of the carriageway for the present contract package.
Configuration of main carriageway, BRT lanes, cycle track, green belt and side walk has to
be followed from the typical cross section drawing attached.
Proposed cross section for the package XV roads has been furnished in the below figure.

Fig. No:1 PROPOSED CROSS SECTION OF E3 ROAD

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Appendix B I (c)
1.0 Geometric design and other features

1.1 General
Geometric design and other features of the Project Roads shall be in accordance with
the Standards and Specifications as per Schedule D.

1.2 Design speed

The Design Speeds for different category of roads are as given below in Table: 2

Table-2:

S. No. Road Name Length (Km) Design Speed (Km/h)

1 E3 18.270 80

1.3 Coordination on Geometric Design

All the roads of trunk network zones are designed in coordination with major arterial, arterial
and sub-arterial roads considering the road levels of the neighbouring roads. The design details
related to the package-XV roads shall be obtained from the employer for integration of the
geometric design features and other services of the project. The approval of the employer for
the design integration has to be obtained.

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Appendix B-I (d)

1.0 Embankment & Pavement Design

Construction of embankment and pavement shall conform to the Standards and

Specifications as per Schedule D.

2.0 Pavement Design Criteria

Pavement design shall conform to the Standards and Specifications as per Schedule
D.

2.1 Type of pavement

Flexible pavement h a ve be e n d es i g n e d f o r M a i n C a r r i a ge w a y ( W M M ,
D B M a n d B C l a y e r s ) a n d B RT l a ne (W M M , D B M a n d B C l a ye rs ) .

The proposed crust composition for the main carriageway and BRT lane is furnished
below.

S. No. Description Thickness (mm)

1 Bituminous Concrete (BC) 50
2 Dense Bituminous Macadam 110
(DBM)
3 Wet Mix Macadam (WMM) 250

2.2 Design requirements

2.2.1 Design Period

Flexible pavement shall be designed for a minimum period of 20 years.

2.2.2 Design Traffic

Notwithstanding anything to the contrary contained in the Schedules, the Contractor

shall design the pavement for 100 MSA.

2.3 Cycle track

Cycle track of width 3 m has been proposed on both the sides of the carriageway.

The proposed crust composition for the cycle track is furnished below.

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S. No. Description Thickness (mm)

1 Premix Carpet 20
2 Wet Mix Macadam 75
3 Granular Sub-base 150
4 Subgrade 300

2.4 Sidewalk

60 mm thick paver blocks are to be used for sidewalk and shall be in confirmation with
the technical specifications in Schedule-D.

Paver blocks are to be placed over sand bed of 30 mm and GSB of 200 mm.

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Appendix B-II (a)

Storm water drainage

Storm water drainage system design for Trunk roads shall be based on following
parameters.

• Invert levels of Trunk and LPS storm water drainage system at the outfalls to
primary channels/vagu’s shall be as far as possible higher than the 1 in 100 year
HFLs of channels/vagu’s but in any case, all design event HGL within Trunk
and LPS storm water will be higher than 1 in 100-year HFLs of channels/vagu’s.

• Design event of 1 in 5-year event flows shall be considered for storm water
drains.

• Storm water drainage system design shall confirm to the design criteria given in
Schedule D.

• Contractor has to get the confirmation about the final HFLs of vagus and
maximum water levels in Trunk storm water drains with Engineer-in-
charge/CRDA/ADC before proceeding with the detailed design of Trunk storm
water Drains. Expenditure incurred towards this, if any, shall be borne by
contractor only. No extra payment shall be given by CRDA/ADC for
ascertaining this data and any consequent design changes.

• The Contractor shall consider the upstream catchment flows contributed to the
zone considered in design of Storm water drain network, based on IDF Curves
provided by the Authority.

• The suggested frequency of flooding is once in 5 years or as appropriate based

on the field conditions.

• A minimum free board of 150 mm has to be followed. The guidelines provided

in IRC SP 50-2013 regarding the freeboard requirements shall be followed in
conjunction with the 80% utilization of drains.
2.0 General Requirements of SW Drains

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The general arrangement shall be as shown in the drawings. All the structural
elements shall be elegantly harmonized in respect of shapes, sizes lines and levels.
All the lines of the storm water drains shall be continuous without any break.

The decision of the Authority/Authorities representative shall be final in respect

above requirements.

The preliminary Geo-Technical investigation report enclosed in the bid document are
for guidance only. The nature of the strata need re-confirmation from the EPC’s
contractors end. The EPC agency must conduct necessary Geotechnical
Investigations where ever necessary and submit the same to Engineer-in-charge for
approval.

The Drawings enclosed/attached are indicative only. The network, drainage basins
and the cross sections are purely for indication & guidance to the EPC agency but
not exhaustive. The detailed designs and drawings shall be furnished by the EPC
contractor for approval after which the BoQs have to be worked out as per
deliverables which will form the basis of payment.

3.0 Drainage Layout Plan and typical details

Drawings of storm water drainage layout plan and typical details of the drainage
arrangement are given in the “Drawings” Volume.
4.0 Longitudinal storm water drains
Longitudinal storm water drain along the road has been proposed keeping in view of
the storm water run-off within the project stretch. The details of the storm water drains
proposed along the package roads are given below in Table 3.
Table - 3 Details of Longitudinal drains along package roads
E3 Road
LHS
S. No. Size (m x m) Length (m)
1 0.6X0.6 1234.88
2 0.75X0.75 1219.7
3 0.9X0.9 891.46
4 1.05X1.05 508.19
5 1.2X1.2 1345.37

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E3 Road
6 1.35X1.2 914.98
7 1.35X1.35 275.41
8 1.5X1.35 71.38
9 1.5X1.5 7029.28
10 1.65X1.5 1931.55
11 1.65X1.65 159.65
12 1.8X1.65 132.49
13 1.8X1.8 637.21
14 1.95X1.8 154.11
15 2.1X1.95 111.04
16 2.1X2.1 1049.05
17 2.4X2.25 107.8
18 3X3.5 14.99
RHS
S. No. Size (m x m) Length (m)
1 0.6X0.6 2165.62
2 0.75X0.75 1221.27
3 0.9X0.9 761.78
4 1.05X1.05 1002.92
5 1.2X1.2 1133.94
6 1.35X1.2 122.8
7 1.5X1.35 122.8
8 1.5X1.5 747.48
9 1.65X1.5 422.98
10 1.65X1.65 985.86
11 1.8X1.8 400.62
12 1.95X1.95 1255.62
13 2.1X1.95 629.11
14 2.1X2.1 531.32
15 2.25X2.1 298.06
16 2.25X2.25 3281.19
17 2.4X2.25 721.74
18 2.4X2.4 924.15
19 3X3 980.24
20 3X3.5 21.5

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5.0 Inlet chambers

Inlet chambers have been provided at an interval of 15 m along the project road to
collect the surface run-off. The details about the inlet chamber has been given in the
below figure.
3D view of the proposed Inlet chamber has also been shown in the below figures.

Typical section showing the Inlet Chamber provided at 15 m interval, The clear depth
of these inspection chambers shall be increased to 900mm at the valley locations
(lowest points) along the road in account for the silt accumulation buildups and
maintenance requirements.

3D view of Inlet Chamber (a)

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3D view of Inlet Chamber (b)

6.0 Access inspection chambers & covers

Access inspection chambers with cover shall be designed and provided subject to
minimum c/c distance of 30 m interval.

7.0 Temporary Drainage/ Diversion of Streams and mobile pumping arrangements

The Contractor shall handle all flows from natural drainage channels intercepted by
the work under these specifications, perform any additional excavation and grading
for drainage as directed and maintain any temporary construction required to bypass
or otherwise cause the flows to be harmless to the work and property.

The contractor shall always carry out construction of cross drainage works in a
manner creating least interference to the natural flow of water while consistent with
the satisfactory execution of work. Temporary diversion shall be formed by the
contractor at his cost where necessary. No extra payment shall be made for this work.
No separate payment will be paid for bailing out sub-soil water/drainage, bailing of
pumping water either from excavation of soils from foundations or such other
incidentals and safety measures for men and materials and all necessary arrangements
to complete the work.

Necessary coffer dams and ring bunds have to be constructed at the cost of contractor
and same are to be removed after the completion of the work. The contractor must
quote be keeping the above in view.
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The work of diversion arrangements should be carefully planned and prepared by the
contractor and forwarded to the Engineer-in-charge technically substantiating the
proposals and approval of the Engineer-in-charge obtained for execution.

Contractor shall arrange for all necessary diversion channel works for the storm water
drain outfall connections to nearest water bodies and mobile pumping arrangements
to drain and bail out the inundated rain water.

Anti-erosion measures such as silt fences shall be planned along diversion channels
such that to prevent silt entering in to the nearest water bodies. Sand / silt removal
facilities such as sand traps, silt traps and sediment basins should be provided to
remove sand / silt particles from run-off.

8.0 Maintenance Requirements

All relevant Materials, Works and Construction operations shall confirm to CPHEEO
Manual on Storm water 2013 Part-B; Operation and Maintenance and Good Industry
Practice to the satisfaction of Engineer-in-charge for storm water drain networks and
outfalls.

During the mandatory maintenance period, the Contractor shall carry out a detailed
pre-monsoon inspection of all existing bridges, culverts and drainage system. The
Contractor shall complete the proposed maintenance works such as clearing debris
and cleaning before the onset of the monsoon and send a compliance report to the
Engineer-in-charge. Post monsoon joint inspection shall be undertaken by the
Contractor/ Engineer-in-charge and the inspection report together with details of any
damages observed and proposed action to remedy the same shall be conveyed to the
Engineer-in-charge.

9.0 Pumping Machinery

The pumping machinery of the prescribed type and capacity should be supplied and
commissioned including maintenance. Pumping Machinery shall be essentially ISO
9001 Certification. The mobile pumping stations procured during operation and
maintenance period shall be handed over to the Authority.

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Appendix B-II (b)

Storm Water Crossings list

The proposed storm water Crossings list in the project stretch are given in Table – 2.

Table - 2 : Proposed Storm Water Crossings across package XV roads

Road Proposed Span

S. No. Chainage Type
Name Arrangement (m * m)

1 E3 11.712 1.95 * 1.8 Box Culvert

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Appendix B-III(a) - Headworks

Potable Water Supply Network
A) General
A safe and reliable water supply is the most basic need of a community for living. Apart from
drinking water needs, standard of living to support basic health and sanitation in a city is judged
by the ample provision of a wholesome water supply. Vision of the proposed water supply
system in Amaravati capital city is to provide water supply to all the stakeholders: domestic,
municipal, commercial, industrial and fire services. ensure continuous 24 x 7 water supply,
maintain best potable water quality standards, and benchmarking the design, operation and
maintenance to international best practices.

The work involves:

Survey, Geotechnical Investigations, planning, designing, supply materials, construction of In-
take-well-cum-raw water pump house of capacity 17050 m3/hr, Water treatment plant capacity
of 8261 m3/hr (190 MLD) with ZLD concept, 64 ML capacity underground clear water reser-
voir-cum- pumping station, trunk pipeline mains, 7 Nos of cushion tanks (ELSRs), 8 SUGRs
cum Pump houses and approach road to Intake site complete with all civil, electrical & me-
chanical works, instrumentation & controls including SCADA through optical fibre cable and
wireless redundant system, including erection, testing and commissioning of pumps, motors,
VFDs, valves, flow meters, RMS, BMS, integration of full water supply system, trail run for 3
months, DLP for two years and O&M for 8 years.
Agency shall supply and lay Optical Fibre Cable (OFC) through PLB HDPE duct and PLB
duct laid by the Agency. Integration of instruments through SCADA for the entire water supply
network from intake well, raw water pumping main, WTP, clear water reservoir-cum-pumping
station, clear water pumping main up to Water Distribution Centres is under the scope of works
by the Agency. O&M of intake well-cum-raw water pumping station, WTP, clear water reser-
voir-cum-pumping station inclusive of pumps, motors and other aligned correlated machineries
of the entire water supply network for a period of 8 years from the date of completion of DLP
(for two years as specified) will be part of the scope of works by the Agency.

B) Location:
Intake Well -cum-raw water pumping station will be located on the right bank of river Krishna,
2 Km upstream of Prakasam barrage at geographical coordinates 16°30'23.27"N latitude and

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80°34'58.70"E longitude. The site of proposed WTP and CWPS will be at Amaravati capital
city near Undavalli village at geographical coordinates 16°30'0.33"N latitude and 80°35'0.62"E
longitude. The water supply network will be for the entire Amaravati capital city.

C) Works under this Tender:

Phase-I of the water supply system comprises the following headwork components:
(i) Intake Well-cum-Raw Water Pumping Station on the right bank of Prakasam
barrage to draw and transmit 17050 m3/hr (392 MLD) of raw water from the river.
(ii) Supply, installation, testing, commissioning, trial run of 2W+1S pumps & motors
of capacity 1184.00 LPS discharge and 21 m head each including all other electro-
mechanical components.
(iii) Approach Road & elevated platform: Intake campus shall be provided with two
level bridge of length 290 Rmt (approx.) (i.e. One level for carrying raw water pipe
line and other for vehicular movement) upto karakatta bund and approach road of
length 218 Rmt (approx.) from bund to seed access road (E3), crossing through
bund Road. The top width of bridge should be 10.60m (two lane carriage way 7.0m
and 1.80m projection on either side for Crash barriers, walkway and utility ducts).
Top width of approach road shall be 11.20m, 1.2m walkway on one side, 2.0 m
walkway on other side & extra 0.5 m on either side and 2-lane (7.0 m) motorable
CC road for inspection, operation and maintenance of the Intake installation. The
elevated platform should be connected between two proposed intake wells and ap-
proach bridge, with provision for installation of manifolds and vehicular movement
during maintenance.
(iv) A pressurized Raw Water Transmission Main of approximately 580 Rmt. length
with 1900 mm diameter to convey 17050 m3/hr (392 MLD) of raw water along
with OFC cable and PLB HDPE duct upto the water treatment plant.
(v) Water Treatment Plant of 16522 m3/hr (380 MLD) capacity at Undavalli with
modular concept of 8261 m3/hr (190 MLD) capacity with modern space saving
technology & Zero Liquid Discharge (ZLD) concept for immediate construction in
this tender and another 8261 m3/hr (190 MLD) addition at a later stage.
(vi) A Clear Water semi underground Reservoir (CWR), of total capacity 128 ML to
be located in WTP campus. However, 64 ML capacity CWR with 2 compartments

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of 32 ML each shall be under the scope of this tender. Minimum depth of CWR
shall be of 5.0 m.

(vii) A Clear Water Pumping Station shall accommodate 19 horizontal split-casing

centrifugal pumps of varying capacities: 10W+3S of capacity 826.39 LPS discharge
and 54 m head each, 2W+1S of capacity 414.00 LPS discharge and 48 m head each
to meet water demand for the entire city apart from Undavalli area and 2W+1S of
capacity 130.25 LPS discharge and 39 m head each to meet water demand for Un-
davalli area, with inlet and outlet manifolds, service bay and control panels to op-
erate the pumps. The Pumping station will be a RCC semi underground structure
with water retaining structure and fire proof protection including round the clock
light arrangements with proper ventilation.
(viii) Design and construct with pleasant architectural plan & view for Administrative
building & Guest house at Intake, Clear water pump house (WTP site & WDC site),
Electric Substation building, Office building, Facade of Pump house, filter house
annexe, staff quarter building, bungalows and office building at WTP premises.

(ix) Supply, installation, testing, commissioning, trial run of pumps & motors with
5w+2S of capacity 826.39 LPS discharge and 54 m head each, 2W+1S of capacity
414.00 LPS discharge and 48 m head each, 2W+1S of capacity 130.25 LPS dis-
charge and 39 m head each for Undavalli area including all other electro-mechan-
ical components.
(x) Pressurized Clear Water Transmission Mains consisting of different diameters of
SWMS & DI K9 pipelines along with OFC cable and PLB HDPE duct.

(xi) Water Distribution Centres comprising 51 Cushion Tanks (ELSRs) and 8 Semi
Underground Reservoir (SUGRs) cum pumping stations. Construction of only 7
Nos of cushion tanks (ELSRs) is within the scope of this tender. Construction of
remaining 44 cushion tanks are beyond the scope of this tender, which will be at
later stage. Construction of boundary wall with ornamental gates, security cabin,
operators room & local PLC/SCADA control rooms, Bypass Management System
etc. in all sites of cushion tanks is under the scope of this tender. Design, detail
engineering and construction of 8 Nos. SUGR cum pumping stations along with its
electro-mechanical component, boundary wall with ornamental gates, security

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cabin, operators room & local PLC/SCADA control rooms, Reservoir Management
System etc. is under the scope of this tender.
(xii) Flow Control Devices to regulate flow in the Water Distribution Centres (WDCs).
It shall consist of 16 No actuator operated SCADA compatible isolation valve along
with flow meter and pressure transmitter with remote and local display at Tapping
points on ring main. 8 No. of Reservoir Management System(RMS) at SUGRs lo-
cation, 7 No. of Reservoir Management System(RMS) at Cushion tanks (ELSRs)
location, and 51 No. Bypass Management System(BMS) shall be provided at
WDCs. There shall be 164 No. of air valves in the entire network.
(xiii) Electrical Works: Supply, installation, testing commissioning of complete electri-
cal distribution system inside the Intake well, WTP, Clear water pumping station
and WDCs and all infrastructure created in this tender. The work shall be carried
out as per the data sheets and SLDs which include electrical items which are given
herewith. Dedicated feeder mains with power cables of suitable capacity from 2
substations for getting 24 x 7 power supply.
(xiv) Illumination Works: Supply, installation, testing commissioning of complete
lighting distribution system inside the Intake well, WTP, Clear water pumping sta-
tion and WDCs, yard lighting for all premises as per the data sheets and SLDs.
(xv) Earthing system & Lightning protection: Supply, installation, testing commis-
sioning of complete Earthing system & Lightning protection inside the Intake well,
WTP, Clear water pumping station and WDCs as per the data sheets. All civil works
associated with the earthing and lighting protection system will be under the work
scope of the Agency.
(xvi) Liaison and getting approval from competent authority for electrical installations.
(xvii) Instrumentation, control and Automation system: Design, supply, installation,
testing, commissioning, trial run for 3 months with O&M for a period of 10 years
including 2 years DLP of complete Instrumentation Control system of Intake well,
Raw water raising main, WTP, Clear water pumping station, Clear water pumping
main and WDCs. The instrumentation and control system shall comprise of
SCADA, PLC based control system and peripherals, Field instrument impulse pip-

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ing, tubes and fittings, field accessories junction boxes, local control panels, trans-
mitter racks, instrumentation control cables, communication data cables, cable
trays, loop testing, calibration of field instruments and its field integration.
A smart and comprehensive Water Supply SCADA and web SCADA system which
will allow an operator to monitor and control the water supply system at every stage
of its operation. An air-conditioned control room, 2 Nos 55-inch LED monitor, 2
Nos work station with 32 inches screen at Raw water pumping station, remote sites
shall allow to communicate with a Control Command Centre (C3) facility (to be
located at WTP control Centre) and shall provide the necessary data to control pro-
cesses in the entire water supply system. SCADA should have provision of fully
auto mode, semi auto mode and manual mode, programming shall be made accord-
ingly. The Agency shall appoint experienced specialized SCADA agency for im-
plementing as per the approved list.
(xviii) Control Command Centre (C3): Design Supply, installation, testing, commis-
sioning, trial run for 3 months, 2 years DLP and 8 years operation & maintenance
of control command centre (C3) located at WTP, shall collect the data from Intake
well, Raw water raising main, WTP, Clear water pumping station, Clear water
pumping main, WDCs shall monitor on 2 Nos 90” Video wall & control, CCTV
footage of WTP. Provision need to be made connecting to C4 (City control com-
mand centre). It should comprise of Engineering station, historian station along with
real time data acquisition server.
(xix) Design, supply, installation, testing, commissioning of CCTV covering entire
premises of Intake well, WTP & WDCs compound. Scope also includes CCTV in-
stallation in pump houses, panel rooms, substations, transformer yards, control
rooms, filtration plant, entrance gates, security cabins and major equipment areas.
(xx) Designing, drawing and construction of Approach/other connecting road includ-
ing kerb channels & footpath, apron & surface drains, sewerage system, compound
lighting/street lighting within the Intake well compound, WTP compound & WDCs
compound and connecting the drainage system outside the campus.
(xxi) Design and providing landscaping within Intake well compound, WTP compound
& WDCs compound.

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(xxii) Agency shall also provide as-built drawing indicating all assets related to water
supply in GIS & AutoCAD format.
(xxiii) Supply of minimum inventory spares as per specifications.
(xxiv) Supply of laboratory instruments, glass works & chemicals.
(xxv) Integration of entire water supply system of Amaravati capital city.
Tender for this work pertains to headwork components of the Amaravati capital city water
supply system as described above.

D) Detail Scope of Work

Scope of works, in general, comprises:
Surveys, investigations, designs, detailed engineering, construction, supply, installation,
testing, commissioning and operation & maintenance of the proposed water supply system
in Phase-I.

Headworks components-wise, the Scope of Works is described as given below:

 Intake Well cum Raw Water Pumping Station:
i. Bathymetric survey of the river reach on 250 Rmt on both the sides of exact location of
Intake and 500 Rmt inside the river using latest echo-sounding instruments and data
loggers synchronised with boat speed shall be under this scope of work. From this Bath-
ymetric survey data, contour lines at 1m interval shall be prepared and map of Bathy-
metric survey for a scale of 1:500. The exact location of the Intake well cum raw water
pumping station shall be decided and layout plan of the structure shall be superimposed
on to the Bathymetric chart. The complete dataset, map and report shall be submitted
to Engineer-in-Charge for approval.
ii. Detailed geotechnical investigation of the Intake site (both on the river bank and inside
the river) using core borehole drilling shall be undertaken by the Agency. Percussion
type Core drilling shall be performed for a minimum depth of 25m from G.L/ Bed level
of the river or up to the bedrock whichever is higher. Four drilling locations shall be
explored, two on the bank side and two in the river portion as per approval of Engineer
in Charge. Standard procedure of geotechnical investigation as per the relevant IS code
shall be followed. Report on geotechnical investigation including Safe Bearing Capac-
ity, pile capacity for different diameter piles for foundation design shall be submitted
to Engineer-in-Charge for approval.

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iii. Designs, detailed engineering, construction, supply, installation, testing, commission-

ing, operation and maintenance of the Intake Well-cum-Raw Water Pumping Station of
capacity 17050 m3/hr. Intake at river bank shall consist of twin RCC Jack Wells of
capacity 8525 m3/hr each inside the river at suitable location as obtained from Bathy-
metric survey and approved by Engineer in charge. Raw water will be lifted by Vertical
Turbine Pumps (2 working + 1 standby) in each well. Wells will have sluice gates with
screen at different levels to allow river water to enter with respect to level variation in
the river through the lean, normal and high flow seasons. Diameter of the Intake well
shall be ascertain based on hydraulic requirement as well as space requirement for 3
Nos of pumps & motors, valves, specials etc. VFD control panel and other accessories
required at the pump house. Arrangements of pumps, motors, manifolds and outlets of
the Raw Water transmission mains etc. shall be finalised in consultation with Engineer
in charge, QAP and data sheet shall submit for Engineer in Charge approval before
procurement. Agency shall provide EOT crane of capacity 15 tonne. The electrically
operated crane/hoists travel together circumferentially (long travel of the crane) and
travel both independently and synchronised in the radial direction in full 360° (cross
travel and lift). Agency shall construct 2 RCC cast in-situ jack wells in all respect based
on Geotechnical investigation and structural requirement. Agency shall supply & install
3 Nos of pumps and motors along with its all accessories only in a single well. Agency
shall make necessary provision in common manifold so that future expansion with other
well can be done without shutdown of raw water pumping station. Agency shall make
necessary provision of tees, actuator compatible sluice valves with blind flange in com-
mon manifold of capacity 17050 m3/hr.
iv. Design, detail engineering, construction of building of the RWPS shall be circular with
symmetry to the shape of Jack well with proper side ventilation and spacing of pumps,
motors and control panel. Besides, the building shall have unique architectural design
with dome shape/inverted cone shape roof top and decorative artefacts outside which
gives a pleasant look to its surroundings and resembles a signature structure of the Am-
aravati capital city. Two intake wells shall be connected by a platform at pump floor
level with unique architectural design compatible with pump house. The platform shall
be designed to carry heavy commercial vehicular load and it shall be connected with

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elevated approach road with sufficient turning radius. The building with complete ar-
chitectural design shall be prepared and submitted along with 3D view to the Authority
for appreciation/ modification and approval from the Engineer in charge. Supply, fab-
rication, installation/ construction of signage, graphics as per the approved Architec-
tural design.
v. Agency shall design and construct boundary wall of height 1.8 m above finished GL
for entire premises and shall provide ornamental gate with MS angle flat and sheets at
entrance one at main entrance and other at river side. The boundary wall shall be of 250
mm thick panel wall with RCC column and beam framework at an interval of 3 m.
Agency shall construct security cabin of size 10 sq.m. Agency shall also construct ap-
proach road from platform level/road level to the raw water pump house premises.
vi. Agency shall design and construct office building cum guest house at raw water pump
house campus. The building shall be of RCC framed structure resting on pile foundation
with 250 mm thick external wall and 125 mm thick internal wall. This building shall be
of 300 sq.m built up area in each floor. Ground floor of the building shall be car parking
and one servant room with toilet and kitchen. First floor shall be office for administra-
tion staff which contains two cabins with air conditioned, ten cubicals with necessary
furniture. Second floor shall be 4 bedrooms with attached bathroom, separate hall and
dining space in 250 sq.m area & 50 sq.m open terrace with an ornamental parapet wall
including all furniture. There shall be a common washroom in hall. The first-floor level
i.e. office floor level shall be same as pump floor level. There shall be access from
platform level to the first-floor level/office floor level through gangway. Finishing of
the building shall be as specified in Schedule D.
vii. Agency shall design and construct one staff quarter (G+4) RCC frame structure build-
ing resting on pile foundation with 250 mm thick external wall and 125 mm thick in-
ternal wall. This staff quarter shall have two quarters of size 100 sq.m built up area in
each floor. Ground floor of the building shall be car parking. Each quarter shall contain
two bedrooms, (one master bed room with attached toilet, one bed room), hall, dining,
kitchen, one common bathroom and a balcony. The building shall consist of one RCC
staircase of width 1.20 m and stair head room of 2.4 m height. Finishing of the building
shall be as specified in Schedule D.

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viii. Agency shall design and construct internal road including storm water drainage net-
work, footpath, kerbs and channels, campus lighting, landscaping of campus etc. as per
the approved internal layout submitted by Agency and as per specification given in
Schedule D.
ix. Agency shall design and construct indoor substation cum SCADA Control room build-
ing of area 607.50 Sqm, transformer yard with separate boundary wall as per electrical
component design given in Schedule D. Floor level of substation building shall be 150
mm above the elevated approach bridge level. There shall be minimum 3.5 m approach
way by RCC gangway from elevated approach road to substation building. The Ground
floor shall be car parking space. Substation building shall be framed structure over RCC
pile foundation. Finishing of the substation building shall be as per specification given
in Schedule D.
x. Electrical:
The Scope of electrical works is given in elsewhere in bid document.
xi. Instrumentation & Control System through SCADA
The scope of works under this sub-head includes the following as given below:
a. Design, Supply, erection and commissioning Instrumentation control through
SCADA with optical fiber networking for 392 MLD Intake-well-cum-Raw water
pumping station. Scope include of all field instruments (gauges/sensors/transmit-
ters/ switches etc.) for control/monitoring/alarm annunciation system of Intake
well, Raw water Pumps (8525 m3/hr) for Phase-I development, Raw water pumping
main (17050 m3/hr), process and electrical system equipment & systems. Design
and provision of expansion and panel with space for PLC and terminals for future
expansion 392 MLD.
b. Preparing I/O list & P&ID for Intake well, Raw water Pumps (8525 m3/hr), Raw
water pumping main (17050 m3/hr), process and electrical system equipment &
systems. The preparation of I/o and P&ID as per detailed specification in schedule
D and shall be submitted for approval of the Engineer-in-Charge.
c. Design, supply, erection, loop checking & commissioning of PLC based control
system for complete Raw water pumping station comprising of Intake well, raw
water pumping main upto WTP, 33kV/6.6 KV substation & associated electrical

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systems and remote I/O cabinet complete with all hardware, software, system cab-
inets, marshalling cabinets, interfaces & accessories as required & considering fu-
ture expansion with specified requirement detailed subsequently. The installation,
commissioning & upgradation of PLC system shall be in line with phase-wise in-
stallation & commissioning activities as specified in Schedule D.
d. Design, supply, erection & commissioning of all erection hardware and accessories
like branch cable trays from field sensors to junction boxes, junction boxes for ter-
minating field sensors etc. as required for erection of field instruments/sensors/PLC
Control system/ local panel etc. for complete scope of work.
e. Design, supply, erection & commissioning of Local UPS Power supply with distri-
bution boards & distribution to I&C system equipment.
f. Design, supply, laying & termination of Instrumentation & Control cables as re-
quired for complete control/ monitoring of entire Raw water pumping. Scope also
includes preparation of engineering documentation like cable schedule and Inter-
connection schedule.
g. Design, supply of necessary consoles & other furniture & accessories to mount
MMI & peripherals including construction of air-conditioned control room, 2 No
55-inch LED monitor, 2 No work-station with 32-inch monitor and good quality
high back cushioned wheeled chairs at Raw Water Pumping station as per specifi-
cation and layout in Schedule D.
h. Design and creation of HMI MIMICS which should graphically represent total ar-
chitecture, functioning for the proposed system.
i. Local SCADA shall consist of Information Management System (IMS) which shall
analyze Annual O&M cost estimate: - Annual energy usage model that will allow
estimation of early utility cost and will assemble all annual costs for operation,
maintenance and repair of plant, distribution and energy transfer station assets. Web
based SCADA shall be supplied for monitoring and recording the hydraulic param-
eters and overall operations of the water supply system.
j. PLC controller as required complete with required I/O modules to be located at
Intake well cum pumping station in local control room (air conditioned) in Control
building. Number of PLC controllers (each hot redundant) to be based on I/O han-

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dling capacity, specified I/O spare philosophy and controller spare loading require-
ment for 392 MLD (17050 m3/hr) Intake well as specified in Schedule D. PLC con-
trollers for entire plant as detailed below shall be provided.
k. The instrumentation system shall comprise of field censors, gauges, switches, trans-
mitters, PLC based control system and peripherals, field instrument piping/slashing
tubes, fittings, field accessories like junction boxes, transmitter racks, instrumenta-
tion and control cable, communication data cable, supply and installation of cable
trays, loop testing, calibration of filed instruments and its PLC interfacing etc. as
per specification provided in Schedule D.
l. One (1) No. colour laser printer and one number black and white laser printer.
m. Provision of remote I/O cabinet for interfacing field instruments located at raw wa-
ter pumping main covering upto WTP.
n. Provision of OFC communication data cable (Fibre Optic Cable) along with PLB
HDPE duct between main PLC of Intake well & Control Command Centre at WTP.
o. Provision of 3 sets of communication hardware for OPC communication link and
standby wireless communication network (Ethernet on TCP/IP protocol) for inter-
facing with overall project master control system at Central Command Centre at
WTP premises for additional facility of operation & monitoring.
p. Provision of 2 sets of spare serial communication links (each for RS-485 & RS-232
using Transmission Control Protocol/Internet protocol) hardware with MODBUS
protocol for future interfacing with other plant control systems like Fire Alarm Sys-
tem.
q. SCADA, networking & other necessary software, required for smooth & satisfac-
tory functioning of Intake well pumping system & raw water pumping main, to be
installed with latest, compatible versions and future system & software upgradation
to be carried out with no extra costs to the ADC during phase-wise installation &
commissioning, trial run, DLP and operation maintenance period.
xii. Agency shall plan, design & execute toilet/washroom, parking facade/floor finishing in
each building and in each floor. Finishing shall be as per details provided in Schedule
D.
xiii. All structures/platforms shall be designed considering pile foundation.

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xiv. Floor/platform level of pump house, substation building, shall be at least 150 mm above
elevated approach bridge level (25 m).
xv. Necessary firefighting as per NFPA guidelines/IS code for Intake well cum pump
house, office building, substation shall be within this scope of work.
xvi. Entire Intake well cum raw water pumping station premises shall be monitored through
CCTV camera with one-month backup storage. Live CCTV footage shall be transmitted
to SCADA screen at Intake well and as well as CCC at WTP.
xvii. Design, supply, installation, testing and commissioning of EPBAX and intercom phone
facility shall be provided in the entire Intake well area.

 Approach Road to Intake Well

The scope of works includes the following as given below:
i. Topographical survey shall be carried out using Total Station and DGPS supported with
electronic Auto Level for accurate alignment plan, L-section and cross-sections of the
Approach Road. For this, nearest GTS bench mark shall be carried forward to the start
/ end point of the road and double leveling to close any inaccuracy in levels and align-
ment plan. Cross-sectional survey at 100m interval with spot level at every 10m spacing
to cover bottom width of the approach road plus 10m additional on either side shall be
carried out. Alignment plan, L-section and cross-sections shall be prepared on 1:5000
scale and shall be submitted to the Engineer-in-Charge for approval.

ii. Geotechnical investigation using electrical resistivity survey and auger well pits at 50m
interval shall be carried out all along the alignment of the approach road to arrive at soil
profile upto 3m depth from the GL. These soil profiles along with the report shall be
submitted to the Engineer-in-Charge for approval.

iii. Approach road from flood bund road shall be combination of elevated platform and
earth-fill road made of cement concrete (M30) with expansion joints at suitable inter-
vals. Formation of the approach road embankment shall be made of earth compacted
with roller. Length of elevated platform shall be approximately of 290 Rmt and approach
road shall be of 218 Rmt. There shall be connectivity from elevated platform/road to
electrical substation also. The elevated platform/road shall be designed with considera-
tion of single Class-A loading as per IRC with allowable gradient of 1 in 20. Suitable
size of RCC cable trench/alley is to be constructed for transmission of power and control

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cables between the elevated substation platform and pump house on the integrity on both
sides of elevated platform/road as well as on earth-fill road. The approach elevated plat-
form/ road towards Intake well shall have to accommodate common delivery manifold
and pumping main. The top width of approach road shall be minimum width of 11.20m.
The Intake well shall be constructed in such a fashion that elevated platform/road shall
connect in between two Jack wells. There shall be sufficient space in between two RCC
Jack wells to facilitate entry of heavy vehicles upto Jack wells. The Project Roads and
Utilities/Services shall be designed and constructed in conformity with the Standards
and Specifications given in Schedule D.

 Raw Water Transmission Main:

The scope of work includes the following as given below:
i. Survey, Geo-technical Investigation, Detailed Engineering of the pipe line based on the
design principle provided by the Authority (pipe diameter, pipe material, valves as pro-
vided in Schedule - D). For SWMS pipes, recommended in-lining is 406-micron food
grade fusion bonded Epoxy and out-coating is 3-layer polyethylene/polyolefin.
ii. Provide Detailed plans, Preparation of L section, Cross Sections etc., GFC’s of pressur-
ized potable pipeline without deviating the design concept considered and details given
below. Agency shall also provide as-built drawings indicating all assets related to water
supply in GIS and AutoCAD format.
iii. Each pump shall have a common manifold of dia 1500 mm, minimum thickness of 14
mm and each manifold will connect with another common manifold of dia 2200 mm,
minimum thickness of 18 mm from which pressurized raw water transmission main of
approximately 580 Rmt length (upto WTP) of 1900 mm diameter SWMS pipe with
minimum thickness of 16mm which shall be provided out by the EPC Agency. All the
pipe line shall have one PLB HDPE duct along with its trench at proper location ap-
proved by the Engineer-in-Charge. Agency shall make necessary provision in the pump-
ing main at WTP, so that future expansion with other stilling chamber of next phase
WTP can be done without shutdown of raw water pumping station. Agency shall make
necessary provision of tees, actuator compatible sluice valves with blind flange in rais-
ing main of capacity 17050 m3/hr. 1900 mm dia raw water pumping main will be bi-
furcated at WTP premise with two No of 1500 mm dia SWMS pipe, minimum thickness
14 mm, one will connect with stilling chamber of proposed WTP and other one for next

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phase WTP. Each 1500 mm dia SWMS pipe will have electrical actuator SCADA com-
patible sluice valve complete in all respects. The external coating shall be 3 LPE/poly-
olefin coating and inside with 406-micron food grade epoxy coating.
iv. Agency shall supply, install, testing and commissioning of 1 No. of 1900 mm dia but-
terfly valve with electrical actuator and SCADA compatible. Agency shall also supply,
install, testing and commissioning of 1 No. 1900 mm dia electromagnetic flow meter
for measurement of raw water flow. Agency shall also construct chambers for valves
and meter.
v. Based on the survey, geo-tech investigation, pipe design analysis, etc., Agency shall
provide accurate alignment Plan, L section, Cross-Sections, geo-tech investigation and
pipe analysis data and reports including provision of surge protection devices at appro-
priate locations at the outlet pipe of the RWPS for approval of the Authority before
proceeding for the construction works.
vi. Agency shall provide necessary surge analysis report for approval by the Engineer in
charge and shall provide necessary surge protection device (bladder vessel) having ca-
pacity 15m3 and minimum 2 Nos.
vii. Construction of RWTM shall be carried out as per approved design and drawings and
as per the following item of works:

o Construction of RWTM shall be buried 1.2 m below the approach road level
o Supplying, fabricating, loading, unloading, transporting and handling of Mild Steel
pipes, specials etc.
o Loading, Unloading, Transporting and handling of PLB HDPE ducts and laying of
ducts along with SWMS Pipes and accessories for laying of OFC.
o Neoprene gaskets required for flange joints shall be supplied by the Agency.
o Lowering, placing and laying such pipe specials, valves etc., properly in trenches,
jointing by proper neoprene gasket, submerged arc welding to the SWMS pipes
including derusting, scraping, brushing and applying heat shrink sleeves as per
specification and hydraulic pressure testing.
o Supplying of all labour, tools & tackles, plants, instruments, equipment, machinery,
accessories as are needed to complete the job in the manner as specified to the entire
satisfaction of the Engineer-In-Charge.
o Construction of supporting arrangements / thrust blocks.

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o Earth work in excavation in trenches

o Pumping out sub-soil water and water from other sources accumulated in excavated
trenches.
o Any other work related to laying of water supply pipe which is not mentioned above
shall be executed by the Agency.

 Water Treatment Plant (WTP)

The scope of work includes planning, designing, detailed engineering, drawing, construc-
tion, supply, erection, testing, commissioning, operation and maintenance of entire water
treatment plant complete in all respects. The plant is proposed to be located at Undavalli.
The details of site plan and land area are provided in the Annexure.
The water treatment plant shall be Modular in construction with 190 MLD (present) + 190
MLD (future expansion). The Agency shall prepare layout plan with unit sizing and Hy-
draulic Flow Diagram (HFD) for two (2) No of 8261 m3/hr (190 MLD) capacity water
treatment plant, 2 No of 64 ML capacity clear water reservoir and one clear water pump
house for housing 19 No of pumps and motors of capacity as given in Schedule D along
with all components given hereunder in approximately 25 acres allocated land for the said
purpose. The Agency shall construct only one 8261 m3/hr (190 MLD) capacity WTP with
1 No. of 64 ML capacity Clear water reservoir and the pump house for housing 19 pumps
along with other items which are given herewith.
The plant shall be a state-of-art facility with modern space saving water treatment technol-
ogy with Zero Liquid Discharge (ZLD) concept for raw water treatment of Krishna river
and shall consist of the following units given below. The WTP units shall be planned &
designed in such a way that there shall be 100% flexibility in operation. Any process unit
of WTP shall not be connected directly to the consecutive process units. Each unit shall be
connected with a common channel.
(a) Stilling chamber and Parshall flume with ultrasonic flow measuring device
(b) Pre-chlorination with liquid chlorine.
(c) Chemical (Alum/PAC) dozing with thorough mixing of raw water
(d) Flash mixer for Coagulation
(e) Flocculation
(f) Sedimentation with plate settler technology
(g) Rapid sand gravity filters with modern under drainage system.
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(h) Backwash sump-cum-pump house for filter beds

(i) Sludge drainage/treatment/thickened, make sludge cake and waste drained water dis-
posal with ZLD concept
(j) All pumps, motors, compressors, air blowers & other electro-mechanical equipment
related to water treatment process
(k) Storage of disinfectant
(l) Filter water conveying main upto semi-underground clear water reservoir
(m) Weigh bridge of capacity 30 MT.
(n) Disinfection/post Chlorination
(o) Chemical house
(p) Recirculation pump house
(q) Filter house annex building
(r) Well-equipped laboratory
(s) WTP control with SCADA & integration with main SCADA
Available Raw water quality parameter of river Krishna water and required clear water
quality parameter are given in Schedule D. However, the Agency shall undertake testing
of raw water quality parameters by their own and design WTP accordingly, then proven
technology installations are to be demonstrated to Authority/Authority engineers for the
approval. Detail specification of WTP units are given in Schedule D.
Apart from the above treatment units, the following works are also under this scope of this
tender.
i. Architectural boundary wall with ornamental gates of entire WTP premises.
ii. Internal road network along with storm water drainage network on both sides of road,
kerb channel & footpath, internal lighting, landscaping of campus and gardening over
the semi underground reservoir roof.
iii. Supply, fabrication, installation/ construction of signage and graphics as per the ap-
proved Architectural design.
iv. Agency shall plan, design & execute toilet/washroom, parking facade/floor finishing in
each building and in each floor. Finishing shall be as per details provided in Schedule
D.
v. Administrative building shall contain reception, visitors lobby, Control Command Cen-
tre (C3) with 2 No 90-inch video wall, office space for Chief Engineer, Superintending

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Engineer, Executive Engineers, Dy. Executive Engineers, Assistant Executive Engi-

neers as provided elsewhere in the bid document.
vi. Two No staff quarter (G+4) building each having 8 No quarters, one building for Group
C employee and 2nd building for Group A&B employees. The built-up area of group C
employee shall be of 100 sq.m and for group A&B shall be of 120 sq.m.
vii. Decorated boundary wall of entire WTP with electrically operated ornamental gate
made of MS flat, angle, square bar, sheet etc. Administrative building, staff quarter,
bungalows and WTP compound shall have separate boundary wall and gate of same
specification. Boom barrier with vehicle access control shall be provided at the entry of
both administrative building and WTP. Number of gates shall be finalized at planning
stage in consultation with Engineer-in-Charge. Each gate shall have one security cabin
of size 10 sq.m.
viii. Two bungalows (G+1 storied) of built-up area of 150 sq.m in each floor with boundary
wall, gate, internal lighting, storm water drainage, internal roads etc., one for the plant
Superintendent and one for the Chief Engineer.

The scope of above stated work includes planning, design, drawing and construction of
civil works with pile foundations for the various units of the plant as listed above including,
planning, design, drawing, manufacture, supply, delivery at site and erection of all
mechanical and electrical equipment including pipes, valves with electrical actuators,
pumps, motors and all other electrical and mechanical equipment as per detailed technical
specification and vendor list that may be necessary and specified herein to make the
treatment plant complete in all respects to treat raw water (quality as shown in Appendix)
delivering 8525 m3/hr of potable water of specified quality (physical, chemical and
bacteriological). The foundation of all civil structures will be of direct mud circulation
bored piles. The scope also includes leak-proof testing of various water retaining units of
the plant, commissioning of the same and trial run for a period of three (3) months.
Thereafter, two-year DLP and operating and maintaining the plant for a period of 96
(Ninety-six) months from the date of completion of DLP including the SUGR, CWPS and
entire water supply system of Amaravati capital city including instrumentation (SCADA)
as specified, under the overall supervision of the Employer/his representative. The date of
commencement of the Trial Run shall be decided by the Authority after taking into
consideration the existing status of the entire works under this tender and after being
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Amaravati Development Corporation Limited

satisfied that the plant is completed in all respects to begin trial run. During the period of
trial run, DLP, operation and maintenance, the Agency shall have to supply all type of
coagulant, chlorine, laboratory reagents and all equipment and chemicals required to run
the plant. During the period of trial run, DLP and operation maintenance, except for the
power charges, which will be borne by the Authority, all other costs related to trial run shall
be borne by the Agency. During the trial run & DLP, it shall be obligatory on the part of
the Agency to justify his process and designs by showing the quality of treated water and
the performance of the electro-mechanical equipment. The tests which shall be undertaken
by the Agency during trial run, DLP and operation maintenance are given below in the
Table.

S Required Test Pa- Frequency of

Sample Water Remarks
No rameters Testing

Agency shall also

Raw Water, Clarified wa- provide necessary in-
ter, filtered water at each Online record struments at labora-
1 Turbidity filter bed, filtered water at through tory for testing tur-
SUGR sump, common SCADA bidity thrice in a day
manifold, WDC to compare with
online data.

Agency shall also

Clarified water, filtered provide necessary in-
water at each filter bed, fil- Online record struments at labora-
2 Residual chlorine tered water at SUGR through tory for testing resid-
sump, common manifold, SCADA ual chlorine six times
WDC in a day to compare
with online data.

Agency shall also

provide necessary in-
Online record struments at labora-
Temperature, Total Raw Water, filtered water
3 through tory for testing tem-
Dissolved Solids, at common manifold
SCADA perature, TDS once
in a day to compare
with online data.

Raw Water, raw water af- Online record Agency shall also
4 pH ter flocculator, filtered wa- through provide necessary in-
ter at common manifold. SCADA struments at labora-
tory for testing pH

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Amaravati Development Corporation Limited

once in a day to com-

pare with online
data.

Total Alkalinity
5 , Hardness, Raw Water, filtered water Once in a day Laboratory test
Chloride

6 Jar Test Raw Water Twice in a day Laboratory test

Fluoride, Sulphate,
7 Filtered Water Once in a week Laboratory test
Nitrate

Arsenic, Iron, Lead, Twice in a

8 Filtered Water Laboratory test
Mercury, month

Mineral Oil, Pesti- Once in a

9 Filtered Water Laboratory test
cide month

Presumptive Coli-
form Count, Faecal Twice in a
10 Filtered Water Laboratory test
Coliform Count month

The Agency shall have to perform all tests in the newly built laboratory of WTP with
necessary reagents, instruments, equipment except those for the Mineral Oil, Pesticide,
arsenic, lead and mercury. The Agency shall arrange to have these tests carried out by any
Government or renowned approved laboratory and shall submit the results to the Engineer-
in-Charge regularly at the Agency's cost.
The item-wise detailed scope of work and specifications are provided in Schedule D.
B. Electrical:
The scope of work for electrical is given elsewhere in the bid document.
C. Instrumentation & Control System through SCADA:
i. Design, Supply, erection and commissioning of Instrumentation and control through
SCADA with optical fiber networking within the 190 MLD Water Treatment Plant.
Scope includes all field instruments (gauges/sensors/transmitters/switches etc.) for
control/ monitoring/alarm annunciation system of WTP consisting inlet chamber,
chemical dozing, Parshall flume, flash mixture, flocculator, plate settler, rapid sand
filter beds, Back wash reservoir, common filter water channel, sludge sump & pump

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Amaravati Development Corporation Limited

house, sludge thickener, centrifuge, Clear water reservoir, clear water pumping sta-
tion, clear water pumping mains, Tapping Control Management System (TCMS), By-
pass Management System, Reservoir Management System, WDCs and all electrical
panels. Design and provision of spare I/O channels/cards considering future expan-
sion for additional (190 MLD) in the WTP premises as specified in Schedule D.
ii. Preparing I/O list & P&ID for WTP process & electrical system, clear water pumping
main and WDC. The preparation of I/O and P&ID as per detail specification in sched-
ule D. The prepared P&ID and I/O list shall be submitted for Engineer-in-Charge
approval.
iii. Design Supply, erection, loop checking & commissioning of PLC based control sys-
tem for complete water treatment, clear water pumping main, Tapping Control Man-
agement System (TCMS) with Sluice valve & Electromagnetic flow meter, Bypass
Management System, Reservoir Management System and WDC, 33kV/6.6kV
switchyard & associated electrical systems and remote I/O cabinet complete with all
hardware, software, system cabinets, marshalling cabinets, interfaces & accessories
as required & considering future expansion with specified requirement detailed sub-
sequently. The installation, commissioning & upgradation of PLC system shall be in
line with phase-wise installation & commissioning activities as specified in Schedule
D.
iv. Design, Supply, erection & commissioning of all erection hardware and accessories
like branch cable trays from field sensors to junction boxes, junction boxes for termi-
nating field sensors etc. as required for erection of field instruments/sensors/PLC
Control system/ local panel etc. for complete scope of work.
v. Design, Supply, erection & commissioning of Local UPS Power supply with distri-
bution boards & distribution to I&C system equipment.
vi. Design Supply, laying & termination of Instrumentation & Control cables as required
for complete control/ monitoring of entire Raw water pumping station. Scope also
includes preparation of engineering documentation like cable schedule and Inter-con-
nection schedule.
vii. Design Supply, installation, testing, commissioning, trial run for 3 months, 2 years
DLP and 8 years operation and maintenance of control command center (C3) with 2
Nos 90-inch LED Video wall located at WTP, shall collect the data from Intake well,

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Amaravati Development Corporation Limited

Raw water raising main, WTP, Clear water pumping station, Clear water pumping
main Air Management System (AMS), Tapping Control Management System
(TCMS), Bypass Management System, Reservoir Management System and WDCs.
Operator shall monitor on 2 Nos 90” Video wall and control. It shall comprise of
Engineering station, historian station along with real time data acquisition server.
Control Command center shall contain 6 No. work station near video wall. Visitors
lobby with furniture and reception as per specification and layout in Schedule D
viii. Design and creation of HMI MIMICS which should graphically represent total archi-
tecture and functioning for the proposed system.
ix. From Control Command Center (C3), provision shall be made connecting to C4 (City
Control Command Center).
x. SCADA shall consist of Information Management System (IMS) which shall analyze
Annual O&M cost estimate: Annual Energy usage model that will allow estimation
of utility cost and will assemble all annual costs for operation, maintenance and repair
of plant, distribution and energy transfer station assets.
xi. SCADA system shall be designed for automatic bill generation for every individual
customer by collecting data from WDCs. Provision of data acquisition system at
WDC shall be provided to collect the data of individual consumers through Water
Management District (WMD).
xii. PLC controller as required complete with required I/O modules shall be located at
local control room (air conditioned) in WTP. Number of PLC controllers (each hot
redundant) shall be based on I/O handling capacity, specified I/O spare philosophy
and controller spare loading requirement for 380 MLD WTP as specified in Schedule
D.
xiii. The instrumentation system shall comprise of field censors, gauges, switches, trans-
mitters, PLC based control system and peripherals, field instrument piping/slashing
tubes, fittings, field accessories like junction boxes, transmitter racks, instrumentation
and control cable, communication data cable, supply and installation of cable trays,
loop testing, calibration of field instruments and its PLC interfacing etc. as per spec-
ification provided in Schedule D.
xiv. Total two (2) No PC based VDU/Keyboard type Operator-cum-Engineering Stations
(OES) complete with SCADA MMI software shall be located in clear water pumping

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Amaravati Development Corporation Limited

station with Local Control Room (LCR) complete with associated furniture for
mounting the same.
xv. Total one (1) No. colour laser printer and one number black and white laser printer.
xvi. Provision of remote I/O cabinet for interfacing field instruments located at clear water
pumping main and WDC.
xvii. Optical Fibre Cable (OFC) communication data cable (Fibre Optic Cable) along with
PLB HDPE duct between Intake well, raw water pumping main, WTP, clear water
pumping main and WDC.
xviii. Provision of 3 sets of communication hardware for OPC communication link and re-
dundant wireless communication network (Ethernet on TCP/IP) for interfacing with
overall project master control system at Central Command Centre located at WTP for
additional facility of operation and monitoring.
xix. Provision of 2 sets of spare serial communication links (each for RS-485 & RS-232)
hardware with MODBUS protocol for future interfacing with other plant control sys-
tems namely Fire Alarm System.
xx. SCADA, networking & other necessary software, required for smooth & satisfactory
functioning of Intake well pumping system & raw water pumping main, shall be in-
stalled with latest, compatible versions future system and software upgradation shall
be carried out with no extra costs to ADC during phase-wise installation and com-
missioning, trial run, DLP and operation maintenance of the system.
xxi. Entire WTP premises shall be monitored through CCTV camera with one-month
backup storage. Live CCTV footage shall be transmitted to SCADA screen at WTP
and as well as CCC at WTP.
xxii. Design, supply, installation, testing and commissioning of EPBAX and intercom
phone facility shall be provided in the entire WTP & WDC area. All the locations of
Intake well, WTP, WDCs has to be interconnected.

 64 ML capacity Semi Under Ground Reservoir (SUGR):

The scope of work includes planning, designing, detailed engineering, drawing,
construction, supply, erection, testing, commissioning, operation and maintenance of the
semi-underground reservoir complete with inlet, overflow and scouring arrangement. The
finished ground level shall be +22.0 m and existing ground level is approximately +19.0
m. Hydraulic design of treatment plant and clear water reservoir shall be such that the top
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Amaravati Development Corporation Limited

water level of semi-underground reservoir will be 0.05 m below the invert level of filter
water channel of water treatment plant and Horizontal Pumps of clear water pumping
station will have positive suction. Accordingly, levels of all the other units of water
treatment plant such as collection well, flash mixers, flocculators, clarifiers, Filter Beds,
Clear water duct, inlet ducts of reservoir etc. shall be fixed.
The SUGR shall be of two compartments with a facility for cleaning and maintenance of
any one compartment without taking any shut down of clear water pump house as well as
depressed sump. There shall be dividing wall between two compartments as well as
depressed sump and compartments. To maintain minimum dead storage within the
reservoir near the dry pit, a depressed sump floor level has to be provided adjoining the dry
pit pump floor having floor level 2.50 m below the reservoir floor level or as prescribed by
the pump manufacturer whichever is higher. The suction pipe of designed diameter from
each individual pump along with the bell mouth shall be placed in the sump. The pipe line,
the bell mouth and puddle collar at prescribed level of the suitable size are also under the
scope of work. The sump floor will gently dip from the reservoir floor level with 45-degree
slope. There shall not be any constriction/column in the suction sump area. Agency shall
provide necessary arrangement for connection to the sump from second 64 ML reservoir
for future expansion. One dewatering sump of suitable size shall be provided in each
compartment of the reservoir for dewatering purpose and shall be marked properly at the
top of the reservoir. Two manholes shall be provided just above the sump. The full water
depth should be at least 5.0 m or more at the time of reservoir full condition. The foundation
of pump house and reservoir will be of direct mud circulation bored pile. The pile shall
have adequate strength to take tension for uplift due to subsoil water assumed at the existing
ground level when the reservoir is empty and also for vertical loads in worst condition. The
construction of pump house shall be completed earlier to facilitate the erection work of
electrical and mechanical equipment. The free board in reservoir shall be of 0.5 m. There
shall be proper overflow arrangement and ventilation arrangement in the reservoir and
depressed sump. Prior approval shall be taken by the Agency for overflow and ventilation
arrangement. There shall be a park with well-designed landscaping arrangement and
walkway (1.5 m wide) with anti-skid tiles over the roof of SUGR. The roof is to be designed
for a live load of 400 Kg/m2 and a superimposed load of saturated compacted earth of 500
mm depth. No relief shall be allowed due to this superimposed load of saturated earth while

55
Amaravati Development Corporation Limited

computing the uplift on the pile of SUGR. The roof slab shall be flat slab designed based
on IS: 3370 and shall have minimum 300 mm projection on all sides and the parapet wall
of the SUGR roof shall be of 200 mm thick RCC. The Agency shall provide proper roof
treatment and drainage arrangement over the roof of SUGR. The site of SUGR shall be
camouflaged with surrounding landscaping. The top of SUGR roof slab shall be one meter
above the Finished GL. Agency shall construct four stairs to reach the top of the
SUGR/Park from FGL. The reservoir shall have 1.0m wide plinth protection along with
proper overflow and storm water drainage arrangement surrounding it. The plinth
protection shall be constructed with 100 mm thick PCC (M15 grade) over single brick flat
soling finished with 25 mm thick artificial stone flooring. There shall be 3.5 m road
surrounding the SUGR and pump house. Agency shall provide proper lighting arrangement
over the roof of SUGR.
The total work includes the civil construction & electro-mechanical installation work of
reservoir, pump house and pump sump and inlet connection to the reservoir from the clear
water duct receiving filter water from filter beds in the filter house. A suitable sluice gate
shall be installed on the clear water duct in front of the semi-underground reservoir so that
the reservoir and the treatment plant can be completely separated as and when required.
RCC Inlet Duct has to be drawn from the clear water duct from filter house.

 Clear water pumping station

The scope of work includes planning, designing, detailed engineering, drawing, construc-
tion, supply, erection, testing, commissioning, operation and maintenance of clear water
pumping station. The work includes proper ventilation system, firefighting system in entire
pumping station as well as air conditioning system in the control room. The pump house
shall be planned for hosing 19 Nos of VFD controlled pumps and motors with different
capacities specified herewith along with valves with electrical actuators and SCADA com-
patible, piping arrangement and all other necessary equipment and accessories. Construc-
tion of control room for VFD control panel, SCADA room, battery room, operators room,
toilet etc. are also under this scope of work. The roof of sump portion may be utilized for
construction of control room. The depth of dry pit pump house shall be compatible with the
sump level of adjacent SUGR. RCC staircase to access pump floor from MCC room shall

56
Amaravati Development Corporation Limited

be provided by the Agency. Height of the soffit level of the roof beam of pump house build-
ing shall be minimum 10.0 m from FGL. There shall be walkway of 1m width surrounding
pump room inside the pump house.
Capacity of pumps and motors
Discharge
No. of Pumps for each Head
S. No Description Remarks
to be installed pump (m)
(LPS)
7 Pumps
To Ring Main out of 13
1 5W + 2S 826.39 54.00
Peak Flow Pumps to
be installed
To Ring Main
2 Avg. Flow (Half size 2W + 1S 414.00 48.00
Pump)

3 Undavalli Area 2W + 1S 130.25 39.00

It is proposed to install 13 Nos of horizontal split case centrifugal pump directly coupled
with drive motor by flexible coupling. The capacity of the electro-mechanical component
shall be as per the above table. The Agency shall install suction pipe with electrically oper-
ated actuator control and SCADA compatible valve for all 19 pumps and shall provide blind
flange on six unused suction pipes & valves. The Agency shall provide 13 Nos delivery
header and additional 6 Nos of delivery line from common manifold to the pump house and
blind flange the same for future expansion. The Agency shall design, detailed engineering
and construct pump foundation and other allied civil structures for all 19 Nos of pumps and
motors. The Agency shall provide space for holding down bolts in civil structures of 6 Nos
of pumps. The positive suction pumps shall be connected to the reservoir through suction
pipes of designed diameter/diameter supplied by the manufacturer along with electrical ac-
tuator operated valves compatible with SCADA & specials. The pumps & motors must be
of continuous duty type. The individual pump delivery pipe lines shall be connected to a
common delivery manifold of designed diameter but not less than 2500 mm placed outside
the pump house 1.2 m below G.L. The individual delivery line shall have a Duck Foot bend
inside the pump house. The delivery manifold shall be equipped with actuator operated
SCADA compatible Butterfly valves, electro-magnetic flow meter, flow meter chamber,

57
Amaravati Development Corporation Limited

valve chamber, blank flange if necessary (detail of which is given in Schedule D). There
shall be two separate manifolds outside the pump house having minimum size of 2500 mm
dia with minimum 20 mm thickness and 1000 mm dia with minimum 10 mm thickness for
Ring Main and Undavalli area. The two manifolds shall be connected with 1000 mm dia
with minimum 10 mm thickness pipeline with electrical actuator with SCADA control
sluice valve. The vertical portion of the delivery line shall be covered with proper cladding
as approved by the Engineer-in-Charge. All the design of the pipelines shall be such that
so as to ensure streamline flow.
The Agency has to submit in due course the specific size of all machineries & equipment
offered along with data related to static & dynamic loads in different operating conditions.
The size of pump house shall be selected in such a way, that all the equipment with suffi-
cient maintenance space can be housed in the pump room. There shall be proper drainage
arrangement & dewatering sump to evacuate the water accumulated over the pump floor.
The size and location of sump pump along with sump shall be designed in such a manner
to evacuate the accumulated water from pump floor from any source within maximum 10
minutes to eliminate the chance of inundation in any case. Minimum 50% standby for the
sump pumps is to be provided.
Gantry arrangement and one E.O.T crane (10 MT) with another 3 MT auxiliary E.O.T crane
are to be provided by the Agency in the pump house. The installed E.O.T crane should
cover three dimensionally entire footprints of the pump house. In order to accommodate
the cables, battery room and control panel room equipment/appliances will be house at a
level higher than pump floor as shown in the tender drawing. Minimum requirement has
been mentioned in Schedule D.
i. The vibration & noise shall be within the acceptable limit as per ISO 10816 code
(latest revision) or as per existing norms for all equipment.
ii. The dimension and centre line of pedestals for supporting the Pumps as well as the
valves shall strictly be in line for both Civil & Electromechanical works.
iii. The clearance in between successive pump sets, clearance from wall for pump sets
shall be based on I.S code, CPHEEO manual and vendor data whichever is higher.
iv. The clearance for installation of all H.T. & L.T. electrical equipment should be
strictly as per I.E. Rules.

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Amaravati Development Corporation Limited

v. The minimum distance from the pump impeller centre to suction sump wall shall
be maintained in such a level so that no vortex formation takes place in the entry of
pump i.e. the flow should be maintained streamlined at the entry point of pump.
vi. The elevation of pump centre line shall be designed in such a manner to maintain
adequate clearance between the bell mouth and the floor of the suction sump to
avoid choakage or vortex formation.
vii. The Agency has to submit parallel operation curves for pumps & the same is to be
matched with the system resistance curve of the delivery grid. Pump selection shall
be based upon that. Family curves for individual and multiple operations at all pos-
sible consequences depending upon the variation in % opening of the PDV are to
be submitted.
viii. The Agency has to consider all sluice valves, PDVs, dismantling joints in individual
pump suction & delivery pipe lines as per detailed technical specification.
ix. The puddle collars needed to be fixed into the wall for entry & exit of suction and
delivery pipelines shall be considered.
x. The Agency shall work out the natural frequency analysis for the structural work
and the same shall be verified with the RPM & critical speed of the rotating equip-
ments to eliminate any chance of vibration. such a level so that no vortex formation
takes place in the entry of pump i.e. the flow should be maintained streamlined at
the entry point of pump.
xi. The puddle collar need to be fixed on the suction and delivery sides inlet and outlet
on the concrete wall and are to be supplied and fixed as per specification/require-
ment.
xii. All the cable works from 33KV RMU to all 6.6KV and LT loads are within the
scope of works. Cabling works required to operate the equipment at pump house,
water treatment plant complex etc., shall be considered from this 33/6.6 KV indoor
sub-station. Power cables of all sizes must be AL, 3 or 3.5 core armored XLPE
cable.

The design of pump house shall be made on the basis of the Static load as prescribed and
Dynamic loading and vibration level supplied by the manufacturer that will be generated
due to operation of each pump motor set or as per relevant IS code.

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Amaravati Development Corporation Limited

The Agency, whose tender will be accepted in due course, shall have to furnish details of
the design of the pump house and sump with all levels to connect the reservoir considering
all the parameters as supplied by the pump manufacturer within the dimensions of the
pumping station provided by them for housing the pumping machinery, compact substation
equipment/appliances. The inlet connection shall be made at a level as shown in the oblig-
atory data in Schedule D. The Agency shall undertake soil investigation studies of their
own and thereby formulate the design criteria for structural work which will be subject to
the approval of the Engineer-in-Charge.

 Laying of Clear Water Pumping main

General scope of work includes laying of 2400 mm dia SWMS pipe (minimum thickness
20 mm) from the common manifold of the clear water pumping station upto E3 road and
making connection with the ring main. Also, Agency shall supply, install 800 mm dia DI-
K9 pipeline for Undavalli area upto E3 road.
Detailed scope of work includes the following as given below:
i. Survey, Geo-technical Investigation, Detailed Engineering of the pipeline system
based on the design principle provided by the authority for civil structures (pipe diam-
eter, pipe material, valves and specifications as provided in Schedule D). For SWMS
pipes, recommended in-lining is 406-micron food grade fusion bonded Epoxy and out-
coating is 3-layer polyethylene/polyolefin.
ii. Provide Detailed plans, Preparation of L section, Cross Sections etc., GFC’s of pres-
surized potable system without deviating the design concept considered and details
given below. Agency shall provide as-built drawing indicating all assets related to wa-
ter supply in GIS and AutoCAD format.
iii. Agency shall provide necessary surge analysis report for approval by Engineer in
charge and shall provide necessary surge protection device (bladder vessel) having
capacity 100m3 and minimum 6 Nos.
iv. Submission of plans, designs and engineering drawings for further approval of the au-
thority.
v. Construction of Water Supply Network as per approved design and drawings
vi. Loading, Unloading, Transporting and handling of 800 mm dia DI-K9 Ductile Iron
pipes and laying of Ductile Iron Pipe and special.

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Amaravati Development Corporation Limited

vii. Supplying, fabricating, loading, unloading, transporting and handling of 2400 mm dia
(minimum 20 mm thickness) Mild Steel pipes, specials etc.,
viii. Loading, Unloading, Transporting and handling of PLB HDPE ducts and laying of
ducts along with MS Pipes & DI-K9 pipeline and accessories for laying of OFC.
ix. Neoprene gaskets, tyton gaskets for maintaining proper alignment shall be supplied by
the Agency.
x. Lowering, placing and laying such pipe specials, valves etc., properly in trenches,
jointing by proper neoprene gasket (Push on joint/ tyton joint etc.,), submerged arc
welding to the MS pipes including derusting, scraping, brushing and applying heat
shrink sleeves as per specification and hydraulic pressure testing.
xi. Supplying of all labour, tools & tackles, plants, instruments, equipment, machinery,
accessories as are needed to complete the job in the manner as specified to the entire
satisfaction of the Engineer in Charge.
xii. Construction of supporting arrangements for pipes.
xiii. Construction of thrust blocks.
xiv. Earth work in excavation in trenches
xv. Pumping out sub-soil water and water from other sources accumulated in excavated
trenches.
xvi. Erection, Testing, Commissioning and O&M of the Potable Water System
xvii. Any other work related to laying of water supply pipe which is not mentioned above
has to be executed by the Agency.
xviii. The Agency shall construct the water supply pipelines for the pressurized water
supply system on continuous running basis, along with installation of scour valves,
thrust blocks and Isolation valves etc. as required.
xix. The Agency shall supply, install, test and commission 2 Nos. of SCADA compatible
electromagnetic flow meters of size 2400 mm dia & 800 mm dia at proper location
inside WTP campus.
xx. The Agency shall furnish all required tools, plant, instruments, materials including wa-
ter, electricity, labor, consumables, etc., any and everything necessary for construction
of the works, whether or not such items are specifically stated elsewhere in this tender.

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Amaravati Development Corporation Limited

Size of all valve chambers shall be considered for electrically actuated valve & com-
patible to SCADA connectivity except scour and air release valves as per the valve
data sheet and location provided in drawings.

 Semi Under Ground Reservoir (SUGR) for WDCs:

Scope of work includes construction of eight (8) Nos of SUGRs at different locations in the
entire capital city area. The details of these 8 SUGRs are given in the table below.

EGL FGL
S No WDC No Capacity (ML) Remarks
(m) (m)

1 18 1.6 33.50 33.50

2 23 1.5 40.50 41.00

3 24 1.8 29.50 30.50

4 42 1.5 33.00 33.50

5 43 1.6 39.00 39.50

6 44 0.85 40.00 41.00

7 45 1.2 32.00 32.50
8 46 1.0 31.50 32.00

The scope of work includes planning, designing, detailed engineering, drawing, construc-
tion, supply, erection, testing, commissioning, trial run, DLP for two years and operation
maintenance of the SUGRs complete with inlet, overflow and scouring arrangement. The
finished ground level of SUGRs shall be as per the table given above.
The SUGR shall be of two compartments with a facility for cleaning and maintenance of
any one compartment without resorting to any shut down of the pump house as well as
depressed sump. There shall be dividing wall between two compartments as well as de-
pressed sump and compartments. To maintain minimum dead storage within the reservoir
near the dry pit, a depressed sump at floor level shall be provided adjoining the dry pit
pump floor having floor level 1.20 m below the reservoir floor level or as prescribed by the
pump manufacturer whichever is higher. The suction pipe of designed diameter from each
individual pump along with the bell mouth shall be placed in the sump. The pipe line, the
bell mouth and puddle collar at prescribed level of the suitable size are also under the scope

62
Amaravati Development Corporation Limited

of work. The sump floor will gently dip from the reservoir floor level with 45-degree slope.
There shall not be any constriction/column in the suction sump area. One dewatering sump
of suitable size shall be provided in each compartment of reservoir for dewatering purpose
and shall be marked properly at the top of reservoir. One manhole shall be provided just
above the sump. The full water depth should be at least 4.0 m or more at the time of reser-
voir full condition. The foundation of pump house and reservoir will be of direct mud cir-
culation bored pile. The pile should have adequate strength to take tension for uplift due to
subsoil water assumed at the existing ground level when the reservoir is empty and also for
vertical loads in worst condition. The construction of pump house shall be completed earlier
to facilitate the erection work of electrical/mechanical equipment. The free board in reser-
voir shall be of 0.5 m. There shall be proper overflow arrangement and ventilation arrange-
ment in the reservoir and depressed sump. Prior approval shall be taken by the Agency for
overflow and ventilation arrangement. There shall be a park with well-designed landscap-
ing arrangement and walkway over the roof of SUGR. The roof is to be designed for a live
load of 400 Kg/m2 and a superimposed load of saturated compacted earth of 500 mm depth.
No relief shall be allowed due to this super impose load of saturated earth while computing
the uplift on the pile of SUGR. The roof slab shall be flat slab designed based on IS: 3370
and shall have minimum 300 mm projection on all sides and the parapet wall of the SUGR
roof shall be of 200 mm thick RCC. The Agency shall provide proper roof treatment and
drainage arrangement over the roof of SUGR. The site of SUGR shall be camouflaged with
surrounding landscaping. The top of SUGR roof slab shall be one meter above the finished
GL. Agency shall construct three stairs to reach top of the SUGR/Park from FGL. The
reservoir shall have 1.0m wide plinth protection along with proper overflow and storm wa-
ter drainage arrangement surrounding it. The plinth protection shall be constructed with
100 mm thick PCC (M15 grade) over single brick flat soling finished with 25 mm thick
artificial stone flooring. There shall be 3.5 m road surrounding the SUGR and pump house.
Agency shall provide proper lighting arrangement, internal storm water drainage, landscap-
ing, internal road etc. for entire WDC compound. Agency shall also provide decorated
framed boundary wall with ornamental gates made of MS angle, flat, square bar, sheet.
Agency shall provide one security cabin of size 10 sq.m at the entry gate.
The total work includes civil construction work of reservoir, pump house and pump sump
and inlet connection to the reservoir from nearby clear water trunk main. The inlet pipe of

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suitable dia given herewith shall be laid by the Agency from the pipeline already laid under
nearest road. The inlet pipeline shall be bifurcated before entering to the SUGR and enter
into two compartments. Electrical operated actuator controlled SCADA compatible valve
of same size of pipeline shall be installed on both the lines in front of the SUGR, so that
the reservoir could be completely separated/controlled as and when required.

 Pumping Stations for SUGRs at WDCs

As per the scope of work, there are eight (8) number of pumping stations at the 8 SUGRs
area. The details of these 8 pumping stations are given in the table below

Capacity
WDC No. of Discharge for
S No Remarks
No pumps each pump Head (m)
(LPS)
1 18 2W+1S 72.11 33.0
2 23 2W+1S 68.75 40.0
3 24 2W+1S 81.83 35.0
4 42 2W+1S 67.94 33.0
5 43 2W+1S 72.81 37.0
6 44 2W+1S 38.20 36.0
7 45 2W+1S 54.29 32.0
8 46 2W+1S 44.10 33.0

The scope of work includes planning, designing, detailed engineering, drawing and con-
struction, supply, erection, testing, commissioning and O&M of pumping station at each of
8 SUGRs. The work includes proper ventilation system, firefighting system in entire pump-
ing station as well as air conditioning system in the control room. The pump house at each
SUGR shall be planned for hosing 5 No (3W+2S) of VFD control pumps and motors with
same capacity specified herewith in the above table along with valves (along with electrical
actuators and SCADA compatible), piping arrangement and all other necessary equipment
and accessories. Construction of control room for VFD control panel, SCADA room, bat-
tery room, operators room, toilet and bathroom etc. are also under this scope of work. The
depth of dry pit pump house shall be compatible with the sump level of adjacent SUGR.
RCC staircase to access pump floor from MCC room shall be provided by the Agency.

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Height of the pump house building shall be minimum 5.0 m from FGL. There shall be
walkway of 1m width surrounding pump room inside the pump house.
It is proposed to install 3 (2W+1S) horizontal split case centrifugal pumps at each SUGR
directly coupled with drive motor by flexible coupling. The capacity of the electro-mechan-
ical component shall be as per the above table. The positive suction pumps shall be con-
nected to the reservoir through suction pipes of designed diameter/diameter supplied by the
manufacturer along with electrical actuator operated valves compatible with SCADA &
specials. The pumps & motors must be of continuous duty type.
The individual pump delivery pipe lines shall be connected to a common delivery manifold
of designed diameter but not less than 200 mm plus diameter of delivery pipe placed
outside the pump house 1.2 m below G.L. The individual delivery line should have a Duck
Foot bend inside the pump house. The delivery manifold shall be equipped with actuator
operated SCADA compatible Butterfly valves, electro-magnetic flow meter, flow meter
chamber, valve chamber, blank flange if necessary (details of which are given in Technical
Specification in Schedule D). The vertical portion of the delivery line shall be covered with
proper cladding as approved by the Engineer-in-Charge. All the design of the pipelines
should be such that so as to ensure streamline flow.
Apart from these, Agency shall also consider the following points:
i. The vibration & noise should be within the acceptable limit as per ISO 10816 code
(latest revision) or as per existing norms for all equipment.
ii. The dimension and centre line of pedestals for supporting the Pumps as well as the
valves should strictly be in line for both Civil & Electromechanical works.
iii. The minimum centre-to-centre distance of the pumps, clearance from the walls should
be as per CPHEEO manual and Latest relevant IS code.
iv. The clearance for installation of all H.T. & L.T. electrical equipment should be strictly
as per I.E. Rules.
v. The minimum distance from the pump impeller centre to suction sump wall is to be
maintained in such a level so that no vortex formation takes place in the entry of pump
i.e. the flow should be maintained streamlined at the entry point of pump.
vi. The elevation of pump centre line should be designed in such a manner to maintain
adequate clearance between the bell mouth and the floor of the suction sump to avoid
choke or vortex formation.

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vii. The Agency has to submit parallel operation curves for pumps & the same is to be
matched with the system resistance curve of the delivery grid. Pump selection should
be based upon that. Family curves for individual and multiple operations at all possible
consequences depending upon the variation in % opening of the PDV are to be sub-
mitted.
viii. The Agency has to consider all sluice valves, PDVs, dismantling joints in individual
pump suction & delivery pipe lines as per detail technical specification.
ix. The puddle collars are needed to be fixed into the wall for entry & exit of suction and
delivery pipelines.
x. The Agency shall work out the natural frequency analysis for the structural work and
the same shall be verified with the RPM & critical speed of the rotating equipment to
eliminate any chance of vibration to such a level so that no vortex formation takes
place in the entry of pump i.e. the flow should be maintained streamlined at the entry
point of pump.
xi. The puddle collar needs to be fixed on the suction and delivery sides inlet and outlet
on the concrete wall and are to be supplied and fixed as per specification/requirement.
xii. All the cabling work required to operate the equipment at all the WDCs has to be
considered and accordingly sizing of each LT cable has to be done. Power cables must
be 1100 V, AL, 3.5 core armored XLPE for LT loads.

The design of pump house shall be made on the basis of the Static load as prescribed and
Dynamic loading and vibration level supplied by the manufacturer that will be generated
due to operation of each pump motor set or as per relevant IS code.
The Agency, whose tender is accepted in due course will have to furnish details of the de-
sign of the pump house and sump with all levels to connect the reservoir considering all the
parameters as supplied by the pump manufacturer within the dimensions of the pumping
station provided by them for housing the pumping machinery, compact substation equip-
ment/appliances. The inlet connection will be made at a level as shown in the obligatory
data in Schedule D. The Agency shall undertake soil investigation studies of their own and
thereby formulate the design criteria for structural works which will be subject to approval
of the Engineer-in-Charge.

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 Cushion Tanks for WDCs:

The scope of work includes design, detailed engineering, construction of decorated bound-
ary wall with ornamental gates made of MS angle, flat, square bar, sheet, security cabins,
operators room & SCADA control rooms, approach road, drainage network, compound
lighting, Bypass Management System etc. in all the 51 sites of cushion tanks complete in
all respect. The agency shall also design, detail engineering and construct Cushion tanks
(ELSRs) of different capacities and staging height as given below. The specification for
ELSRs is given in Schedule D.

S No WDC No EGL FGL Capacity Staging Height

(m) (m) (KL) (m)
1 3 18.69 20.88 2000 22.0
2 11 20.67 21.81 1250 21.0
3 20 22.22 22.86 1750 23.0
4 30 19.71 20.62 2400 26.0
5 41 26.55 27.50 1850 27.0
6 59 29.41 29.40 2150 23.0
7 37 20.65 20.65 1600 22.0

The agency shall design and construct unique ELSR structure and shall have decorative
artefacts which gives pleasant look to its surroundings and resembles a signature structure
in Amaravati capital city. The contractor shall submit different types of design & elevation
of ELSRs to the EIC for approval. Each ELSR shall have different elevation and look. The
specification for ELSRs is given in Schedule D.

The Agency shall provide inlet arrangement from nearest clear water main to the cushion
tank compound, bypass management system and outlet arrangement. Agency shall provide
tee connection with electrical actuator control and SCADA compatible sluice valves and
blind flange before and after bypass management system. Outlet pipe shall be extended
from bypass management system to nearest road. Diameter of inlet pipe and outlet pipe,
tees are given below.

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Cushion Inlet pipe Material Dia of Outlet Material Dia of

tank/WDC dia Tees & pipe dia Tees &
No valves valves
1 700 DI K9 700 700 DI K7 700
2 600 DI K9 600 600 DI K7 600
3 600 DI K9 600 600 DI K7 600
4 600 DI K9 600 600 DI K7 600
5 700 DI K9 700 700 DI K7 700
6 600 DI K9 600 700 DI K7 700
7 600 DI K9 600 600 DI K7 600
8 700 DI K9 700 700 DI K7 700
10 600 DI K9 600 600 DI K7 600
11 600 DI K9 600 500 DI K7 500
12 600 DI K9 600 600 DI K7 600
14 600 DI K9 600 600 DI K7 600
15 600 DI K9 600 700 DI K7 700
16 600 DI K9 600 600 DI K7 600
17 600 DI K9 600 600 DI K7 600
19 600 DI K9 600 700 DI K7 700
20 600 DI K9 600 700 DI K7 700
21 600 DI K9 600 600 DI K7 600
22 600 DI K9 600 600 DI K7 600
25 600 DI K9 600 600 DI K7 600
26 600 DI K9 600 600 DI K7 600
27 700 DI K9 700 700 DI K7 700
28 600 DI K9 600 600 DI K7 600
29 600 DI K9 600 600 DI K7 600
30 700 DI K9 700 700 DI K7 700
31 600 DI K9 600 600 DI K7 600
32 600 DI K9 600 600 DI K7 600
33 600 DI K9 600 600 DI K7 600
34 600 DI K9 600 600 DI K7 600

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35 600 DI K9 600 600 DI K7 600

36 600 DI K9 600 600 DI K7 600
37 600 DI K9 600 600 DI K7 600
38 600 DI K9 600 600 DI K7 600
39 500 DI K9 500 500 DI K7 500
40 600 DI K9 600 600 DI K7 600
41 700 DI K9 700 700 DI K7 700
47 500 DI K9 500 500 DI K7 500
48 600 DI K9 600 600 DI K7 600
49 600 DI K9 600 700 DI K7 700
50 800 DI K9 800 800 DI K7 800
50A 800 DI K9 800 800 DI K7 800
51 600 DI K9 600 600 DI K7 600
52 700 DI K9 700 700 DI K7 700
53 600 DI K9 600 600 DI K7 600
54 600 DI K9 600 600 DI K7 600
55 700 DI K9 700 700 DI K7 700
56 700 DI K9 700 700 DI K7 700
57 600 DI K9 600 600 DI K7 600
58 700 DI K9 700 700 DI K7 700
59 700 DI K9 700 700 DI K7 700
60 700 DI K9 700 700 DI K7 700

 Laying of Clear water pumping main in WDC with SUGR

The scope of work includes laying of different diameter SWMS pipe & DI-K9 pipe from
common manifold of clear water pumping station upto nearest road and making connection
with distribution system. Details of inlet and outlet pipes are given below.
SUGR/WDC Inlet pipe Material Outlet pipe Material Remarks
No dia dia
18 600 DI K9 600 DI K7
23 600 DI K9 600 DI K7
24 600 DI K9 600 DI K7

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42 600 DI K9 600 DI K7
43 600 DI K9 600 DI K7
44 500 DI K9 500 DI K7
45 600 DI K9 600 DI K7
46 600 DI K9 500 DI K7

i. Survey, Geo-technical Investigation, Detailed Engineering of the pipeline system

based on the design principle provided by the Authority for civil structures (pipe
diameter, pipe material, valves and specifications as provided in Schedule D). For
SWMS pipes, recommended in-lining is 406-micron food grade fusion bonded
Epoxy and out-coating is 3-layer polyethylene/polyolefin.
ii. Provide detailed plans, preparation of L section, Cross Sections etc., GFC’s of pres-
surized potable pipeline system without deviating the design concept considered
and provided in Schedule D. Agency shall also provide as-built drawing indicating
all assets related to water supply in GIS format.
iii. Submission of plans, designs and engineering drawings for further approval of the
authority.
iv. Construction of Water Supply Network as per approved design and drawings
v. Loading, Unloading, Transporting and handling of DI-K9 Ductile Iron pipes and
laying of Ductile Iron Pipe and special.
vi. Supplying, fabricating, loading, unloading, transporting and handling of SWMS
pipes, specials etc.,
vii. Loading, Unloading, Transporting and handling of PLB HDPE ducts and laying of
ducts along with MS Pipes & DI-K9 pipeline and accessories for laying of OFC.
viii. Neoprene gaskets, tyton gaskets for maintaining proper alignment shall be supplied
by the Agency.
ix. Lowering, placing and laying such pipe specials, valves etc., properly in trenches,
jointing by proper neoprene gasket (Push on joint/ tyton joint etc.,), submerged arc
welding to the MS pipes including de-rusting, scraping, brushing and applying heat
shrink sleeves as per specification and hydraulic pressure testing.

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x. Supplying of all labour, tools & tackles, plants, instruments, equipment, machinery,
accessories as are needed to complete the job in the manner as specified to the entire
satisfaction of the Engineer in Charge.
xi. Construction of supporting arrangements for pipes.
xii. Construction of thrust blocks.
xiii. Earth work in excavation in trenches
xiv. Pumping out sub-soil water and water from other sources accumulated in excavated
trenches.
xv. Erection, Testing, Commissioning and O&M of the Potable Water System
xvi. Any other work related to laying of water supply pipe which is not mentioned above
shall be executed by the Agency.
xvii. The Agency shall construct the water supply pipelines for the pressurized water
supply system on continuous running basis, along with installation of scour valves,
thrust blocks and Isolation valves etc. as required.
xviii. The Agency shall supply, install, test and commission of SCADA compatible elec-
tro-magnetic flow meters of same size of outlet pipeline at proper location inside
WDC campus.
The Agency shall furnish all required tools, plant, instruments, materials including water,
electricity, labor, consumables, etc., any and everything necessary for construction of the
works, whether or not such items are specifically stated elsewhere in this bid. Size of all
valve chambers shall be considered for electrically actuated valve & compatible to SCADA
connectivity except scour and air release valves as per the valve data sheet and location
provided in drawings.

 Electrical Works
A. General:
Agency shall design and supply all electrical equipment in accordance with the Specifica-
tion, Data sheets and the enclosed Single Line Diagrams (SLD). The scope covers design,
manufacture, supply, testing at Manufacturers works, packing and forwarding, delivery to
site, inland transit insurance, unloading at site, handling and safe storage of materials at
site, installation, testing and commissioning of Electrical system/Equipment for the pro-

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posed works of Intake well cum raw water pumping station of 196MLD for Phase-I devel-
opment and future provision of 196 MLD for Phase-2 development, considering the total
capacity of the unit is 392 MLD. For the proposed works of WTP of 190 MLD for Phase-I
development and future provision of 190MLD for Phase-2 development, considering the
total capacity of the plant is 380 MLD.

B. Scope of work:
The scope of work for Intake and WTP is as follows:
i. Supply, Installation, testing and commissioning of the complete Electrical Distri-
bution System inside the plant as per Specifications, Data Sheets & Single Line
Diagram provided in Schedule D. Following electrical items shall be considered
and provided by the Agency accordingly:
a. 33KV supply from two sources
b. 33KV Ring main unit
c. 33kV Switchgear Panel
d. 6.6KV switchgear panel
e. 33/6.6kV Oil Filled Power Transformers (1W+1S).
f. 6.6/0.415kV Dry type indoor Transformers for station auxiliaries
g. 33/0.415KV CSS for WTP
h. 6.6kV Neutral Earthing Resistors
i. 6.6kV Pump Panels
j. Main LT PCC Panel
k. Pump Motors
l. Pump MCC Panels
m. Fresh air & Exhaust Panel
n. AC Panel for cabin air condition
o. Main Lighting & Power Panel DB
p. Lighting Panel for Admin Building
q. Variable Frequency Drive for Pumps (VFD)
r. Capacitor and APFCR panel to maintain Power factor greater than 0.90
s. UPS - 2 Nos with Battery Banks & Battery chargers
t. DC Distribution Board

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u. UPS DB - 1 & UPS DB - 2

The above-mentioned panels shall be SCADA compatible including all metering
and protection devices.
ii. Design, supply, installation, testing and commissioning of complete electrical dis-
tribution system as per the designed load. Provide protection tripping matrices and
tripping logics for SCADA during the design stage.
iii. Design, Supply, installation, testing and commissioning of the complete lighting
system as per technical specification mentioned in Schedule D, approved data
sheets and single line diagram including following items:
a. Indoor Lighting Fixtures with necessary accessories for Minimum Average Lux
Level of 200Lux.
b. Outdoor lighting fixtures with poles, junction boxes & necessary accessories for
Minimum Average Lux Level of 40Lux.
c. Conduiting.
d. Point Wiring.
e. Lighting Control switches.
f. Receptacle Units/Socket Outlets for Indoor & Outdoor installations.
iv. Design, Supply, installation, testing and commissioning of the complete HT & LT
cabling system as per technical specification mentioned in Schedule D, approved
data sheets & single line diagram including following items:
a. HT Power Cable & Termination kit
b. LT Power & Control cables & terminations with necessary glands & lugs.
c. Testing equipment’s for checking the healthiness of cables.
d. Cable trays and conduits.
v. Design, Supply, installation, testing and commissioning of Earthing grid system in
the proposed water-work sites like Intake well, WTP, WDCs, connection of earth-
ing leads of equipment to main grid, Transformer neutral & body earthing etc. with
necessary earthing pits, including necessary clamps, nuts, bolts, etc all including
welding, bolting and associated civil works as per layout diagram, technical speci-
fication & data sheets provided in Schedule D.
vi. Design, Supply, installation, testing and commissioning of Plant Lightning Protec-
tion in the proposed water-work sites like Intake well, WTP, WDCs, connection of

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Lightning Arrestor leads to main grid with necessary Earthing pits, including nec-
essary clamps, nuts, bolts, etc all including welding, bolting and associated civil
works as per approved layout diagram.
vii. All civil construction associated with the Electrical Works shall be in the Agency’s
scope of works as per Technical Specification mention in Schedule D.
viii. Scope of work also includes lesioning and getting approval of all Electrical instal-
lation works from the competent authority of the Govt. of Andhra Pradesh.

 Boundary Wall & Security Cabins

The Agency shall design, construct and maintain RCC framed 250 mm thick brick filled
decorated boundary wall with ornamental gates made of MS angle, flat, square bar, sheet.
Security cabins of floor space 10 sq.m shall be provided in all the water work sites like
Intake well, WTP, WDC compounds.
The height of the boundary wall shall be 1.8 m above the finished ground level. Height of
the MS gates shall be of 1.8 m. There shall be atleast two ornamental covered gates suffi-
cient to provide access to heavy vehicular trucks in Intake well & WTP compound. There
shall be at least one ornamental covered gates sufficient to provide access to heavy vehic-
ular trucks in WDC compound. The gates shall preferably be made of MS bars, flats and
plates welded together. The design of the entire work shall be submitted to the Engineer in
charge for approval. The location of the gates shall be as instructed by the Engineer in
charge. The Agency shall also provide plaster finish over both the sides of boundary wall
and two coats of decorative weather coat exterior paint on the surface of the entire boundary
wall.

 Access Roads and internal roads

The Agency shall design, make detailed engineering, construct and maintain approach
roads of not less than 6 m wide and cross roads of 4 m wide made of cement concrete with
minimum reinforcement over single brick flat soling over 400 mm thick sand filling. The
approach road shall connect the gates and all the main units, such as, clear water pump
house, annexe building, alum godown, chlorine electric storage room, chemical house,
administrative building, staff quarters, bungalows, electric substations, etc. The cross roads
shall connect the approach roads and the ancillary units. Access road to all WDCs shall be

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of 6 m wide and internal road shall be of 4 m wide. All roads shall have raised kerb &
channels with proper 1.2 m wide footpath. The approach road shall be designed for Class
A loading as per IRC. The Agency shall submit layout and design of road network to the
Engineer-in-Charge for approval. The technical specification for road development is given
in Schedule D.

 Storm Water Drains

The Agency shall design, make detailed engineering, construct and maintain storm water
drains for disposal of rain water from the compound of all water work sites like Intake well,
WTP & WDCs. The Agency shall also connect the internal drains with the city storm water
drain outside the premises at suitable location. The storm frequency shall be one in five
years. The Agency shall submit layout and design of storm water drainage network to the
Engineer-in-Charge for approval. The technical specification for storm water drainage
development is given in Schedule D.

 Site Development and Landscaping

Wherever necessary, the agency shall develop all the sites by filling with locally available
earth for installation of water supply infrastructure as per specification given in Schedule
D. The agency shall also provide RCC retaining wall wherever the filling is more than 1.0
m. The agency may consider the retaining wall as a foundation of boundary wall. The
Agency shall design, detailed engineering, provide, maintain gardening/beautification &
landscaping in the entire campus area of Intake well, WTP, over the roof of SUGRs &
WDCs. Agency shall also develop all the sites as per the EGL & FGL given in Schedule D

The Agency shall design, make detailed engineering and construct appropriate irrigation
system (combination of sprinkler and drip irrigation) for the entire landscaping/gardening
area. The Agency shall submit layout and design of landscaping to the Engineer-in-Charge
for approval. The technical specification for landscaping the area development is given in
Schedule D.

 Integration of entire water supply scheme of Amaravati capital city

The agency shall design, supply, installation of all control valves, electromagnetic flow
meters, air valves, sluice valves, butterfly valves, pressure transmitters, RMS, BMS at

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strategic locations, OFC etc. required for integration of entire water supply system of
Amaravati capital city. The agency shall undertake all necessary works for integration of
entire water supply system.

 Testing, commissioning and performance of water supply system

The scope of work includes testing of all electro-mechanical equipment like pumps &
motors, panels, transformers, UPS, SCADA as per the detailed specification given in
Schedule D. Arranging water, power, tools & tackles and other consumables is under the
Agency scope.
The scope of works also includes commissioning all electro-mechanical equipment,
demonstrate and provide the performance data as per the approved QAP and data sheet.

 Operation & Maintenance (O&M)

The scope of work includes testing, commissioning, trial run of 3 months, DLP for 2 years
and O&M for 8 years period.
After the water supply system is deemed to be ready and to be put into normal use, the
Agency shall provide commissioning procedure document, O&M manual and accordingly
they shall operate and maintain the system for a period of three months trial run, thereafter
2 years of DLP and thereafter 8 years of O&M by engaging his own personnel under the
overall supervision of the Agency. The agency shall provide biometric attendance system
for all staff at all installations i.e. Intake well cum pump house, WTP, WDCs, Admin
building, Clear water pump house created under this scope of work. The specification for
biometric system has provided in Schedule D. Biometric system will be connected with
SCADA for attendance report generation. All consumables, tools and tackles, spares and
all other necessary stores required for the operation of the water supply system shall be
supplied by the Agency at his cost. The Employer shall bear the cost of electrical charges
to the extent it is required. During the aforesaid period of operation of the water supply
system, the Agency’s supervisory staffs shall train and instruct technicians and other staffs
to be deputed by the Employer about the correct method of operation and maintenance of
the water supply system as a whole and its various mechanical and electrical components.
The training shall be such as would enable the Employer's staffs to take over the water

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supply system from the Agency for its operation and maintenance independently. The
Agency’s training personnel shall give special attention to this.
During the period of operation and maintenance, the Agency shall arrange to take regular
samples as given here above/as directed by the Engineer-in-Charge and shall have such
samples tested at Agency’s cost in the WTP laboratory or any other laboratory nominated
by the Engineer-in-Charge, to determine the quality of the samples and the performance of
the water supply system. Such tests shall be continued upto the penultimate week prior to
the end of the O&M period and the water supply system shall be taken over by the
Employer subject to the final performance tests being certified as satisfactory by the
Engineer-in-Charge. O&M includes carrying necessary repairs of all equipment and
machineries to meet the original specifications, replacement of any component, required
for smooth running of the system etc. including breakdown maintenance, preventive
maintenance, predictive maintenance and conditional monitoring. Supply of minimum
inventory spare is under this scope of work. The detailed specifications of O&M are given
in Schedule D.
The tenderers shall submit with their offer a list of technical and non-technical staffs they
propose to engage for operation and maintenances of the water supply system for ten years
including two years of DLP.

 Handing over of water supply system of Amaravati Capital City

The agency shall handover the entire water supply system in good working condition after
completion of 10 years O&M period including 2 years DLP to the authority. All electro-
mechanical equipment shall be in good working condition at the time of handing over to
the authority. All laboratory instruments shall function properly at the time of handover.
Control Command Centre (C3), Instrumentation & SCADA of entire system shall be
functionally fully automated condition without any fault while handing over to the
authority. There shall be no sign of leakages in the entire pipeline and water retaining
structures of the water supply system. The agency shall maintain and handover minimum
spares and consumables (Alum, PAC, chlorine, oil & lubricants etc.) for 3 months usage.
The agency shall maintain sufficient quantity of laboratory chemicals for 3 months usage
at the time of handing over. The agency shall maintain stock register and handed over to
EIC for physical verification. The condition monitoring of major electromechanical

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equipment like pumps and motors, blowers, compressor, VFD, MCC panels etc. has to be
done by the agency and vetted by the 3rd party before handing over to the authority for
submission to the EIC. All instruments with valid calibration certificate has to be submitted
at the time of hand over. There shall not be any sign of splashing of concrete, worn out of
plaster and/or damage to any civil structures while handing over. The Engineer-in-Charge
shall inspect all electro-mechanical, instrumentation as well as civil installations and verify
stock registers for his satisfaction prior to taking over the water supply system from the
agency. Decision of EIC regarding non-functionality of any electromechanical,
instrumentation and civil installations is final and binding by the agency.

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Appendix B-III(b) – Pipeline Network

Potable Water Supply Network
General

Water supply system is planned for the Amaravati capital city on continuous water supply
(24x7) to meet the water demand of the projected population and other civic services by the
year 2050. For the greenfield city, projected population of 38,33,120 is arrived based on the
proposed Land Use Plan and Floor Space Index (FSI) method. Water demand of 931 MLD by
the horizon year 2050 is estimated by adopting unit norms of water supply for various service
categories, recommended by CPHEEO. Source of water supply is Krishna river near Undavalli
for Phase-I and Proposed Vaikuntapuram barrage for Phase-II.

Scope of Work
As part of the proposed water supply scheme for Amaravati capital city, the following
works are needed to be executed in this project.
The scope of work includes construction of water supply pipe lines with appurtenances
and civil works required along the Roads. In general, this work shall include supply, low-
ering, laying, jointing and testing of all MS, DI (K7 and K9) pipes, specials, appurte-
nances, PLB HDPE duct and civil structures required for the water supply network along
the roads.

The Scope of Work shall include:

 Survey, Geo-technical Investigation, Detailed Engineering of the pipe line system based on
the design principle provided by the authority for civil structures (the pipe diameter, pipe
material, valves and specifications is provided below)

 Provide Detailed plans, Preparation of L section, Cross Sections etc., GFC’s of pressurized
potable system without deviating the design concept considered and details given below.
Contractor shall also provide as built drawing indicating all assets related to water supply
in GIS format.

 Submission of plans, designs and engineering drawings for further approval of the author-
ity.
 Construction of Water Supply Network as per approved design and drawings
 Loading, Unloading, Transporting and handling of Ductile Iron pipes and laying of
Ductile Iron Pipe and special.

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 Supplying, fabricating, loading, unloading, transporting and handling of Mild Steel

pipes, specials etc.,
 Loading, Unloading, Transporting and handling of PLB HDPE ducts and laying of
ducts along with MS & DI K9 Pipes and accessories for laying of OFC.
 Tyton gaskets, DI specials required for maintaining proper alignment shall be supplied
by the contractor.
 Lowering, placing and laying such pipe specials, valves etc., properly in trenches,
jointing by proper rubber gasket (Push on joint/ tyton joint etc.,), submerged arc weld-
ing to the MS pipes including derusting, scraping, brushing and applying heat shrink
sleeves as per specification and hydraulic pressure testing.
 Installing the pipe at RCC box section/Utility duct in bridges. Design and detailed
engineering of saddle for pipe support at RCC box section in bridges shall be submitted
for EIC approval before proceeding to work.
 Supplying of all labour, tools & tacklets, plants, instruments, equipment, machinery,
accessories as are needed to complete the job in the manner as specified to the entire
satisfaction of the Engineer-In-Charge.
 Construction of supporting arrangements for pipes.
 Construction of thrust blocks.
 Earth work in excavation in trenches
 Pumping out sub-soil water and water from other sources accumulated in excavated
trenches.
 Erection, Testing, Commissioning of the Potable Water System
 Any other work related to laying of water supply pipe which is not mentioned above
has to be executed by the contractor.

The contractor shall construct the water supply pipelines for the pressurized water sup-
ply system on continuous running basis, along with installation of scour valves, thrust
blocks and construction of valve chambers for TCMS (Tapping control management
system) and Isolation valves etc. as required.

The Contractor shall furnish all required tools, plant, instruments, materials including
water, electricity, labor, consumables, etc., any and everything necessary for construc-
tion of the works, whether or not such items are specifically stated elsewhere in this

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bid. Size of all valve chambers shall be considered for electrically actuated valve &
compatible to SCADA connectivity except scour and air release valves as per the valve
data sheet and location provided in drawings.

1.0 Details of Pipe lines in E3 Road

This contract package includes providing, laying, jointing, testing and commissioning
of water supply pipe lines of various diameters as provided in Table-1 for roads includ-
ing appurtenances and construction of Valve chambers and allied works.
Table-1 Water Supply Network details in E3 Road

Road Nomenclature E3
Pipe Material
Diameter of Pipe (mm) Diameter wise Length (m)
2400 MS / 20mm 1125.0
2000 MS / 16mm 5974.0
1900 MS / 16mm 4742.0
800 DI K9 2814.0
600 DI K9 3032.0

2.0 Encasing at Road Crossings

Encasing is proposed for pipe lines under the carriage way of the road and storm water
drains for E3 road. The details are provided in Table-2 as well as in the drawings:

Table-2 Road wise Water Supply Pipes with Encasing details for Road
Remarks
Road Nomenclature E3
Pipe Material
Diameter wise
Diameter of Pipe (mm)
Length (m)
MS pipe encasing with
2500 MS / 20mm 58.25
HDD
1900 MS / 16mm 60 RCC encasing
25 (Karakatta MS pipe encasing with
1900 MS / 16mm
bund crossing) HDD
MS pipe encasing with
1500 MS / 14mm 58.25
HDD
MS pipe encasing with
800 DI K9 58.25
HDD
MS pipe encasing with
700 DI K9 58.25
HDD
600 DI K9 58.25 RCC encasing

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MS pipe encasing with

600 DI K9 58.25
HDD
MS pipe encasing with
300 DI K9 58.25
HDD
MS pipe encasing with
500 DI K7 60
HDD
MS pipe encasing with
450 DI K7 60
HDD
MS pipe encasing with
400 DI K7 60
HDD

3.0 Pipe Material

The type of pipe shall be MS pipe above 1000mm and DI K9 / DI K7 class pipes for
diameter upto 1000mm. The details of DI K7 & DI K9 locations are provided in Table-
1. The type of pipe shall be MS, DI K9 for water supply trunk network and DI K7 for
water supply distribution network.

4.0 Pipe Cover

The pipeline shall be buried with minimum cover of 1.20 m from Finished Road Level
(FRL), however pipeline shall be laid as per detailed Engineering approved by Engineer
In-charge. In case of required cover is more than 1.20 m at different locations, contrac-
tor has to lay the pipeline accordingly as directed by the Engineer in Charge.

No pipe shall be laid in position until the bedding/foundation has been approved by the
Engineer in charge. If two or more pipes are to be laid adjacent to each other, they shall
be separated by a distance equal to at least half the diameter of the pipe subject to a
minimum of 450mm.

5.0 Specials
MS Pipes: All Specials, such as tees, Y-pieces, bends (single or composite), tapers, etc.
shall necessarily be fabricated at site from same pipe sections used in straight reach and
shall be manufactured as per standards and tested and laid in the same manner as the
pipes.

DI Pipes: All types of DI fittings shall be manufactured and tested in accordance with
IS: 9523.
 flanged socket
 flanged spigot
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 double socket bends (900, 450, 22.500, 11.250)

 double socket branch flanged tee
 all socket tee
 double socket taper
 blind flange/dummy flange
The road wise specials/fittings for E3 road are given in Table-3.
Table-3 Road wise Specials/Fittings details for Road
DI Specials/Fittings E3
DI Pipe Bends Number
22.50o
150 -
250 -
300 4
350 -
400 4
450 4
500 2
600 22
700 -
800 11
900 -
45o
150 -
250 -
300 -
350 -
400 -
450 -
500 -
600 4
700 -
800 6
900 -
90o
150 -
200 -
250 -
300 -
350 -
400 1
450 -
500 -
600 4

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DI Specials/Fittings E3
700 -
800 3
MS Bends
22.50o
1600 -
1900 27
2000 24
2500 2
45o
2500 -
90o
2400 1
DI Tees
200 x 200 x 200 -
300 X 300 X 300 -
350 X 350 X 350 -
400 X 400X 400 -
500 x 500 x 500 -
600 x 600 x 600 -
800 x 800 x 600 -
800 x 800 x 800 1
900 x 900 x 900 -
DI Reducers
200x150 -
250x200 -
450x150 -
450x250 -
450x350 -
450x400 -
300x200 -
350x150 -
350x200 -
350x300 -
400x200 -
400x300 -
500x150 -
500x250 -
500x300 -
500x350 -
500x450 -
600x300 -
600x350 -
600X400 -
600x450 -
600x500 -
800x600 1

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DI Specials/Fittings E3
800x700 1
900x700 -
MS Tees
2400x2400x1900 -
MS Tapers
2400x1900 -

Note: Specials to be considered as per requirement based on the design subjective to the mini-
mum numbers defined above.

6.0 Permanent lubricant based HDPE Duct (PLB)

For laying of the fibre optic cable, 1 No. of PLB HDPE Ducts of 40 mm (OD) / 33 mm
size all along the length of MS & DI K9 pipe line with required accessories with appro-
priate spacing approved by Engineer-in-Charge.

7.0 Civil Structures

Design and Construction of Thrust Blocks at bends and Valve Chambers to house iso-
lation valves, scour valves and Tapping Control Management System as per the loca-
tions provided in the GAD. All the structures related to water supply pipe line i.e., valve
chambers, thrust blocks are to be designed considering the ground water table at ground
level with M25 grade concrete. The design and drawings shall be submitted to the En-
gineer-in-Charge for approval.

8.0 Cross Drainage Structures (If any as per the table below)
Water supply pipe lines crossing the canals/vagus are categorized into two types. Pipe
lines of sizes 1000mm and below are to be in the utility ducts provision on the east side
of the road bridge as shown in the drawings. Pipe lines of sizes above 1000mm diameter
are to be provided with a separate pipe carrying bridge and as per the GA drawings. The
material of water supply pipe line is MS in both utility ducts and pipe carrying bridges.
PLB HDPE duct runs along with the MS Pipe in both utility ducts and pipe carrying
bridges. The details of canal crossing are given in the table below:

Road Length of Dia of

Road
S. No Canal Chainage Crossing Pipe Type of Crossing
Nomenclature
(m) (m) (mm)

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1 Pala Vagu 3950 105.00 2000 mm Pipe carrying Bridge

3 E3 Canal 8740 42 1900 mm Pipe carrying Bridge

Konda- Utility Duct provided

4 18290 175.00 800 mm
veeti Vagu in Road bridge

9.0 Backfilling
The space around the foundations in trenches or sites shall be cleared of all trash and
loose debris. After laying of pipe lines on 150mm thick sand bedding, the pipe lines
shall be covered with 300mm sand filling and the rest filled with approved earth (all
clods being broken up to the finished G.L.) as per the instructions of the Engineer-in-
charge.

10.0 As Built Drawings

The Contractor shall submit “As Built” drawings to the Engineer-in-charge; these
Drawings shall be accurate and correct in all respects and shall be shown to and ap-
proved by the Engineer-in-Charge. The completion drawings shall be grouped into two
categories (i.e.) Plan and L-section to be submitted both in Auto cad and GIS format.

 Plan with scale 1:1000 (A1 Size) showing the roads along with other details such
as property width, storm water drains, footpaths, location of electrical / telephone
poles along with all the dimensions wherever possible shall be prepared. The type
of road, footpath details etc., shall be further elaborated in terms of their dimensions
and material used. Finally, exact alignment of water supply line and appurtenances,
alignment shall be marked on the plan. Nomenclature of network shall be same as
given in the network design drawing furnished to the Contractor during execution.

 L-Section & Cross Section: The L-Section should show the water supply profile,
bends and appurtenances ie., Air valve, Scour valve, Isolation valve details (X, Y, Z
Coordinates), PLB HDPE duct profile. Cross Section of the pipe line shall be pro-
vided at an interval of 500m and also at junctions. The other details such as ground
level, pipe invert level, pipe cover, pipe material, diameter, hydraulic gradient line
(as per data provided by authority), chainages, etc. shall be shown in the L-section.

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The scale for L-section shall be decided as per the directions of Engineer-in-Charge.
Also, plan of the water supply line with roads of concerned length and other im-
portant feature should be shown above the L-section profile along with all utility
services encountered during execution.

 Pressure testing

After laying/installation of the pipe, pipe network need to be tested as per the spec-
ifications given in Schedule-D. After successful completion of erection, testing and
commissioning, entire pipe network to be hand over to main contractor of WTP
system (Head Works)

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Appendix B-III(c) – Valves & Integration of entire Water Supply System

Potable Water Supply Network

Scope of Work
As part of the proposed water supply scheme for Amaravati capital city, the following
works are needed to be executed in this project.
The scope of work includes installation, testing and commissioning of required Valves
and civil works required along the E3 Road and also Valves along the other Roads for
entire Water Supply System. The scope of work also includes integration of entire water
supply system starting from Intake well to WDCs of Amaravati capital city for smooth
operation and maintenance of the entire system. It includes integration of Instrumenta-
tion & Control through SCADA for the entire water supply system. The agency shall
also construct RCC valve chambers & RCC chambers for electromagnetic flow meters
where ever necessary.
The agency shall provide QAP, Data Sheets and Detailed drawings for Engineer in
charge approval. Supply, delivery and installation of valves properly in valve chambers
already constructed and integrating the valves with SCADA as per approved design and
drawings. The agency shall provide shop testing & in-situ testing of valves as per spec-
ification.

The Contractor shall furnish all required tools, plant, instruments, materials including
water, electricity, labor, consumables, etc., any and everything necessary for construc-
tion of the works, whether or not such items are specifically stated elsewhere in this bid.
Size of all valve chambers shall be considering for electrically actuated valve & com-
patible to SCADA connectivity except scour and air release valves as per the valve data
sheet and location provided in drawings.

Appurtenances

The minimum requirements for the provision of valves are given below. Prior to the
procurement of valves, the agency shall obtain the Engineer in charge approval for the
materials to be used as per specified MoC and types of Valves. General applicable
Standards to be applied to the works under this Section shall be Indian Standards and
British Standards or other approved International Standard.

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Isolation Valves
In Water Supply Pipe lines, Isolation valves are provided as line valves or sectionalizing
valves to divide the pipe line into suitable sections so that in the event of damage or
defect in the pipe line or for providing new fixture etc.

In Isolation valves, Sluice valves and Butterfly valves are generally used. In this project,
Sluice valves are provided where there is a requirement for control of flow upto 1200
mm dia and for isolation upto 600 mm dia. Butterfly valves are provided for isolation
of pipelines above 600mm dia. All the valves are provided with SCADA compatible
Electric Actuators and shall be controlled through SCADA. There shall also be provi-
sion for local operation of the valves.

Table-1 Isolation valve details in E3 Road

Road Nomen- Size of Valve

Type of Valve Quantity
clature (mm)
600 Sluice Valve 2
E3 1900 Butterfly Valve 4
2000 Butterfly Valve 4

Table-2 Isolation valve details in other Roads

Road No- Size of Valve

Type of Valve Quantity
menclature (mm)
N14 600 Sluice Valve 1
N9 1900 Butterfly Valve 5
600 Sluice Valve 3
E8 500 Sluice Valve 1
1900 Butterfly Valve 1
1900 Butterfly Valve 1
800 Butterfly Valve 1
E10
700 Sluice Valve 1
600 Sluice Valve 1
1500 Butterfly Valve 2
E14
600 Sluice Valve 1
2000 Butterfly Valve 1
E6 700 Sluice Valve 1
600 Sluice Valve 2

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E12 600 Sluice Valve 2

600 Sluice Valve 2
E4 1900 Butterfly Valve 1
2400 Butterfly Valve 1
700 Sluice Valve 1
E15 800 Butterfly Valve 1
1100 Butterfly Valve 1
500 Sluice Valve 1
E9 800 Butterfly Valve 1
1600 Butterfly Valve 3
N10 600 Sluice Valve 1
1800 Butterfly Valve 1
N15
2000 Butterfly Valve 2
700 Sluice Valve 1
N6
1900 Butterfly Valve 3

Air Valves
In pressure pipe lines, Air valves are used to protect the pipe line by filling air during
draining, venting air during filling and Continues venting of entrapped air during opera-
tion. Details are given in table below:

Table-3 Air valve details in E3 Road

Number of
Size of Air Valve (mm)
Valves
200 20
100 10

Table-4 Air valve details in other Roads

Road Nomenclature Size of Valve Quantity
(mm)
N14 100 2
N9 200 17
N4 100 1
100 9
E8
200 1
100 5
E10
200 1
200 5
E14
150 1
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100 3
100 12
E6
150 1
E12 100 1
100 4
E4
200 6
100 1
E15
150 1
N1 100 5
N18 100 2
N2 200 1
E1 200 1
100 7
E9 150 1
200 11
N8 100 1
N15 200 14
E5 100 1
100 2
N6
200 16

Scour Valves

In pressure pipe lines, scour valves are provided at low points above line valves situated
in the line on a slope such that each section of the line between valves can be emptied
into a natural or storm water drainage channel. Details are given in table below:

Table-4 Scour valve details in E3 Road

Number of
Size of Scour Valve (mm)
Valves
600 1
500 4
200 1
150 1

Note: Valves to be considered as per requirement based on the design subjective to the
minimum numbers defined above.

Control Valves

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Control Valves at TCMS are provided at Tapping points on Ring main at specified loca-
tions mentioned and located in the drawing. These are provided with Electrically Actuated
Sluice valve, Electromagnetic Flow meter and Pressure transmitter with SCADA connec-
tivity. These are to be provided with Valve chambers.
Road Control Valve (TCMS) Quantity
Nomenclature Size (mm)
E3 800 2
E10 900 1
1100 1
E15
800 1
E14 1100 1
E6 800 1
E12 800 1
N7 800 1
800 5
N15
900 1
900 1
E9
1000 1

Electromagnetic Flow Meters

Electromagnetic flow meters are to be provided at all the locations of TCMS with electri-
cally actuated Scada compatible sluice valve, all WDC locations near Reservoir manage-
ment system for SUGRs and near Bypass management system at Cushion tank location.
These are to be provided with necessary protection of valve chambers.

Integration of Entire Water Supply System

The agency has to integrate the entire water supply system from Intake well (source) to
WDC integrating all components i.e., Headworks, Pipe lines in E3 road as well as pipe-
lines constructed in other roads, appurtenances etc., to operate and maintain the entire
water supply system for 2 years DDLP and 8 years ADLP.

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Appendix-B IV
Recycled Water Supply Network

General
Reuse water supply system is planned for the Amaravati capital city on recycled reuse
water supply to meet the water demand of the projected green spaces and District
Cooling application by the year 2050, for the greenfield city. The entire capital city area
is divided into 13 sewerage zones with 12 STP’s and 1 CETP for industrial area. Source
of reuse water supply is from the STP/CETP serving with in the respective sewerage
zone through pumping with Reuse water supply pumping and reservoir system located
within the STP of the respective zone. Reuse water supply network comprises of a
Trunk network followed by distribution network running on either side of the entire
road network under the green zone or multi-function zones further connected to drip
irrigation laterals.
Scope of Work
As part of the proposed reuse water supply scheme for Amaravati capital city, the fol-
lowing works are needed to be executed in this project.
The scope of work includes construction of reuse water supply pipe lines with appurte-
nances and civil works required along the Roads. In general, this work shall include
supply, lowering, laying, jointing and testing of all DI (K7) and HDPE (PE100 PN10)
pipes, specials, appurtenances, and civil structures required for the reuse water supply
network along the roads.

The Scope of Work shall include:

 Survey, Geo-technical Investigation, Detailed Engineering of the pipe line system

based on the design principle provided by the authority for civil structures (the pipe
diameter, pipe material, valves and specifications is provided in Tables-1, 2, 3, 4, 5
& 6 of this section.

 Provide Detailed plans, Preparation of L section, Cross Sections etc., GFC’s of pres-
surized treated reuse water system without deviating the design concept considered
and details given below need to be submitted for EIC approval before installation.
Contractor shall also provide as built drawing indicating all assets related to reuse
water supply in GIS format.

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 Submission of plans, designs, and engineering drawings for further approval of the
authority.

 Construction of Reuse Water Supply Network as per approved design and drawings

 Loading, Unloading, Transporting and handling of Ductile Iron pipes and laying
of Ductile Iron Pipe and special.
 Supplying, fabricating, loading, unloading, transporting and handling of HPDE
pipes, specials etc.,
 Tyton gaskets, DI specials required for maintaining proper alignment shall be
supplied by the contractor.
 Lowering, placing and laying such pipe specials, valves and air valves etc.,
properly in trenches, jointing by proper rubber gasket (Push on joint/ tyton joint
etc.,).
 Supplying of all labor, tools & tacklets, plants, instruments, equipment, machin-
ery, accessories as are needed to complete the job in the manner as specified to
the entire satisfaction of the Engineer-In-Charge.
 Construction of supporting arrangements for pipes.
 Construction of thrust blocks.
 Earth work in excavation in trenches
 Pumping out sub-soil water and water from other sources accumulated in exca-
vated trenches.
 Erection, Testing, Commissioning of the Reuse Water System.
 Any other work related to laying of reuse pipe which is not mentioned above
has to be executed by the contractor.

The contractor shall construct the reuse water supply pipelines for the pressurized water
supply system on continuous running basis, along with installation of scour valves,
thrust blocks and construction of valve chambers air valves and Isolation valves etc. as
per the Drawings.

The Contractor shall furnish all required tools, plant, instruments, materials including
water, electricity, labor, consumables, etc., any and everything necessary for construc-
tion of the works, whether such items are specifically stated elsewhere in this bid. The
valve shall be a butterfly valve manually operated and also be compatible for motorized
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operation. Size of all valve chambers shall be considering for electrically actuated valve
& compatible to hSCADA connectivity except scour and air release valves as per the
valve data sheet and location provided in drawings.

1.0 Details of Pipe lines in E3 Road

This contract package includes providing, laying, jointing, testing and commissioning
of reuse water supply pipe lines of various diameters as provided in Table-1 for E3 road
including appurtenances and construction of Valve chambers and allied works.

Table-1 Reuse Water Supply Network pipe details in E3 Road

Road Nomenclature E3
DI-K7 REUSE TRUNK NETWORK
Diameter(mm) Dia. Wise Length in (m)
TRUNK-150 0
TRUNK-200 0
TRUNK-250 69.072
TRUNK-300 0
TRUNK-350 0
TRUNK-400 421.077
TRUNK-450 996.437
TRUNK-500 1104.997
TRUNK-600 149.171
Sub-Total 2740.754

Road Nomenclature E3
HDPE-PE100-PN10 REUSE DISTRIBUTION NETWORK
Diameter(mm) Dia. Wise Length in (m)
DISTRIBUTION -50 13769.884
DISTRIBUTION-75 6828.52
Sub-Total 20598.4

Road Nomenclature E3
DI-K7 REUSE DISTRIBUTION NETWORK
Diameter(mm) Dia. Wise Length in (m)
DISTRIBUTION-100 3527.666

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DISTRIBUTION-150 1294.647
DISTRIBUTION-200 599.605
DISTRIBUTION-250 0
DISTRIBUTION-300 0
DISTRIBUTION-350 0
DISTRIBUTION-400 0
Sub-Total 5421.918
Total Length in (m) 28761.08
Total Length in (km) 28.76

2.0 MS Encasing Pipe at Road Crossings

MS encasing pipe is proposed for pipe lines under the carriage way of the road and
storm water drains. The details are provided in Table-2 as well as in the drawings.

Table-2 Reuse Water Supply Network MS Encasing Pipe details in E3 Road

Road Nomenclature E3
MS Pipe ENCASING Length
Diameter(mm)
Dia. Wise Length in (m)
TRUNK-150 0
TRUNK-200 0
TRUNK-250 0
TRUNK-300 0
TRUNK-350 0
TRUNK-400 105
TRUNK-450 0
TRUNK-500 0
TRUNK-600 35
DISTRIBUTION-50 140
DISTRIBUTION-75 35
DISTRIBUTION-100 210
DISTRIBUTION-150 70
DISTRIBUTION-200 140
DISTRIBUTION-250 0
DISTRIBUTION-300 0
DISTRIBUTION-350 0

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Road Nomenclature E3
DISTRIBUTION-400 0
Total Length in (m) 735
Total Length in (km) 0.735

3.0 Pipe Material

The type of pipe shall be DI K7 class pipes for 100mm & above and HDPE-PE100-
PN10 class pipes for diameter below 100mm. The type of pipe shall be DI K7 for reuse
water supply trunk network and DI K7/ HDPE-PE100-PN10 for reuse water supply
distribution network. The details of DI K7 & HDPE pipes are provided in Table-1.

4.0 Pipe Cover

The pipeline shall be buried with minimum cover of 1.00 m at top, however pipeline
shall be laid as per detailed Engineering approved by Engineer In-charge. In case of
required cover is more than 1.00 m at different locations, contractor has to lay the pipe-
line accordingly as directed by the Engineer in Charge.

No pipe shall be laid in position until the foundation has been approved by the Engineer
in charge. If two or more pipes are to be laid adjacent to each other, they shall be sepa-
rated by a distance equal to at least half the diameter of the pipe subject to a minimum
of 450mm.

5.0 Specials
DI Pipes: All types of DI fittings shall be manufactured and tested in accordance with
IS: 9523.

 flanged socket

 flanged spigot

 double socket bends (900, 450, 22.500, 11.250)

 double socket branch flanged tee

 all socket tees

 double socket taper

 blind flange/dummy flange

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HDPE Pipes: Laying and jointing of HDPE pipes and fittings by butt fusion welding as
per IS:7634-Part-II/1975 as amended from time to time to the alignment and gradient and
testing the pipe line to the required pressure.

The road wise specials/fittings for roads are given in Table-3.

Table-3 Reuse Water road wise Specials/fittings details for E3 Road
Road Nomenclature E3
DI-PIPE DI Pipe Bends 22.6
Diameter(mm) Road wise numbers of units
100 0
150 0
200 0
250 0
300 0
350 0
400 0
450 0
500 0
600 0
Total 0
DI-PIPE DI Pipe Bends 45
Diameter(mm) Road wise numbers of units
50 4
100 0
200 0
300 0
450 4
500 4
Total 12
DI-PIPE DI Pipe Bends 90
Diameter(mm) Road wise numbers of units
50 1
100 1
200 0
300 0
400 0
450 0
500 1

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600 0
Total 3
DI-PIPE DI Pipe TEEs
Diameter(mm) Road wise numbers of units
50X50X50 9
100X100X100 6
150X150X150 3
200X200X200 2
50X50X100 1
75X75X50 9
75X75X100 1
100X100X50 8
150X150X50 2
150X150X75 3
150X150X100 3
200X200X50 2
200X200X100 1
450X450X250 1
500X500X300 1
Total 52
DI-PIPE DI Pipe Reducers
Diameter(mm) Road wise numbers of units
75X50 6
100X50 6
100X75 3
150X50 2
150X100 2
200X50 1
200X100 2
450X400 1
500X450 1
Total 24

Note: Valves and specials to be considered as per requirement based on the design subjective
to the minimum numbers defined above.

6.0 Appurtenances
The minimum requirements for the provision of valves are given below. Prior to the
procurement of valves, the Contractor shall obtain the Engineer in charge’s approval

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for the materials to be used as per Specified MoC and types of Valves. General
applicable Standards to be applied to the Works under this Section shall be Indian
Standards and British Standards or other approved International Standard.

6.1 Scour Valves

In pressure pipe lines, scour valves are provided at low points above line valves situated
in the line on a slope such that each section of the line between valves can be emptied
into a natural or storm water drainage channel.

Scour valve arrangement of sizes 150mm to 600mm.

Table-4 Scour valve details in E3 Roads

Road Nomenclature E3
DI-PIPE Scour Valves DI-Pipes
Diameter(mm) Road wise numbers of units
100 0
250 0
400 1
450 1
Total 2

6.2 Air valve

Air valves are considered on the pipeline at suitable location. Air valves is necessary
for effective working of system as the chock air will leads to water hammer and less
flow. Air valves of sizes 100mm to 250mm.

Table-5 Air valve details for E3 Road

Road Nomenclature E3
DI-PIPE Air Valves DI-Pipes
Diameter(mm) Road wise numbers of units
200 0
300 0
400 1
450 1
Total 2

6.3 Butterfly Valve

Supply, Installation, and Commissioning of butterfly valves which should be able to
control and isolate the flow as per demand to facilitate uniform distribution of reuse

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water to serve the green spaces. The butterfly valve should be as per the specifications
defined in schedule D.

Table-6 Butterfly valve details in E3 Road

Road Nomenclature E3
DI RWMS-Numbers
TRUNK-200 0
TRUNK-250 0
TRUNK-300 0
Sub-Total 0

7.0 Civil Structures

Design and Construction of Thrust Blocks at bends and Valve Chambers to house iso-
lation valves, scour valves, air valves and butterfly valves as per the locations provided
in the GAD with M25 grade concrete. The design and drawings shall be submitted to
the Engineer-in-Charge for approval.

8.0 Backfilling
The space around the foundations in trenches or sites shall be cleared of all trash and
loose debris. After laying of pipe lines on 150mm thick sand bedding, the pipe lines
shall be covered with 300mm sand filling and the rest filled with approved earth (all
clods being broken up to the finished G.L.) as per the instructions of the Engineer-in-
charge.

9.0 As Built Drawings

The Contractor shall submit “As Built” drawings to the Engineer-in-charge; these
Drawings shall be accurate and correct in all respects and shall be shown to and ap-
proved by the Engineer-in-Charge. The completion drawings shall be grouped into two
categories (i.e.) Plan and L-section to be submitted both in Auto cad and GIS format.

 Plan with scale 1:1000 (A1 Size) showing the roads along with other details such
as property width, storm water drains, footpaths, location of electrical / telephone
poles along with all the dimensions wherever possible shall be prepared. The type
of road, footpath details etc., shall be further elaborated in terms of their dimensions
and material used. Finally, exact alignment of water supply line and appurtenances,

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alignment shall be marked on the plan. Nomenclature of network shall be same as

given in the network design drawing furnished to the Contractor during execution.

 L-Section & Cross Section: The L-Section should show the water supply profile,
bends and appurtenances i.e., Air valve, Scour valve, Isolation valve details (X, Y,
Z Coordinates), PLB HDPE duct profile. Cross Section of the pipe line shall be
provided at an interval of 500m and also at junctions. The other details such as
ground level, pipe invert level, pipe cover, pipe material, diameter, hydraulic gradi-
ent line (as per data provided by authority), chainages, etc. shall be shown in the L-
section. The scale for L-section shall be decided as per the directions of Engineer-
in-Charge. Also, plan of the water supply line with roads of concerned length and
other important feature should be shown above the L-section profile along with all
utility services encountered during execution.

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Appendix- B V
Domestic Sewerage Collection Network

1. General

Waste water system for Amaravati capital city will cover entire 217.23 sq.km area with
100% collection, conveyance and safe disposal. Waste water generation of 600 MLD
by the horizon year 2050 is estimated by adopting unit norms of waste water for various
service categories, recommended by CPHEEO. Decentralized sewerage system is pro-
posed in tune with topography, land use and development plans, accordingly ,12 STPS
and 1 CETP proposed for Amaravati Capital city area. Treated wastewater shall dis-
charged (after recycle & reuse) into navigational canals after meeting discharge stand-
ards.

Scope of Work
The scope of work includes, but not limited to, providing sewerage collection system
including Gravity network pipe lines and Manholes required in Package Road. In gen-
eral, this work shall include supply, lowering, laying, jointing and testing of all DWC-
HDPE, , Inner HAC lined DI K7 & K9 pipes with outer polyethylene sleeves, Inner
HAC lined RCC NP4 pipes for gravity network and HAC lined DI K9 pipes for pump-
ing mains and Precast RCC manholes required for the sewerage collection network in
the road. The work should be executed as per the details given in the drawing and the
detailed scope of works includes:
 Survey, Geo-technical Investigation, Detailed Engineering of the pipe line system
based on the design principle provided by the authority for civil structures (the pipe
diameter, pipe material and specifications is provided below)

 Provide Detailed plans, Preparation of L section, Cross Sections etc., GFC’s of

wastewater pipe network without deviating the details given below. Contractor shall
also provide as built drawing indicating all assets related to waste water in GIS
format.

 Submission of Network plans, structural designs & engineering drawings of man-

holes for further approval of the authority.

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2. Design Period
Sewerage projects are designed to meet the future requirement of a stipulated design
period. The design period considered for Sewer Network system is 30 years.

3. Details of Sewerage Network in Package-XV Road

This contract package includes providing, laying, jointing, testing and commissioning
of Sewerage collection pipe lines of various diameters in the above-mentioned roads
as per the details furnished in the Table-1.
Table-1 Sewerage Collection Network details
Road Nomenclature E3
DWC HDPE Dia. Wise Length in (m)
200 2074
250 0
300 430
400 65
490 0
Sub-Total 2569

Road Nomenclature E3
DI K7 & K9 Dia. Wise Length in (m)
600 0
700 611
800 0
900 149
1000 0
1100 20
1200 1922
Sub-Total 2702

Road Nomenclature E3
RCC NP4 Dia. Wise Length in (m)
1400 0
1600 1298
1800 3106
Sub-Total 4404
Total Length in (m) 9675.0
Total Length in (km) 9.675
* Length means effective network length excluding manholes

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4. Details of Sewer Manholes in Package-XV roads

The Manholes shall be RCC construction with Sulphate Resistant Cement with M-30
Grade Concrete. The Manholes may be Precast or Cast in-situ as per design and de-
tailing submitted by the contractor and subsequent approval by the Engineer In-
Charge. The Manhole shall be plastered internally with SRC mortar (1:3) and neat
cement finish over the same. Manholes shall be provided with CI rung ladder with
epoxy painting having diameter 16mm at a spacing of 300mm. Providing drop con-
nections wherever mentioned in drawing. Providing and fixing SFRC manhole frames
and covers over manholes as per the Table-4 given below. Construction of Manholes
includes all civil works, like excavation, dewatering, backfilling, RCC works etc. The
Manhole details are furnished in Table 3. Datasheet for manholes is provided in Sched-
ule D.
Table-2 Sewerage Manhole details(Tentative)

Road Nomenclature E3
Type of Manhole Road wise Manholes
Type-A 12
Type-B 11
Type-C 75
Type-D 5
Type-E 77
Total No. Manholes 180

5. Pipe Material
The type of pipe shall be DWC HDPE up to 490mm diameter and Inner HAC lined DI
K7 & K9 pipes with outer polyethylene sleeves up to 1200mm diameter for gravity
network and HAC lined RCC NP4 pipes for diameters above 1200mm. Inner HAC
lined DI K9 for pumping mains. The total length of Sewerage collection network is
around 9.961 km.
6. Bedding
6.1 Bedding for RCC pipes
For RCC (NP4 class) pipes bedding shall be of plain cement concrete of grade M-10.
Contractor shall provide bedding design as per CPHEEO Manual considering Super-
imposed loads (concentrated and distributed), back fill load and Uplift pressure for
approval.
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6.2 Bedding for HDPE DWC pipes

As per IS 7634 (Part 2): 2012 clause no. 6.2, Polyethylene pipe requires no special bed
preparation for laying the pipe underground, except that there shall be no sharp objects
around the pipe. However, while lying in rocky areas suitable sand bedding should be
provided around the pipe and compacted. Be noted that all the HDPE DWC pipes shall
be provided with minimum 200mm of uniform river natural graded sand bedding free
from any foreign /sharp etc. material to avoid the damage of the outer surface of the
HDPE DWC pipes.

No pipe shall be laid in position until the bedding/foundation has been approved by
the Engineer in charge. If two or more pipes are to be laid adjacent to each other, they
shall be separated by a distance equal to at least half the diameter of the pipe subject
to a minimum of 450mm.

7. Manhole size, depth, and type

The channels in manholes at junctions and bends shall be smooth with gradual transi-
tions to avoid turbulence and deposition of solids. Manholes will be constructed di-
rectly over the line of the sewer. They are circular, rectangular or square in shape.
Manholes should be of such size that will allow necessary cleaning and inspection. As
per IS-4111: 1986 “Circular type manholes are much stronger than rectangular and
arch type manholes and thus these are favored over rectangular as well as arch type
manholes”. Therefore, circular manholes are provided on all sewer lines for all depths
starting from 1.2m. Diameter of manhole varies with change in depth of manhole &
internal diameter of Sewer. Manholes are provided as per the space requirements given
in the CPHEEO Manual, 2013 and at necessary locations like change in alignment,
bends and junctions.

Table-3 Manhole Sizing

Type of Manhole Internal Diameter of Manhole (mm) Depth Range (m to m)

Type-A 900 0.9 to 1.65
Type-B 1200 1.65 to 2.29
Type-C 1500 2.29 to 5
Type-D 1800 5 to 8
Type-E 2400 5 to 8

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8. Cover Frame
 As per IS-4111: 1986, the size of manhole covers should be such that there should
be clear opening of not less than 560 mm diameter for all manholes.
 Manhole cover and frame with SFRC (Steel Fiber Reinforced Concrete) conform-
ing to the IS 12592 as per the Table 4.
Table -4 Manhole cover details as per IS 12592

Load withstanding
Manhole Type Suitable Locations
capacity

M.D (Medium Duty) 10.00 MT Footpaths, cycle tracks, Two

wheelers & Light four wheelers
H.D (Heavy Duty) 20.00 MT Heavy vehicles
E.H.D (Extra Heavy 35.00 MT Heavy traffic roads
Duty)
9. Pipe Cover

The pipeline shall be provided with minimum cover depth of 1.0 m as per the details
furnished in the drawing. The pipe shall not be laid in position, until the foundations
are approved by the Engineer In-charge.

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Appendix-B VI
Power Conduits and Concrete duct for power cables

1.1 General

Power Supply in the proposed capital city Amaravati is to make quality and reliable
power available for 24/7 supply with Smart Grid & Smart Metering with energy
efficient transmission and automation in distribution. The power supply system will be
underground cables which will not be vulnerable to surges from lightning, earthquakes,
wind storms, cyclones and have the system be able to 'heal' itself when outages occur,
isolating problem areas .and minimum electrical losses to improve overall efficiency.

1.2 Scope of Work:

As part of the proposed power supply system in Amaravati capital city, following
works shall be executed in this project.
i. Design, Detail Engineering, Supply, lowering, laying, jointing and testing of HDPE
pipe conduits and RCC manholes required for 33kV Power cables along and across
the roads.
ii. Design, Detail engineering and Construction of 220KV RCC ducts and junctions
with shafts/openings for cable access, emergency exits and MEP services.
iii. RCC Ducts and junction including shafts/openings shall be RCC M30 grade
(Sulphate Resistant Cement Concrete) and Manhole chambers for Pipe Conduits
shall be RCC M25 grade.
iv. RCC NP4 encasing pipes shall be given for 33kv pipe conduits with spacer
arrangement for road crossing as indicated in drawings.
v. RCC Ducts should have MS plates inserts with min 10mm thickness as per the IS
2062 embedded in the structure where ever necessary for 220/33KV cable tray
supports, MEP services and hooks/rollers (cable installation) as indicated in the
drawings.
vi. Wherever slopes of more than 15 degrees are provided in RCC Ducts, steps shall
be provided in access way for movement of maintenance personal.
vii. Construction of Exhaust shafts in RCC Duct at 500m intervals should have
provision for future installation of ventilation equipment such as exhaust fans,
sound attenuator, dampers, louvers, filters, bird screens etc., as shown in drawings.
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viii. Construction of Fresh air/cable access shafts in RCC Duct at 500m intervals should
have fresh air louvers, precast RCC cover and MS plates inserts embedded in shaft
for rollers as shown in drawings.
ix. Construction of Control room for MEP services with controlled access from road
including steps from road level and with access into the RCC duct as per the
drawings.
x. All pipes entering/exiting the RCC duct should have puddle flange embedded in
RCC Duct.
xi. Pipe Conduits shall be laid in groups with uniform spacing arrangement with
spacers (made of ABS) to sustain the loads.
xii. Manhole chambers for Pipe conduits should have sufficient space inside for cable
laying, bending (20D) and jointing as well as for future maintenance as given in
drawing.
xiii. Procurement and laying of RCC ducts and HDPE inner ribbed layer of solid
permanent lubricant (PLB) i.e. Silicore pipe conduits as defined in schedule-D.
xiv. The size, length and numbers for pipe conduits and the size and length for RCC
ducts are provided in table-1 & 2 respectively. Accordingly, contractor shall furnish
the structural design and GFC drawing based on IS 3370 & IS 456 after conducting
geotechnical investigation and construct based on relevant IS standards conforming
to water tightness for electrical RCC ducts & Pipe Ducts including manholes.
xv. 3D modelling & Clash Analysis shall be done using a standard software by the
contractor considering the sequence of the utility crossings like storm water, water
supply, sewer, ICT etc.
xvi. Contractor shall connect his work with the other adjacent contractor’s electrical
RCC duct/Pipe Conduit based on the details provided by the Authority.
xvii. Contractor shall design proper ventilation system for RCC duct by taking inputs
from the Authority and making provisions/openings for MEP provisions.
xviii. Contractor shall design the drainage & dewatering facilities in the RCC duct along
with the sump at each junction or the lowest point with 2 No’s submersible pumps
each with a capacity of 10 lps flow with 20m head necessary pumping systems to
the nearby storm water drains with puddle flange embedded in RCC Duct. Detailed
design of dewatering system shall be submitted for authority engineer’s approval.

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xix. Contractor shall provide reinforced HDPE grating arrangement for drain channels
and dewatering sumps.
xx. Contractor shall submit data sheet, QAP of pump, and layout showing connectivity
to the nearby storm water drain for EIC approval before proceeding for
procurement.
xxi. Power cable laying, MEP works will be done by a separate contractor and is not
part of this contract except for lighting arrangement inside RCC Duct.
xxii. Any other works required for the above but not mentioned elsewhere.
In addition to the standards provided in the schedule-D, Contractor shall also observe the latest
editions of the following standards, specification or requirements. In case of any conflict,
technical advice from EIC shall be obtained.
Power conduit sizes:
In table-1, 2 & 3, Road wise power conduit sizes and length for roads are provided.
Table-1 Number of Conduit Details in E3 Road
225mm HDPE Duct Configuration (mm) Length (m)
2-Conduits 909.108
3-Conduits 2242.676
4-Conduits 1771.7
6-Conduits 3054.602
8-Conduits 2192.127
10-Conduits 433.539
12-Conduits 429.588
14-Conduits 135.845
16-Conduits 869.039
18-Conduits 41.111
20-Conduits 213.092
22-Conduits 84.539
23-Conduits 553.772
29-Conduits 283.922
31-Conduits 41.975
Total 13256.6

Table-2 MS Encasing Pipe with HDD method in E3 Road

Encasing Pipe Dia (mm) Pipe Encasing Length (m)

800 540
1200 162
1600 270
Total Length (m) 972
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Table-3 Manhole Details for E3 Road

Road Manhole Loca-

Chainage Type of Manhole Position X Position Y
no. tions
150 440001.564 1829309.574
449 440304.160 1829311.167
1305 441176.745 1829317.075
3478 443347.276 1829318.418
3580 443450.238 1829311.244
3930 443797.697 1829307.753
4350 444238.253 1829308.440
4560 444429.923 1829307.753
5005 444876.658 1829310.002
5372 2.5 x 2.5 445234.504 1829310.113
5596 445461.569 1829309.815
5715 445584.373 1829309.570
5865 445735.274 1829310.254
8445 448068.870 1828381.166
Side of the road 9682 449209.445 1827806.812
11858 451142.379 1826807.414
12125 451382.811 1826690.398
12370 451585.789 1826574.144
12560 451776.533 1826477.719
4140 444010.526 1829318.419
4276 444115.440 1829307.600
E3 6848 446690.942 1829100.517
7621 447404.391 1828717.707
3.0 x 3.0
9017 448599.404 1828108.851
10660 450075.294 1827350.053
10965 450359.833 1827215.880
11953 451224.759 1826759.596
6472 446339.373 1829257.680
4.5 x 4.0
10073 449546.475 1827623.299
448855.576 1828020.364
448815.906 1828003.097
448900.895 1827958.364
E3 x N9 448806.246 1827931.363
448797.175 1827964.830
Junctions 4.5 x 4.0
448891.549 1827995.324
E3 X N16 440753.126 1829352.832
E3 X N7 450891.143 1826970.950
E3 X N14 442853.572 1829340.981
E3 X N10 447799.990 1828554.711

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E3 X N10 447813.042 1828514.706

442003.510 1829344.113
E3 x N15
442028.999 1829314.574
3.0 x 3.0
449838.140 1827484.903
E3 x N8
449824.791 1827524.027
E3 X N11 446101.180 1829313.582
E3 X N11 446098.852 1829261.608
E3 X N10 447769.932 1828575.956
E3 X N10 447729.379 1828567.093
E3 E3 X N12 445027.326 1829348.043
E3 X N12 444953.879 1829317.201
E3 X N11 446072.698 1829235.734
E3 X N12 445053.606 1829318.180
E3 X N8 449787.441 1827540.206
E3 X N16 440786.737 1829311.783
Junctions
E3 X N6 451947.578 1826389.744
E3 X N16 440684.489 1829316.519
E3 X N16 2.5 x 2.5 440715.548 1829349.807
E3 X N7 450905.617 1826936.190
E3 X N8 449746.617 1827527.693
E3 X N7 450814.754 1826979.725
E3 X N7 450856.713 1826994.958
E3 X N14 442813.522 1829346.308
E3 X N14 442889.301 1829313.536
E3 X N12 444982.156 1829348.043
E3 X N14 442783.495 1829316.718
E3 X N15 441933.160 1829316.990
E3 X N15 441962.366 1829346.990
E3 X N14 442886.816 1829266.615
E3 X N14 442851.203 1829230.778

Construction Requirement for Ventilation system & Access staircase

Provision of ventilation shaft & Access staircase is shown in drawings. Contractor shall
provide detailed construction drawing & design for approval by EIC and construct ventilation
system and access staircase as per the location road-wise.

Lighting Arrangement
Contractor shall design the lighting system for the entire RCC duct considering 20 Lux.
Contractor shall submit data sheet, QAP of lighting fixtures, schematic and SLD of lighting
circuit including control panel for EIC approval before proceeding for procurement and

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constructions. All lighting designs, drawings and proposed materials/equipment shall be

submitted to Engineer-in-Charge for approval before installation. The Engineer-in-Charge will
not take over any completed lighting arrangements without prior approval.

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Appendix B VII

ILLUMINATION SYSTEM
1.0 Design

The public lighting installations shall be designed to appropriate lighting levels in an

energy efficient and environmental-friendly manner. In this Document, there are re-
quirements on lighting level, uniformity etc. for different types of roads and highway
structures. Lighting designers shall prepare the lighting scheme strictly according to the
specified limits or values in this document for approval by the EIC.
Illumination system shall be designed as per the design parameters defined in CEI129,
Indian standards and state electricity rules. The required LUX levels as per areas are
defined in the table 1.0 below.
Scope of work:
 Design of the street lighting system as per the lux levels provided in the Table1.0 below
and as per lighting arrangement given in the drawing.
 Fabrication, supply, erection & Commissioning of smart poles, ordinary poles and post
top lanterns including all civil works.
 Supply, installation & Commissioning of luminary system along with smart controlling
provisions along with street light central management software for monitoring and con-
trolling of lights with all necessary accessories.
 Supply, erection along with installation and commissioning of Distribution boards used
for incoming power supply and distribution to the poles with all necessary accessories
like cables, fuses, MCB’s, bus bars, etc.
 Incoming power source cables shall be routed underground from the nearest source
available or as per the instruction given by EIC. Procurement, laying of the HDPE con-
duits along with necessary cables for incoming power supply source where ever re-
quired.
 Supply, excavation, laying, crimping & termination of the cables within the ducts with
all necessary accessories for the above said lighting system.
 The bidder must also provide a detailed operation and maintenance manual specific to
the installed systems.
 Supply and installation of control equipment’s required for the system.

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 Training to the user for operation and maintenance of the system after 2 years.
 Civil work for all the above mentioned works shall be done.

Any additional works not covered above, but necessary for the functioning of the system and
required as per specification incorporated. The works of minor nature, which are not men-
tioned, shall be incorporated by the bidder.
Any other work required for complete illumination of Arterial/Sub-arterial roads along with
footpath and cycle track but not mentioned elsewhere.
Road and Open Area Lighting

It is proposed that roads and street shall be illuminated by using Smart Lighting Poles/High
Masts. Each Lighting pole shall be supplied with LED based luminaries to Be connected and
monitored by Streetlight Central Management Software, Collect and forward streetlight infor-
mation, including power, voltage, current, power factor, alarms, and metering etc. The Smart
pole shall have inbuilt junction boxes (for looping with other poles). However, other open areas
like park/Green belts shall be illuminated by fancy Post Tops with LED.
Luminaire System Requirements:
Luminaires Street Light/ Post top should be a Class I luminaire with good Impact Resistance
IK 08 necessary to resist Vandalism, System Efficacy: ≥ 110 lm/W, CCT to be 4000K for nat-
ural and eco-friendly lighting, P.F > 0.95, Driver Efficiency >85%, The Upper light output
Ratio (ULOR) should be 0%* to avoid glare and light pollution, should have inbuilt NEMA
Socket for supporting Lighting Management System. Must have internal 6KV and external
surge protection 10/10KV (in both CM and DM modes), Ingress Protection: IP66 tightness for
both Optical and Control Gear, Dimmable Driver.
Smart Pole Details:
Smart Pole with Smart City Management Cloud having Smart Street light controller (having
IPV6 addressing, NEMA compliance with Advance encryption standard, Secure hash algo-
rithm) be connected and monitored by Street Light Central Management Software and shall
have following smart features like Having Laser PM environmental Sensor, RF Wi-Fi (Sup-
porting dual band concurrent 802.11ac(5.8GHz), WLAN RF Capacity upto 1200 Mbps, Ether-
net port(10/100/1000 Base-T 802.3, 802.3 u, 802.3 at/af POE input), provide wireless intrusion
detection and endpoint GPS location services, Crowd Camera with 30 X optical zoom, 16 X
digital zoom( support H.265 coding, Ultra-low streaming transmission, Horizontally rotate 360

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degrees, continuous monitoring rotating to 180 degree, no blind spot, Support facial detection-
single view/ multiple view and full view settings, support standard protocols( Onvif, CGI,
GB/T28181), with LED panel for Advertisement ( Max. brightness>= 5500 cd/m2, Max visible
angle 150 degree, Display Color: 16.7M, Video input: Cable, USG, LED Lifetime:100000 hrs,
Continuous working hours>72 hrs, IP65, Synchronized cycle play up to 1000 panels for word
messages), Public service platform( IP55, Resolution: 1920*1080, Visible angle:178 degree
Hor/Ver, Max Power:330W, Temperature Control, Android System, Touch Screen and Internet
browsing), SOS Button( GB/T15279-94 Standard, IP65, Pulse dialling, M-B Ratio: 1.6+-
0.2:1:0, Embedded sim card, Pre-set SOS service, allow real time video call and GPS location,
SOS message to Smart City Management Platform), Street light+ EV charger( Charging Sta-
tions can charge vehicles display charging mode, time, electricity consumption and cost and
support various payment platforms), Electrical Charger( charging Mobile, Laptop), Pole
Height: 10-12 Meters, Made of Hot dip galvanized with PU paint double coat designed Aes-
thetically .

The type, location and spacing between two lights shall be decided based on the LUX require-
ments, Smart poles shall be located at all junctions and rest of the poles shall be normal one
with same look of Smart pole. The poles both smart & normal shall be of architectural design
for aesthetic purpose. Design & details of poles shall be submitted by the bidder to EIC for
approval prior to procurement. The minimum height of the poles for street lighting & footpath
lighting shall be 10mtr & 3mtrs respectively.

Design Requirement for Road Lighting

a. Visibility of road and its surrounding.

b. Visual guidance of the shape of road. Motorist should be able to clearly identify
bends and curves in roads.
c. Identification of obstacle.
d. The visual comfort of the driver. The visual field comprises carriageway, surrounds
to the road including road sign, the sky and bright luminaire.
e. Light should appear continuous and uniform.

Illumination levels

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Taking into account consideration of principles of vision, criteria of quality and char-
acteristics of sources and luminaries, Table-1 given below gives for the desirable level
of illumination which are recommended as per IUT (Institute of Urban Transport) &
uniformity from IS:1944.
Table-1 Illumination Level
S. No Type of Remarks Illuminance Criteria
Road
E avg E avg E min: E min: E min: E min:
(IS (Pro- E avg E avg E max (IS E max
standard) posed) (IS (Pro- Standard) (Pro-
standard) posed) posed)
1 Arterial High speed, 30 40 0.4 0.6 0.3 0.4
Roads high density
traffic and
mixed Traffic
2 Sub-Ar- Medium 15 40 0.4 0.6 0.3 0.4
terial speed, High
Roads Density traf-
fic
3 Conflict Medium 50 50 0.4 0.6 0.2 0.4
Areas speed, high
density traffic
and pedes-
trian zone
4 Pedes- 5-10 0.6 0.4
trian
Path-
ways,
jogging
tracks
and
cycle
tracks

*Lux level mentioned above shall be uniform average luminance level measured at road sur-
face.
Junctions: -

Lighting provision at a junction should reveal its configuration, positions of kerbs and road
markings, directions of roads, presence of pedestrians or obstructions and movements of
vehicles in the vicinity of the junction.
The provision should also meet the needs of drivers approaching the junction to see vehicles
approaching from other directions. The lighting level on the carriageway throughout a junc-
tion shall not be lower than that provided on the main roads leading to the junction. Road
lights shall not be placed at the curved corner of a road junction as this will reduce the
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effectiveness of the main beams from all on-coming traffic at different branches of the
junction

Roundabouts: -

The lighting provision at a roundabout should enable drivers to see clearly any traffic at the
preceding entry and the traffic already in the roundabout. When in the roundabout, the
lighting provision should also enable drivers to have adequate forward vision to see traffic
entering from the left and to decide whether it is safe to proceed. It should reveal the form,
direction and edges of the carriageway all the way round the roundabout.
Lighting columns shall not be installed on the central traffic islands as they would confuse
the visual guidance required above and increase the possibility of vehicle collisions. They
shall be placed behind the outer kerb at appropriate spacing.

Power Supply for Lighting System

Power distribution scheme for lighting shall be designed in coordination with the service
area. The street lighting system shall be fed from their respective lighting distribution
board.

For street lighting poles, the power supply shall be received from nearby substation. For
this purpose, a dedicated main lighting distribution board shall be provided in the substa-
tion, which shall further feed the power supply to lighting small distribution board or high
mast Feeder Pillar.

Each small distribution board shall be capable of feeding power to maximum 1000W or
10No.of light fixtures, whichever is lesser.

The location of small distribution boards for street lighting shall be strategically decided as
per site actual conditions. To avoid the tempering, all the small distribution board shall be
located away from public areas.

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While deciding the location of small distribution board, the Voltage drop shall be kept in
consideration. The voltage drop in lighting system should be less than 5% as per National
Electrical Code.

SUBMISSIONS FOR APPROVAL: -

All lighting designs, computer simulations, drawings and proposed materials/equipment

shall be submitted to the EIC for approval before installation. The EIC will not take over
any completed lighting installations without prior approval.

HANDOVER OF LIGHTING SYSTEM: -

Handover Inspections: -

After the completion of installation work, the Contractor shall arrange the first inspection
for staff of departmental authorities and corresponding EIC to inspect the lighting installa-
tion. In general, a list of defects and outstanding items list shall be agreed by all relevant
parties and the EIC. The EIC shall highlight those major defects. After the Contractor has
rectified all the major defects, a handover inspection shall be arranged.
Provision of Spare Parts: -

The exact quantities and types of spare parts for the road lighting installations shall be
confirmed with the EIC at design stage. Spare parts shall be provided and delivered to the
EIC before handing over the lighting installations for maintenance, 100% of the installed
luminance meters and 1 set of controller shall be provided as spare parts. For more compli-
cated installation, the EIC shall be consulted at design stage. For lighting installations at
other types of structures such as covered public transport interchanges, covered pedestrian
routes and high mast lights, 10% of each type of the installed luminaires shall be provided
as spare parts if typical luminaires are used. The exact quantities of spare parts for non-
typical luminaires shall be confirmed with the EIC at design stage.

As-built Drawings and Other Required Documents: -

On completion of the lighting installations, the Contractor shall provide soft copies of as-built
drawings in Autocad format in appropriate size and also in GIS format to the EIC to facilitate
the handover inspection.
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For the final handover, the Contractor shall provide the EIC with 2 sets of CD ROMs each
containing the following documents in editable format and 2 sets of hard copies:
(a) As-built drawings including lighting layouts, schematic drawings, circuit diagrams and con-
duit routes layouts;
(b) Lighting measurement results (pdf format);
(c) Electrical test reports (pdf format);
(d) Equipment database in required format; and
(e) Operation and maintenance Document.

For as-built drawings, 1 more set of CD ROM containing the drawings in shall be provided.
For lighting systems with software/electronic control, the design logic flow chart and
associated software protocols of the controller shall be submitted to the EIC after
commissioning and testing.

2.0 Lighting Small Distribution Board (DB’s)

Each indoor Distribution board shall be with minimum IP-42 protection, dead front, front op-
erated and shall be designed as per IEC-61439. The outdoor lighting distribution boards shall
be with minimum IP65 protection. The number of ways of lighting DB’s shall be decided based
on the number of the circuit and the spare MCB’s for future use.

The type of lighting distribution board shall be provided as per the location of lighting poles.

1) Lighting Distribution Board (Type-1) for street lighting poles: : In this type of dis-
tribution board 40Amp ELCB for incomer is considered. 18no.of outgoings (6no.on R-
Phase, 6no.on Y-Phase, 6no.on B- Phase) of 16 Amps SP shall be controlled by 32 Amp
(3No.) DP MCBs.

3.0 Lighting Management System

The lighting will be designed to illuminate the entire areas with the minimum necessary lumi-
naires in an efficient manner, through directing the light to the areas to be illuminated through
minimizing the tilt angle and appropriate aiming of the luminaries thereby minimizing the

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wasteful use of light, reducing required power and ensuring that the surrounding environment
is not subject to obtrusive lighting of the site.

Therefore, Utilizing controllable streetlights as a communication link and smart poles as a car-
rier to build a smart city management platform, Maximizing the platform friendliness, compat-
ibility and scalability, and utilizing reliable network to sense, collect and analyze key data that
can help cities make efficient and smart respond to improve city management on infrastructure,
public service and safety.
Lighting system shall be controlled via Smart Street Light Controller for the luminaires
mounted on each lighting pole.
8.1 Smart Lighting Controller:
IPV6 addressing, opening standard, NEMA compliance, 868MHZ,915-928MHz, 902-928
MHz/2.4GHZ
Advanced encryption standard. Secure hash algorithm to secure from hackers.
Each Node in the luminaire Collect and forward streetlight information, including power, volt-
age, current, power factor, alarms, and metering etc.
Smart Lighting Diagnosis individually, the defect luminaire to pin point location on a GPS
remotely by LMS for necessary actions.
Be connected and monitored by Streetlight Vision Central Management Software.

LMS shall be pre-programmed/ re-programmed as per the requirement for automatic switch
‘on’ and ‘off’ the luminaries remotely. The dimming option in the luminaries will give the LMS
to program lighting levels based on traffic and weather conditions remotely at SVCMS.
The successful contractor shall submit lighting design, layout & calculations (generated by
reputed software like DIALUX) based on the lighting design standards and LUX levels men-
tioned in the table 1.0 here in this section for client’s approval.
Utilizing controllable streetlights as a communication link and smart poles as a carrier to build
a smart city management platform.
Maximizing the platform friendliness, compatibility and scalability, and utilizing reliable net-
work to sense, collect and analyze key data that can help cities make efficient and smart re-
spond to improve city management on infrastructure, public service and safety.
4.0 Standards and Codes

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The illumination system shall be designed, installed and tested in accordance with the latest
editions of the standards - IS-2149, IS-3646, CIE129.
In addition to this Document, lighting designers shall also observe the latest edition of the
following standards, specifications or requirements mentioned in schedule-D and, in case
of any conflict, technical advice from the EIC shall be obtained.

Table-3 (Street Light- Standard for installation)

Code Standard for installation

IS: 1255 Code of practice for installation and maintenance of

power cables up to and including 33 kV rating.
IEC:60947 Switchgear Protective Compon ents.
IEC: 60598 – 2 – 3 Particular requirements luminaries for road & street
IUT (Institute of Urban Transport) lighting.
Standard for road lighting.
IS: 2309 Code of practice for Lightning Protection.

IS: 3043 Code of practice for Earthing.

Table-4 (Street Light- Design Standards)

Code Standard for installation

IS: 7098 (Part-II& Part-III) Standard for XLPE Cables, Part – II up to 3.3 kV to 33 kV and
2003 Part– III from 33 kV to 220 kV).
IS: 8130 Specification for conductors for insulated electric cables &
flexible cords.
IS 1554 (Part I & Part – II) Specification for PVC insulated (Heavy Duty) electric cables
 Part 1 For working voltages up to and including 1100
 Part 2 For working voltages from 3.3 kV up to and
including 11 kV
IEC: 61439 Feeder Pillar & Switchgear (Totally Type Tested Assembly
IEC:60947 TTTA).
Switchgear Protective Components.

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 IEC: 60598 – 2 – 3 (a) Particular requirements luminaries for road& street

 IUT (Institute of Urban
lighting
Transport)
 CIE (Industrial (b) Standard for road lighting
commission of
(c) Road Transport Lighting for Developing Countries
illumination)
IS: 2309 Code of practice for Lightning Protection
IS: 3043 Code of practice for Earthing
IS: 1944 Code of practice for lighting of public thoroughfares

Appearance

For daytime appearance, the design and siting of road lighting and other road equipment can
make a great difference to the overall street scene. At locations such as a processional way,
monumental bridge and roads abutting onto heritage buildings, the design and placing of light-
ing columns shall match with the architectural setting, in order to make a positive contribution
to the street scene.
For the selection of luminaire, in urban centres, shopping streets, boulevards, promenades and
other places that are the hubs of social activities, decorative road lights are highly desirable. In
general, proposals using decorative road lights should be agreed by the EIC and all relevant
parties such as the APCRDA.
Lighting designers should also consider whether the lighting scheme could make a positive
contribution to the night environment, especially for areas of civic importance. A higher colour
rendering index (Ra ≥ 60) of the light source is paramount to the nighttime appearance of the
street scene and can enhance the sense of nighttime security.

Luminaires

Lanterns shall be of sound and robust construction to BS EN 60598-2-3. The IP rating for
decorative and conventional lanterns shall not be less than 65 and 66 for decorative and con-
ventional lanterns respectively. They shall be for use on 220V, 50Hz single phase mains supply.
To ensure high energy efficiency of public lighting system, the overall efficacy of the whole
lantern for new road projects shall not be less than 100lm/W.
In addition to above, LED luminaires shall comply with IEC 62471 hazard class Group 1 or
Exempt Group and shall have a correlated colour temperature at 4000K. The luminaire shall

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be in modular type so that replacement of parts such as drivers, LED circuit boards and other
components can be carried out as necessary. LED luminaires shall have a minimum of 50,000
hours of lifetime at 70% lumen maintenance.
Luminaires installed on a bridge deck shall be capable of withstanding the effects of vibration
from structures, passing vehicles and prevailing winds. Vibration studies/analyses and tests
shall be carried out on the proposed luminaires beforehand in order to illustrate that no prema-
ture failure of lamps would occur under the structural vibration of the bridge. Studies/anal-
yses/test reports and any proposed vibration reduction measures on the luminaires shall be sub-
mitted to the EIC for approval.

Light Sources

The choice of light source depends on the number of lumen per watt, life time, flux mainte-
nance, colour rendering, initial costs and lamp replacement costs. The luminous efficacy of a
light source has a dominating influence on the energy consumption and consequent running
costs of a road lighting installation. The requirement on minimum luminous efficacy for LED
is 100lm/W with considering the standard IEC 62471.

Ballasts/Drivers

In general, electronic ballasts shall be used for road lighting for higher energy efficiency. The
use of conventional magnetic ballasts shall be agreed by the EIC. An electronic ballast shall be
a solid-state converter capable of converting single phase mains supply of 230V ± 6% and
50Hz ± 2% to a high frequency voltage output at its rated power to suit the lamps connected.
Electronic ballasts shall conform to IEC 61000-3-2, IEC 61000-3-3, BS EN 55015 and IEC
61547.
The whole electronic ballast shall be housed in a single front-access enclosure with appropriate
terminal blocks for easy connection of wires. Electronic ballasts shall be suitable to operate at
an ambient temperature range of 0oC to 50oC and at maximum relative humidity of 95%. The
electronic ballast shall go into a shutdown or lower power stand-by state when the connected
lamp is failed or when overload occurs in the lamp circuit.
LED drivers shall comply with IEC 61347-1 and IEC 61347-2-13. For drivers with dimming
function, they shall be capable of providing continuous dimming range of 10% to 100%. An
external surge protection device capable of withstanding surges of 10kV shall be provided to
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the driver. The driver and the surge protector shall be housed in a separated front-access enclo-
sure to be installed at the column door level of the lighting column.

Power Cables

Cables shall be of 600/1,000V grade with cross-linked polyethylene (XLPE) insulation, galva-
nized steel wire armored and PVC outer sheath as per specification confirming to IS:7098 (Part
- I)
Makes: Torent / Universal / Unicab / Havells / KEI / Gloster/ Polycab
Astronomical Time Switches and Digital Photoelectric Controllers
The on/off control of lighting circuits shall be by means of an astronomical time switch and a
digital photoelectric controller as a backup. The astronomical time switch shall comply with
IEC 60730-1. It shall have 2-channel, an accuracy of ± 0.5 sec/day and a battery reserve for at
least 5 years. The digital photoelectric controller shall be of electronic fail-safe type, and have
a LCD display showing the local time, on/off settings and measured illuminance level. It shall
also have a plug-in and replaceable photo sensor, and an on/off adjustable setting from 1 to
2,000lux with adjustable time delay of 0-60 seconds. Both the switch and the controller shall
be suitable for use in exposed weather conditions and shall function correctly at a temperature
range of -5°C to +50°C at the local supply voltage and frequency.

Road Lighting Circuits

Road lighting shall be fed from PLCCs. For the security of road lighting circuit systems, 100%
back feed capability is mandatory for road lighting along trunk roads or above including slip
roads. The same arrangement shall be adopted for other roads as far as possible. Back feed will
be needed when the power supply for a series of lights fed from one PLCC is suspended, faulted
or affected and could not be immediately restored.

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Cable Circuits
All road lights fed from the same circuit shall be looped together by turning in and out the
lighting cables and terminating them with cable glands at the base section of lighting columns.
Alternative connection means, such as teeing underground lighting cables in the proximity, are
unacceptable.
To maximize the number of road lights that can be supplied by one circuit, the whole length of
lighting cables shall be of the same size. Reducing the cable size or the number of cable cores
at any section of the circuit shall not be allowed for consistent circuit design and for circuit
backfeed. The maximum number of lights to be connected to an outgoing circuit shall be de-
termined by wattage of the lamps and voltage drop of the cables. For circuits with back-feed,
a two-stage approach shall be adopted:
Care must be taken to ensure that the voltage of the last light during the most critical backfeed
condition shall be maintained at no less than 216V, i.e. a total voltage drop of the entire circuit
be no more than 14V, assuming the supply voltage is 230V.
(ii) During normal operation, the minimum voltage of the last light up to the normal open (N/O)
point, shall be no less than 216V by taking into account the ± 6% voltage fluctuation as speci-
fied by the respective Power Company.
A full ducting system for protecting road lighting cables is required. For all road projects in-
cluding reconstruction of carriageways/footpaths, a full ducting system comprising either
HDPE ducts and GI pipes and draw pits shall be specified to facilitate future maintenance of
the cables.
Whenever possible, ducts/pipes shall be laid under footpaths instead of carriageways. On foot-
paths or carriageways where a minimum cover of 450mm from the finished surface of the
footpath and 900mm from the finished surface of the carriageway could be provided, HDPE
ducts shall be used. GI pipes of appropriate size shall be used. The GI pipes shall comply with
BS EN 10255 and be of medium grade. The HDPE ducts shall comply with BSEN - 500 86/IS
14930 Part-II.

PLCCs

There are two different types of PLCCs, i.e. pole-mounted and ground-mounted PLCCs. De-
tailed construction of these PLCCs shall comply with the requirements as specified by the
Lighting Division.
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The locations of PLCCs and earth pits shall be chosen at places where they are practically
accessible for maintenance and less obstructive to pedestrian flow. For the accurate operation
of the photoelectric controller, the PLCCs shall not be sited in shaded areas, such as under trees
and structures, in order to avoid mis-operation of the road lighting system. Wherever possible,
especially at new developments, the respective Power Company shall be consulted at the early
design stage for the availability of power supply.

Fuse and MCB

Incoming and outgoing circuits at a PLCC shall be protected by high rupturing capacity (HRC)
fuses of an appropriate rating to BS EN 60269-2 and BS 88-2. Each lighting point shall be
separately protected by an MCB unit to BS EN 60898-1. For double arm road lights, each lamp
shall be supplied from a different circuit to avoid total loss of light in the event of fault. The
rating of fuses and MCBs shall be properly designed according to circuit cable size and loading.

Earthing

The complete road lighting installations, including PLCCs, lighting columns, lanterns, control
gear, conduits, cables fittings and other exposed conductive parts, shall be effectively earthed
to the ground by means of copper conductors of appropriate sizes and shall comply with the
recommendations as per standards. The results of the earth fault loop impedance test for each
road light and PLCC shall be submitted to the EIC for acceptance.
A separate earthing system shall be provided at each PLCC. Earth electrodes of 16mm diameter
copper bonded steel core rods shall be used. The electrode shall be driven into the ground and
connected to a sufficiently sized copper earth terminal inside the PLCC. It may require more
earth electrodes connected in parallel to achieve the required earth fault loop impedance value.
The earthing of each outgoing circuit shall be bonded to the main earth terminal of the PLCC.

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Appendix B VIII
Pipe Conduits for ICT cables
General
As a part of the Smart city concept in Amaravati capital city, the latest advanced technology of
ICT (Information & Communication Technology) is proposed to be implemented. ICT will
provide high speed internet as a core utility for delivery of services to citizens, cradle to grab
digital identity that is unique, lifelong, online and authenticable to every citizen, mobile phone
& bank account enabling citizen participation in digital & financial space and easy access to a
Common Service Centre shareable private space on a public cloud safe and secure cyber-space,
making financial transactions electronic & cashless and leveraging Geospatial Information
Systems (GIS) for decision support & development.

Scope of Work
As a part of ICT implementation in Amaravati capital city, following works shall be carried
out in this project.
i. Communication pipeline as an underground communications network will consist
of DWC HDPE pipe and 7-way honeycomb ducts. DWC HDPE will be carrier for
220 Core ICT cables and 7-way Honeycomb duct will be carrier for 4 core ICT
cables. The arrangement is shown in the drawing AG-1957-DDR-AM-ICT-SD-CS.
7-way Honeycomb ducts are hexagonal in shape readily available in the market.
ii. For E3 road, configuration of DWC duct and 7 Way Honeycomb ducts has been
provided in the drawing along with tables.
iii. ICT bundle of cables will be residing inside the DWC-HDPE pipes and 7-way
Honeycomb ducts. ICT cable laying and connectivity will be done by a separate
contractor and is not part of this contract.
iv. This contract shall include supply, lowering, laying, jointing, and testing of all
DWC-HDPE main ducts & honeycomb ducts and RCC manholes required for the
ICT communication network along the E3 road. The work shall be executed as per
the details shown in the drawings.
v. The sizes, length and number of DWC and 7-way Honeycomb ducts are given in
table-1. Accordingly, contractor shall lay pipe ducts for ICT.

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vi. Contractor shall construct RCC (M25 grade) manholes following relevant IS
standards & considering the sequence of the utility crossings as given in the
schedule-D.
vii. RCC NP4 encasing pipes shall be given with spacer arrangement for road crossing
as indicated in drawing.
viii. Contractor shall consider end-to-end connectivity between adjacent contractor’s
ICT ducts based on the details provided by the authority.
Details of ICT Duct
In Table-1, length and diameter of DWC HDPE duct and 7-Way Honeycomb ducts are
provided.
Table-1 ICT Roads Ducts length
Package-XV Roads ICT Ducts length & MH details
E3
Package-XV Roads
TRUNK DISTRIBUTION
ICT Ducts configurations (DWC(dia-160mm)
6+8 2+6
+7way honeycomb (inner dia of each duct 40mm)
Length of the duct (m) 19856.76 715
Total length of DWC duct (km) 117.99 1.404

Total length of 7-way honey comb duct (km) 158.932 4.212

Details of ICT Communication Network

This contract package includes providing, laying, jointing, testing and commissioning of DWC
HDPE ducts (IS: 14930 part-2) of 160 mm diameter as per the details furnished in the drawing.
Double-wall corrugated pipe is a kind of pipe material with ring-structure external wall and
smooth internal wall at a length of 6 m each piece as shown in figure-1.

The Contract package includes providing, laying, jointing, testing and commissioning of
Communication Honeycomb pipe lines outer diameter 110 mm as per the details furnished in
the data sheet provided in Schedule -D.

Honeycomb pipe is a kind of communications piping made mainly of HDPE pipes (IS) and
molded into honeycomb shape with smooth internal wall for direct cable threading and laying
as shown in figure -2 Thickness of Inner core and outer core

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Figure-1 Double Wall Corrugated Pipes Figure-2:7-way honeycomb ducts

In table-1, Road-wise number of manholes are provided. Total requirement of DWC HDPE
ducts and 7-way honeycomb ducts road-wise will be provided by the authority for the E3 road.
Manhole for ICT duct

The ICT pipes are connected through the manhole, whose major functions are to provide
maintenance and repair space for communication pipes as well as operation space for laying
communication wires. In general, manholes shall be spaced at an interval of 100m. At junctions
of road crossings, additional manholes shall be provided as per the drawing.

The precast manhole shall be designed and constructed with M25 grade concrete. The cover of
manhole shall be removable RCC slab as per design thickness. A SFRC manhole cover of
560mm dia shall be provided in removable RCC slab.
ICT Manhole Details
Road Nomenclature E3
Type of Manhole Road wise Manholes
4-way direction 18
3-way direction 122
2-way direction 174
Big hand hole 0

Small hand hole 0

Total No. Manholes 314

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Type of Manhole & Hand holes MH & HH Inner Dimensions (L x B x H) mm

2-Direction manhole 2200x1400x2030

3-direction manhole 3200x1550x2230
4-direction manhole 3200x1700x2230
Small hand hole 1200x900x1350
Big hand hole 1700x1200x1600

Number and Location of the manhole shall be decided based on manhole spacing and the road
junctions and other site factors to be approved by the Engineer-in-Charge.
The manholes sizes for 2-way, 3-way & 4-way are 2m x 2m, 2m x 3m and 2m x 4m respec-
tively. The contractor has to design the manholes duly considering the criteria as mentioned in
Schedule-D and shall obtain approval from Engineer-in-Charge.

Trench:
In the trench where the ducts will be residing, the backfilling shall be done as follows:
1. Up to 20 cm above the top of the duct shall be filled with sand and the remaining space
up to the road level shall be filled up by earth. (There shall not be any stone in the
backfill)

2. To lay HDPE duct and 7-way honeycomb duct, spacers (ABS-HDPE make) shall be
provided at an interval of 1.5 mts to sustain the loads.

3. Two-layer warning tapes (Orange and Yellow color) shall be provided along the ICT
ducts route, one at 100mm below G.L and other one at a depth of 800mm below G.L.

4. Contractor shall furnish layout, Longitudinal Sections, Cross sections of ducts, details
of manholes, GFC’s, datasheets etc., and shall take approval from Engineer-in-Charge
prior to execution of work. As Built Drawings (GIS compatible & AutoCAD Format)
shall be provided by contractor.

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Appendix B IX
Gas Crossings
1.0 MS Encasing Pipe at Road Crossings
MS encasing pipe is proposed for pipe lines under the carriage way of the road and
storm water drains. The details are provided in Table-1 as well as in the drawings.

Table-1 Gas Network Crossings - MS Encasing Pipe details in E3 Road

Road Nomenclature E3
Diameter(mm) Dia. Wise Length in (m)
500 550
600 150
Total 700

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Appendix B X
ITS
ITS Ducts and Chambers Requirements

ITS Ducts
The requirements for ducting along major arterial roads shall be 4 x 100 mm, High
Density Polyethylene (HDPE) ducts running parallel to the arterial roads in the reserved
location within the utility corridor on both sides of the major arterial roads. In a circum-
stance, whereby ducts cannot be provided on both sides of the major arterial roads due
to space constraints or other conflicts, use an 6 x 100 mm configuration along one side
of the roadway.
In 4-way configuration, the top two ducts shall be designated for communications ca-
bles of ITS, and the bottom two shall be designated for power cabling of ITS. In 6-way
configuration, the top four ducts shall be designated for communication cables of ITS
and the bottom two ducts shall be designated for power cabling for ITS. Ducts on both
sides of the arterial roads in the 4 x 100 mm configuration is the standard requirement
and shall be followed on all major arterial roads unless an exception is provided in
writing from client.
Transverse arterial road ducts shall be 4 x 100 mm HDPE ducts with a maximum spac-
ing of 125 m between road crossings and shall be encased in concrete.
All ducting shall be type HDPE with uniform plastic or rubberised clip spacers, placed
evenly throughout the duct run to ensure duct banks keeps uniform shape and order.
Spacer shall consist of one uniform component and ducting shall be tied together with
the use of plastic or rubberised cable ties.
High Density Polyethylene (HDPE) ducts suitable for underground installation for both
electric power and Telecommunications shall be provided and installed. Product data
sheets and specifications shall be submitted for review and approval from the client.
Ducts shall be designed to be parallel to the main carriageway and at all junctions, a
ring shall be provided.
ITS Chambers
ITS chambers shall be located on both sides of all arterial road crossing locations. The
maximum spacing of ITS chambers is 125 metres. Where significant changes of direc-
tion of ducting are required, this will be through a chamber. Typical dimensions of the
chamber shall be 1m x 1m and 0.8 m deep.

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ITS chambers are to be installed at the following locations:

 along the ITS duct network at intervals of no more than 125 metres
 both ends of carriageway duct crossings
 at signalized junctions
 proposed locations of ITS elements
 at termination of duct bank / future connection to the longitudinal duct network.

A chamber shall be installed in the median where there is a planned or potential future need for
the provision of communications and power cabling to ITS equipment in the median.
HDPE chambers and duct management boxes which can be easily handled, buried and have
locking lids shall be used. Sufficient drainage shall be allowed for in the area surrounding each
chamber, and each chamber shall have a sump to prevent flooding of the ITS network through
the conduit system.

Typical arterial road dual 4-Way duct mid-block arrangement

Typical arterial road dual 4-Way duct junction arrangement

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Appendix B XI
Utility Corridor/Clash Analysis
1. Introduction
The design of utility corridors involves a thorough understanding of the design of the
new street families. In addition, a comprehensive understanding of the requirements of
all utility providers and agencies is necessary.
There are different standards adopted by different countries based on their technological
advances in laying and maintaining. Some of the standards are
 Indian Standards IS & IRC
 French Standard NF P 98-332
 Abu Dhabi Guidelines
 Vancouver Guidelines
 Chinese Guidelines

1.1 Type of Utilities

Utilities considered for this report include all the utilities that are currently used in urban
local bodies of India as well as the utilities that may be considered in the future. In
general, utilities that occupy part of roads ROW can be divided into two categories
 Road Utilities
 Building Utilities
Road utilities include the infrastructure systems that serve the road itself, such as storm
water
drainage, street lighting, fiber optic systems and landscape irrigation systems. Building
utilities include infrastructure systems that service the buildings located on the side of
the road; these include the water supply, power supply, telecommunication system, gas
network, district cooling system and wastewater collection system. These utilities fall
under the responsibility of the respective utility providers in conjunction with Munici-
pality.
Following utilities are considered for corridor requirements
 Water distribution system

 Wastewater collection system

 Landscape irrigation water supply system

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 Urban storm water drainage system

 Gas network

 Power supply, including extra high voltage (EHV), high voltage (HV) that
supplies primary substations, medium voltage (MV), low voltage (LV)

 Telecommunication network

 Fiber optic networks, that include: The DoT’s, (Intelligent Transportation

System: ITS), Area Traffic Control: ATC),

 Street Lighting

In addition to the above, allocation of corridors for trees/ landscaping are accounted for,
and guidelines for the arrangement of solid waste collection facilities/ bins, infor-
mation/ advertisement boards, fire hydrants are provided for.

1.2 MANAGEMENT AND COORDINATION OF UTILITIES

Effective management and design of utility installations are imperative for the safe and
expedient construction and maintenance of the road network. Close coordination with
utility providers is essential to meet these objectives. This will necessitate that the ADC,
CRDA, DoT, the Municipality and the utility companies’ representatives meet regularly
to exchange information to help avoid conflicts between utility companies’ projects and

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Municipal projects, in terms of location, construction or method of installation of utili-

ties within the ROW of streets. Work within the public ROW by contractors and / or
utility companies requires proper coordination between these companies and the au-
thorities to ensure appropriate utilization of the ROW. Among the issues that need to be
coordinated, public safety, pedestrians’, cyclists and drivers’ comfort, aesthetics and
cost-effectiveness of the implemented reinstatement strategy are considered to be of
utmost im-
portance.

The operation and maintenance of the utilities will benefit from efficient and effective
coordination. Inter-agency coordination during the installation and/ or operation and
maintenance activities will maximize the benefits and ensure the following:

 Reduction in road maintenance costs

 Provision of smoother roads with fewer closures for maintenance/ rehabilitation
activities
 Provision of cost effective engineered solutions which are suitable for the local
conditions
 Promotion of consistent policies which eliminate disputes among stakeholders
 Expediting project delivery and avoidance of project delays in the preliminary
engineering, preconstruction and construction phases.
2. Design Considerations and Requirements

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Several factors affect the design of utility corridors. Some factors might differ depend-
ing on the utility in question; however, many factors are common and govern the design
of corridors for almost any utility. Moreover, factors are divided into two major cate-
gories; factors which govern the corridor in terms of its width, and factors which govern
the corridor in terms of its location.
The required corridor widths are normally governed by the minimum width needed to
properly install the utility and this comprises proper excavation, laying, backfilling,
compaction and reinstatement. The corridor width is also governed by the size/ width
of the associated chambers and manholes that are installed along the corridor. Other
factors also include operation and maintenance, repair and replacement requirements.
Factors governing the location of the corridor include clearance requirements from
other utilities (mainly applicable between water and wastewater/ treated sewage efflu-
ent), clearance requirements from plot limits and connections to plots and inspection
chambers, in addition to public safety considerations. Other important considerations
in locating utilities are the factors which govern whether a utility can be installed under
the carriageway or whether it should be placed under the sidewalk.
Utilities, which require frequent access, should not be placed under the carriageway
because operation and maintenance requirements may cause frequent traffic interrup-
tions and frequent asphalt cutting and repairs. Also, pressurized pipes such as water and
irrigation water supply pipes might cause significant damage to asphalted roads if pipe
failure occurs; consequently, these utilities are normally placed under sidewalks and/ or
block paved surfaces. The utilities that can be accessed for repair through manholes are
selected to be installed under the travel lanes/ carriageway.
In order to reduce the width of the ROW and optimize the location of each utility cor-
ridor width, the design of the utility corridor is done considering the concept of stag-
gering, whereby appurtenances (chambers and manholes) are allowed to extend beyond
the corridor limits to a shared corridor between adjacent utilities.
However, in all instances, the encroachment will respect the minimum clearance from
the utility pipe/ cable and accordingly, no encroachment on the pipe/ cable corridor will
be allowed. This is mainly applicable to utilities which require a wider corridor at the
locations of the appurtenances/ chambers. Thus, a shared corridor is created between
adjacent utilities to accommodate the appurtenances of the utilities. The shared corridor

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will also be useful during operation and maintenance for accessibility space require-
ments. Each utility will have a dedicated corridor that accommodates the minimum
pipe/ cable requirements, referred to as the pipe/ cable corridor.

Figure 1: Sample Utility corridor with manhole in shared corridor

In addition, minimum clearance of 0.5m is maintained between the plot boundary and the first
utility adjacent to it. Clearance next to the plot boundary shall be used for the installation of
riders/ inspection chambers/ house connections. Consequently, the plot boundary wall founda-
tion shall not be allowed to extend beyond the plot boundary limit into the ROW. All utilities
shall be installed up to the plot boundary limit, whereby the pipe and/ or cable will be extended
to the inspection chamber, valve box, etc. inside the plot boundary.
For utilities installed on one side of the ROW or under the carriageway, ducts for utility cross-
ing to the opposite plots will be installed through riders along with primary system within the
ROW. For spacing between utilities please see Schedule-D.

2.1 Water Supply Corridor

Two criteria govern the required corridor width for the water supply network. The first
is the pipe corridor width determined by the pipe size/ diameter, and the second is the
chamber corridor width determined by the width of appurtenance(s)/ chambers. While
the former dictates the minimum width to house the pipe, the latter is normally required
to house the outer width/ dimension of the chambers/ manholes, as required. Fire Hy-
drants are generally provided in multifunction zone.
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2.1.1. Water Supply Pipe Corridor Width Requirements

Pipe corridor width requirements are based on the pipe material and/ or pipe diameter.
Pipe diameters vary depending on the land use context as well as the street type, as
larger streets are expected to contain larger pipes. Minimum pipe corridor width re-
quirements were estimated based on best practices prevailing in India, the requirements
for different pipe diameters are shown in Table 0-1.

Table 0-1 Water Supply Pipe Corridor Requirements

Size of Pipe Corridor Width
150mm 350mm
200mm 400mm
250mm 450mm
300mm 500mm
350mm 550mm
400mm 600mm
450mm 650mm
500mm 700mm
600mm 800mm
700mm 900mm
800mm 1000mm
900mm 1100mm
1000mm 1200mm
1100mm 1300mm
1200mm 1400mm
1300mm 1500mm
1400mm 1600mm
1500mm 1700mm
1600mm 1800mm
1700mm 1900mm
1800mm 2000mm
1900mm 2100mm
2000mm 2200mm

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2100mm 2300mm
2200mm 2400mm
2300mm 2500mm
2400mm 2600mm
2500mm 2700mm

Street Family Pipe Corridor Chamber Corri-

Width dor Width
Table 0-2 Water Sub Arterial Roads 3.00m 4.20m Supply Corridor
Allocation
Arterial Roads 3.00m 4.20m

Major Arterial 3.00m 4.20m

Roads

In addition to isolation valve chambers, water networks comprise other chambers/ ap-
purtenances including washout valve chambers, air vent chambers, flow meter cham-
bers, sector meter chambers and several others. All details will be in accordance with
relevant standards. For valve chambers at intersecting pipes, it is recommended to uti-
lize chambers with single valve installation for reducing the chamber dimensions. In
instances where two valves are installed at a T connection, it is recommended that the
valves are installed in separate chambers before the street intersection. However, if a
common chamber for the valves is to be used, the chamber will be allowed to encroach
on the adjacent corridor.

2.1.2.Water Supply Chamber Corridor

The minimum chamber corridor width will be equal to the width of the largest chamber
required for the pipe installed and at no point is less than the required pipe corridor
width. In instances where the street ROW is limited, the chambers are allowed to en-
croach on the corridor (shared corridor) of the adjacent utility provided the pipe corridor
width of the adjacent utility is maintained. Based on the same principle, chambers/ ap-
purtenances of adjacent utilities are allowed to encroach on the water chamber corridor
provided the required pipe corridor width is maintained. The standard minimum pipe
and chamber corridor widths required for the water pipes for the different street families

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are presented in Table 0-2. In some instances, where the ROW is limited, and taking
into consideration the land use context and expected demands, absolute minimum pipe
and chamber corridor widths are also estimated and are included in Table 0-2.

2.1.3. Water Supply Special Arrangements

Although the corridor allocations, as summarized in Table 0-2, can accommodate most
of the water appurtenances, a few specific appurtenances/ chambers might require spe-
cial arrangements/ considerations. Accordingly, the necessary allocations are provided
within development plan outside the ROW of the streets (away from footpaths and the
furnishing zone) for the following appurtenances, whenever required
 District Meters (DMS) will be installed in open areas. In instances where the
DMS need to be installed within the street ROW, a localized widening of the
street ROW can be considered

 Washout chambers will be installed, whenever possible, within parks and open
spaces

 House connections along with flow meters will be placed within the plot
boundary

In addition, transmission water lines are accounted for as per transmission water
corridor requirements, independently of the above required water corridors.
Transmission water corridors will be installed based on one of the following
guidelines on the approach adopted
 Increasing the ROW of the street where a transmission water main is installed;

 Introducing within the development a dedicated corridor for the transmission

water main.

2.1.4.Water Supply System Pipe Depth

The depth of the water supply system will be in accordance with the requirements of
CPHEEO/ IRC 98. The minimum depths for water pipes is 1.0m. consideration for var-
ying the depth of water pipes is done so as to allow for the vertical clearance of pipe
and other utilities, in particular at intersections and for house connection installation.

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2.1.5.Water Supply System Horizontal and Vertical Clearances with Other Utilities
The minimum clearance with power distribution will be in accordance with the require-
ments of IS:1255. For other utilities international standards like, NF P 98 – 332 (French
Guidelines), GB50289 (Chinese Guidelines) were followed. Minimum Clearance’s for
water supply mains with other utility mains are given in Table 0-3.

Table 0-3 Minimum Clearances for Water Supply Mains with other Utility Mains

Utility Horizontal Clearance (m) Vertical Clearance (m)

Water supply 0.4 0.2

Sewerage 3.0 0.2
Reuse Water Line 0.6 0.2
Storm 0.6 0.2
Power 220KV 0.6 0.2
Power 33KV 0.3 0.2
Power 415V 0.3 0.2
Gas 0.6 0.4
ICT 0.6 0.2
District Cooling 0.6 0.3

In all instances, the water pipe will be installed above wastewater pipe with minimum
vertical clearance as specified above. In case where a wastewater line crosses over a
water pipeline, all pipes will be encased in concrete.
Risks that might arise due to noncompliance of minimum horizontal and vertical clear-
ances are as follows
 Contamination of Sewage and reuse water with water supply water.

 Operation and maintenance issues during pipe bursts, leakages, etc.,

 Ultimately with age, pipelines corrode, leak and fail; adequate spacing to be
provided as a barrier for separation

2.1.6. Location of the Water Pipe Corridor

The corridor adjacent to power corridor has been reserved for the water lines on both
sides of the street. Whenever valve chambers are required, the chambers are allowed to
encroach into the shared corridor between power and water supply. Whenever the cor-
ridor width for the primary main is not sufficient for the construction of the appurte-
nances, the chambers are allowed to encroach on adjacent utility corridors provided the
encroachment does not extend into the pipe/ cable corridor reservation of the adjacent
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utility. Similarly, adjacent utility appurtenances are allowed to encroach on the water
supply main corridor, provided that such encroachment does not extend into the water
main pipe corridor.

2.2 Reuse Pipe Corridor

As is the case for water, the same criteria dictate the required corridor width for reuse
pipe network. The minimum corridor width will be that imposed by the pipe corridor
requirements which is determined by the pipe diameter. The maximum corridor width
allowed is based on the outer dimensions of the appurtenances / chambers used for reuse
pipe systems.

2.2.1 Reuse Pipe Corridor Width Requirements

Pipe corridor width requirements are based on the pipe material and/ or pipe diameter.
Generally, reuse pipes are either ductile iron pipes, PVC or HDPE pipes. Reuse pipe
diameters vary depending on the landscape scheme which may vary from one land use
context to another. Since irrigation systems within urban areas are generally decentral-
ized, the maximum pipe diameter of these systems will be 600mm.
This report provides corridors for larger diameters in providing a primary supply / trans-
mission main through the development. The larger corridors are only permitted on
wider streets or in open spaces. The pipe corridor width requirements for the different
pipe diameters are shown in Table 0-4.

Table 0-4 Reuse Pipe Corridor Requirements

Size of Pipe Corridor Width

150mm 350mm
200mm 400mm
250mm 450mm
300mm 500mm
350mm 550mm
400mm 600mm
450mm 650mm
500mm 700mm
600mm 800mm

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2.2.2 Reuse Pipe Appurtenances

Reuse water system appurtenances mainly include isolation valve chambers. However,
other types may be used on primary supply mains, such as washout valve chambers,
and air vent chambers. All details will be in accordance with Bureau of Indian standards
and typical details, with the exception of surface finishes, which will be in accordance
with the requirements of the street scape standards. For valve chambers on the main
line at intersecting pipes, the chamber shall be designed for single valve installation so
as to reduce the chamber dimensions. In instances where two valves shall be installed
at a T connection, each valve shall be installed in a separate chamber before the street
intersection.

2.2.3 Reuse Pipe Corridor

The minimum primary Reuse pipe corridor width will be equal to the width required
for the pipe installation. The maximum allowed corridor width is determined by the
outer dimensions of the largest chamber required for the pipe to be installed. In in-
stances where the street ROW is limited, the reuse pipe chambers are allowed to en-
croach on the corridor of the adjacent utility provided the pipe / cable corridor width of
the adjacent utility is maintained. In most cases, the reuse pipe chamber is allowed to
encroach on the tree corridor. Based on the same principles outlined for other utilities,
chambers / appurtenances of adjacent utilities will be allowed to encroach on the reuse
pipe corridor provided the required pipe corridor width is maintained. The pipe and
chamber corridor widths required for the primary irrigation system for the different
street families are presented in Table 0-5.

Table 0-5 Reuse Pipe Corridor Allocation

Street Family Pipe Corri- Chamber
dor Width Corridor
Width
Local Roads <=0.350m 1.50m
Collector 0.50m 2.00m
Roads
Sub Arterial 0.80m 2.20m
Roads
Arterial 0.80m 2.20m
Roads
Major Arte- 0.80m 2.20m
rial Roads

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The number of Reuse pipe corridors per street is determined by the number of tree
corridors required. With regard to secondary supply lines, these shall be installed within
the tree corridor.

2.2.4 Reuse Pipe Depth

The depth of Reuse pipes will be in accordance with the CPHEEO/IS standards. The
minimum depth of Reuse pipes is 1.0m for primary lines and 0.3m for secondary lines.
In all instances, the Reuse pipe will be installed below water pipes with a minimum
vertical clearance of 300mm. In cases where an irrigation pipe crosses over a water
pipeline, especially at house connections and at intersections, all pipes will be encased
in concrete or installed within a sleeve.

2.2.5 Special Arrangements

Although the foregoing corridor requirements can accommodate most Reuse pipe ap-
purtenances, a few appurtenances/ chambers might require special arrangements/ con-
siderations, such as washout chambers. It is recommended that such chambers be in-
stalled, whenever possible, within parks, landscaped areas and open spaces.

2.2.6 Location of The Reuse Pipe Corridor

A minimum clear distance of 1.0m shall be maintained between the reuse pipe corridor
and any potable water corridor. This distance can be reduced to 0.8m if a third utility
separates the water from the irrigation corridor. Irrigation corridors will not be allowed
under the carriageway unless there is no available space under the sidewalk and / or
block paved surfaces. However, it is placed as close as possible to any landscaping strip
/ tree corridors.

2.2.6.1. Reuse Pipe Horizontal and Vertical Clearance with Other Utilities
The minimum clearance with power distribution will be in accordance with the require-
ments of IS:1255. For other utilities international standards like Gainesville Regional
Utilities - Utility Separation Requirement, NF P 98 – 332 (French Guidelines),
GB50289 (Chinese Guidelines) were followed. Minimum Clearance’s for reuse mains
with other utility mains are given in Table 0-6.

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Table 0-6 Minimum Clearances for Reuse Pipe Mains with other Utility Mains
Utility Horizontal Clearance (m) Vertical Clearance (m)

Water supply 0.6 0.2

Sewerage 0.5 0.2
Reuse Water Line 0.5 0.2

Storm 0.5 0.2

Power 220KV 0.5 0.2
Power 33KV 0.3 0.2
Power 415V 0.3 0.2
Gas 0.5 0.4
ICT 0.5 0.2
District Cooling 0.5 0.3
In all instances, the reuse pipe will be installed below water supply pipe with minimum
vertical clearance as specified above. In case where reuse line crosses over a water
pipeline, all pipes will be encased in concrete.
Risks that might arise due to noncompliance of minimum horizontal and vertical clear-
ances are as follows
 Contamination of reuse water with water supply water.

 Operation and maintenance issues during pipe bursts, leakages, etc.,

 Ultimately at ages, pipelines corrode, leak and fail; adequate spacing to be

provided as a barrier for separation.

2.3 Wastewater Collection Corridor

Similar to the water supply system, two criteria dictate the required corridor width for
the wastewater collection network. The first is the pipe corridor width as determined by
the pipe diameter, and the second is the manhole width/ diameter. While the former
imposes the minimum width required for the whole length of the corridor, the latter is
normally required at connections and changes in direction or slopes at manhole loca-
tions.

2.3.1. Wastewater Pipe Corridor Width Requirements

Pipe corridor width requirements are generally based on pipe diameters. The required
pipe diameter varies depending on the wastewater flow which in turn depends on the
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land use context as well as the street type. In general, larger pipes are expected to run
within the wider roads. The pipe corridor width requirements for the different pipe di-
ameters are shown in Table 0-7.

Table 0-7 Waste Water Pipe Corridor Requirements

Size of Pipe Corridor Width

200mm 600mm
250mm 650mm
300mm 700mm
350mm 750mm
400mm 800mm
450mm 850mm
500mm 900mm
600mm 1000mm
700mm 1100mm
800mm 1200mm
900mm 1300mm
1000mm 1400mm
1100mm 1500mm
1200mm 1600mm
1300mm 1700mm
1400mm 1800mm
1500mm 1900mm
1600mm 2000mm
1700mm 2100mm
1800mm 2200mm
1900mm 2300mm
2000mm 2400mm

2.3.2. Wastewater Manholes

Manhole dimensions and details will be in accordance with CPHEEO standards and
typical details.
Additional space will be given wherever drop manholes are provided. For riders 0.80m
diameter inspection chambers are provided at the edge of RoW

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2.3.3. Wastewater Pipe Depth

The minimum depth of the wastewater pipe will be in accordance with the requirements
of CPHEEO, and as per the design requirements. The minimum depth of wastewater
pipe is 0.6m for wastewater riders and 1.0m for wastewater mainlines. Consideration
for varying the depth of sewer lines is done so as to allow for vertical clearance of storm
drains, in particular at intersections and for house service connection installation.

2.3.4.Wastewater Pipe Horizontal and Vertical Clearances with Other Utilities

The minimum clearance with power distribution will be in accordance with the require-
ments of IS:1255. For water supply clearance is in accordance with CPHEEO guide-
lines. For other utilities, international standards like NF P 98 – 332 (French Guidelines),
GB50289 (Chinese Guidelines) were followed. Minimum Clearance’s for wastewater
mains with other utility mains are given in Table 0-8.

Table 0-8 Minimum Clearances for Wastewater Mains with other Utility Mains
Utility Horizontal Clearance (m) Vertical Clearance (m)

Water supply 3.0 0.2

Sewerage 0.5 0.2
Reclaimed Water Line 0.5 0.2
Storm 0.5 0.2
Power 220KV 0.5 0.2
Power 33KV 0.3 0.2
Power 415V 0.3 0.2
Gas 0.5 0.4
ICT 0.5 0.2
Solid Waste Chute 0.5 0.3

In all instances, the wastewater pipe will be installed below water supply pipe with
minimum vertical clearance as specified above. In case where a wastewater line crosses
over a water pipeline, all pipes will be encased in concrete. For wastewater riders, the
clearance with ICT and power distribution is reduced to 0.3m.
Risks that might arise due to noncompliance of minimum horizontal and vertical clear-
ances are as follows

 Contamination of ground water, water supply.

 Extensive damage caused to neighborhood streets by the collapse of a sewer

line.
 All piped utilities suffer damage, aging and wear.
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2.3.5.Wastewater Corridor
The minimum corridor width will be equal to the width/ diameter of the largest manhole
along the pipe and will not be less than the required pipe corridor width. In instances
where the street ROW is limited, the manholes will be allowed to encroach on the ad-
jacent space, which is defined as a shared corridor between adjacent utilities. The shared
corridor will under no circumstances extend into the dedicated pipe/ cable corridor of
the adjacent utility. Based on the same principle, chambers/ appurtenances of adjacent
utilities will be allowed to encroach on the wastewater corridor provided the required
pipe corridor width for wastewater pipes is maintained. The standard minimum pipe
and manhole corridor widths required for the wastewater system for the different street
families are presented in Table 0-9.

Table 0-9 Wastewater Corridor Allocation

Street Family Pipe Corri- Manhole Cor-

dor Width ridor Width
Local Roads <=0.80m 1.80m
Collector 1.40m 2.30m
Roads
Sub Arterial 2.00m 3.16m
Roads
Arterial 2.00m 3.16m
Roads
Major Arte- 2.00m 3.16m
rial Roads

In some instances, where the ROW is limited, and taking into consideration the land
use context and expected discharges from the various buildings/ dwellings along the
streets, the pipe and manhole corridor widths may be eliminated and only riders with
inspection chambers are provided.

2.3.6. Location of The Wastewater Corridor

A minimum clearance of 3.0m will be maintained between the wastewater pipe and any
potable water pipe. Wastewater corridors are provided under the carriageway to avoid
the clearances with potable water supply pipes. And wastewater riders are provided at
the edge of RoW for house service connections.

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2.3.7. Wastewater Force Mains

Wastewater force mains will be installed in accordance with design requirements as per
CPHEEO standards. Based on the design of the wastewater system, the force main shall
be installed within a dedicated corridor under the carriageway in accordance with cor-
ridor widths for force main requirements.
2.4 Storm water Drainage
The corridor widths for the storm water collection system are determined by the re-
quirements for drain and appurtenance installation. The corridor width is determined
by the drain widths.

2.4.1. Storm Water Drainage Corridor Width Requirements

Corridor width requirements are generally determined by the minimum requirements
for drain installation and hence depend on the drain size and the type of soil. Drain sizes
vary depending on the street type and its ROW since in general, storm water is drained
from smaller streets to larger streets provided the gradient allows for such gravity flows
in order to optimize the storm water corridor width. The corridor width requirements
for the different sizes are shown in Table 0-10.

Table 0-10 Storm water Drain corridor requirements

Size of Drain (mm) Corridor Width (mm)
450x450 700mm
600x600 1000mm
750x750 1250mm
900x900 1400mm
1000x1000 1500mm
1500x1500 2000mm
2000x2000 2600mm
2400x2400 3000mm

2.4.2. Special Arrangements

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Although the foregoing corridor requirements can accommodate most drains, few
chambers might require special arrangements/ considerations, such as Silt, Floating de-
bris/grease removal chambers. It is recommended that such chambers be installed,
whenever possible, within parks, landscaped areas along roads and open spaces.

2.4.3.Storm water Drain Horizontal and Vertical Clearances with Other Utilities
The minimum clearance with power distribution will be in accordance with the require-
ments of IS:1255. For water supply clearance CPHEEO guidelines are maintained. For
other utilities international standards like Sydney water, NF P 98 – 332 (French Guide-
lines), GB50289 (Chinese Guidelines) were followed. Minimum Clearance’s for storm
water drains with other utility mains are given in Table 0-11.

Table 0-11 Minimum Clearances for Storm water Drain with other Utility Mains
Utility Horizontal Clearance (m) Vertical Clearance (m)

Water supply 0.6 0.2

Sewerage 0.5 0.2
Reuse Water Line 0.5 0.2
Storm 0.5 0.2
Power 220KV 0.5 0.2
Power 33KV 0.3 0.2
Power 415V 0.3 0.2
Gas 0.5 0.4
ICT 0.5 0.2
District Cooling 0.5 0.3

In case where a storm water line crosses over a water pipeline, water lines will be en-
cased in concrete.
Risks that might arise due to noncompliance of minimum horizontal and vertical clear-
ances are as follows

 Obstruction to runoff discharge.

 Structures life may be reduced due to wear & tearing effect/abrasion during the
floods.

2.4.4. Storm water Drainage Corridor

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The storm water corridor width will be greater of the width of the largest drain along
the road or the required corridor width. In instances where the street ROW is limited,
the storm water drains will be allowed to encroach on the corridor of the adjacent utility,
provided the pipe/ cable corridor width of the adjacent utility is maintained. Similar to
other utilities, chambers / appurtenances of adjacent utilities shall be allowed to en-
croach on the storm water corridor provided the required corridor width is maintained.
The corridor widths required for the storm water pipes for the different street families
are presented in Table 0-12.

Table 0-12 Storm water corridor allocation

Street Family side 1 side 2

Local Roads 1.25m 1.25m

Collector Roads 2.00m 2.00m
Sub Arterial Roads 3.00m or swale 3.00m
Arterial Roads 3.00m or swale 3.00m
Major Arterial Roads 3.00m or swale 3.00m

2.4.5. Location of the Storm Water Corridor

Local storm water corridors are located at the edge / curb of the carriageway with catch
pit arrangement. The main storm water corridor will be located under the NMT
zone/sidewalks, as shown in the proposed utility disposition drawings. Where ever pos-
sible, green buffer zones adjacent to roads were proposed for swales. In instances where
a subsurface drainage system is needed to lower the groundwater table, the system shall
be located within the same corridor allowed for the main storm drains.
2.5 Power Supply Corridor
The power supply comprises EHV, HV, MV, LV and street lighting. The following sub-
sections define the corridor width and location for each of these installations.

2.5.1. Extra High Voltage and High Voltage Corridors

All HV trenches, joint pits and corridors shall conform to, and be in accordance with,
AP Transco requirements and typical details. The maximum external chamber widths
are 4.5m for EHV and HV Corridors respectively. The EHV and HV corridors will be
located under the median/walkway. The allowed corridor width will accommodate the

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EHV/HV cables, joint pit, link box including joint and route markers. All the lines are
taken through accessible concrete duct. The power cables are placed with a horizontal
spacing of 330mm (3 x dia of cable) between each other and vertical spacing of 500mm
between each other. AP Transco cables are generally installed with a minimum cover
of 1.2m.
The typical
arrangement of
HV lines inside
accessible
RCC duct is shown
in Figure 2.

Figure 2 : Typical EHV cable arrangement inside accessible RCC duct

2.5.2. Medium and Low Voltage Corridors
According to the current practice worldwide, fiber optic cables (FOC) are installed
alongside the power cables. All MV pipe conduits/manholes, FOC conduits/manholes
and corridors will be installed within the same allocated corridor. The FOC will be laid
through separate PVC conduit(s) at the same depth as and adjacent to the power cable
conduit(s), and in the same trench. All LV trenches and corridors will conform to the
requirements and typical details. In order to allow for more flexibility in installation,
combined corridors will be allocated for both MV and LV cables. The number of cables,

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and consequently Conduits / corridor width for both MV and LV, varies between land
use contexts and street types depending on the electrical loads and the number of storeys
per building. The spacing between MV cables (33Kv) will be 150mm. Whenever nec-
essary, the spacing can be reduced to 100mm, subject to approval. Similarly, LV cables
will be installed with a spacing of 100mm and the spacing can be reduced to 50mm
whenever necessary, also subject to approval.
Table 0-13 provides the corridor width for LV / MV / HV, for guidance only. All LV /
MV conduits will be located under sidewalks and / or NMT corridors. LV / MV cables
are generally installed at depths varying between 0.75m and 1.05m respectively.

Table 0-13 Power corridor allocation

Street Family Side 1 Side 2

Local Roads 1.10m 0.85m

Collector Roads 1.10m 1.10m

Sub Arterial Roads 6.00m -

Arterial Roads 6.00m -
Major Arterial 6.00m -
Roads

Power Distribution networks comprise chambers for connections to/from feeder pillars
and house service connections. All details will be in accordance with relevant standards.
External chamber dimensions for different pipe conduit types are shown in Table 0-14.
For chambers at intersections, it is recommended to have chambers before and after the
bends for reducing the chamber dimensions as the cable required minimum of 20 times
the diameter as bending radius. However, if a common chamber is to be used, the cham-
ber will be allowed to encroach on the adjacent corridor.

2.5.3. Power Cables Horizontal and Vertical Clearances with Other Utilities
The minimum clearance with power distribution will be in accordance with the require-
ments of IS:1255. For other utilities international standards like NF P 98 – 332 (French
Guidelines), GB50289 (Chinese Guidelines) were followed. Minimum Clearance’s for
power cables with other utility mains are given in Table 2.5.4 1.

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In all instances, the Power conduit will be installed below gas pipe with minimum ver-
tical clearance as specified below. In case where a power conduit crosses over a gas
pipeline, all conduits will be encased in concrete.
Risks that might arise due to noncompliance of minimum horizontal and vertical clear-
ances are as follows
 Increased magnetic fields.
 Increased risk of Short circuits through other utilities (metal pipes).

2.5.4. Special Arrangements

The Compact substations within residential developments will be strategically located
in the middle of the block of buildings/ villas within a street / access lane, to the extent
possible, so as to distribute the load in two directions and thus optimize availability of
adjacent corridors for LV cables. EHV substations will be strategically located on
50m/60m roads with access. 33KV switching stations are strategically located along
25/50m roads. Duct banks may also be used to distribute the load from a EHV substa-
tion to reach the first junction on major roads. Wherever grid stations(400/220KV) are

Utility EHV / HV Cables MV/LV Cables

(<=220KV) (>=33KV)

Horizontal Vertical Clear- Horizontal Vertical Clear-

Clearance (m) ance (m) Clearance (m) ance (m)
Water supply 0.6 0.2 0.3 0.2
Sewerage 0.5 0.2 0.3 0.2
Reclaimed Water 0.5 0.2 0.3 0.2
Line
Storm 0.5 0.2 0.3 0.2
Power 220KV 0.2 0.2 0.2 0.2
Power 33KV 0.2 0.2 0.25 0.2
Power 415V 0.2 0.2 0.15 0.15
Gas 1.0 0.5 0.3 0.3
ICT 0.5 0.4 0.3 0.2
Solid Waste 0.5 0.3 0.3 0.3
Chute
proposed, a dedicated corridor for the EHV lines connecting grid stations are given in
accordance with APTRANSCO requirements. In Distribution Feeder pillar will be
placed along the edge of the RoW and with a provision of 0.6m width and the sidewalks
and nmt zones at those locations will encroach into the multifunction zones.
Table 0-14 Minimum Clearances for Power with other Utility Mains
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Where RCC ducts are used the Verticle and Horizontal clearences shall be 0.1 m from the edge
of the duct subject to the clearances given in the table above for the cables.

Where HDPE ducts are used the Vertical and Horizontal clearances shall be 0.2 m from the
edge of the pipe subject to the clearences given in the table above for the cables.

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2.5.5. Location of the (MV/LV) Corridor

MV / LV corridors shall be located under the sidewalk, NMT Zones so as to facilitate
maintenance operations. The allocated corridor width for MV / LV corridors shall be
maintained and no encroachment by other utilities is allowed into this corridor.

2.5.6. Street Lighting Corridors

Street lighting (SL) cables / trenches shall be installed in accordance with the require-
ments and will follow the same configuration required for LV cables. Street lighting
poles shall be in accordance with relevant standards. The street lighting corridor will be
shared with the corridor allocated for trees/multifunction zones. The power supply to
street lights shall be provided from the feeder pillars located on the edge of the RoW
and fed from the LV cables installed adjacent to streel lights in tree zones/multi-function
zone. The SL cable arrangement shall be in accordance with design requirements. At
the tree pit, the cables shall be installed in conduits and arranged at the corridor edge.
The SL corridor width shall be 1.0m depending on space limitations. Street lighting
corridors shall be provided on one or both sides of the road and on the median, depend-
ing on road width and street lighting design.
Table 0-15 summarizes the street lighting corridor requirements depending on the dif-
ferent street types.

Table 0-15 Streetlight corridor requirements

Street Family side 1 Median side 2

Local Roads 1.0m - 1.0m

Collector Roads 1.0m 1.0m 1.0m

Sub Arterial Roads 1.0m 1.0m 1.0m

Arterial Roads 1.0m 1.0m 1.0m
Major Arterial Roads 1.0m 1.0m 1.0m

2.6 ICT Corridors

The Fiber Optic lines generally pertain to the following requirements:
 Telecom operators
 Intelligent Transportation System (ITS)
 Police
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 Area Traffic Control (ATC)

 Safety and security
 Disaster Management.
 Public Utilities operation and control systems (SCADA)
Fiber optic lines are grouped in three main categories, as follows:
 High security fiber optic lines, which include Safety and security lines, Police lines.

 Regular fiber optic lines, which include Intelligent Transportation System lines, and
Police, traffic police related communication lines, public utilities control lines, other
public services lines.

 Telecom fiber optic lines

High Security fiber optic lines, regular fiber optic lines and telecom fiber optic lines are
installed in the same corridor. But separate manholes are being provided for each cate-
gory on all major roads. For local roads, only regular fiber optic lines and telecom fiber
optic lines are installed. ICT and power distribution corridors are combined for distri-
bution systems.

2.6.1. ICT Duct Corridor Width Allocation

The duct corridor width of the installations is governed by the number and size of ducts
to be installed, the spacing between ducts.
In order to accommodate the various utilities sharing the corridor and their require-
ments, the fiber optic duct corridor dimension shall be based on the formation compris-
ing 40mm dia each 7-way conduits and 110mm diameter conduits. The minimum spac-
ing between conduits is maintained at 100mm for spacers.

Table 0-16 ICT corridor allocation

Street Family side 1 side 2
Local Roads 0.30m 0.30m
Collector Roads 0.60m 0.60m

Sub Arterial Roads 1.00m -

Arterial Roads 1.00m -
Major Arterial Roads 1.00m -

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Similar to other utilities, if allocated space is not sufficient for the installation of the
telecom manhole, the designer is allowed to use the shared corridor. In this instance,
the manhole is allowed to encroach on the corridor of adjacent utilities provided the
minimum pipe / cable corridor width of the adjacent utility is maintained. Similarly,
other utility appurtenances are allowed to encroach on the telecom corridor provided
the encroachment does not extend into the telecom duct corridor. The minimum cover
requirement for ICT line is 0.75m.
2.6.2. ICT Manhole Corridor Width Requirements
As stated previously, the manhole corridor width is determined by the outer dimensions
of the manholes used. Based on the currently used manhole sizes of both utility provid-
ers, the maximum outer width of manholes is 2.0m for major roads. For local roads,
common manholes are provided for power distribution and ICT conduits. Manhole cor-
ridor width requirements for telecom cables in distribution are indicated in Table. Sim-
ilar to other utilities, if allocated space is not sufficient for the installation of the telecom
manhole, the designer is allowed to use the shared corridor. In this instance, the manhole
is allowed to encroach on the corridor of adjacent utilities provided the minimum pipe
/ cable corridor width of the adjacent utility is maintained. Similarly, other utility ap-
purtenances are allowed to encroach on the telecom corridor provided the encroachment
does not extend into the minimum telecom duct corridor.
2.6.3. Special Arrangements
Security camera poles for the Falcon Eye system, where required, shall be located along
the corridor dedicated for street lighting / trees. The locations of the poles will be given
priority / precedence over trees and lighting poles. When placed within the street light-
ing / trees corridor, a minimum of two pass-thru conduits shall be provided within the
manhole and pile foundation of the pole of the FE system to secure passage for the
street lighting cables.
2.6.4. ICT Horizontal and Vertical Clearances with Other utilities
The minimum clearance with power distribution will be in accordance with the require-
ments of IS:1255. For other utilities international, standard NF P 98 – 332 (French
Guidelines) are taken. Minimum Clearance’s for ICT lines with other utility mains are
given in Table 0-17.

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Table 0-17 Minimum Clearances for ICT pipes with other Utility Mains
Utility Horizontal Clearance (m) Vertical Clearance (m)

Water supply 0.6 0.2

Sewerage 0.5 0.2
Reclaimed Water Line 0.5 0.2
Storm 0.5 0.2
Power 220KV 0.5 0.4
Power 33KV 0.3 0.2
Power 415V 0.3 0.2
Gas 0.2 0.2
ICT 0.2 0.2
District Cooling 0.3 0.4

Risks that might arise due to noncompliance of minimum horizontal and vertical clear-
ances are as follows
 will not have enough space for overhaul & Maintenance.

2.6.5. Location of the ICT Corridor

ICT Corridors will be located under the parking lane, Sidewalks and NMT Zones so as
to facilitate maintenance operations.

2.7 Gas Corridors

Gas pipes and valve chambers, as well as all related gas supply network elements, will
be in accordance with APGDC Distribution general requirements and standard details.
Similar to the other piped systems, two criteria dictate the required corridor width for
the gas network. The first is the pipe corridor width as determined by the pipe diameter,
and the second is the manhole width/diameter. While the former imposes the minimum
width required for the whole length of the corridor, the latter is normally required at
control valves.

2.7.1. Gas Pipe Corridor Width Requirements

Pipe corridor width requirements are generally based on pipe diameters. The required
pipe diameter varies depending on the gas flow which in turn depends on the land use

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context as well as the street type. In general, larger pipes are expected to run within the
wider roads. The pipe corridor width requirements for the different pipe diameters are
shown in Table 0-18.

Table 0-18 Gas Pipe Corridor Requirements

Size of Pipe Corridor Width

150mm 350mm
200mm 400mm
250mm 450mm
300mm 500mm
350mm 550mm
400mm 600mm

2.7.2. Gas Manholes

Manhole dimensions and details will be in accordance with APGDC standards and typ-
ical details.
2.7.3. Gas Pipe Depth
The minimum depth of the Gas pipe will be in accordance with the requirements of
IS:15663, and as per the design requirements. The minimum depth for gas pipe in resi-
dential industrial and commercial areas is 1.0m and for road crossings it is 1.2m.

2.7.4. Gas Pipe Horizontal and Vertical Clearances with Other Utilities
The minimum clearance with power distribution will be in accordance with the require-
ments of IS:1255. For other utilities, international standards like NF P 98 – 332 (French
Guidelines), GB50289 (Chinese Guidelines) were followed. Minimum Clearance’s for
gas lines with other utility mains are given in Table 0-19.

Table 0-19 Minimum Clearances for Gas mains with other Utility Mains

Utility Horizontal Clearance (m) Vertical Clearance (m)

Water supply 0.6 0.4

Sewerage 0.5 0.4
Reclaimed Water Line 0.5 0.4
Storm 0.5 0.4
Power 220KV 1 0.5
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Power 33KV 0.3 0.3

Power 415V 0.3 0.3
Gas 0.15 0.6
ICT 0.2 0.2
District Cooling 0.5 0.4

In all instances, the gas pipe will be installed above power lines with minimum vertical
clearance as specified above. In case where a gas line crosses below a power line, gas
pipe joints will be away from those crossings.
Risks that might arise due to noncompliance of minimum horizontal and vertical clear-
ances are as follows
 Increase in risk due proximity with power lines.

 will not have enough space for overhaul & Maintenance.

 All piped utilities suffer damage, aging and wear.

2.7.5. Gas Corridor

The minimum corridor width will be equal to the width/ diameter of the largest manhole
along the pipe and will not be less than the required pipe corridor width. In instances
where the street ROW is limited, the manholes will be allowed to encroach on the ad-
jacent space, which is defined as a shared corridor between adjacent utilities. The shared
corridor will under no circumstances extend into the dedicated pipe/ cable corridor of
the adjacent utility. Based on the same principle, chambers/ appurtenances of adjacent
utilities will be allowed to encroach on the gas corridor provided the required pipe cor-
ridor width for gas pipe is maintained. The standard minimum pipe and manhole corri-
dor widths required for the gas system for the different street families are presented in
Table 0-20.

Table 0-20 Gas Corridor Allocation

Street Family Pipe Corri- Manhole Cor-
dor Width ridor Width
Local Roads 0.40m 1.20m
Collector 0.45m 1.30m
Roads
Sub Arterial 0.60m 1.50m
Roads
Arterial Roads 0.60m 1.50m
Major Arterial 0.60m 1.50m
Roads

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To facilitate house connection crossings with other utilities, ducts shall be installed to
allow for gas pipe crossings during the installation of gas pipes.
2.7.6. Location of the Gas Corridor
Gas corridors are provided under the NMT Zones/Sidewalks.
 Minimum proximity distance from buildings to PE gas mains is 5.0m for pipe
diameters of up to 315mm (MOP 4 barg);
 Minimum proximity distance from buildings to PE gas mains is 8.0m for pipe
diameters of more than 315mm (MOP 4 barg);
 Minimum proximity distance from buildings to steel gas mains of MOP 16 barg is
13.0m.
 Minimum clearance between gas mains and low voltage electrical cables is 300mm
in any direction; and
 A minimum clear distance of 500mm will be maintained between gas pipeline
corridors and any electrical / power cables (MV/HV), other than low voltage
electrical cables.
3. Utility Installation Overview
Installation of all utilities shall be carried out in accordance with the specifications and
concerned authority.
All utilities shall be installed prior to the final finishing of roads and sidewalks in order
to avoid the breaking up of finished surfaces. Similarly, all house connections shall be
installed up to the plot limit, to avoid cutting the surfaces for utility connections.
All utilities crossing the carriageway shall be encased in concrete if the minimum depth
requirements cannot be achieved to protect the utilities from damage due to traffic
loads. Also, any utility which is required to be placed under the sidewalk, but instead is
placed under the carriageway due to space limitations, shall also be encased in concrete
if the minimum depth requirement cannot be achieved.
Root barriers and / or root-directors shall be used in all tree pits, so as to direct the
growth of the roots in downward direction. During paving, the backfill surrounding the
root barrier / root director must be compacted sufficiently to support the paved surface
material and discourage roots from reaching back up to the surface layers. The barrier
must be installed from the surface level to a minimum of 1.0m below surface level with
joints overlapped by 300mm.

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4. Utility Corridor Arrangement

The typical utility corridor sections were prepared, taking into consideration all the re-
quirements discussed in previous chapters. All plot connections are provided through
collector and local roads as specified in master plan. The allocated corridor for each
utility is the maximum allowed for each utility, unless otherwise stated.
The number and width of utility corridors for each utility have been allocated based on
the expected demands / discharges taking into consideration the context type, the street
category, and ultimate capacity calculations and the same have been given in Annexure
I. The type / nature of connections to the plots, and the crossing requirements were also
maintained. All spacing requirements as given in Schedule-D are maintained while pre-
paring Typical cross sections. To avoid conflicts near junctions/ crossings and for mak-
ing decision whenever a conflict occurs between utilities, a conflict mitigation matrix
has been prepared and presented in Schedule-D.

Annexure I
Utility Corridor Allocation in Street Family

Road / Item Water Sewerage Reuse Storm Power Power Power ICT Gas District
supply 220KV 33KV 415V Cooling

Sub arterial 2.5 2.4 0.6 3+3 6.0 2.4 0.8 0.5 -

Sub arterial 2.5 2.4 0.6 3+3 6.0 2.4 0.8 0.5 4.5
@ Govt Com-
plex
Arterial 2.5 2.4 0.6 3+3 6.0 2.4 0.8 0.5 -

Arterial @ 2.5 2.4 0.6 3+3 6.0 2.4 0.8 0.5 4.5
Govt Complex

Major Arterial 2.5 2.4 0.6 3+3 6.0 2.4 0.8 0.5 -

Major Arterial 2.5 2.4 0.6 3+3 6.0 2.4 0.8 0.5 4.5
@ Govt Com-
plex

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Schedule C - Project Facilities

(See Clause 2.1)

Contents

Project Facilities..................................................................................................................

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1.0 Project Facilities

The Contractor shall design and construct the Project Facilities in accordance with
the provisions of this Schedule C. Such Project Facilities shall include;
1.1 Project Facilities
Each of the Project Facility is briefly described below;
Road Side Furniture / Road Markings & Signage
Road Side furniture and Road markings & signage shall be provided in accordance
with the provisions as per Schedule D.
The road side furniture shall include the provision of the:
i) Traffic Sign:
Traffic signs include roadside signs and curb mounted signs along the entire road
network in scope. Signage shall be provided as per IRC Standards.
ii) Pavement markings:
Pavement markings shall cover road marking for the entire road network in scope as
per IRC standards.
iii) Pedestrian facilities:
The Pedestrian facilities shall include the provision of the;
Pedestrian crossing facilities at intersections and mid-block locations required by the
Employer.
iv) Street Lighting
Street lighting within the scope of work in the Right of Way shall be as per road
plans in drawings volume. This work comprises of poles & fixtures, lighting cables,
optical fibre cables, controllers etc.

Proposed Minimum
S. No. Element Illumination Level (Lux)
1 Roads (BRT lane)
In accordance with the
2 Cycle track and side walk Standards and
specifications
3 Junctions and Pedestrian Crossings

Street lighting shall be provided in accordance with the Standards and Specifications
as referred in Schedule-D.

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Schedule D - Specifications and Standards

(See Clause 2.1)

Technical Specifications and Standards:

Annexure-I (A): Specifications and standards for construction of roads............................

Annexure-I (B): Storm water drainage................................................................................

Annexure-I (C): Potable water supply.................................................................................

Annexure-I (D): Recycled water supply..............................................................................

Annexure-I (E): Sewerage network....................................................................................

Annexure-I (F): Pipe Conduits and RCC ducts for power Cables......................................

Annexure-I (G): Pipe Ducts for ICT.............................................................................................

Annexure-I (H): Design Life........................................................................................

Annexure-I (I): Clash Analysis........................................................................................

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Contents

1.0 Construction

The Contractor shall comply with the Specifications and Standards set forth in Annex-
I of this Schedule-D for construction of the Project Road.

2.0 Design Standards

The Project Road shall conform to design requirements set forth in Annex-I of this
Schedule-D.

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Annexure – I (A)

Specifications and Standards for Construction of Roads

1.0 Roads
Standards and Specifications of following project components are given in this section;
• Road works: road furniture, road markings, road signage, traffic control
devices, safety works, pedestrian facilities, median plantation, etc.
 Structures: storm water drainage structures etc.

1.1 The Codes, Standards and Technical Specifications applicable for the design and
construction of project components are:

i. Indian Roads Congress (IRC) Specifications, Standards, Design Codes

ii. IRC Special Publications

iii. Ministry of Surface Transport Publications (Now Ministry of Shipping,

Road Transport & Highways)

iv. IRC Seminar Publications

v. Policy circular/Advisory letters issued to all states/UTs on the matter

pertaining to urban transport April 2008 – October 2014
vi. Geometric Design standards for Urban roads in Plains i.e. IRC: 86-1983
vii. Any supplement issued with the bid document

Latest version of the Codes, Standards, Specifications, etc., notified/published at least

60 days before the last date of bid submission shall be considered applicable.

1.2 Where the Contractor intends to use an alternative to these Standards/Guidelines for
delivering an equal or better product, he shall be permitted to use such alternative
subject to the following conditions:
He shall demonstrate that the proposed alternative conforms to any of the following
International Standards, Codes of Practice, Specifications, Guidelines, etc.

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i. American Association of State Highway and Transportation Officials

(AASHTO)
ii. American Society for Testing of Materials (ASTM)
iii. Euro Codes
iv. National Standards of any of the following countries: United States of
America (USA), Canada, United Kingdom (UK), France, Germany,
Sweden, Denmark, Norway, Netherlands, Spain, Australia, New Zealand,
Japan and South Africa
In case the Contractor intends to use any alternative material/ technology/ method,
whether patented or otherwise, that is not specifically covered in the Indian or
International Standards as listed above, but the use of which has been permitted on
similar projects (similar in category of road, traffic and climatic conditions) as the
Project Road, he would be permitted, its use on certification by the owners of such
similar projects regarding the continued successful performance of such materials,
technologies, methods, procedures or processes for at-least 5 years of the service life
of the project. Such a certification shall be supported with details of critical
performance parameters.

1.3 Standards and Specifications for Construction

The Contractor shall comply with the Standards and Specifications for Construction
of roads and utilities / services as given below.
All materials, works and construction operations shall conform to the Specifications
for Road and Bridge Works (Fifth Revision, April 2013), issued by the Ministry of
Road Transport & Highways (MoRT&H). Where the Standards and Specifications for
a work are not given, Good Industry Practice shall be adopted to the satisfaction of the
Employer’s Engineer.
1.4 List of Standards

List of Standards are given in Table: 1, Table: 2, Table: 3 and Table: 4.

Latest revision of codes shall be referred.

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Table-1
Code/
S. No. Description Document
No
1 Recommended Practice for the Design and Layout of Cycle Tracks IRC:11

2 Space Standards for Roads in Urban Areas IRC:69

3 Guidelines on Regulation and Control of Mixed Traffic in Urban IRC:70

Areas
4 Geometric Design Standards for Urban Roads in Plains IRC:86

5 Guidelines on Accommodation of Underground Utility Services Along IRC:98

and across Roads in Urban Areas (Second Revision)
6 Tentative Guidelines on the Provision of Speed Breakers for Control of IRC:99
Vehicular Speeds on Minor Roads
7 Guidelines for Pedestrian Facilities IRC: 103

8 Guidelines for Capacity of Urban Roads in Plain Areas IRC: 106

9 Guidelines for the use of Interlocking Concrete Block Pavement IRC: SP: 63

10 Tentative Recommendations on the Provision of Parking Spaces for IRC: SP: 12

Urban Areas
11 Code of Practice for Road Markings (with Paints) (First Revision) IRC:35

12 Code of Practice for Road Signs (Third Revision) IRC:67

13 New Traffic Signs IRC: SP:31

14 Vertical Curves for Highways IRC: SP:23

15 Guidelines for the design of curves for Highways & Design tables IRC:38
(First Revision)
16 Guidelines on Design of At-Grade Intersections in Rural & Urban Areas IRC: SP: 41

17 Highway Safety Code IRC: SP: 44

18 Guidelines on Urban Drainage IRC: SP: 50

19 Tentative Guidelines for the Design of Flexible Pavements IRC:37

20 Dimensions and weights of Road Design Vehicles IRC:3

21 Guidelines for the Design and Construction of Cement Concrete IRC: SP: 62
pavements for Low Volume Roads

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Table-2

Design Standards/Guidelines used for design

Element of
roads/services Code No. Description

Ground HRB SR No.14 State-of-the-Art-Report: High Embankments on Soft

improvemen t Ground, Part B – Ground Improvemen t

HRB SR No.3 State-of-the-Art-Report: Compaction of Earthwork and

Embankment filling
Subgrades
IRC: 37 Tentative Guidelines for the Design of Flexible Pavements
IRC: 58 Guidelines for the design of plain jointed rigid pavement
Pavement design for highways
IRC: SP:62 Guideline for the design and construction of cement
concrete pavements for low volume roads
Road markings IRC: 35 Code of Practice for Road Markings (First Revision)

Signage IRC:67 Code of Practice for Road Signs (Third Revision)

Landscaping IRC: SP:21 Guidelines on Landscaping and Tree Plantation

Pedestrian facilities IRC:103 Guidelines for Pedestrian Facilities (First Revision)

IRC:11 Recommended Practice for the Design and Layout of Cycle

Cycle tracks Tracks
Safety features IRC: SP: 44 Highway Safety Code
IRC: 93 Guidelines on Design and Installation of Road Traffic
Traffic lights Signals
Junctions / Median IRC: SP:41 Guidelines on Design of At-Grade Intersections in Rural &
openings Urban Areas
Kerb and separator IRC:86 Geometric Design standards for Urban roads in plains
CPHEEO,
Guidelines for Road Drainage
Drains IRC SP-42
Guidelines for Urban Drainage
IRC SP-50

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Table -3 (Street Light- Standard for installation)

Code Standard for installation

IS:1255 Code of practice for installation and maintenance of power

cables up to and including 33 kV rating.
IEC:60947 Switchgear Protective Components.
IEC:60598 – 2 – 3 Particular requirements luminaries for road & street lighting.
IUT (Institute of Urban Transport) Standard for road lighting.
IS:2309 Code of practice for Lightning Protection.

IS:3043 Code of practice for Earthing.

Table-4 Street Light- Design Standards

Code Design Standards

Standard for XLPE Cables, Part – II up to 3.3 kV to 33 kV and Part– III
IS:7098 (Part- II & Part-III) 2003 from 33 kV to 220 kV).
IS:8130 Specification for conductors for insulated electric cables & flexible
cords.
Specification for PVC insulated (Heavy Duty) electric cables
 Part 1 For working voltages up to and including 1100
IS 1554 (Part I & Part – II)
 Part 2 For working voltages from 3.3 kV up to and including
11 kV

IEC:61439 Feeder Pillar & Switchgear (Totally Type Tested Assembly TTTA).
IEC:60947 Switchgear Protective Components.

IEC: 60598 – 2 – 3
 IUT (Institute of Urban  Particular requirements luminaries for road & street lighting
Transport)  Standard for road lighting
 CIE (Industrial commission of  Road Transport Lighting for Developing Countries
illumination)
IS:2309 Code of practice for Lightning Protection
IS:3043 Code of practice for Earthing
IS:1944 Code of practice for lighting of public thoroughfares
IS: 1367 Standards for Poles & Masts
 BS EN ISO 1461 (1) Recommended practice for hot-dip galvanizing of iron & steel
 BS EN 10025-1:2004 Hot dip galvanized coatings on fabricated iron and steel articles.
Specifications and test methods
(a) Hot rolled products of structural steels. General technical
delivery conditions

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Annexure – I (B)

Storm Water Drainage

Standards and Specifications for the Design & Construction of Storm Water Drainage are given
in this section.

The Scope of Work shall include:

 Detailed design, plans, L sections and construction drawings of storm water drain-
age system;
 Submission of SWD design calculations, plans and drawings for approval to the
client;
 Construction of storm water network as per approved design and plans; and
 Erection, Testing, Commission of the System and,
 Integration of main road trunk drains with the connecting LPS storm water drainage
network.

The contractor shall design and construct the storm water drainage network and shall
furnish all required tools, plant, instruments, materials including water, electricity, la-
bour, consumables, etc., any and everything necessary for construction of the works,
whether or not such items are specifically stated elsewhere in this bid.

The primary objective of drainage design is to protect the area from flooding and effi-
cient operation of systems during the design storm events. The drainage system is de-
signed to collect storm water run-off from roadway surface and right-of-way along with
runoff from LPS lots drainage network and convey it along and through the storm water
network and discharge into a receiving body above the design HFL without causing
adverse site impacts.

Storm water collection systems shall be designed to provide adequate surface drainage.
Surface drainage is a function of transverse and longitudinal pavement roughness, inlet
spacing and inlet capacity.

The discharge design facilities for storm water collection and conveyance systems in-
clude consideration of storm water quantity and quality. The general considerations in
design of storm water drain shall be:

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 Drains shall be design for appropriate design frequency/return period depending

on importance of development and economic considerations.

 Drains shall be planned taking into consideration the ground levels, slope of the
ground, valley and ridges and also the land uses planned for urban development.

 Drains shall be planned to get good longitudinal slope, considering the nature
of soil and subsoil water level. Drainage of large area can be better achieved by
subdividing it into small grids to avoid a long main drain. Aim should be to get
a high velocity for the dominant flow.

 Efficiency in maintenance of drainage system is an important consideration in

selecting the size, shape and the location. The specification of the drain shall
also aim at preventing the possibility of ingress of other extraneous materials,
debris, vegetation etc. where grating are provided on drains, they shall be so
located as to attract attention of maintenance staff, easy to approach, inspect and
clean it.

1.0 Catchments

Catchments shall be divided based on the topography and road layout. The outfalls shall
be proposed considering the topography and location of Trunk Drains /primary chan-
nels within the area.

1.1 Storm Frequency/ Return Period

The components of proposed storm water drainage system shall be designed for the
following design standards based on the national and international best practices:

 Once in 5year event flows for storm water drains;

The average intensity of rainfall for the above return period (t) event will be calculated
from rainfall data for the derived time of concentration of the catchment.

1.2 Rainfall Intensity

As no hourly rainfall data is available within proposed Capital City area, hourly rainfall
data for Gannavaram Airport has been considered in order to derive the Intensity-Du-
ration-Frequency curves. Hourly rainfall data for 47 years (1969 to 2015) is available
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from meteorological department. Rainfall intensity derived by analyzing the rainfall

data with rainfall Intensity-Duration-Frequency (IDF) curves for once in 2-year, 5- year
and 10-year criteria. Based on above data/information, Intensity-Duration-Frequency
(IDF) Curves for 2,5 and 10 years return period to estimate the design rainfall intensity
of various durations has been worked out and given below:

Table-1 - IDF
Table for
Gannavaram Airport (Hourly Rainfall Data 1969-2015)

Figure-1 IDF Curves at Gannavaram Airport (Hourly Rainfall Data 1969-2015)

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1.3 Other Design Parameters

1.3.1. Minimum and maximum velocity within drains

To ensure self-cleaning of the drain, a minimum velocity of 0.6 m/ s may be desirable.

(Ref: CPHEEO manual). The velocity of flow in a drain shall not be too great to cause
excessive scouring or hydraulic jumps. Hence maximum velocities shall be limited to
3.0m/sec within concrete drains.

1.3.2 Inlet Spacing

The spacing of inlets depends on condition of road surface size and type of inlet and
rainfall. They shall be provided at closer intervals near junctions and valley curves;
however maximum spacing shall not be more than 20 m.

1.3.3 Freeboard

Freeboard refers to the depth from the top of the drain (cope/bank) to the top of the
water surface in the drain at design flow condition. Sufficient freeboard shall be pro-
vided to prevent waves or fluctuation of the water surface from overflowing the
cope/bank. Free board shall be as per IRC SP 50 as below:

Table-2 Minimum Free Board

S. No. Drain Size Free Board

1. Beyond 300 mm bed width 10 cm

2. Beyond 300 mm & upto 900 mm bed 15 cm

width
3. Beyond 900 mm & upto 1500 mm bed 30 cm
width

Table-3 Design Basis Parameters

Parameter Expert Committee Recommendation

Design Storm Frequency 1 in 5 year
Check for Extreme Storm 1 in 100 year (for Hazardous Index)
Bridges 1 in 100 year

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Method Rational
Time of Concentration Overland Flow (IRC SP 42) + Time in
Drain
Runoff Coefficient Land Use Based (weighted)
Minimum Velocity 0.6 m/s
Maximum Velocity 3.0 m/s
Minimum slope 0.1% (Others-Min Velocity)
Minimum size 450mm for Box Drain
Minimum Freeboard Varies with Width of Drain

Preferred type of Drain Box 0.45 x 0.45 (minimum)

Maximum spacing of Manholes 30 m

Minimum Tc 5 min
IDF curves Gannavaram Airport 1-hour Rainfall data
and Using the CPHEEO step Method
Manning’s n As per industry standard

1.4 Design Methodology

1.4.1 Rational Method

Storm runoff is that portion of the precipitation which drains over the ground surface.
Estimation of such runoff is dependent on the intensity and duration of rainfall, charac-
teristics of tributary area and the time required for such flow to reach the drain. The
usual case for urban drainage system, the Rational method is widely used for estimating
the peak runoff rates. The formula is:

Q = 0.278 CIA

Where:

Q = flow, m3/s

C = weighted runoff coefficient

I = rainfall intensity in mm/hr

A = drainage area in square kilometres

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Assumptions
Assumptions inherent in the Rational Formula are that:

 Peak flow occurs when the entire watershed is contributing to the flow.
 Rainfall intensity is the same over the entire drainage area.
 The frequency of the computed peak flow is the same as that of the rainfall intensity,
 The coefficient of runoff is the same for all storms of all recurrence probabilities.
1.4.2 Time of concentration
The storm duration chosen for design is equal to the time of concentration. Maximum
discharge in drainage system occurs when the entire catchment is contributing to the
flow. The time of concentration, (t c) is the time required for a given drop of water from
the most remote part of watershed to reach the point of interest.The concentration time
depends on the distance from the critical point to the inlet te and the time of travel in
drain td.

1.4.3 Critical Intensity

The critical intensity for a catchment is that maximum intensity which can occur in a
time interval equal to the concentration time tc of the catchment during the severest
storm (in the region) of a given frequency Ic

Overland flow equations are to be considered to calculate the time of entry in to storm
water drainage system inlets. The most popular equation used around the world for
overland flow is Kerby equation. For Indian conditions, The IRC SP:42-2014 sheet
flow equation as below is to be considered for the time of entry for the storm water
designs.

Tsf = 0.092*((n*L)0.8/((P2)0.5 *(S)0.4))

Where, Tsf = Travel time in hours; n= Manning’s roughness coefficient; L = Flow

length in m;

P2 = 2 year, 24-hour rainfall in mm/hr; S = Slope of catchment area (m/m)

1.4.4 Runoff Coefficient

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The runoff coefficient, C, in Equation is a function of the ground cover and a host of
other hydrologic abstractions. It relates the estimated peak discharge to a theoretical
maximum of 100 percent runoff. Typical values for C are given in table below based on
land use pattern. If the basin contains varying amounts of different land cover or other
abstractions, a composite coefficient can be calculated through area weighing using
Equation below:

Weighted C = Σ(Cx*Ax)/Atotal

Where: x = subscript designating values for incremental areas with consistent land
cover.
1.4.5 Hydraulics

The size of the drains shall be determined using Manning’s formula. The Manning’s
equation is given below:

Q = (A R2/3 S1/2)/n

Where,

Q = discharge capacity of the drain in m3/s

N = manning’s roughness coefficient

A = flow area in m2

R = A/P = hydraulic radius in m

P = wetted perimeter in m

S = channel slope

Table-4 Runoff Coefficients for Rational Formula

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I
Zone Land Use Runoff Coefficient C
value

C1 MIXED USE ZONE 70 0.7

C2 GENERAL COMMERCIAL ZONE 74 0.74
C3 NEIGHBOURHOOD CENTRE ZONE 78 0.78
C4 TOWN CENTRE ZONE 80 0.8
C5 REGIONAL CENTRE ZONE 80 0.8
CENTRAL BUSINESS DISTRICT
C6 80 0.8
ZONE
CANALS 10 0.1
DRAINS 10 0.1
HILLS 10 0.1
I1 BUSINESS PARK ZONE 70 0.7
I2 LOGISTICS ZONE 80 0.8
I3 NON-POLLUTING INDUSTRY ZONE 80 0.8
OPEN LAND 15 0.15
P1 PASSIVE ZONE 20 0.2
P2 ACTIVE ZONE 20 0.2
P3 PROTECTED ZONE 10 0.1
P3-HILLS PROTECTED ZONE 10 0.1
R1 VILLAGE PLANNING ZONE 35 0.35
R2 LOW DENSITY ZONE 50 0.5
R3 MEDIUM TO HIGH DENSITY ZONE 60 0.6
R4 HIGH DENSITY ZONE 75 0.75
ROADS 90 0.9
S1 GOVERNMENT ZONE 60 0.6
S2 EDUCATION ZONE 60 0.6
S3 SPECIAL ZONE 60 0.6
EXISTING SETTLEMENTS 25 0.25
STREAMS 10 0.1
U1 RESERVE ZONE 15 0.15
U2 ROAD RESERVE ZONE 90 0.9
WATERBODIES 10 0.1
UPSTREAM PROTECTED CATCH-
10 0.1
MENT ZONE (KONDAVEEDU HILLS)
REST OF THE SUB-CATCHMENT AR- 15 0.15
EAS
EXISTING VILLAGES 25 0.25

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1.5 Network for Storm Water System

Collection Network shall be planned considering natural topography and planned grade
levels. The network is designed on the assumption that although silting might occur at
minimum flow, however it should be flushed out during peak flows.

The source controlled and volume restricted storm water from the roof and open area
of developed residential, commercial, and industrial LPS plots gets into the system
though downspouts and catch basins. The road drainage is catered through horizontal
gratings at a specified interval along the road kerbs. The type of material for the inlet
gratings decided considering the factors of vehicular loading, non-clogging, easy
maintenance, and anti-theft.

The SuDS measures should come into picture and detain/ intercept/ clean runoff and
convey to the nearest storm drains. Topographic survey of site and proposed plot lev-
elling plan shall be utilized for hydraulic gradient of storm drains, for fixing invert lev-
els, HGL, drain top levels, etc. The storm drains run along the roads within a block
collecting the storm water and conveys it to the tertiary collector storm drains running
on all the major arterial/ sub-arterial roads. Tertiary network consisting of box drains
eventually discharge in the vagu directly or through the secondary network of box
drains.

The tertiary drains are to be box type and to withstand the expansive soil pressures,
minimization of cover due to flat terrain and for easy maintenance regime later. The
access for maintenance in to precast box drains shall be from short depth precast cham-
bers and covers at a specified interval. The tertiary drains are in turn connected to box
drains as secondary drains, and these drains shall outfall into primary channels i.e.,
vagus above the HFL within the Capital city. Secondary and Tertiary storm water drain-
age network is to be designed using an industry standard storm water analysis design
software (ex: Sewer GEMS) with an in-built storm water design module to arrive at
size, capacity, nodes/ junction points and outfall points etc., for each planning zone.

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1.6 Access Inspection Manhole Covers

 As per IS-4111: 1986, the size of manhole covers should be such that there should be
clear opening of not less than 560 mm diameter.

 Manhole cover and frame will be SFRC (Steel Fiber Reinforced Concrete) conform-
ing to the IS 12592.

Table-5 Access Manhole Cover Details as per IS 12592

Manhole Type Load withstanding Suitable Locations

capacity

M.D(Medium 10.00 MT Light four wheelers, NMT,

Duty) walkways

H.D (Heavy Duty) 20.00 MT Heavy vehicles

E.H.D (Extra Heavy 35.00 MT Heavy traffic roads

Duty)

1.7 List of Standards and Specifications

The design and Construction of storm water drainage network and the outfalls shall
conform to design requirements and Construction specifications set out in the following
Indian and International Standards.
 IS - 456 Code of practice for Plain & Reinforced concrete;

 IRC SP-50-1999 - Guidelines on Urban Drainage

 IS - 458 Pre-cast Concrete Pipes (with and without reinforcement);

 IS 783 -1985 Width and depth of trench for R.C.C. Pipes;

 IS 1726 Specification for Cast Iron Manhole Covers and Frames;

 IRC SP-42-1994 - Guidelines on Road Drainage

 IS 4985-2000 Un-plasticized PVC pipes for potable water supplies - specification;

 IS 12235- (Parts 1 to 19) Thermoplastics pipes and fittings - methods of test; and

 IS 12592 Pre-cast Concrete Manhole Covers and Frames – Specifications.

 Schedule of specifications of Govt. Of Andhra Pradesh and C.P.W.D. specifications

(Govt. of India) 2009 with all latest amendments issued from time to time;
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 CPHEEO Manual for Sewerage and Drainage -2014 - MoUD, GoI

 SP 35:1987 - Hand book of Water Supply and Drainage, Bureau of Indian Stand-
ards;
 Manual on artificial recharge of ground water by Central Groundwater Board Min-
istry of Water-Resources Government of India;
 Rain water harvesting and conservation Manual by consultancy services organiza-
tion CPWD, New Delhi, India;
 Code of Practice on Surface Water Drainage by Public Utilities Board, Singapore;
and
 Managing Urban Runoff Drainage Handbook by Public Utilities Board, Singapore.

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Annexure – I (C) - i
Potable Water Supply
Standards & Technical Specifications

SECTION - I
GENERAL TECHNICAL SPECIFICATION
1. SITE CONDITION
The sites of the intake well-cum-raw water pumping station, water treatment plant, clear
water reservoir and pumping station, water distribution centers and pipelines are on plain
to undulated lands. The Tenderer shall verify the location of the above installations by in-
spection of the sites and shall apprise himself of the local condition before submitting the
Tender.

2. SUB-SOIL REPORT
Sub-soil investigation was carried out by the ADC/APCRDA mostly along the arterial and
sub-arterial roads. Sample soil data are presented in Appendix-1.

These soil data can be referred for design of pipeline layout and for road. The Tenderer
shall satisfy himself about the adequacy of these data for design of pipelines and roads
under this Tender. For structures like intake well-cum-raw water pumping station, water
treatment plant, clear water reservoir-cum-pumping station, electrical sub-stations and
other ancillary structures, pile foundation is strongly recommended. The tenderer shall
carry out detailed geotechnical investigation by drilling bore holes at these work sites for
foundation design, before submission of his tender, tenderer may visit these work sites and
assess quantum of geotechnical investigation at his own cost for his own satisfaction. After
getting the L.O.I., it is mandatory that the successful Tenderer shall have to undertake fresh
geotechnical investigation of soil at the exact locations of the structures to design the foun-
dation properly. At each work site, at least four bore-holes shall be drilled for proper inves-
tigation and records of such sub-soil investigation such as bore hole logs, soil samples, SPT
values etc., shall be done by the Agency duly witnessed and authenticated by the Engineer-
in-Charge- in- Charge or his competent authorized representative.

In the event of variation in preliminary soil data put up in NIT and those obtained by the
Agency during execution, the more conservative values obtained from the two sets of re-
ports shall be adopted for design without any extra claim over the quoted price as accepted
by the Authority.

3. TENDER DRAWINGS

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3.1 Site Layout Plan including alignment of the trunk pipelines, general arrangement of the
Intake Well-cum-Raw Water Pumping Station, Water Treatment Plant, Clear Water Reser-
voir -cum- Pumping Station are shown in Tender Drawings. These drawings are meant for
giving the Tenderer a general idea of the proposed water-work components. The various
levels and dimension of these structures are to be fixed by the Agency according to the
guidelines provided by the Authority. All levels are to be approved by the Engineer-in-
Charge before execution. The effective capacity of the Clear Water Reservoir excluding
free board, columns, baffle walls and any other civil structures in the reservoir, volume of
water in depressed sump, 0.15m dead storage will be 64 million litre. If as per dimension
proposed by the Tenderer, the Capacity of the Reservoir is found to be more than 64 million
litre, no extra payment on account of increased capacity will be made.

There may be variations in details and sizes of pump bases, cable trenches, different work-
ing rooms, sump depth, levels etc. depending on the specification of the suppliers of Pump,
Motor etc. which shall be accommodated by the successful Tenderer during construction
without any extra cost to ADC. The final working drawings will be vetted by the pump &
motor suppliers to satisfy their requirements and also be approved by EIC.

3.2 A tentative Lay-out Drawing showing the location and levels of the Intake Well-cum-Raw
Water Pumping Station, Water Treatment Plant, Clear Water Reservoir-cum-Pumping Sta-
tion, alignment of raw water and clear water trunk mains and WDCs is enclosed in the NIT.
The Tenderer has to quote his Rate for Construction of Entire Water Supply system as spec-
ified considering all structures except certain minor structures like valve chambers, thrust
blocks, small building (upto G+1) in deep cast-in-situ R.C.C. Bored Piles Foundation. The
Tenderer has to quote his rate on the basis of his own design as per Tender Stipulations,
which is not to be submitted with the Tender.

However, a tentative design and lay-out drawing if different from the tender drawing, show-
ing the scope of civil work including size, shape, inlet and outlet arrangements, overflow
arrangements etc. as proposed by him, shall have to be submitted with the tender. The work
will however, be executed on the basis of the detailed designs and drawings submitted by
the successful Tenderer which will be prepared on the basis of the Technical Parameters
and the terms and conditions of the NIT duly approved by the Authority.

The RCC pile foundation has to be in such a manner that the same can withstand all dead
loads, live loads, effect of wind, earthquake and service loads. The pile foundation must
satisfy the settlement criteria.

4. FLOOR SPACE REQUIREMENT

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Requirement of Floor Spaces and tentative Room Sizes at various water-work sites are
given below:

Min. Area of Room

S. No Description
(Sq.m)
At Intake Well
Electric Indoor Substation /
1 607.50
SCADA Control Room
Office cum-Guest House
2 300 in each floor
(G+2)
100 in each quarter
3 Staff Quarter (G+4) – 2 Nos
in each floor
4 Security Cabin 10
At WTP
5 Administrative Building (G+2) 600
Electric Indoor Sub-Station /
6 649.25
SCADA Control Room
Chief Engineer’s Bungalow
7 150 in each floor
(G+1)
Chief Engineer’s Bungalow
8 120 in each floor
(G+1)
Staff Quarters (G+4) - 1 No - A
120 in each quarter
9 & B Category Employees-8
240 in each floor
no’s
Staff Quarters (G+4) - 1 No - C 100 in each quarter
10
Category Employees-8 no’s 200 in each floor
11 Command Control Centre 180
12 Security Cabin 10

At SUGRs
Location of SUGR-cum-Pump house along with minimum area required is given below.
Location Area
Nearby Vil- Available
WDC No. (Sq.m)
lage Name
18 Dondapadu 5055.50
23 Ananthavaram 5234.72
24 Thulluru 5134.31
42 Nekkallu 3825.99
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43 Ananthavaram 6670.42
44 Ananthavaram 5930.88
45 Nekkallu 5948.35
46 Nekkallu 6217.54
Note: Need to confirm with APCRDA

5. MANDATORY LEVELS
Mandatory Levels for various water-work units are given below:
 Avg. Existing Ground Level at WTP : +19.0 M
 Seed Access Road Level (finished) : +21.5 M
 HFL of Krishna River at Prakasam Barrage : +21.5 M
 HFL of Kondaveeti Vagu : +15.0 M
 Finished Ground Level of WTP campus : +22.0 M
 MWL of CWR : +22.5 M
 Free Board in CWR : 0.50 M
 Minimum depth of water in CWR : 5.00 M
 Repair Bay floor level of CWPS : + 22.50 M
 Top level of Crane Rail in CWPS : + 29.00 M
 Clear height of Substation Room / H. T. Room: 4M
 Office room : 4M
 Clear height of Control Room/L. T. Panel Room: 5.0 M
 Clear Opening for Roller Shutter for unloading Bay: 3.60 M wide x 4.50 M Height
 Plinth Level of Building : 0.5 M above FGL

6. DESIGN CRITERIA
6.1 The basic layout of the Intake-cum-Raw Water Pumping Station, Water Treatment Plant,
Clear Water Reservoir and Pumping Station shall be as per Indicative Drawings provided
in the Tender Document necessary modification will be allowed if found suitable by the
Authority. The Elevation of the Intake-cum-Raw Water Pumping Station, Administrative
building, Chemical and Filter house in the Water Treatment Plant and other superstructures
shall be of suitable Architectural design. The Tenderer shall submit with his Tender, the
Architectural Elevation of these buildings. However, the architectural Elevation may have
to be modified at the time of approval by the Authority for which no extra charge will be
paid.

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Design and construction of all RCC Structures, brick masonry walls and Foundation shall
conform to the latest edition of the following IS Codes:

a) Loading Standards IS: 875

b) Earthquake Resistant Design IS: 1893 & IS: 4326

c) Reinforced and Plain Concrete IS: 456

d) Foundations IS: 1080, IS: 2950

IS: 2911 & IS: 2974

e) Liquid Retaining Structures IS: 3370

f) Structural Steel IS: 800

g) Reinforcement

Mild Steel IS: 456 & IS: 432

Ribbed Tor Steel IS: 1786 & IS: 1139

h) Masonry and Brickwork IS: 1905 & ISS: 2212

i) National Building Code of India

j) Design & Construction of Pile Foundation IS: 2911

6.2 All the structures of the Water Supply system except minor structures shall be including the
Clear Water Reservoir, the Pump House Building the Pump Suction Sump and mainte-
nance/repairing Bay shall be designed with deep Cast-in-situ RCC bored Pile Direct Mud
Circulation Foundation. It is to be noted that no foundation other than Pile Foundation will
be accepted. Minor structures like valve chambers, Weigh Bridge etc. may be constructed
on the virgin soil if its bearing capacity is found to be sufficient to take the entire load from
the structures. The Agency has to satisfy the Authority about the justification of the ordinary
foundation for the minor structure. It may be noted that only the Engineer-in-Charge has
the right to designate a structure as minor structure.
Such piles shall be bored Cast-in-situ R.C.C. Piles. The design, construction and workman-
ship for these piles shall fully conform to and satisfy the codal requirements of IS 2911
(Latest Edition). Concrete to be used in Piles shall be of M-25 Grade having a Cement
content not less than 400 kg/m3. Reinforcement in piles shall be in conformity with the
requirements contained in IS:2911 (Latest Edition). The minimum area of Longitudinal

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Reinforcements shall be as per Codal requirements and such requirements shall be provided
for the full length of piles. For piles subject to Upward Tension, reinforcement shall be
provided throughout the full length and such reinforcement shall be designed on the basis
of upward load they are supposed to carry.

The safe working loads of the R. C. C. Cast-in-situ bored piles shall be that as computed as
per IS:2911 on the basis of Sub-soil Parameters of the Site with a minimum Factor of Safety
2.5 (Compression) and 3.00 (Tension) applied there on. The safe working load or the design
capacity of the piles shall be least of the design capacity calculated according to the Agency
soil exploration data and the data provided in the Tender Document. The Diameter, Length,
Cut Off level, Termination Depth of piles under the different structures shall be according
to the layout and levels of the structures following the Department's guidelines. It is man-
datory to the Agency to approve his proposal of general arrangements, layouts and levels
of the different structures including foundation details by the Authority prior to the execu-
tion.
In case of any change in Cut off levels, necessary adjustment in the safe working load will
be made. Pile Termination levels shall be chosen carefully. The safe working load of the
piles shall be substantiated by Routine Load Test. Sub-soil investigation after award of
contract by the Tenderer shall be witnessed by the Engineer-in-Charge or his authorized
Representative. The Pile Termination Level shall not be reduced from that stated herein the
Soil Investigation Report attached with the Tender Document unless otherwise permitted
by the Engineer-in-Charge.
The Agency shall maintain the cutoff level of the piles under Underground Reservoir and
Clear Water Pump House at a required depth below existing ground/road level. If not pos-
sible, the pile cutoff level of the other structures shall be in such a level that it shall be well
below the respective ground level, whatever undulation there will be at the respective site.
This Piles shall be designed for Seismic Condition also. The Important factor for Seismic
Analysis of Structure shall be 1.50. The Tenderer shall include in his Lump Sum price the
cost for Load Test of at least one working pile (Routine Test) per 100 piles or part thereof.
The testing shall be as per codal Stipulations. The Tenderer shall also include in his price
the cost of installation of one R. C. C. cast-is-Situ, Bored Non-working pile having same
Structural Details as of Working Pile and Pull out Test of the same as per Codal Stipulations.

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6.4 If during initial pile load testing at site, the safe load bearing capacity is found to be more
than what has been tabulated in the Agency Soil Investigation Report, the least safe load of
the two as furnished by the department or as per Agency Soil Investigation Report shall be
followed for which no extra claim will be entertained. In case, the safe load bearing capacity
during load testing of piles of site is found to be less that what has been provided in the
table furnished by the department, the lesser value shall be followed, in this case also, no
extra claim be entertained.
6.5 While designing the Foundation of different structures, the Tenderer may use the Soil In-
vestigation results provided in the Tender. The successful Tenderer shall have to undertake
fresh investigation of soil by an approved agency at locations decided by the Engineer-in-
Charge after the entire layout of the plant have been decided upon and approved at his own
cost for submitting the final design of the foundation and for detailing the piles in conform-
ity with the Soil Test Report.
In the event of variation in Soil Data provided in the NIT and those obtained by the Agency
during execution, the more Conservative Values between the two sets of Reports shall be
adopted for design. While adopting the conservative values, if the number, diameter and
the length of the piles to be provided for safe design increases, the cost of such additional
piles shall be paid in accordance to the Schedule of Rates of Public works (Roads) Depart-
ment for Roadworks, Bridge, Culvert Works & Carriage etc. as was in vogue on the date of
submission of the tender. The decision of such payment rests with the Authority.

7. DESIGN PARAMETERS
The parameters and methodologies of hydraulic designs and process designs shall strictly
comply with the requirements of the latest edition of “Manual on Water Supply and Treat-
ment” and “Manual on Sewerage and Sewage Treatment” by Central Public Health and
Environmental Engineering Organization. Wherever limit has been mentioned for design
parameter in CPHEEO manual, minimum average of upper limit and lower limit shall be
considered. Wherever the parameters and methodologies are not available, the same can be
adopted from the IS Codes or Standard Textbooks. No design parameters and methodolo-
gies shall be allowed to use unless those are supported by the basic law of physics and
chemistry.

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All structural analysis and design procedures must comply with the norms as stipulated in
relevant latest IS Codes. It is mandatory to the Agency to abide by all the norms or instruc-
tions of the relevant latest IS Codes. No other software will be accepted for structural design
except STAAD.
The Authority will accept no hydraulic, process or structural analysis and/or design proce-
dures or methodologies, which are not stated and defined in CPHEEO Manual, IS Codes
or in Standard Textbooks. The Agency shall not declare any such book as Standard Text-
book, which will not be accepted by the IITs regarding the procedures and/or methodolo-
gies under question.
The design ambient temperature and water temperature shall be 15ºC.
For all liquid retaining structure and other RCC structures except piles, micro silica admix-
ture of approved quality and make at the rate of 5% by weight of cement used in concrete
as per IS Code of practice shall be applied for protection from leakage and corrosion.

8. LOADINGS
Loading shall be as per relevant IS code. However, following Live Load are specified in
the respective areas for this project:

i. Operating platform and walkways 300 kg/m2

ii. Pipe gallery 750 kg/m2
iii. Control panel switch room, chlorination room, laboratory, wash pump room, blower
room, store room etc. 500 kg/m2
iv. Passage, corridors, entrance lobby, toilet etc. 300 kg/m2
v. Accessible flat roof 150 kg/m2
vi. Shell roof and other inaccessible roof 75 kg/m 2
vii. Space in front of alum/coagulant dosing tank 750 kg/m 2
viii. Walkway over clear water channel of filter house 500 kg/m2
ix. Live load on pump house Floor 500 kg/m2
x. Live load on Control Room Floor 300 kg/m 2

8.1 Clear Water Reservoir

A park is proposed to be located on the roof of the Clear Water Reservoir. The roof is to be
designed for a live load of 400 kg/M2 and the superimposed Load of saturated compacted
earth of 500 mm. depth. No relief shall be allowed due to this Superimposed Load of satu-
rated earth while computing the Uplift on the reservoir.

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8.2 Clear Water Pumping Station

Besides the above, the Tenderer shall assess the loading arising from various machines,
control panels, pumps & motors including base frame, cable and pipe trenches etc. and the
supporting units are to be designed to withstand all types of dead and live combinations.
The effect of impact loading and vibration effect due to rotating machinery as per relevant
IS Codes are to be analyzed and properly assessed by the Tenderer during design and exe-
cution. Other live loads not specified above shall generally conform to IS:875 latest edition.

N.B. Loading details given herein above are tentative and subject to verification during
final execution. No extra cost will be paid to the Agency on account of variation within +
30 % limit.

Vertical load data for pumps and motors are inclusive of impart factor subject to confirma-
tion of the Pump Manufacturer during final design. The cost in this regard shall by included
in the lump sum offer by the Tenderer and no additional claim will be entertained in future
due to variation in load data, if any.

The floor slab is to be designed for the worst loading conditions that the floor will be sub-
jected due to the equipment to be housed and may be put anywhere on this floor. The floor
slab shall be so designed as to withstand such loads.

The floor supporting M. S. suspenders / Cable trays are to be designed for a concentrated
static load of 200 Kg. at any point. The Cable Trenches wherever provided shall be abso-
lutely free from any obstruction so as to allow the Cables to be lowered in the trenches from
top only during laying.
Live load in Battery Room, operator Room and
500 Kg/Sq.m
Store
Load of M. S. Chequered Plates 500 Kg/Sq.m
For trench covers over opening in Floor 500 Kg/Sq.m
Loading from all Electrically & Manually oper-
As per Crane Manufac-
ated
turer’s Specifications
Crane

The Unloading Bay of Clear Water Pumping Station is to be designed for 18 MT full truck
load. All cover slabs placed on the drains, cable ducts etc. subjected to thoroughfare of
vehicles are to be designed for 18 MT full truck load.

While designing the side walls of the water retaining structures, clear water reservoir, pump
house, and all other relevant structures, a surcharge of 500 Kg/Sq.m on the soil is to be
taken into consideration.
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The tenderer has to design in such a way that the permissible limit of vibrations of Rotody-
namic Equipment shall be within the limit as specified in IS:11724 (latest edition).

The R.P.M. of pump Motor set may be 740 to 990 RPM subject to confirmation of the
manufacturers and duly approved by EIC.

N. B. For calculating earth pressure on the walls of water retaining structures including
underground reservoir and pump house, the worth value among co-efficient of active earth
pressure (Ka) and that of Earth pressure at rest (Ko) is to be considered. Standard backfill
materials with conservative soil data are to be considered. No extra claims are to be enter-
tained in this regard. Where passive earth pressure will be considered in the design, the
Agency shall have to refill the excavated ground with properly compacted silver sand only,
and not with fly ash or other material.
8.3 Level and Other Salient Information

A list of figures highlighting the following are given herein below:

 Levels in Meters

 Difference in Height / Clearance

 Minimum Length, Slopes etc.

Out of the above list, the figures marked with “Astericks” are mandatory requirements
whereas the others are suggestive only.
A. Levels in Meters (Mandatary)
S No Description Level in mts
1 Existing E3 road level + 21.50
2 Finished ground level + 22.00
3 Sub-Station floor level + 22.50
4 Top of Crane Rail over Crane Girder + 29.00
Minimum clearance between Crane Top and Bot-
5 + 1.0
tom of Roof beam
6 Unloading Platform Level + 22.50

B. Difference in Height, SWD and Head Room in Building and Structure

S No Description Level in mts
Side Water Depth (SWD) in Semi Un-
1 Not less than 5.00 M
derground Clear Water Reservoir
0.50 M from TWL to below
2 Free Board in Clear Water Reservoir the soffit of Slab/Beam/Drop
Panel
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C. Minimum Length, Slope, Clearance etc.

S No Description Remarks

1 Minimum Length along direction of Flow near 3.75 M

pump sump (slope portion)
Maximum slope from clear water Reservoir to
2 45o
Sump
3 Minimum length of the flat Sump Along the di- 2.85 M
rection of flow

9. Special Notes on Horizontal Centrifugal in Horizontal Execution Pump Foundation

Design
9.1 Foundation system for support of Rotary machines such as Horizontal Pumps shall strictly
comply with the requirements of Code IS:2974 (Part-IV)-1979. The Rotary Machine sup-
port system require careful study of the foundation system with due consideration of vibra-
tion characteristics. For satisfactory design and construction, the following precautions
need be taken with careful dynamic analysis of machine foundation and its supporting
structures:

 The natural frequency of the Foundation System shall be analyzed and the mass of the
Foundation System shall be considerably larger than the mass of the whole machine.

 Dynamic Analysis due to insufficient clearance between impeller and causing of Pumps
shall be checked and frequency out of this type of vibration need to be made as per
relevant IS Code.

 Dynamic Response check of the block foundation may be carried out as per relevant IS
Code.

 Permissible amplitude of Vibration of displacement as per IS Code 2974 (Part-IV),

Clause 5.4 Page No. is to be calculated and the design will be checked accordingly.

 Permissible stresses in Soil / Concrete be suitably as per IS Code.

 Natural frequency of Foundation System shall be such as will avoid resonance with the
Operating Speed of the Machine. The natural frequency of the foundation system shall
not be within +20% of the operating of the machine.

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 The foundation system shall be so dimensioned that the resultant force due to mass of
the machine and mass of the Foundation passes through the Centre of gravity of the
base area of the Foundation.

9.2 The Tenderer is required to submit a “Technical Write-up” with relevant details of Founda-
tion System along with the Part-I of this Tender. This would help the Authority to fix up the
accepted Parametric Norms of the foundation System that would finally be adopted in the
design and construction of the Building and Structures after award of the contract.

9.3 The Agency shall be aware of the fact that various cables, ducts, small machinery, lighting
arrangements, electrical appliances etc. of considerable weight, will have to be supported
from the concrete or brick walls or from the roof slab. MS plates or hangers of requisite
sizes with suitable weight carrying capacity shall have to be inserted on wall or roof slab.
It is the responsibility of the Agency to insert the MS plates or hangers during the casting
of concrete slab/wall in time to avoid dismantling of the wall/slab.

10. ARRANGMENT OF ROOF TREATMENT: EARTH FILL VENTILATING

SYSTEM
10.1 It is proposed that the Clear Water Reservoir top shall have minimum 500 mm thick earth
fill.
10.2 The provision for saturated earth load on the roof slab shall be considered in the design
of roof slab of the Clear Water reservoir by the Tenderer. The actual earth fill work is also
included in the Scope of this Tender. The load from the earth fill shall not be considered
while calculating the buoyant force of the reservoir as well as to calculate the pile capacity
in tension under the reservoir.
10.3 The R. C. C. Roof Slab of the Clear Water Reservoir shall be protected with water proof-
ing treatment as per specification given in the other relevant section of this tender book.

11. SUBMISSION OF DESIGNS, DRAWINGS & OTHER INFORMATION

11.1 Within Thirty days of getting the Work Order, the Agency shall conduct topographical
survey and geotechnical investigation at all the sites and shall prepare a report to submit
the same to the Authority for approval.

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The Agency shall submit, within fifteen days of getting Work Order, the Time-Activity
Bar Chart showing all the major activities and sub-activities and its individual commenc-
ing and completion times. Each Bar in the Bar Chart will represent the time duration of
each activity or sub-activity, which may be proportional within its each sector of time
duration. A tentative work programme in Network Diagram using CPM technique is also
required to be submitted by the successful tenderer within a fortnight from the date of
issue of the letter of acceptance.

Within the thirty days’ of getting Work Order, the Agency shall submit the concrete mix
design along with sufficient numbers of test results and get it approved by the Authority.
Requisite number of concrete cubes shall be casted according to the mix design and tested
by an Agency approved by the Authority. It is obligatory that the cube crushing strength
will be more than the mix design strength submitted by the Agency. It is advisable to
install a Weigh-Batcher at the site for maintaining the exact proportion of concrete ingre-
dients. If not possible, it is the Agency responsibility to make sufficient numbers of buck-
ets of suitable sizes to carry fine aggregates and coarse aggregates within one month after
getting the Work Order. The size of the bucket shall be in accordance with its carrying
capacity in weight to make requisite design grade of concrete. The size and shape of the
buckets must be approved by the Authority prior to use it at site. Agency has to declare
in written whether he would consider any mound of aggregates above the carrying bucket
top surface in calculating the size of bucket and he has to practice that accordingly at site
while carrying the aggregates with the bucket. While calculating the bucket size consid-
ering the mound of aggregates, the Agency has to consider the mound angle as follows,

Type of aggre- Geome- Mound angle Dynamic an-

gates try (degree) gle (degree)
Fine aggregates Angular 378 36.58
Coarse aggregates Angular 37.58 348

On the award of the Contract, Agency shall submit to the EIC layout drawing, process
design, hydraulic flow diagram and the general arrangement drawings and designs of
different structures within twenty-one (21) days from the date of issue of Letter of Ac-
ceptance and thereafter the balance detailed design and drawings and design calculations

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will have to be submitted phase wise keeping pace with the work programme. The differ-
ent levels of the units shall be designed in such a way that the R.L. of the top water level
of the underground reservoir is at a higher level than the R.L. of the invert level of the
filter water channel.

The Agency shall submit six copies of design and drawing along with editable soft copy
to the EIC for approval. On approval of design and drawing for any RCC members, the
Agency shall submit six copies of the Bar Bending Schedule for those members without
delay. Cutting, fitting, fixing of the reinforcement will be in accordance with the Bar
Bending Schedule at site.

If called upon the Agency shall also submit within reasonable time relevant books and
other reference which have been referred to or used in the design. Such books and other
relevance will be returned to the Agency when done with Secrecy in regard to details of
design materials and equipment etc. shall not be pleaded by the Agency in the name of
“Trade Secret” for not furnishing the requirement details asked for by the EIC. The design
and drawings shall be subject to modifications at no extra cost, if found necessary and
such modifications shall not vitiate the contract. Similarly, any additional new drawings
as found shall be submitted by the Agency and the drawings shall form part of the Con-
tract Drawings.

Notwithstanding what has been stated above the Agency shall be responsible for the cor-
rectness and soundness of the design and if any provisions are found inadequate or faulty
necessary modification will have to be carried out at any stage upto the expiry of the
Guarantee period.

The Agency will not be permitted to commence the Actual Work at site unless detailed
design and working drawings are approved by the EIC. Four copies of the approved de-
sign and six copies of the approved drawings are to be furnished by the Agency free of
cost for use by the Authority during execution of the work. Any additional copies of same
drawings, if required, shall also be submitted by the Agency free of cost at the request of
the Authority.

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The drawings from foundation onward will have to be submitted by the successful ten-
derer successively as per the work programme to be approved by the EIC. Adequate re-
sources are to be mobilized during execution of the work, for which no extra payment
shall be made.

Agency shall provide the necessary tools and apparatus like standard sieves, balance etc.,
to test the quality of coarse and fine aggregates according to IS:2386 and IS:383. It is
mandatory to carry out tests for the quality of coarse and fine aggregates as per relevant
IS Codes at site and as instructed by EIC. The EIC retains the right to instruct the Agency
to test one or more representative samples from any stack of aggregates supplied by the
Agency at site, and if the result of testing is not satisfactory, the Agency has to remove
the entire stack of aggregates from the working site without delay at his own cost.

Agency shall provide the necessary tools and apparatus to test the quality of brick accord-
ing to IS:3495 and IS:1077. It is mandatory to carry out tests for the quality of bricks as
per relevant IS Codes and as instructed by EIC. The EIC retains the right to instruct the
Agency to test one or more representative samples from any stack of bricks supplied by
the Agency at site, and if the result of testing is not satisfactory, the Agency has to remove
the entire stack of bricks from the working site without delay at his own cost.

The Agency shall provide required tools and instruments to carry out tests for compres-
sive strength of concrete regularly at site as per IS:456 and IS:516. Also, apparatus re-
quired for slumps test of concrete shall be available at site and the Agency has to carry
out the slump tests as per instructions of relevant IS Codes and the EIC.

11.2 Completion of Drawings and Other Documents to be Submitted the Agency

The Agency shall submit, within one month after the completion of all construction
works, the followings drawings and document, free of cost.
a. Six copies of all approved Completion drawings. These drawings shall be on black
and white prints of thick paper and there shall be one RTF transparency of each
drawing. These drawings are to be submitted in a presentable form as directed by the
EIC.
b. Four copies of final designs in properly bound from as directed by the EIC.
c. Four copies of detailed specification and schedules of the completed installations etc.

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d. Two copies of Manufacture's Manual of all pumps, motors and all other mechanical,
electrical, electronic instruments, SCADA and laboratory equipment.
e. All license copy related to WTP operation shall be renewed up to end of O & M
period without any additional cost.
f. Public liability insurance, explosive license etc. The Agency shall renew insurance
and explosive license as per requirement to the end of O&M period without any
additional cost.

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SECTION - II
GENERAL SPECIFICATIONS OF WORKMANSHIP & MATE-
RIALS FOR CIVIL WORKS
1. GENERAL
1.1 Materials
1.1.1 All materials used in the permanent works shall be of the best quality of the kind and
upon approval of the Engineer-in-Charge. Any material not covered by these Specifica-
tions, shall comply with the relevant latest Indian Standard Specifications (Referred to as
IS as revised or modified up to date one month prior to Tender date). British or American
Standard Specifications shall be referred to in case any specification is not available in
any of the aforesaid Specifications.

1.1.2 Samples of materials to be supplied and used by the Agency in the works shall be to the
prior approval of the Engineer-in-Charge. For this purpose, the Agency shall furnish in
advance representative samples in quantities and in the manner as directed by the Engi-
neer-in-Charge for his approval. Materials brought to the Site, which in the option of the
Engineer-in-Charge do not conform to the approved sample, shall, if so directed by him,
be removed by the Agency from the Site and replaced by the materials of approved qual-
ity.

1.1.3 In spite of approval of the Engineer-in-Charge of any materials brought to the site, he
may subsequently reject the same if in his opinion the materials have since deteriorated
due to long or defective storage or for any reason whatsoever and is thereby considered
unfit for use in the permanent works. Any material thus rejected shall be immediately
removed from the Site at Agency cost and expense.

1.1.4 All materials brought to the Site shall be properly stored and guarded in the manner as
directed by the Engineer-in-Charge and to his satisfaction.

1.1.5 The Engineer-in-Charge may carry out test of materials as he may decide. The Agency
shall, at his cost and expenses, for this purpose supply requisite materials and render such
assistance to the Engineer-in-Charge as he may require.

1.2 Workmanship
All works are to be carried out in proper workmanship like manner. Items of works not
covered by these Specifications or by other tender documents, shall be carried out as per
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best practice according to the direction of the Engineer-in-Charge and to his satisfaction.
The relevant IS Specifications, and in case of necessity, British or American Standard
Specifications shall be taken as guide for the purpose.

1.3 Works Included

The rates for all items, unless specifically stated otherwise in the Contract, must cover
the cost of all materials, labour, tools, machinery, plant, pumps, explosives, scaffolding,
staging strong props, bamboos, ropes, templates and all appliances and operations what-
soever necessary for efficient execution of work.

1.4 Ground Conditions

The Agency shall visit the site and ascertain local conditions, traffic restrictions, obstruc-
tions in the area without asking for extra expenses likely to be incurred due to any limi-
tations whatsoever.

1.5 Setting Out and Leveling

The Agency shall set and level the works, and shall be responsible for the accuracy for
the same. He shall provide all instruments and proper qualified staffs required for check-
ing the Agency works.

1.6 Safety
The Agency shall take adequate precaution to provide complete safety for prevention of
accidents on the site.

1.7 Keeping Works Free from Water

The Agency shall provide and maintain at his own cost, electrically or other power-driven
pumps and other plants and equipment to keep the sites, excavated foundation pits and
trenches free from surface as well as subsoil / leakage water from the Primary Grid of
any other source thereof and shall continue to do so during construction and afterwards
to the complete satisfaction of the Engineer-in-Charge till the site is handed over. Method
of dewatering shall need approval of the Engineer-in-Charge but no payment whatsoever
shall be allowed on this count. The pumped water shall be drained out in such a manner
so that it doesn't create any inconvenience to others.

1.8 Rubbish

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1.8.1 The Agency shall clear all rubbish, vegetation, roots, soda etc., and dump then in the area
indicated to the satisfaction of the Engineer-in-Charge. No separate rate shall be allowed
for the above work.

1.8.2 After the work is completed, the Agency shall clear the area surrounding the built-up
structures and buildings, of all hutments and excess stores and remnants of building ma-
terials such brick, metal, sand, timber, steel, etc.

1.9 Bench Marks and Ground Water Gauges

The Agency shall protect surveyor's bench marks and ground water gauges, zero-line
marks and base line marks from damage of movement during the works in progress and
thereafter.

1.10 Inspection
The Agency shall inspect the Site of works and ascertain site condition and the nature of
soil to be excavated.

1.11 Agency Staff

The Agency must provide always efficient staff of trustworthy, skillful and experienced
assistance capable of carrying out the work in accordance with the drawings and specifi-
cation and to correct levels. The cost towards this establishment shall be included in his
quotes.

1.12 Method of Measurement

Unless otherwise specified, the method of measurement for building works shall be as
per IS:1200.

1.13 Specifications Referred to

1.13.1 The specification contained herein are not exhaustive and for such items of works which
may arise and which are not covered by this specification, the provisions in the relevant
Indian Standard (Latest Edition) shall apply.

1.13.2 A list of some Indian Standards is given herein.

1.13.3 Wherever reference to the Indian Standard mentioned below or otherwise appears in the
specification, it shall be taken as reference to the latest version of the Standard.

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IS Code No. Description

General IS:1200 Method of measurement of building

And Civil Engineering works.

Cement IS:269 Ordinary, Repair Hardening and

Low Heat Portland Cement.

Sand IS:1242 Sand for plaster.

Aggregates IS:383 Aggregates-Coarse and fine, from

Natural source for Concrete.

IS:515 Aggregates for use-in Mass Concrete,

Natural and manufactured.

Concrete-Plain IS:456 Code of Practice for Plain and

And Reinforced Reinforced Concrete for General
Building Construction.

IS:3370 Code of Practice for Concrete

Structures for the Storage of Liquids.

Brick Work IS:1077 Common Burnt Clay Building Bricks.

Paving and IS:1235 Flooring Tiles, Cement Concrete.

Floor Finish
IS:1443 Cement Concrete, Flooring Tiles
Laying and finishing.
Plaster and IS:1661 Cement and Cement Lime
Pointing Plaster finishes on walls and
Ceilings.
Steel and IS:226 Structural Steel (Revised)
Iron Work
IS:800 Code of Practice for use of
Structural Steel in General
Building Construction.

2. EARTH WORK IN EXCAVATION & FILLINGS

2.1 General
Applicable provisions of Conditions of Concrete shall govern work under this section.
2.2 Excavation for Foundation, Trenches, Pit etc.
The excavation work shall be carried out in all kinds of Soil including Sand in workman-
ship like manner without endangering the safety of the nearby structures or works and

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without causing any hindrance to other activities in the area. The existence of old build-
ings, boundary walls, hutment, sewer lines, water lines, if any, very close to the area of
excavation shall be given careful consideration while designing and carrying out the ex-
cavation work. The excavation shall be done in such a manner as would technically be
appropriate and befitting the site conditions subject to the approval of the Engineer-in-
Charge. All foundation trenches shall be excavated to the full width and depths shown on
the approved drawing or to such ordered to the Agency.

The Agency shall not undertake any earth work without having obtained prior approval
from the Engineer-in-Charge and the methods EIC proposes to employ in order to execute
the work in the most efficient manner. He shall not modify such methods without the
approval of the Engineer-in-Charge. This approval, however, shall not in any way make
the Engineer-in-Charge responsible for any consequent loss or damage.

2.2.1 Shall any excavation be taken down to the specified levels, the Agency shall fill in such
excavation at his own cost with concrete as specified for foundations, well rammed in
position until it is brought up to the specified level.

2.2.2 The Agency shall notify when the excavation is completed and no concrete or masonry
shall be laid until the soil for each individual footing, rafts etc. is approved.

2.2.3 The Agency shall keep the site clear of water always. To this end, he shall provide ar-
rangements for bailing and pumping or any special arrangements as required within his
quoted prices.

2.2.4 All foundation pits shall be refilled to the finished ground level (formation level) with
approved materials, which shall be suitably consolidated in layers to the satisfaction of
the Engineer-in-Charge.

2.2.5 Nothing extra will be paid for bailing out water collecting in excavation due to rains,
ordinary springs, leakage from existing primary grid etc., or any other reason.

2.2.6 For the work of excavation, the Tenderer shall include in his quotation the shoring, sheet-
ing, bracing and sheet pilling (if required). The quotation shall also include the cost of
compaction of foundation sub-base, removal and storage of excavated materials and
back-filling.

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Road crossing by the trench less technology / HDD (Horizontal directional drilling):
Work include the laying by hydraulic jacking and smooth controlled pushing method un-
der running traffic condition as per standards including carrying out the survey work at
the site for determining underground cable trenches like telephone, cables , water , sani-
tary drains and resistivity test for finding the soil strata using necessary equipments for
completeness of works mobilizing of the machineries and specialized crews at construc-
tion site etc complete in all respects including the excavation of the driven pit and exit pit
with proper protection at 3 sides with shoring sheets and ISMB (providing and castinf
MS cutting edges for front shield and construction thrust bed at designated level as di-
rected by the engineer, necessary dewatering and providing the concrete foundation at the
base of the driven pit, crane for holding the pipe and any other machinery, tools , tackle
required, construction of the temporary works as per the requirement and approval of the
concerned authorities and engineering in charge, as per the scope of work defined.

2.3 Shoring
Timber shoring whenever required, shall be closed boarded with minimum 50mm thick
good and seasoned timber planks of sufficient length driven side-by-side to the required
depth. The gaps between adjacent timber planks shall be such as would not allow any
flow of soil particles. If necessary, the sides of the planks shall be placed smooth to ensure
this. Sufficient number of bracing struts, walling etc. are to be provided to make the shor-
ing rigid and non-yielding by earth pressure. Where necessary, sheet pilling shall be done
to ensure safety to the adjoining structures, if it is found that it is not feasible to protect
the structure by timber shoring only. The Tenderer is strongly advised to inspect the site
before tendering and apprise himself of the requirement of any Sheet piling in addition to
the timber shoring before submitting his Quotation accordingly.

2.4 Back Filling

The space around the foundations in trenches or sites shall be cleared of all trash and
loose debris and filled with approved excavated earth, all clods being broken upto the
finished G.I. Filling shall be done in 200mm layers, each layer to be property moistened
and well rammed. Excavated materials which is surplus or which is consolidated unsuit-
able for back filling is to be disposed of in spoil dumps as directed by the Engineer-in-
Charge. No extra payment will be made for this.

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3. CONCRETE
3.1 General
3.1.1 Applicable provisions of Conditions of Concrete shall govern work under this section.
3.1.2 All concrete work, plain or reinforced shall be carried out strictly in accordance with this
specification and any working drawing or instructions given from time to time to the
Agency.
3.1.3 The Agency states shall allow for wastages in all materials as well as for all tests of ma-
terials and concrete.
3.1.4 No concrete shall be cast in the absence of the Engineer-in-Charge or any other person
duly authorized by him. The Agency Engineer-in-Charge shall personally check that both
the form work and reinforcement have been correctly placed and fixed, and shall satisfy
himself that all work preparatory to the casting is completely ready, before informing the
Engineer-in-Charge for final inspection and approval and for which purpose at least 24
hours’ notice shall be given by the Agency.
3.1.5 The Indian Standards wherever referred to herein shall be the latest addition of such
standards.
3.2 Cement
Cement shall conform for IS:269. Cement tests shall have to be carried out at Agency
expense as and when directed. Cement which has or practically set shall not be used under
any circumstances.
3.3 Aggregates
The fine and coarse aggregates shall conform to all provisions and test methods of IS:383
and / or IS:515. Samples of aggregates, proposed to be used in the work shall be submitted
free of charge in sufficient quantities to the Engineer-in-Charge with sieve analysis and
other physical and chemical analysis data for his approval. Approved samples will be
preserved by him for future reference. This approval will not in any way relieve the
Agency of his responsibility of producing of specified qualities.

3.3.1 Coarse Aggregates

Coarse aggregates for use all reinforced and other plain cement concrete works shall be
crushed black granite trap stone obtained from approved source and shall consist of un-
coated, hard, strong dense and durable pieces of crushed stone, and be free from undesir-
able matters, viz. Disintegrated stones soft, friable, thin, elongated or laminated pieces,
dirt, salt, alkali, vegetable matter or other deleterious substances. The aggregates shall be
thoroughly washed with water and cleaned before use to the satisfaction of the Engineer-
in-Charge at no extra cost of the Authority.
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The maximum size of coarse aggregates shall be as follows unless specified otherwise
elsewhere.

Reinforced Concrete : 20 mm
Plain Concrete : 20 mm.
Thin R. C. C. Members
With very narrow space : 12 mm.
Mat/Lean Concrete : 20/40 mm.
(The actual size to be agreed by the Engineer-in-Charge)
Grading of coarse aggregates for a size shall generally conform to relevant I. S. Codes
and shall be such as to produce a dense concrete of the specified proportions and or
strength and consistency that will work readily in position without segregation.

3.3.2 Fine Aggregates

Sand shall be clear River sand brought from approved source and consist of siliceous
material, having hard, strong, durable uncoated particles, free from undesirable matters
viz. dust lumps, soft or flaky particles or other deleterious substances. The amount of
undesirable shall not exceed the percentage limits by weights as specified in relevant IS
Codes. Washing of aggregates by approved means shall be carried out, if desired by the
Engineer-in-Charge, at no extra cost to the Authority.

Coarse and fine sand shall be well graded within the limits by weight as specified in
relevant IS Code. Fineness Modulus shall not vary by more than plus or minus 0.20 from
that of the approved sample. Fineness Modulus for sand shall not be less than 2.5.

3.4 Reinforcement

3.4.1 The Agency shall prepare and furnish to the Engineer-in-Charge, Bar Bending Schedules
in considerations of the approved drawings for all R. C. C. works for review and checking
by the Engineer-in-Charge before taking up the work.

3.4.2 The mild steel reinforcement shall conform to IS:432 & the for-steel reinforcement shall
conform to IS:1788.

All steel for reinforcement shall be free from loose, oil, grease, paint or other harmful
matters immediately before placing the concrete.

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3.4.3 The Reinforcement shall be bent to the shapes shown on the approved drawings prior to
placing and all bars must be bent cold. The Steel shall be placed in such a way that it is
rigidly held in position while concrete is being cast. The correct clearance from the form
shall be maintained by either precast mortar blocks or by metal supporting chairs to be
supplied by the Agency free of charge.

The intersection of roads crossing one another shall be bound together with soft pliable
with No. 16 to 18. S. W. G. at every intersection so that reinforcement will not be dis-
placed in the process of depositing concrete. The loops of binding wire shall be tightened
by pliers.

3.4.4 The work of reinforcement shall also be inclusive of stirrups distribution bars, binders,
initial straightening and removing of loose rust, if necessary, cutting to requisite length,
hooking and bending to correct shape, placing in proper position including supplying and
binding with block annealed wire as stated in clause 3.4.3 above.

3.4.5 Welding of reinforcement shall be done according to the IS specifications where binding
wire will not be sufficient without any extra payment to the Agency.

3.5 Water

The Water shall be clean and free from acid, alkali, oil or injurious amounts of deleterious
materials. As far as possible, the water be of such quality that it is potable. If any chemical
analysis of water is necessary and ordered, the same shall be carried out at an approved
laboratory at the Agency cost and expenses.

3.6 Concrete Proportioning

3.6.1 The concrete proportions shall be as indicated on the approved drawings and shall con-
form to IS:456 & IS:3370. The quality and character of concrete shall be governed by
IS:383. It shall be sampled and analyzed as per IS:1199. The concrete shall stand the test
specified in IS:516.

3.6.2 The minimum cover of main reinforcement shall be 25 mm or the diameter of the bar
whichever is greater. Cover to any reinforcement of R. C. C. piles shall be minimum 65
mm. In case in-situ and 50 mm. In case of precast piles. Suitable spacer blocks shall be
provided at intervals not exceeding 1.2 m. throughout the length of the pile.

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3.6.3 The workability shall be measured by slump. Slump for different grades of concrete shall
be as per IS 456 unless specifically permitted by the Engineer-in-Charge.

3.6.4 All concrete works shall be thoroughly compacted and fully worked around the reinforce-
ment, around embedded fixtures and into corners of the form work.

The Concrete shall be thoroughly and shall be efficiently vibrated during laying. The use
of mechanical vibrators shall comply with IS:2608, IS:2506 and IS:4656. Whenever vi-
bration has to be applied externally, the design of form work and deposition of vibration
shall receive special consideration to ensure efficient compaction and to avoid surface
blemishes.

3.6.5 Test for Water Tightness of Structures / Pipes

All liquid retaining structures including underground reservoir, and different units of wa-
ter treatment plant like inlet chambers, flocculator, clarifier, filter etc. shall be deemed to
be satisfactory water tightness test as per relevant clause of IS:3370. Approved corrective
measures, if necessary, shall be undertaken by the Agency at his own expenses. This water
tightness test is mandatory for all type of water retaining structure and no security deposit
shall be released without satisfactory water tightness test results.

As regards the pipe lines, the tests shall be performed for the Hydrostatic Pressure of 10
Kg/Sq. cm in case of Mild Steel & DI K9 pipes and 2 Kg/Sq. cm. for P.S.C./R.C.C. re-
spectively. The tests shall be carried out as per relevant IS Codes and pipes shall be con-
sidered satisfactory if the tests results satisfy the requirements of the relevant clauses of
the Codes. The Agency shall give all these Hydraulic Tests by making his own arrange-
ments for water supply and filling and disposing the water after the tests. The Agency
shall rectify the defects noticed and carry out the tests again and repeat the testing opera-
tion till successful result is obtained and accepted by the Engineer-in-Charge. The rates
Quoted for the work shall be considered as inclusive of cost of all Labour, materials and
equipment required to give successful tests for Water tightness.

3.7 Workmanship
3.7.1 All Concreting work shall be carried out according to the IS:456 and IS:3370. It shall,
however, be noted that for every 15 Cu.m. of concrete placed or for everyone day’s vol-
ume of concrete whichever is lower, a minimum of 3 (three) Cubes shall be cast for test
purpose, and tested at the Agency cost and expenses at a Laboratory as approved by the
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Authority. The number of test cubes may, however, be altered at discretion of the Engi-
neer-in-Charge. It is compulsory to test 3 (three) cubes in each case.

3.7.2 Structural Concrete

Design mix Concrete shall be on all concrete works except in case of Mud-mat con-
crete/lean concrete where nominal mix concrete will be allowed.
Design mix Concrete will be used in Reinforced Concrete Structures shall be in Grade or
M20 or richer.
The mix shall be designed to produce the grade of concrete having required workability
and a Characteristic Strength not less than appropriate values given in Clause 5.1 or
IS:456-1978. For mix design, procedure given in Indian Standard.

Recommendation or any other standard procedure shall be adopted. As long as the quality
of materials does not change a mix design done earlier may be considered adequate for
later work. Batching mixing, sampling and Strength Test of concrete shall be carried out
in compliance with the relevant clause of IS:456-2000 and all other relevant Indian Stand-
ards recommended therein.

The mix design by the Agency shall be used for works only after obtaining written ap-
proval of the Engineer-in-Charge. Mix design shall be entirely the responsibility of the
Agency and any approval by the Engineer-in-Charge shall not relieve him of his respon-
sibility in respect thereof.

The Agency shall prepare all the Calculations. Tabulations, Graphs etc. pertaining to Mix
design/Test result and supply copies of such Calculations, tabulations, Graphs etc. re-
quired by the Engineer-in-Charge. The minimum Cement content in each grade of Con-
crete shall be as per relevant IS codes

On proportioning concrete, the quantity of both cement and aggregate shall be determined
by weight, where the weight of cement is determined on the basis of weight per bag a
reasonable number of bags be weighed periodically to check the net weight or shall be
either weighed or measured by volume in calibrated tanks. All measuring equipment shall
be maintained in a clean serviceable condition and shall periodically checked for accu-
racy.

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The grading of coarse and fine aggregates shall be checked frequently and frequency of
testing shall be determined by the Engineer-in-Charge. Where weight batching is not pos-
sible or practicable, the quantities of coarse and fine aggregates may be determined by
volume but cement in any case shall be weighed by weight only. If fine aggregate and
volume batching is adopted, allowance shall be made for bulking. The bulking shall be
determined in accordance with IS:2386 (Part-III).

The Water-Cement Ratio shall be maintained to its correct value. Surface moisture con-
tent of aggregate shall be determined as per IS:2386 (Part-III) and the amount of water to
be added shall be adjusted accordingly to maintain the correct Water-cement Ration.

During the progress of work in order to ensure correct strength of concrete proper control
shall be exercised by the Agency as specified in Specifications mentioned in the Clause
3.7.1 above. Test strength of every sample shall be determined in accordance with the
recommendations of IS:456-1978. If one out of ten consecutive test cubes show a defi-
ciency in strength up to a maximum limit of 10%, the concrete will be deemed satisfac-
tory. If two of the test cubes out of ten show a deficiency in strength up to a limit of 10%,
the concrete shall be deemed to be less satisfactory and a reduction of 1% will be made
on the cost of such concrete. If three out of ten test cubes show deficiency in strength up
to a limit of 10%, a reduction of 5% will be made on the cost of such concrete. If more
than three rest cubes show a deficiency in strength up to a limit of 10% a reduction of
10% will be made on the cost of such concrete. If more than five show a deficiency in
strength up to a limit of 10%, the concrete shall be rejected. Such rejected concrete work
shall have to be dismantled and replaced to the satisfaction of the Engineer-in-Charge by
the Agency free of cost to the Authority. No payment for the dismantled concrete, the
relevant from work and reinforcement, embedded fixtures etc. wasted in the dismantled
portion, shall be made. In the course of dismantling, if any damage is done to the embed-
ded items or adjacent structures, the same shall also be made good free of charge by the
Agency to the satisfaction of the Engineer-in-Charge.

If the deficiency in strength of one test cubes exceeds the 10% limit, a reduction of 5%
will be made on the cost of such concrete. if the deficiency in strength to two out of ten
test cubes exceeds the 10% limit, a reduction of 10% will be made on the cost of such
concrete. If the deficiency in strength of two out of ten test cubes exceeds the 10% limit,

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a reduction of 10% will be made on the cost of such concrete. If the deficiency in strength
of three out of ten test cubes exceeds the 10% limit, a deduction of 20% on the cost of
such concrete will be made.

With permission of the Engineer-in-Charge for any above-mentioned grades of concrete,

if the quantity of water has to be increased in special cases, cement shall also be increased
proportionally to keep the ratio of water to cement same as adopted in trial mix design
for each grade of concrete. No extra payment for additional cement will be made.

3.8 Precast Concrete

Precast Concrete items shall conform to relevant IS Specifications. Precast items shall be
suitably marked with the date of casting identification marks and shall show the right way
up as may be required. The arrangements to be made by the Agency for Site manufacture
and handling of precast items shall be done to the approval of the Engineer-in-Charge.
Each precast unit shall be cast in one operation and no construction joints shall be per-
mitted. No damaged or defective units shall be built into the works and units shall be so
stored that they are not over stressed.

Precast units shall be provided in places as shown in the approved drawings. The precast
units shall be cast at site strictly following the Specifications of Precast Concrete work.
Proper care shall be taken to ensure that the units are obtained from the moulds without
any damage. Before erecting in position, the position units shall be cured adequately by
keeping units immersed in water.

3.9 Form Work

3.9.1 The Form Work shall conform to IS:456. Whenever necessary, shuttering must be pro-
vided. The work shall also include providing all necessary staging, centering, form work
and moulds for placing concrete. Shuttering may be for approved dressed timber true to
line, not less than 37 mm. thick. Surface to be in contact with concrete are to be planed
smooth. Alternatively, sufficiently rigid plywood shuttering or steel shuttering may be
used. In every case, joints of the shuttering are to be such as to prevent the loss of liquid
from the concrete. In timber shuttering the joints shall, therefore, be either lounged and
grooved or the joints must be perfectly close and lined with draft paper polythene films
or other types of approved materials. In case of plywood or Steel shuttering also the joints

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are to be similarly lined. All shuttering and framing must be adequately stayed and braced
to the satisfaction of the Engineer-in-Charge for properly supporting the concrete, during
concreting and the period of hardening. It shall be so constructed that it may be removed
without shock or vibration to the concrete. No through bolts are allowed for holding the
shuttering in water retaining structure.
3.9.2 Cleaning, Treatment and Removal of Forms

All forms shall be thoroughly cleaned of old concrete, wood shavings, saw dust, dirt and
dust striking to them before they are fixed in position. All rubbish loose concrete chip-
pings, shavings, saw dust etc. shall be scrupulously removed from the interior of the forms
before the concrete is poured. Form work shall not be used/reused, if declared unit or
unserviceable by the Engineer-in-Charge.

If directed by the Engineer-in-Charge, compressed air jet/or water jet shall be kept handy
along with wire brushes, brooms etc. for the purpose of cleaning.

Before shuttering is placed in position, the form surface in contact with the concrete shall
be treated with approved non-staining oil or composition. Care shall be taken that the oil
or composition. Care shall be taken that the oil or composition does not come in contact
with reinforcing steel or existing concrete surface. They shall not be allowed to accumu-
late at the bottom of the shuttering.

Forms shall be truck in accordance with the relevant clause of IS:456 or as directed by
the Engineer-in-Charge. The Agency shall record on the drawings or in other approved
manner, the date in which the concrete is placed in each part of the work and the date on
which the form work is removed therefrom and have this recorded checked and counter-
signed by the Engineer-in-Charge.

The Agency shall be responsible for the safe removal of the form work, but the Engineer-
in-Charge may delay the time of removal if he considers it necessary. Any work showing
signs of damage through premature removal of form work or loading shall be entirely
reconstructed without any extra cost to the Authority.

3.10 Protection and Curing of Concrete

Newly placed concrete shall be protected by approved means; from rain, sun and wind
and extreme temperature. Concrete placed below the ground level shall be protected from

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failing earth during and after placing. Concrete placed in ground containing deleterious
substance shall be kept free from contact with such ground or, with water draining from
such ground during placing of concrete and for a period of at least 3 (three) days or as
otherwise directed by the Engineer-in-Charge. the ground water around newly poured
concrete shall be kept to an approved level by pumping or other approved means of drain-
age at the cost of the Agency. Adequate steps shall be taken to prevent flotation or flood-
ing. Steps, as approved by the Engineer-in-Charge, shall be taken to project immature
concrete from damage by debris, excessive loading, vibration, abrasion, mixing with
earth or other deleterious materials, etc. that may impair the strength and durability of the
concrete.

As soon as the concrete has hardened sufficiently for the surfaced to be marked it shall
be covered with hessian, canvas, or similar materials and kept continuously wet for at
least 7 (seven) days after final setting. This period may be extended at the direction of the
Engineer-in-Charge, up to 14 (fourteen) days. Concrete slabs and floors shall be cured by
flooding with water of minimum 25 mm. depth for the period mentioned above.

Approved curing compounds may be used in lieu of moist curing with the permission of
the Engineer-in-Charge. Such compound shall be applied to all exposed surface of the
concrete as soon as possible after the concrete has set. No extra payment is allowed on
such count.

3.11 Concrete Finish

The Concrete surface on removal of form work shall be such that no finish in necessary,
If, however, the surfaces is not satisfactory the Agency shall, if so instructed, remove
unwanted, projecting parts by chipping and smoothening the surface with cement render-
ing at his own expenses. The shutter marks shall invariably be removed by rubbing with
carborandum stone. The Agency shall therefore take all precaution for avoiding the shut-
ter marks.

3.12 Construction Joints

These shall be in according with IS:337 or as directed.

3.13 Expansion Joints

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Expansion joints shall be provided at position as directed and the spacing shall not exceed
the limits specified in IS:456. These shall comply strictly with the details shown on ap-
proved construction drawings. Reinforcement shall not extend across any expansion joint
and the break between the two sections must be complete.

3.14 Details of typical expansion joints and construction joints shall comply with the sugges-
tive arrangements shown in IS:3370 (Part-I), Clause 8.1 (a)(2), Figure 2 (for expansion
joints) and Clause 8.1(a) Figure 1, Clause 8.1 (b) Figure 4 (for construction joints).

3.15 P.V.C. Water Stops

The materials shall be durable and tough and as per approval of the Engineer-in-Charge.
The minimum thickness of PVC sealing strips shall be 6 mm. and the minimum width
225 mm. actual shape and size shall be as per drawings. The materials shall be of good
quality polyvinyl chloride highly resistant to leading abrasion and corrosion as well as to
chemicals likely to come in contact with during use. The physical properties will gener-
ally be as follows:

Specific Gravity 1.3 to 1.35

Shore Hardness 60 A to 80 A
Tensile Strength 100 to 150 Kg/Cm2

Minimum Safe Continuous Temperature 750C

Ultimate Elongation Not less than 275%
Water Absorption Not more than 5% by weight
in a 7-day test.
3.16 Rubber Water Stops

The materials must be very durable and tough and as per approval of the Engineer-in-
Charge. The ribs shall be sufficient to ensure proper bonding with concrete. The width
shall be minimum 225 mm. and thickness minimum 6 mm. The rubber water stop must
be used in long lengths to avoid splicing as far as practicable. Ends shall have at least 200
mm. overlaps and volcanized. The materials shall be natural rubber and be resistant to
corrosion tear and to attacks from acid, alkalis and chemicals normally encountered in
service. The physical properties will generally be as follows:

Specific Gravity 1.1 to 1.15

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Shore hardness 65 A to 75 A

Tensile Strength 250 to 300 Kg/Cm2

Maximum safe continuous temperature 750C

Ultimate elongation Not less than 350%
Water Absorption Not more than 350% by
weight in a 7-day test.

3.17 Agency Supervision

The Agency shall provide constant and strict supervision of all the items of construction
during progress of work, including the proportioning and mixing of the concrete and
bending and placing of reinforcement. Before any important operation such as concreting
or stripping of form work adequate notice shall be given.

3.18 Laying Cement Concrete Foundations and Under Floors

Before laying the concrete, the bottom and sides of the trench up to the proposed height
of the concrete shall be moistened.

The concrete shall be laid and not thrown, in layers not exceeding 150 mm. in depth and
shall be tamped / vibrated immediately after laying.

3.19 Chases, Holes, Recesses and Inserts

All chases, holes and recess for foundation or other bolts, various services and other re-
quirements must be formed as shown on the approved drawings or as directed during the
execution of the work, without any extra charge. The Agency shall fix all necessary in-
serts or fixtures in the concrete for support of hangers etc., for pipes and cables, ceiling
clamps for lights and fans or for duct etc. If any of the inserts are to be supplied by other
agencies, no extra payment will be made to the Agency for placing the inserts in position.
The approximate nos. of MS inserts required for fixing of cable tray/hangers in 400. The
load carrying capacity of inserts per sq. m. may be taken as 100 kg.

3.20 Load Testing of Structure

Load tests shall be carried out in accordance with IS:456, if required.

4. BRICK WORK
4.1 Applicable provisions of Conditions of Concrete shall govern work under this Section.
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4.2 The Agency shall build the whole of brick work, shown on the approved drawings with
first class bricks conforming to IS:1077 and IS:2212 in cement mortar as described. All
brickwork, unless otherwise specifically mentioned, shall be of 1st Class brick of ap-
proved quality.

4.3 Unless otherwise specified, the proportions of cement-sand mortar for various classes of
brick work shall be as given below:

S No Type of Work Cement Sand

Ordinary brick work with Thickness 250
1 1 6
mm. above for building superstructure
2 Brickwork in pillars and foundation 1 4
Half brick or brick-on-edge portion wall
3 with H.B. netting in every alternative 3rd 1 4
layer

The cement and sand shall be thoroughly mixed dry in specified proportions. Water shall
then be added just sufficient to make a stiff and workable paste. The mortar shall be used
within half an hour of mixing.

4.4 The Agency shall build all brickwork uniformly, no one portion being raised more than 1
meter above another at a time. The joints shall not exceed 12 mm. in thickness and shall
extend the full thickness of the brickwork. All joints shall be properly raked and the sur-
face washed down.
4.5 All the bricks shall be kept fully immersed in water at least for a minimum period of six
hours till they are completely soaked and only thoroughly soaked bricks shall be used in
the work.
4.6 The Agency shall keep wet all brickwork for at least 10 (ten) days after laying. The sur-
face of unfinished work shall be cleaned and thoroughly wetted before joining new work
to it.
4.7 Before supplying the bricks, quality and grade of the bricks must be approved by the
Engineer-in-Charge on the representative sample.

5. PLASTERING, PAINTING AND SURFACE TREATMENT

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All outside and inside walls, ceiling etc., of the building shall be finished with cement
plaster, 1.5mm thick cement based putty over plaster. Visible External surface of water
retaining structures shall be finished with cement plastering. The external surface shall
be plastered up to 0.1 m below FGL. The Agency shall provide neat Cement finish over
plaster up to 0.1 m below FGL and 0.3 m above FGL on all external surface as directed
by the EIC. The visible external surface of all the structures shall be painted with two
coats of acrylic exterior emulsion paint over a coat of primer. Internal wall and ceiling of
all structures except water retaining structures shall be finished with cement plaster,
1.5mm thick cement based putty over plaster and painted with two coats of superior grade
emulsion paint (plastic paint) over a coat of cement based primer. The shade of the paint
shall be approved by EIC. The thickness of plaster is mentioned here under.

5.1 Cement Plaster

5.1.1 The plastering work shall be governed by IS:1661. Unless otherwise specified cement
plaster shall be composed of 1 part of cement and 6 parts of sand. For ceiling plaster, the
composition shall be 1 part of cement and 4 parts of sand. The thickness of sealing plaster
shall be 6 mm. The thickness of plaster to the fair faces of brickwork shall be 15 mm,
uneven faces of brickwork shall be 20mm and ceiling plaster shall be of 12mm. The
thickness mentioned shall be minimum thickness. The Agency shall allow in his rate for
any rubbing out due to inequalities of brickwork. Except underground reservoir and un-
less otherwise specified by the Engineer-in-Charge, cement plaster shall be applied on all
inner and outer surfaces except floors of all structures.
5.1.2 The rate shall also include for forming of any moulding drip course etc., and for extra
thickness due to corbelling of brick work in parapet or at any other place. If required, all
internal angles shall be rounded off as per drawing or as directed by the Engineer-in-
Charge without any extra charges.
5.1.3 Cement and sand shall be measured and mixed dry thoroughly to a uniform color on a
platform specially constructed for the purpose. Care shall be taken to see that no foreign
matters get mixed with the mixture. Only enough water shall be mixed to make the mix-
ture workable. The mix shall then be turned over and again to a uniform color and texture.
No. more cement mortar shall be mixed at a time than cannot be used within thirty (30)
minutes of mixing.

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5.1.4 Surface to be plastered are to be brushed clean, wetted for 24 hours before the plaster is
put in and the joints of the brick work raked out 12 mm. deep minimum. The concrete
faces to be plastered shall be chipped, roughened and soaked with water for achieving
required bond with the plaster without any extra cost.
5.1.5 The surface of the plaster shall be finished absolutely in one plane. All unevenness shall
be rubbed down by the Agency with corboandum stones at his cost and expenses. Care
shall be taken to see that no mark remains at the junction of plastering done at different
times. If necessary, the junctions shall be rubbed with corborandum stones to eliminate
such undesirable marks. The Agency may be required to use normal sprinkling of thin
cement slurry on the surface for satisfactory finishing of the plastering work for which
no extra payment shall be made.
5.1.6 Plaster shall be protected and cured by keeping it thoroughly wet with sprinkling of water
for 10 (ten) days continuously.
5.1.7 The cost of plastering work shall also include the cost of necessary scaffolding, staging
etc. as would be required for the work.

6. SURFACE FINISHING

6.1 General

The cost of all the items of work under this section shall include the cost of necessary
scaffolding, staging, preparing sub base, removing stains from the floor, skirting, wood
work, glass etc. caused through execution of the work.

6.2 Acrylic exterior emulsion paint

6.2.1 Acrylic emulsion paint shall be applied in the same way as for plastic emulsion paint. A
minimum of 2 finishing coats over one coat of primer shall be provided unless otherwise
specified. For the external surfaces of the Pump House, Chemical House, Annexe Build-
ing, the quality and colour scheme shall be as per direction of the EIC.

6.2.2 Plastic (Acrylic) Emulsion Paint: All internal surfaces including ceiling of the Buildings
constructed under this tender shall be finished with plastic (acrylic) emulsion paint. On
the plastered surfaces, a cement priming coat is required before application of plastic
emulsion. Plastic emulsion paint of approved brand and manufacturer and of the required
shade shall be used. The paint will be applied in the usual manner with brush and roller.

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The paint dries by evaporation of the water content and as soon as the water has evapo-
rated the films gets hard and the next coat be applied. The time for drying varies from
one hour on absorbent surfaces to 2 to 3 hours on non-absorbent surfaces. The thinning
of emulsion is to be done with water and not with turpentine. Thinning with water will be
particularly required for the undercoat which is applied on the absorbent surface. The
quantity of thinner to be added shall be as per manufacturer's instruction. The surface on
finishing shall present a flat, velvety, smooth finish. If necessary more coats shall be ap-
plied till the surface present a uniform appearance.

6.3 Painting to Steel Works

6.3.1 Any shop coat of paint shall not be considered as a coat of paint for the purpose of spec-
ification.

6.3.2 Ready mixed synthetic enamel paint of 'Jenson & Nicholoson' 'British Paints', 'Shalimar
Paints' or similar other approved make and approved color and shade shall only be used.
The primer shall be red oxide zine chromate primer (IS:2074) or any other anticorrosive
primer as approved and directed by the Engineer-in-Charge. The Agency shall furnish the
details of paints to the Engineer-in-Charge for approval of paints before commencement
of painting work.

6.3.3 The surface to be painted shall be properly cleaned, de-rusted, all loose scales removed
and smoothened with emery papers. Then a coat of anticorrosive priming shall be evenly
applied. After this has dried up, two successive coats of best quality ready mixed synthetic
enamel paint shall be given to the entire satisfaction of the Engineer-in-Charge. Brushes
of approved size and make shall only be used for application of paint and use of cloth is
definitely prohibited.

6.4 Painting to Internal Walls

Whether or not specified, entire internal surfaces of all buildings (except Alum godown)
shall be given two coats of acrylic interior emulsion (plastic) paint of approved make,
color and shade on a coat of approved primer. The surfaces are to be prepared and both
primer and paint are to be applied as per manufacturer's specification. Painting works
shall be carried out only by trained hands with roller in order to achieve a high-grade
finish to the entire satisfaction of the Engineer-in-Charge.
6.5 Painting to Doors and Windows
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All doors and windows unless otherwise mentioned shall be painted with high quality
(Grade-I) synthetic enamel paint of approved shade over a coat of primer. The wooden
doors and windows of guest house, SCADA room, superintendent bungalow, Chief En-
gineer bungalow, etc., shall be provided with high quality polish finish.

7. DAMP PROORING WORK

7.1 Unless otherwise specified, damp proof course shall be 25 mm. thick cement concrete
(1:2:4) with stone chips graded 10 mm to 3 mm with 3% Cico or similar approved water
proofing compound conforming to IS:2645 by weight of cement. The proportioning, lay-
ing etc., shall be done is conformity with specification for cement concrete work. The
damp proof course shall be used for all brick walls of the building. Wherever brick wall
is there, above or below the plinth level, the Agency shall provide plinth protection as per
the direction of EIC.

8. ROOF WATER PROOFING TREATMENT

8.1 Unless otherwise mentioned, both flat and curved roofs, whether accessible or inaccessi-
ble, shall be provided with polyurethane based water proofing paint over 35 mm thick
skid concrete with proper slope.
Specification for Roof Water Proof Treatment with Polyurethane based Water Proof
Paint:

8.2 Preparation of Surface

The top surface of the roof shall be chipped off where necessary and all loose particles,
dust impurities, are to be removed by rubbing the entire roof surface with wire brush and
by application of High Pressure Compressed Heated Air to have a complete dust free and
moisture free surface.
The roof surface, receiving polyurethane based Water Proofing paint, shall be provided
with cement punning having smooth finish over 35mm thick skid concrete (1:2:4) with
12mm down stone chips. A cross slope of 1 in 300 shall be provided in the roof of Build-
ing to allow proper drainage of rain water.
8.3 Specification of Materials
The polyurethane based paint is essentially an elastic and water proof film having a good
adhesion to concrete; water and abrasion resistant properties and shall have long term
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weather proof characteristics. The paint/film material shall be of two components which
is to be mixed and processed as per manufacturer's specification. The mixture shall be
homogeneous before applications, as it has tendency to settle.
The polyurethane based water proofing system shall be manufactured by reputed manu-
facturers of proven record and shall be approved by the Central Building Research Insti-
tute (CBRI) / National Chemical Laboratory (NCL) / Council of Scientific and Industrial
Research (CSRI) / National Test House or similar such Government/Public Sector Un-
dertakings.
The materials are to be inspected/approved by the Engineer-in-Charge as per procedure
to be mutually agreed upon by the agency and Engineer-in-Charge of the work.
8.4 Since the product has a very short self-life, the materials are to be used in the work shall
not be older than four (4) months from the date of manufacture (i.e. the date of bottling).
Necessary Test Certificate of CBRI/NCL/CSIR/National House etc. are to be furnished
by the Agency to the Authority, for the materials procured for the water proofing work.
8.5 Application
The two components of polyurethane based water proofing system shall be mixed as per
manufacturer's specification before application. The tack coat shall be applied by brush-
ing or roller to the entire surface in normal temperature and 4 to 6 hours setting time or
as specified by the manufacturer shall be allowed before application of the second coat.
The record and final coat of polyurethane based mixed water proofing sealing over the
priming coat to be applied at normal temperature and curing time between 36 to 48 hours
or as specified by the manufacturer shall be allowed.
The application to be made by technically trained and approved applicators duly certified
by the manufacturers.
8.6 Guarantee Period
The entire water proofing job shall be covered with a written guarantee of leak proof
performance for a minimum period of 10 (ten) years.
8.7 Defects Liability Period
The percent (10%) of the cost of water proofing work shall be retained by the Authority
for two (2) years from the date of completion of work. Any defect observed during the
Defect Liability Period shall be rectified by the Agency without any extra cost to the
Authority.

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9. FLOORING
Unless otherwise mentioned, requirement of flooring of different buildings is given be-
low:

S. Description of Minimum
Type of Flooring Remarks
No Building Thickness
Min. 5 mm Skirting shall be
thick epoxy minimum 150mm
Intake Well Epoxy flooring over
1 flooring over height. Flooring pattern
Pump house ironite flooring
50mm thick shall be submitted for
ironite flooring EIC approval.
Vitrified tiles
Office and Skirting shall be
2 (600mm x 600mm) 8 - 10mm
Guest house minimum 150mm height
flooring
Vitrified tiles
Skirting shall be
3 Staff Quarter (600mm x 600mm) 8 - 10mm
minimum 150mm height
flooring
Nonskid Vitrified Skirting shall be
4 MCC Room 8 - 10mm
tiles minimum 150mm height
Filter House Vitrified tiles
Skirting shall be
5 Annexe (600mm x 600mm) 8 - 10mm
minimum 150mm height
Building flooring
Vitrified tiles
Skirting shall be
6 Operator Room (600mm x 600mm) 8 - 10mm
minimum 150mm height
flooring
Vitrified tiles
Skirting shall be
7 Security Cabin (600mm x 600mm) 8 - 10mm
minimum 150mm height
flooring
Toilet wall shall also be
Toilets & Nonskid Vitrified
8 8 - 10mm provided vitrified tiles
Bathroom tiles
upto 1.8 m height
Skirting shall be
9 Filter House Polished Granite 25 mm
minimum 150mm height
Platform of Skirting shall be
10 Polished Kota Stone 25 mm
Intake well minimum 150mm height
Filter house Granite slab of area Skirting shall be
11 Ground Floor not less than 1.5 25 mm minimum 150mm
lobby sq.m each height.

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Granite slab of area Skirting shall be

Kitchen
12 not less than 1.5 25 mm minimum 750mm height
platform
sq.m each over the platform.
Vitrified tiles
Skirting shall be
13 Kitchen floor (600mm x 600mm) 8 - 10mm
minimum 150mm height
flooring
Chemical resistant Skirting shall be upto
14 Laboratory 8 - 10mm
vitrified tiles window sill level
Skirting shall be upto
Chemical Bituminous Mastic
15 25 mm 0.3 m above chemical
Storage Area Asphalt
storage height
Chemical Skirting shall be
16 Kota Stone 25 mm
house minimum 150mm height
Min. 5 mm Skirting shall be
thick epoxy minimum 150mm
CWPS Pump Epoxy flooring over
17 flooring over height. Flooring pattern
floor ironite flooring
50mm thick shall be submitted for
ironite flooring EIC approval.
Walkway of Skirting shall be
18 Polished Kota Stone 25 mm
Pump house minimum 150mm height
Walkway of
Treatment
19 Chequered tiles 25 mm
Plant (Open to
Sky)
Italian Marble Slab
Chief Engineer Skirting shall be
20 of size not less than 8 - 10mm
Bungalow minimum 150mm height
2 Sqm
Vitrified tiles
Superintendent Skirting shall be
21 (800mm x 800mm) 8 - 10mm
Bungalow minimum 150mm height
flooring
Vitrified tiles
Administrative Skirting shall be
22 (600mm x 600mm) 8 - 10mm
building minimum 150mm height
flooring
Command
Granite slab of area
Control Center Skirting shall be
23 not less than 1.5 8 - 10mm
and SCADA minimum 150mm height
sq.m each
room
Anti-skid Ceramic
Car parking Skirting shall be
24 tiles (450 mm x 450 8 - 10mm
area minimum 150mm height
mm) flooring
Stair case Marble (single stone) Skirting shall be
25 12 mm
(except pump for rise and tread. minimum 150mm height

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house &
SUGRs)

9.1 'Ferrosite' or 'Ironite' Flooring shall be 50mm. Thick to be laid in two layers. First a layer
of 25mm. thick patent stone flooring shall be laid in M15 grade concrete and allowed to
dry. Then the second layer of 25mm.thick flooring of M15 grade concrete with 10mm.to
6mm. stone chips using at least 1Kg/Sq.m. of floor hardening compound of approved
quality and make shall be laid and cured. The flooring shall be laid in rectangular panel
with diagonal length not exceeding 3.0 Meters. All floors with pump and motors, chlo-
rinator and chlorine drums, pipeline higher than 300 mm diameter, electrical panel board,
blowers, alum/coagulant storage room, unloading bay, stack yards for pump and motors
shall be of this type of flooring.

10. IRON MONGERY

10.1 The rain water pipe of the materials and of size as specified shall be of approved manu-
facture end jointed as follow:
10.1.1 For heavy cast iron pipes with gasket and lead properly caulked.
10.1.2 Where required these are to be run in chase left out in walls, columns, slabs and to be
encased in cement concrete 1:2:4 (1 Cement, 2 Sand, 4 washed Stone Chips 19mm. down)
with metal lath wrapping or with M.S. loops placed at approximately 325mm. centres or
as directed by the Engineer-in-Charge. All pipes encased in walls, columns or under floors
must be heavy cast iron with lead caulked joints. For exposed lengths of pipes, these are
to be neatly secured clear from the finished wall face with nails and bobbing in the case
of cast iron pipes, nails or screwed to hard wood tapping pugs embedded in wall.
10.1.3 All cast iron rain water pipes shall be painted two coats inside with approved anticorro-
sive paint. The exposed cast iron pipes shall be painted outside with two coats of ready
mixed Synthetic Enamel Paints of approved make, shade and color over a coat pf priming
of approved make.
10.1.4 The mouth of rain water pipes shall be fixed with C.I grating and the pipe jammed in
position in 1:2:4 cement concrete with stone chips and neat finish on the surface.

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10.1.5 The work shall include all supply, fitting and fixture of materials cutting, making chases,
encasing, painting, jointing, etc.- complete in all respect. The work shall include supply-
ing, fitting, fixing, and jointing of all the specials required for the completed work.
10.1.6 Rain water Spouts shall be of C.I pipes cut to exact length as per approved drawing or
direction of the Engineer-in-Charge and laid in position in 1:2:4 cement concrete with
stone chips, adjoining roof being finished in neat cement. The interior faces shall be
painted two coats with anticorrosive paint and the faces shall be painted with two coats
of ready mixed Synthetic Enamel paint of approved make, shade and color over a coat of
priming of approved make.
10.2 Metal Casement
10.2.1 Unless specified otherwise, all doors, windows and ventilation in general shall be of
mild steel casement with sections as per I:1038. They shall be of approved make. The
Agency will submit the name and address of the manufacturers whose mental casements
he intends to use for approved of the Engineer-in-Charge. The workmanship shall be of
high quality and shall be upto the entire satisfaction of the Engineer-in-Charge.
10.2.2 All the steel doors and windows sashes shall be given a shop coat of Red Oxide Zinc
Chromate Primer I.S:2070 after these are thoroughly cleaned off dust, dirt, scales etc.,
and passed after inspection by the Engineer-in-Charge.
10.2.3 Windows are to be prepared for puffy glazing from the outside and for opening outwards
unless otherwise mentioned. All steel sashes shall have holes drilled at suitable places for
inserting glazing clips which shall also be supplied by the Agency. All glazing shall be
fixed to the shutters or frames in addition to glazing clips with quality putty of Shalimar
or equivalent make. Glass must not be placed directly against the metal. A thin layer of
putty must be evenly spread over the glazing rebate and the glass pressed firmly against
it.
10.2.4 Ventilators shall be constructed from solid filled universal casement section being dou-
ble weathered at all points to ensure water tightness and bedded in mastic and screwed to
the sashes.
10.2.5 The fitting shall be of heavy pattern bronze oxidized brass and of approved quality, side
hung casement will have two-point locking handle and casement fasteners. The hung
windows shall have 200mm. long adjustable casement stay, arrange to lock the windows
from inside horizontally at the center, hung windows shall have spring catch designed for

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hand cord or pole operation as approved by the Engineer-in-Charge. The fitting to be

fitted either by screwing to the window sections or to steel bracket welded to the window
section as approved by the Engineer-in-Charge.
10.2.6 Galvanized weather bars shall be provided to sills of all windows.
10.2.7 Mental casement are on no account to build in at the time the walls are constructed.
Holes to accommodate the fixing lugs are to be left or cut and the casement fixed after all
rough masonry plaster works have been finished. The lugs of the casement shall be
jammed in 1:2:4 cement concrete with stone chips after holding the casement in proper
position, line or level.
10.2.8 Glazing for windows and ventilators shall weight not less than 8.0 Kg/Sq.m. For doors,
6mm. thick wire net reinforced glazing shall be used as approved by the Engineer-in-
Charge. The glasses shall be cut to size accurately to suit all openings to glazed with slight
margin of about 1.50mm. on all sides or as directed. These shall be securely fixed in
position in the manner described earlier. On completion of the building, the Agency shall
clean all the glass and leave the same perfectly in a tidy condition.
10.2.9 The cost of marginal doors, windows and ventilations shall include supplying fixing,
fitting, glazing cleaning, necessary scaffolding, staging etc. and shall be for the complete
work in all respects to the satisfaction of the Engineer-in-Charge.
10.2.10 The Agency shall without any extra charge, submit three sets of shop drawings from
the manufacture showing full details of each type of doors, windows and ventilators in-
cluding section, position of all fittings and fixtures for the approval of the Engineer-in-
Charge before manufacture and finally six sets of approved final drawings with notes on
the method of fixing.
10.2.11 Where specified, mosquito fly proof brass wire screen of approved gauge and mesh
shall be used in combination with windows. The screen shall be fixed to the inside of the
frames and the windows to be opened outside and be fitted with 'Folio operator' for open-
ing to any position and closing. Additional intermediate members be fixed to the frames
to receive the fly screen so that the clear span of the screen does not exceed 300 m. or as
approved by the Engineer-in-Charge.
10.2.12 All windows shall be provided with grills of approved design made of 12 mm x 12 mm
M.S. square with clear openings not exceeding 100 mm.

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10.2.13 The work for grill shall also include the cost of painting with 2 coats of ready mixed
synthetic enamel paint of approved make, quality color and shade over a coat of approved
anticorrosive primer.
10.3 Collapsible Gate
The M.S. collapsible gates will be obtained from manufacturer as approved by the Engi-
neer-in-Charge. These shall be of mild bar type, out of 20 mm. channels and shall be top
ung with roller bearing and shall have locking arrangement. Collapsible gates under 2.700
m. height shall be with 4 sets of lattices. Guide tracks shall be to the entire satisfaction of
the Engineer-in-Charge. The gates shall be fixed in position, de-rusted, descaled and
painted with 2 coats of approved ready mixed paint over a coat of approved anticorrosive
primer.

10.4 Rolling Shutter

10.4.1 The M.S. roller shutter shall be obtained from manufacturer as approved by the Engi-
neer-in-Charge. The roller shutter shall be of 18 G x 75 mm. galvanized mild steel laths
of convex corrugation complete with one-piece construction. These shall be fitted with
pressed side guides and pressed bottom rail, brackets, door suspension shafts, top rolling
springs (of strong English Continental Spring Steel Wire) with a four-lever concealed
lock as also separate locking arrangement for padlocks, pulling hooks, handles and top
cover. The roller shutters shall be fixed in position with all accessories and the design and
the workmanship shall be to the entire satisfaction of the Engineer-in-Charge. This shall
be finished with two coats of approved ready mixed paint over a coat of approved anti
corrosive primer.

11. STRUCTURAL STEEL WORK

11.1 All Structural Steel to be used for gantry beam etc. shall be of tested quality conforming
to IS:226 and IS:2062 latest addition.
Finished steel shall be free from cracks, lamination and other visible defects. Section shall
be adequately protected from rusting and scaling. Rivets and bolts, nuts and washers shall
be of mild steel and comply with requirements of relevant IS Codes. Steel used for rails
shall have tensile strength of about 50-60 Kg/Sq. mm. and yield point at 26 Kg/Sq. mm.
The electrodes for welding shall conform to IS:814. All steel work shall be fabricated and

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erected as per IS:800 and IS:806. Welding shall be carried out as per IS:814, IS:815,
IS:816 and IS:823, all of the latest editions.
11.2 All steel work, after preparation of surface, shall be given a coat of red oxide zinc chro-
mate primer (IS:2074) and finished with two coats of Synthetic enamel paint. Surface to
be painted shall be thoroughly cleaned of mill scale, oil grease, rust etc. over coating and
finishing paints shall be of well-known make (viz Jenson & Nicholson / British Paints
(Berger Paints) / Shalimar Paints). The Agency shall furnish details of Paints to the En-
gineer-in-Charge for approval of paints before commencement of painting work.
11.3 Steel work shall be hoisted and erected in position in a safe and proper manner. No. riv-
eting or permanent bolting shall be down until proper alignment has been made. For
grouting, cement and clean fine sand shall be used in a proportion of 1:2 and properly
mixed with water. All trapped pockets shall be fully vented for full penetration of grout.
All grouting shall be cured for a minimum period of seven days.
12. CABLE TRENCHES
12.1 The Agency shall design the size of cable trenches and shall provide insert plates made
of M.S. of dimension 100 mm x 750 mm x 12 mm (W x D x Th) are to be provided at an
interval of 600 mm all along. The cable trench shall be of RCC M30 grade.
12.2 The Cable Trenches shall be covered with precast concrete slabs of required dimension

and adequate thickness to withstand a load of 500 Kg/m2 are to be provided as covers of
trench all along. For easy access of cable from room to room, the design of the tie beam
and level of the rooms may be adjusted to avoid bend in the cable.
12.3 The cable trenches shall be free from any obstructions as to allow the cables to be lowered
in the trenches from top only during laying. The space inside the trenches throughout the
entire lengths shall in no case be encroached by any beam or columns.

13. POCKETS & HOLDING DOWN BOLTS

Provision have also to be kept for pockets and holding down bolts as per requirement of
the electrical and mechanical equipment at no extra cost. The extract details of such pock-
ets and holding down bolts will be supplied to the Agency as per specifications of the
suppliers of the equipment after award of the contract. It is contemplated that M.S. hang-
ers shall be provided from the underside of slab/beam of the operating floor, and is to be

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executed in a separate contract. However, for the above arrangement suitable pockets and
holding down bolts are to be left.

14. CHEQUERED PLATES ETC.

These shall be manufactured from structural steel conforming to IS:226. They shall be of
the specified size, thickness and pattern as per relevant drawings or as directed by the
Engineer-in-Charge. Cover plates will generally be of chequered plates with or without
stiffeners as detailed in the drawings. For convenience, the Agency shall prepare detailed
floor plans of the layout of cover plates for floors and platforms to include all openings,
cuts etc. and so as to match the patterns of adjacent cover plates/gratings. Where neces-
sary, the floor will have to be made leak proof by properly welding cover plates. If nec-
essary, packing shall be welded to the bottom of cover plates to raise the cover plates on
sides, so as to provide necessary slopes as shown in the drawings or as directed by the
Engineer-in-Charge in the floors and platforms to drain away any liquid failing on the
floors and platform. Necessary gutters at the ends of platforms shall be provided for slop-
ing floors and platforms as shown in the approved drawings or as directed by the Engi-
neer-in-Charge. Kerbs of flats shall be provided where necessary, around openings and
cuts in order to prevent liquids falling to lower floors or platforms.

15. HAND RAILING

Double rows of 30 mm. dia. S.S. tubular hand railing fixed in S.S. stanchions shall be
provided on the edge of walkways and platforms as specified. The stanchions shall be
fixed with mild steel rag bolts with chromium plated cap nuts. The stanchions shall not
be less than 1000 mm. high and placed at a distance not exceeding 2500 mm. The hand
railing shall be fixed true to exact line and level. S.S stanchions and hand railing layout
shall be of architectural design with pleasing appearance.
16. SANITARY INSTALLATIONS
16.1 The Urinals shall be of flat back, front lipped having a size of 46.5 cm. x 36.5 x 26.5 cm.
or nearest available size. The Indian type W.C. shall be of minimum 58 cm. Complete
with foot rest in one piece.
16.2 All Sanitary works shall be of "Parry, "Neycer", "Hindusthan Sanitaryware" or any other
equivalent make. They shall be of approved quality conforming to relevant IS Codes and

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shall bear ISI Certification marks. All G.I. pipes shall be of ITC or equivalent make heavy
quality conforming to relevant IS Code. Wheel valves and stop cocks shall be of gun
metal and of "leader" or "Annapurna" or equivalent make as approved by the Engineer-
in-Charge and shall conform to relevant IS Codes.
16.3 Minimum two urinals, one bathroom, one European W.C. (Commode), one change room
with cupboards shall be provided in each toilet block.
17. MANHOLE COVERS
Heavy duty plastic fiber reinforced concrete manhole covers shall be of heavy duty type
conforming to IS:1726.
17.1 Overflow Arrangement
Overflow line shall be provided with openable SS net at Outlet fixed with a flange ar-
rangement.
18. DOORS
Timber doors
The timber door shall be of 1st. Class CP Teak Wood for both frame (100 mm x 100 mm)
and shutters (49 mm thick). All such doors shall be fully paneled. All timber shall be of
best quality, well-seasoned and/or well treated for prevention and protection against de-
cay etc. It shall be uniform in substance, straight in fibers, free from large or dead knots,
sap, flaws, sub cracks, shakes, or blemishes of any kind. Any insect damage or splits
across the grain shall not be permissible. The color of the timber shall be uniform through-
out, firm and shining with a silky lustre when placed and shall not emit dull sound when
struck. The doors shall be made as per approved drawings and as directed by the Engi-
neer-in-Charge and the timber shall be sawn in direction of the grains and shall be straight
and square. The door fittings shall be highly polished as per direction of the Engineer-in-
Charge.
Aluminium Doors
Main entrance of all main buildings shall be of glazed anodized aluminium door of ap-
proved shade with hydraulic door closer.
WINDOWS
All windows shall be of glazed anodized aluminium door of approved shade. Sliding
window with Double glazing glass shall be provided at Control room and SCADA room
at WTP.

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19. Painting of PIPELINES

All above-ground pipelines shall be painted with epoxy coating.
19.1 R.C.C N.P-3 CLASS PIPELINE
The Agency shall design detail Engineering of storm water drainage as per the specifica-
tion given in other section of the bid document.
20. ELECTRICALLY OPERATED OVERHEAD CRANE
Provisions shall be made at Intake well-cum-pump house for a 15.0 M.T. capacity and at
clear water pump house for a 10.0 M.T. capacity Electrically Operated Traveling Crane
(E.O.T.) suitable for inching operation with a lift to operating above Ground Level for
handing pump, motor and other accessories. The horizontal travel of the EOT crane shall
cover the maximum possible length along longitudinal and transverse direction of the
pump-motor room including operation/maintenance platform and unloading bay. They
shall be of reputed make as per vendor list and as approved by Engineer-in-Charge. Suit-
able type of crane rails, girders and all other accessories as necessary for installation and
operation of the crane are to be designed and provided by the Agency within the Lump
Sum pipe quoted. The two travels and two hoists i.e. long, cross & main Auxiliary etc.
must be electrically operated with provision for mechanical operation. The buffers must
be spring loaded operation. The speed and other criteria are as follows:
Speed for Hoisting 4-5 (normal) MPM

Speed for Cross Travel 1-12 (normal) MPM

Speed for Long Travel 15-20 (normal) MPM

Type of Brake - AC (Electromagnetic) shoe type for hoist and disc type for C.T.

Motor - Ship disc type.

Suitable vertical clearance is to be provided over the rail level to the bottom of the roof
beam.
There shall be another additional 3.0 MT capacity EOT crane at CWPS covering same
horizontal and vertical limit as of 10 MT capacity EOT crane. Provisions shall be made
at Backwash Pump room, Chlorine drum storage room, chlorine rom at chemical house
for a 5.0 M.T. capacity Electrically Operated Monorail Trolley with Auxiliary hook of 1.0
MT capacity suitable for inching operation with a lift up to operating above-Ground Level

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for handling pump, motor and other accessories. At Alum/coagulant mixing tank room (2
nos. of 2.0 MT capacity) having above specification shall be provided.
Provisions shall be made at clear water pump house at WDC with SUGRs for a 3.0 M.T.
capacity Electrically Operated Monorail Trolley with Auxiliary hook of 1.0 MT capacity
suitable for inching operation with a lift up to operating above-Ground Level for handling
pump, motor and other accessories.

21. SLUICE GATE/PEN STOCK GATE

Electrically actuator operated SCADA compatible Cast iron single faced Thimble
Mounted Sluice Gate/Penstock Gate shall be designed as per IS:13349-1992.
22. D.I. SLUICE VALVE
Electrically actuator operated SCADA compatible D.I. Sluice Valve conforming to
IS:2906-1869 suitable for water works purposes and as per requirements of the Clear
Water Reservoir/Clear Water Pump Sump. The detailed specification has been given in
the “Specification for Valves” in this bid document.
23. S.S COWL VENTILATOR
150 mm. diameter Specially designed heavy-duty S.S. 316 Cowl Ventilator with mos-
quito-proof SS Net shall be provided in the outer peripheral walls below the reservoir
roof. The Agency shall design the number of SS Cowl Ventilator to be required and shall
submit the same to the EIC for approval.

24. ARRANGEMENTS OR PLASTIC FIBRE REINFORCED CONCRETE MAN-

HOLE COVER M.S. LADDER ETC.

24.1 Manhole Cover

Heavy duty plastic fiber reinforced concrete manhole covers with frame shall conform to
relevant IS Code. The clear opening for access to the M.S. Ladder for going inside the
reservoir shall be 600 mm. and the overall dimension of the Heavy-Duty Manhole Cover
shall be specified by the Tenderer conforming to relevant IS Code. The manhole cover
with frame shall be of 'Double Seal Type'. The Agency shall design the number of man-
hole to be required and submitted to the EIC for approval. The specification for manhole
in sewer line and drainage line has been given elsewhere in this bid document.

24.2 RCC Stair case

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The Agency shall provide RCC (M30) staircase with handrail for going inside of the res-
ervoir. The width of the stair shall be of minimum 1.0 M. The riser and tread shall be of
150mm and 250mm respectively.
24.3 Rung Ladder
Where over specified, shall be formed out of 20 mm. dia M.S. Rods. The rods forming
Rung Ladder shall be properly bonded inside the R.C.C. walls. The spacing of Rung Lad-
der shall not exceed 300 mm. and the size of the rung formed shall be 300 mm. wide x
150 mm. deep. The rods are to be painted with anti-corrosive paint with suitable primer
as per manufacturer's specification to be approved by the Authority.
25. MOTOR FLOOR AND CONTROL ROOM
There must not be any column in the motor floor for easy movement of the E.O.T. Crane.
Similarly, in the Control room, office room and Scada room, these must not be any col-
umn in the room. The motor floor shall have suitable openings at appropriate location as
per requirement of the pump manufacturer for lowering and taking up of pumps, motors,
valves, entry for cable etc. The motor floor shall be suitably designed to take care of the
vibration generated from the motor pump assembly while in operation.
26. ARCHITECTURAL VIEW
Pleasant architectural view shall be provided for Guest house at Intake, Clear water pump
house (WTP site & WDC site), Electric Substation building, Office building, Façade of
Pump house and buildings.
27. TRIAL RUN AND COMMISSIONING
When in the opinion of the Engineer-in-Charge the initial performance tests as specified
in Other Section are satisfactory the Agency shall arrange for trial run of the plant at its
rated capacity and their performance tests in presence of OEM representative after his
certification. Before proceeding for the trial run of the plant, individual electromechanical
equipment to be trial run with no load condition in presence of the OEM representative
after his certification. Also, all electromechanical equipment, performance parameter of
the individual equipment like head, discharge, power consumption, Vibration, dB level,
pressure, ampere, voltage, earthing etc., shall be performed in the presence of EIC/repre-
sentative of EIC and OEM representative as per the approved QAP and Data sheet. The
performance reading is tabulated and submitted for EIC approval. The performance test
of the pump shall be as per IS 11346 (latest edition). During such tests and trial run of

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WTP, the Agency shall arrange to collect samples of water from the different units as
specified in Schedule-B. These samples shall be sent by the Engineer-in-Charge or his
authorized representative to the plant laboratory or any other laboratory nominated by the
Engineer-in-Charge, for analysis and determination of the quality of the water samples.
All costs of the sample collection, delivery to the laboratory and test shall be borne by
the Agency.
Before proceeding for the trial run, mock tests of Instrumentation and control system and
SCADA shall be completed and certified by the EIC so that all the trial run performance
shall be recorded through SCADA.

After completion of successful performance test of the system, the entire system shall be
put to trial run and commissioning for 3 months duration.

The proposed water supply system shall be deemed to be ready to be put into normal use
when trial run of the system and the quality of the clarified water and filtered water are
certified satisfactory by the EIC/representative of EIC. The period of maintenance shall
be reckoned from the date of the Engineer-in-Charge's certificate.
28. OPERATION AND MAINTENANCE
After the proposed water supply system is deemed to be ready to be put into normal use,
the Agency shall operate and maintain the same for a period of 10 years including the 2-
year DLP by his own men under the overall supervision of the Agency. chemicals and
other consumable and stores required for the operation of the water supply system shall
be supplied by the Agency at its cost. The Authority shall bear the cost of electrical energy
as mentioned in KPI. During the aforesaid period of operation of the water supply system,
the Agency supervisory staff shall train and instruct technicians and other staff deputed
by the Authority about the correct method of operation and maintenance of the proposed
water supply system as a whole and its various mechanical and electrical components.
The Training shall be such as would enable the Authority's staff to take over the proposed
water supply system from the Agency for its operation and maintenance independently.
The Agency training personnel shall give special attention to this.
During the period of operation and maintenance, the Agency shall arrange to take regular
samples of the clarified and filtered water as directed by the EIC and shall have such
samples tested at his cost in the plant laboratory or any other laboratory nominated by the

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EIC, to determine the quality of the samples and the performance of the water treatment
plant. Such tests shall be continued up to the penultimate week prior to the end of the
maintenance period and the plant shall be taken over by the Authority subject to the final
performance tests being certified as satisfactory by the Engineer-in-Charge.

The tenderers shall submit with their offer a list of technical and non-technical staffs they
propose to engage for operation and maintenance of the proposed water supply system
for the entire duration of 8+2=10-year O&M period.

29. GUARANTEE PERIOD

The Agency shall stand guarantee for the successful operation of all the civil, mechanical,
electrical, electronic components and structures including all types of pipelines and road-
works for 10 (ten) years period from the date of the certified commissioning. as stated in
relevant clause within which any defects and shortcoming due to faulty design of the
water supply system, defective mechanical and electrical equipment or defective con-
struction shall have to be made good without any extra cost to the Authority. During the
guarantee period, the Agency shall ensure thorough checking of the proposed water sup-
ply system at least once every month and shall arrange for immediate rectification of any
defects detected during this special checking by his experts.
30. GUARANTEES
The Agency shall give the following guarantees:
30.1 Civil and Structural Works
The Agency shall guarantee the proposed water supply system against any structural fail-
ure due to faulty design, bad workmanship, substandard materials, etc. for a period of 10
years. Any defect found during the guarantee period shall be rectified by the Agency to
the satisfaction of the Engineer-in-Charge without any extra cost.
30.2 Plant and Equipment
Even when a plant or equipment has been manufactured and / or marketed by a vendor,
it shall be deemed to have been supplied and installed under the Agency supervision. The
Agency shall provide back to back guarantee along with the vendor but shall solely be
responsible for its repair/replacement. He shall not cite the vendor and claim absolvement
of responsibilities. In addition, all equipment shall be free from any defects due to faulty
designs, materials and / or workmanship. The equipment shall operate satisfactorily and

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performances and efficiencies shall not be less than the values guaranteed by the manu-
facturer and endorsed by the Agency.
Formal acceptance of the work or equipment covered under the Contract by the Engineer-
in-Charge shall not be made until all the works done by the Agency has satisfactorily
passed all tests required by the specifications.

If, during testing of work and / or equipment prior to formal acceptance, any equipment
or materials shall fail in any respect to meet the guarantees, the Agency shall replace such
equipment in a condition which will meet the guaranteed performance. Any such work
shall be carried out by the Agency at his own cost and expenses in necessity thereof, shall
in the opinion of the Engineer-in-Charge be due to the use of materials or workmanship
not in accordance with the Contract or to neglect or failure on the part of the Agency to
comply with any obligation expressed or implied on the Agency part under the Contract.
If in the opinion of the Engineer-in-Charge, such necessity shall be due to any other cause,
the value of such work shall be ascertained and paid for as if it were additional work.

If the Agency shall fail to do any such work as aforesaid, required by the Engineer-in-
Charge, the Authority shall be entitled to carry out such work by its own workman or by
others of such works supposed to be carried out by Agency, the cost thereof shall be de-
ducted that may become due to the Agency.

30.3 Treated Water Quality.

The Agency shall guarantee the quality of the clarified, filtered and disinfected water and
these guaranteed results shall conform to the following;
i. Clarified water - The turbidity of the clarified water effluent from each
clarifier/plate settler shall be less than 5 NTU when the plant is operated under
normal design flow conditions and less than 10 NTU when under overload
condition due to one of the clarifiers/plate settlers taken out of operation for
maintenance, repair, etc. even when handling raw water at its worst condition i.e. at
its highest turbidity level.

ii. Filtered and disinfected water - The turbidity of filtered and disinfected water shall
be less than 1.0 NTU even with the maximum turbidity of raw water. The finished
water must not be acidic in nature under any circumstances and shall not at any time
contain less than 10 ppm of total alkalinity (as CaCO3). In no case, pH value shall

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be less than 6.5 or exceed 8.5. Iron content shall not exceed 0.3 mg/l. There shall
not be any nitrate (as NO3).

30.4 Wash Water Consumption

The Agency shall guarantee that the wash water required for backwashing shall not ex-
ceed 3% of the total water filtered, based on the average working of the units over a period
of the year.

30.5 Zero Liquid Discharge

The Agency shall implement ZLD concept as envisaged in Central Pollution Control
Board (CPCB) most recent guidelines and shall implement the same in the WTP design
and construction fully.

31. IMPORTANT GUIDELINES & SPECIFICATIONS

31.1 Unless otherwise specified elsewhere, the work shall be carried out as per the following
specifications. Wherever any work is not covered in this entire document, the decision of
the Engineer-in-Charge regarding the specification of the same shall be deemed final and
binding on the Agency.

31.1.1 Pleasant architectural plan & view shall be provided for Guest house at Intake, Clear
water pump house (WTP site & WDC site), Electric Substation building, Office building,
Façade of Pump house, filter house annex, staff quarter building, bungalows and office
cum guest house.

31.1.2 All civil works shall be carried out as per specifications contained in other sections of
the tender specifications.

31.1.3 All electrical works including supply of all electrical equipment shall be carried out as
per specifications contained in other sections of the tender specification.

31.1.4 All mechanical works including supply of equipment shall be carried out as per specifi-
cations contained in other section of the tender specifications.

31.1.5 The erection and commissioning works shall be carried out as per specifications con-
tained in other section of the tender specifications,

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31.2 A minimum free board of 500 mm shall be provided for all water containing structures
viz, collecting well, flash mixer, filter beds, channels, etc. except underground reservoir
and unless otherwise specified elsewhere.

31.3 For the convenience and ready accessibility to the operating level, each unit of the treat-
ment plant shall be so interconnected by walkways/gangways as will permit reaching one
end of the treatment plant to the other by means of walkways/gangways without having
any necessity to get down to the ground level.

31.4 Walkways and operating platforms shall be provided with SS hand railings as specified
in other sections.

Open to sky Walkways and operating platforms shall be provided with Chequered tiles
floor finish

31.5 All Roofs shall be provided with water proof polyurethane paint,

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

31.7 All windows and ventilators/skylights shall be provided with mild steel square bar grills
of approved design.

31.8 Construction of permanent roads within the proposed water-works sites are within the
scope of this contract up to the porches of all the buildings like filter house, annexe build-
ing, etc. Tenderer shall also include the cost of construction of temporary access roads
required for their construction of different units of the treatment plant and reservoir units
for easy maneuver of their construction equipment. This would necessitate cutting of
trees, clearing of bushes, filling of a pond, leveling and dressing of site, the cost of all of
which shall be taken into account by the Agency while arriving at their quoted cost. Wher-
ever cutting of trees becomes inevitable, the Agency shall maintain an inventory of trees
cut by the Agency and handover the inventory as well as the trees removed to the EIC.

32. GENERAL TECHNICAL SPECIFICATION FOR R.C.C. PILE FOUNDATION

32.1 General

32.1.1The design of the tenderer shall be based on cast-in situ Bored reinforced concrete piles.

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For this, Sub-soil investigation shall be carried out by the Agency for arriving at the ap-
propriate foundation design.

32.1.2 The specialist firm engaged by the Agency may quote any proprietary system of piling
subject to approval of the Engineer-in-Charge consistent with the load, moment and
forces to be encountered by each pile.

The Tenderers shall submit with his tender drawings, calculations explaining his scheme,
draw up specification and submit the schedules of prices following the format of the
schedules of prices accompanying this tender document.

32.3 Design and Concrete Quality

32.3.1 The grade of concrete of all types of R. C. C. pile shall be minimum M-20/M-25 unless
otherwise specified elsewhere. The cement content in concrete to piling work shall be
minimum 400 kg/M3 with ordinary Portland Cement. Water cement ratio and slump shall
be as per I. S. Specification for relevant piling work. Maximum size of coarse aggregate
shall not exceed 20 mm.

Grading and other requirement of coarse and fine aggregates, water and concrete shall be
as specified for reinforced cement concrete work under this Contract.

32.3.2 The average basis length of the piles is to be assumed from cut off level to the tip of the
pile (however for piles with muff the basic length shall be from tip of the pile up to
underside of muff). The final length shall be decided by the Agency with approval of
the Engineer-in-Charge on the basis of driving/boring resistance actually observed at
site. It will be the responsibility of the Agency to prove by subsequent load test/pullout
tests that the adopted length of pile shall carry the specified safe load, tension and the
resulting deflections being within the permissible limits. In no case, extra claim over
the originally quoted price will be entertained for any increase in number/length/cross-
sectional area/reinforcement of piles and in the site of other foundation structures if
required at the time of execution after the load tests of piles. Similarly, no deduction in
payment will be made from the lump sum price quoted for decrease in num-
ber/length/cross-section of area/reinforcement and in the size of other foundation struc-
tures at the time of execution or after the load tests of piles, provided that the complete
safety of the Structures is fully assured.

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32.3.3 For Intake Wells, pile foundation shall have permanent steel casing/approved alterna-
tive methodology. Scour depth below bed level will be a major guiding factor. All relevant
provision of I.S. code for R.C.C. Structure on river bed (under water) will have to be
strictly followed. However, Tenderers may suggest other methodology without deviating
from major objectives & provisions well within I.S. standards. In any case, the Agency
shall ensure the stability of the structure.

32.3.4 Tenderers/Agency will be given full liberty to opt for design mix as per satisfaction of
E.I.C. with minimum cement content as mentioned.

32.4 Specification for Bored Cast-in-Situ piles

32.4.1 Unless specified otherwise in the following paragraphs, stipulations of relevant section
of current I. S. 2911 shall be followed.

32.4.2 The tenderer shall submit within his tender the layout and number of piles based on
allowable load carrying capacity, tension on the pile section design by him.

32.4.3 Boring equipment and accessories shall generally conform to IS: 2911 relevant section.
Boring may be done by either rotary or percussion equipment or grassing equipment us-
ing reverse or direct non-circulation method. In case of unstable soils, the boring tools
used shall be such that, suction effects are minimized. Stabilization of the sides of bore
hole shall be done by the use of bentonite slurry or casing. The size of cutting tool shall
not be less than the diameter of the pile by more than 75 mm.

32.4.4 In case of boring with casing, the casting shall be used from the ground level. The casing
shall be kept ahead of boring in cases where there is danger of carrying in due to subsoil
entering into the borehole or where soil is loose. While boring below sub-soil water, pre-
caution shall be taken so that no boiling of the bottom of the hole occurs due to difference
in hydrostatic head.

32.4.5 Concreting of bore holes shall start soon as possible after its completion. Shall a bore-
hole be left without concreting for more than two hours, it shall be cleaned thoroughly as
directed by the Engineer-in-Charge before placing concrete. Concrete under water shall
be placed by means of a tremie pipe. It shall, however, be ensured that concrete entering
the tremie pipe does not get mixed up with the slurry and ¼ kg of granulated vermiculite

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shall be poured in the tremie pipe before pouring concrete as directed by the Engineer-
in-Charge.

32.4.6 The tremie pipes and funnel shall be filled and lifted just 15 cm above bottom before
releasing the concrete column to facilitate flushing out of the bottom. The concrete levels
in the tremie shall be checked every meter in order to judge the difference, if any, between
the theoretical quantity that shall have been placed and the actual quantity that has gone
in. This is to locate the position of cut off during boring.

In addition to the normal precautions to be taken in tremie concreting as per relevant

Section of current IS: 2911, the following specifications shall be particularly applicable
for the use of tremie concrete in pipes.
i) The concrete shall be coherent, such in cement (not less than 400 kg/m3) and of
slump not less than 100 mm.
ii) The hopper and tremie shall be closed system.
iii) The tremie shall be large enough with due regard to the size of the aggregate. For
20 mm aggregate the tremie pipe shall be of diameter not less than 200 mm.
iv) The first charge of concrete shall be placed with a sliding plug pushed down the
tube of it or with a steel plate of adequate charge to prevent mixing of concrete and
water. However, the plug shall not be left in the concrete as a lump.
v) The tremie pipe shall always penetrate the concrete with an adequate margin of
safety against withdraw of the pipe surged to discharge the concrete.
vi) The pile shall be concreted wholly by tremie and the method of deposition shall
not be charged way up the pile to prevent into laittance from being trapped within
the pile.
vii) All tremie tubes shall be scrupulously cleaned after use.

Normally concreting of the piles shall be carried out without any interruption. In the
exceptional case of interruption in concreting, but which can be resumed within 1 hour,
the tremie shall not be taken out of the concrete. Instead, it shall be raised and lowered
slowly, from time to time to prevent the concrete around the tremie from setting. Con-
creting shall be resumed by introducing a little richer (5% additional amount) concrete
with a higher slump for easy displacement of the partly set concrete.

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If the concreting cannot be resumed before final set of concrete already placed, the pile
so cast may be rejected or accepted with modifications at the sole discretion of the En-
gineer-in-Charge.

In case of withdrawing of tremie out of the concrete, either accidentally or to remove a

blockage in the tremie, the tremie may be reintroduced in the following manner to pre-
vent impregnation of laittance or sewer laying on top of the concrete already deposited
in the bore.

The tremie shall be gently lowered on the old concrete with very little penetration ini-
tially. A vermiculite plug shall be introduced in the tremie. Fresh concrete of slump be-
tween 150 mm. And 175 mm. Shall be filled in the tremie which will push the plug
forward and will emerge out of the tremie displacing laitance/sewer. The tremie will be
pushed further in steps, watering fresh concrete sweeping away laittance/scum in its way.
When tremie is buried by about 60 to 100 cm. concreting may be resumed.

32.4.7 The top of concrete in a pile shall be brought above the cut off level to permit removal
of all laitance and weak concrete before capping to ensure good concrete at the cut off
level for proper embedment into the pile cap. Where cut off level is less than 1.5 M.
below the working level concrete shall be cast to a minimum of 500 mm. Above cut-off
level. For each additional 0.3 m. increase in cut-off level below the working level addi-
tional coverage of 50 mm. Minimum shall be allowed. Higher allowance may be neces-
sary depending on the length of the pile as directed by the Engineer-in-Charge. When
concrete is placed by using tremie material, concrete shall be cast to the piling platform
level to permit overflow of concrete for visual inspection or to a minimum of one meter
above cut-off level. In the circumstances where cut off level is below ground water level
the need to maintain pressure on the freshly laid concrete equal to or greater than water
pressure shall be formed out and accordingly the length of extra concrete above cut-off
level shall be determined and provided in works.

32.4.8 During piling, the sequence of construction and installation of piles shall as per direction
of the Engineer-in-Charge.

32.4.9 In case defective piles are formed during construction, they shall be removed or left in
place whichever is found convenient without adversely affecting the performance of the
adjacent piles or the pile cap. Additional piles shall be provided at Agency cost to replace
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them as per direction of the Engineer-in-Charge and in this respect the Engineer-in-
Charge’s decision shall be final and binding upon the Agency. Any deviation from the
designed location, alignment or local capacity of any pile shall be noted and adequate
measures shall be taken well before concreting of the pile cap, etc. if the deviations are
beyond the permissible limit. All such alternations shall be done at Agency own cost and
expenses and to the entire satisfaction of the Engineer-in-Charge.

32.4.10 Piles shall be installed accurately as per approved design and drawings. For vertical
piles, a deviation of 1.5 percent from vertical line shall not be exceeded. Piles shall not
deviate more than 75 mm. or one tenth of diameter whichever is more (in case of piles
having diameter more than 600 mm) from their designed positions at working level of
the piling rig.

In case of piles deviating beyond the above-mentioned limits and such an extent that
the resulting eccentricity cannot be taken care of by a redesign of the pile cap & pile
trees, the piles shall be replaced or supplemented by one or more additional piles by
the Agency at his own cost and expenses along with any additional cost for pile cap,
etc. being borne by him.

32.4.11 While manual chipping may be permitted after casting of pile, pneumatic chipping, if
permitted by the Engineer-in-Charge, shall not be started before 7 days under any cir-
cumstances.

32.4.12 Main longitudinal reinforcement in the length of the piles and links or spirals shall be
provided as per the approved drawing. Longitudinal bars where possible shall preferably
be in one length. Every care shall be taken in handling of the reinforcing cage so that its
shape is not damaged.

32.4.13 When working adjacent to existing structure every care shall be taken to avoid any
damage to such structures, in the case of bored piles care shall be taken to avoid effect
due to loss of ground. In the case of deep excavations adjacent to piles proper protec-
tion shall be provided to safeguard against the lateral movement of soil stratum or
releasing the confirming soil stress.

32.4.14 During piling work the following data shall be recorded along with any other data as
may be directed by the Engineer-in-Charge. These data shall be submitted to the En-
gineer-in-Charge in triplicate copies on completion of installation of each pile.
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i. Sequence of installation of piles in a group.

ii. Dimensions of the pile including reinforcement details and mark of the pile.
iii. Depth bored and founding level along with a bore log depicting the nature of
strata encountered during boring.
iv. Time taken for penetration of every 15 cm during last 2 m depth before founding
level.
v. Method of cleaning bottom of hole at founding level before concreting.
vi. Time taken for concreting.
vii. Cement consumption and slump of concrete.
viii. Cut off level/working level/R. L. of top concrete Any other relevant/important
observation.
32.4.15. During execution at any stage if any variation is required to be made to suit the site
condition, E.I.C shall be technically satisfied and his decision will be regarded as final.
All/ any of data /information given if not found reasonable (this will also include data
of Design Parameters) shall be given during detailed engineering. Tenderers/Agency
therefore are advised to consult with manufacturer/ experts at his own cost, if so felt,
to reach more correct figure for Tendering purpose. The same is also advised for any
other data supplied/missing. But in no case, it shall be treated as a Fault of the Tender-
ing Authorities. If any data is found in variance in same chapter/ section or anywhere
of the tender document, the same shall be brought to the notice of the Tendering Au-
thority & his interpretation/ decision shall be considered as final.

32.5 Load Test on Piles

32.5.1 The load tests shall be carried out as per IS: 2911 unless specified otherwise in the
following paragraphs. The tests shall be carried out on test pile and a selected repre-
sentative pile as approved by the Engineer-in-Charge. Sufficient time shall be allowed
before tests to permit adjustment on the soil conditions following disturbance from
the method of installation. The period between installation of the test pile or any other
pile in the vicinity and the test loading of the pile shall be least 28 days.

32.5.2 The test load shall be applied by jacking against Kent ledge or any other structure
approved by the Engineer-in-Charge. No working pile shall be permitted to be used
for any loading for load test on pile. The design of the Kent ledge shall be such as to

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prevent instability, particularly in the event of a sudden change in the load reaction
from the pile. The reaction from Kent ledge to be made available for the test shall be
at least 25 percent more than the final test load to be applied. The test shall be carried
out at cut off level or at maximum 1.5 m below G. L. as directed by the Engineer-in-
Charge. Anchors, if provided, for load test shall be at specified distance away from
test pile as per relevant I. S. Code of Practice and there shall be minimum two anchors
at two ends of the pile.

Details regarding the testing arrangement shall be submitted well in advance to the
Engineer-in-Charge for his approval. Load tests shall only be undertaken after ob-
taining the approval.

32.5.3 The jack is to be hydraulically operated. The load applied to the pile shall be recorded
either by a gauge in the hydraulic system or a proving ring duly calibrated from an
approved laboratory before load tests. The sensitivity of the full load and in any event,
the accuracy and sensitivity of the system is to be checked against an approved instru-
ment.

A test certificate and fresh calibration chart as obtained from an approved laboratory
for jack as well as pump supplying hydraulic power shall be produced before the En-
gineer-in-Charge well in advance before use for any load testing pile.

32.5.4 The settlement of the pile shall be recorded by three dial gauges recording to 0.02 mm
and placed at equal distance around the test pile. The dial gauges shall be fixed on
datum bars whose ends rest upon non-movable supports. The supports for datum bars
with reference to which the settlement of the pile would be measured shall be at least
5d (d being the diameter of the circular pile of the side of the square pile) away and
clear from the test piles, subject to a minimum of 1.5 m.

32.5.5 The testing equipment employed shall be capable of loading a pile to failure or to three
times the design loading.

32.5.6 Before testing the top of the pile shall be clipped off carefully till sound concrete is
encountered. The projecting reinforcement shall be cut or bent suitably and the top
finished smooth and level with Plaster of Paris, when required or as directed by the
Engineer-in-Charge. A series 25 mm thick bearing plates shall be placed on the head
of the pile for jack to rest as directed by the Engineer-in-Charge.
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32.5.7 The Agency shall have to perform rotating load test on working piles on load as de-
cided and selected by the Engineer-in-Charge and the results must satisfy the require-
ments of the test. At least one working pile of each diameter shall be tested. The test
shall be carried out at cut-off level or at such level as per direction of the Engineer-in-
Charge. The Agency shall also have to carry out initial test on a non-working test pile
as described below:

A. Initial Test on a Non-working pile:

i. At least one non-working pile test shall be performed before execution of

working pile.

ii. The test load shall be applied in equal increments of amount one-fifth of the
estimated safe load as directed by the Engineer-in-Charge. Each state of
loading or unloading shall be maintained till the rate of movement of the
pile top is not more than 0.02 cm per hour in the case of clayey soils and 0.1
mm per hour in 2 hours whichever is greater.

iii. The estimated safe load shall be maintained for 24 hours and settlements
shall be observed and recorded every hour during the period.

iv. Time-settlement observation shall be made at the commencement and

completion of each increment. The rebound observation shall be made with
suitable unloading as per direction of the Engineer-in-Charge.

v. The loading shall be continued till the settlement of the pile top equals one
tenth of the diameter of the pile stem (one tenth of the side in case of square
piles) or the load is two times the estimated safe load on the pile, whichever
is earlier.

vi. The safe load on pile shall be the minimum of the following:

a) Two thirds of the final load at which the total settlement attains value of 12
mm unless it is specified that a total settlement different from 12 mm is
permissible or required in given case on the basis of nature and type of struc-
ture in which case the safe load shall correspond to actual total settlement
permissible or required.

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b) Fifty (50) percent of the final load at which the total settlement equal one
tenth of the pile diameter of the size of the pile.

B. Routine Test on Working pile:

 Routine Load test in working pile shall be as per current IS 2911.Pile integ-
rity test shall be at least 1 in 100 or part thereof.

Load on the pile in routine test shall be applied up to and a half times the estimated
safe load carrying capacity of the pile. The loading procedure and settlement ob-
servations shall be the same in initial test described hereinabove. The safe load on
the pile shall be the minimum of the following:

a. Two third of the final load at which the total settlement attains a value of 12
mm unless it is specified that a total settlement different from 12 mm is
permissible in a given case on the basis of nature and type of structure.

b. Fifty percent of the final load at which the total settlement equals one tenth of
the pile diameter of size of the pile.

C. Lateral Load on Working pile:

i) The Agency shall have to carry out lateral load test on one vertical working pile.
Reaction may be obtained from suitable set up as approved by the Engineer-in-
Charge and hydraulic jack shall be inserted in between the loading set up and pile
in order to apply the lateral load. Thrust pieces need be inserted on either end of
the jack to fill up the gap. Lateral deflections shall be measured at cut-off level or
at maximum 1.5 M below G. L. as directed by the Engineer-in-Charge by means of
dial gauges fixed to immovable supports.

ii) Loading shall be applied in increments of about 20% of the estimated safe load till
the rate of deflection reduces to 0.02 mm per hour in the case of clayey soil and
0.05 mm per hour in the case of sandy soils or 2 hours whichever is earlier.

iii) Displacements shall be measured by issuing at least two dial gauges spaced at 30
cm and kept horizontally one above the other on test pile. Where it may not be
possible to place one of the dial gauges on the line of jack axis, then the two dial
gauges shall be kept at a distance of 30 cm at a suitable height and the displacement

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interpolated at load point from similar triangles. To fix dial gauges on the pile sur-
face, uneven surfaces shall be chipped of and 25 to 30 mm square glass piece shall
be fixed to provide a smooth surface. The dial gauge tips shall rest on the central
portion of the glass plate.

iv) The safe lateral load shall be the least of the following:

a. Fifty (50) percent of the final load at which the total displacement increases to
12 mm.
b. Final load at which total displacement corresponds to 5 mm.
c. Load corresponding to any other specified displacement due to performance
requirements.

32.5.8 All pile test data i.e., load, displacement and time shall be recorded in a suitable chart
along with other information about the pile in a manner as directed by the Engineer-
in-Charge.

From the data, curves shall be drawn showing load displacements and displacement
time and safe load shall be indicated on the graphs.

All data and curves shall be submitted to the Engineer-in-Charge in triplicate copies
along with the originals.

32.5.9 If on load testing, it is found that the capacity of the pile is more than the designed
capacity nothing shall be paid extra for such extra capacities.

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SECTION - III
DETAILED TECHNICAL SPECIFICATIONS FOR CIVIL
WORKS
1. SPECIAL NOTES
1.1 The layout of the Intake well-cum-pumping station, water treatment plant and semi un-
derground reservoir (SUGR) at WDCs, as shown in the drawing attached, is not binding
on the tenderer but is only indicative. However, the floor areas and other requirements
specified hereinafter shall not be curtailed and shall be binding.
1.2 The tenderer shall not quote for works differing from the specifications of the tender
unless specifically permitted elsewhere in the tender document.
1.3 The suitability of the proposed water supply system shall not be decided only by the
low capital cost but the economy in the operational costs shall also be considered. For
this purpose, all relevant details shall be furnished by the Agency.
1.4 There shall not be any ambiguity in the offer. Tender containing any ambiguity may be
interpreted in a manner advantageous to the Authority.
1.5 If not mentioned elsewhere in the tender document, the Agency shall provide the fol-
lowing arrangements:
a. Water supply to different treatment processes namely chemical dosing including
lime dosing; disinfection shall not be made solely dependent on the operation of
clear water pumps. Separate pumping arrangement for supplying water to alum
solution tank and chlorine dosing equipment are to be provided. Maximum pressure

available in the proposed supply main may be considered as 3.0 kg/cm2.

b. Disposal of drainage of the treatment units shall be made by gravity system as far
as practicable. If ultimate disposal has to be pumped, emergency gravity overflow
must be provided.
c. Care shall be taken for satisfactory disposal of sludge from the clarifier.
d. All electrical components, appliances, switches, flow measuring devices etc.,
installed outside, shall be well protected from rain and other weathering effects by
providing sheds, enclosures, canopies, etc.
e. All sluice valves, gates and their passages shall be placed under proper sheds as per
instruction of the EIC.

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f. The levels of the Intake well-cum-pumping station, water treatment plant units and
the SUGR at WTP shall be fixed in such a way that all the units of WTP can be
isolated and kept dry (free from water) for maintenance even at 100% filled up
condition of the SUGR.

1.6 All valves, sluice gates, etc. shall be of reputed make and shall conform to available
I.S. specifications and the manufacturer shall have IS accreditation where name of man-
ufacturers does not appear in the List of Venders. In case of non-availability of relevant
I.S. specifications, it shall conform to British Standard Specification or American
Standard Specification.
1.7 The water works being a process plant, it is imperative that the layout of the plant in-
clusive of all Civil, Mechanical and Electrical Components shall meet the requirements
of Indian Factory Act. Indian Explosives Act. and all other relevant statutes of the State
and Central Government. The Agency has also to procure Explosive License for use of
chlorine during Trial Run. All Structures, Vats, implements etc. forming part of on-site
emergency plan shall be provided by the Agency.
1.8 The water treatment plant shall be designed to provide a net output of 3000 m3/hr. Fil-
tration, the inflow, flash mixers, alum dosing, flocculators and plate settler clarifiers

shall be designed for a flow of 3000m3/hr with required overloading. The subsequent

units may be designed for 3000 m3/hr. with over loading capacity as prescribed in this
document or by the Engineer-in-Charge.
1.9 Proper bypass arrangements shall be provided so that the water could be flown avoiding
the flocculation, clarification and filtration units. If the situation needs, the raw water
could be flown from the flash mixer to directly the filter water channel.

2. MAJOR WORKS
The requirements and the design criteria for the following major works of the proposed
water supply system as given herein below are mandatory.
a) Raw water Intake well cum pumping station
b) Raw water trunk main
c) Water Treatment Plant
d) Sub-Underground Clear Water Reservoir

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e) Clear water Pumping Station

f) Clear water pumping main
g) Distribution Pipelines up to WDCs
h) Site development
i) Work-site Boundary walls
j) Work-site Internal road network
k) Work-site Internal drainage
l) Work-site Landscaping

3. RAW WATER INTAKE WELL CUM PUMPING STATION:

3.1. Description & Scope of Work:
The Intake well-cum-pumping station will be located on the bank of River Krishna, 2
km. upstream of the Prakasam barrage to draw raw water throughout the year. The exact
location of the structure shall be finalized based on the bathymetric survey and geotech-
nical investigation to be conducted by the Agency and as per approval of the Engineer-
in-Charge.
The work involves, as per Tender contained in Schedule-B of the Tender Document:
(i) Planning, designing and construction on EPC basis of two No of R.C.C. Jack wells
including raw water pump house for housing 3 No. of 8265 m3/hr capacity vertical
turbine pumps and motors in the present tender and 3 No. of 8265 m3/hr capacity
vertical turbine pumps and motors as future provision along with required diameter
suction main, delivery main fabricated from 14.2 mm thick SW Mild Steel pipe in
each well connection for supplying of raw water to the proposed 380 MLD Water
Treatment Plant at Undavalli for Amaravati water supply project.
(ii) Design, drawing and construction of the intake well-cum pumping station shall be
based on R.C.C. well sinking method of designed diameter. The pump house floor
shall be of reinforced concrete along with all the structural works
(iii) Providing an elevated approach road and RCC bridge of approximate lengths 218
Rmt and 290 Rmt from the Seed Access Road to the Intake well-cum-pumping
station with necessary structural support / pile foundation including fixing R.C.C.
hand railing with R.C.C. post of adequate size to serve as precaution on both sides
of elevated approach road.

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(iv) Providing suitable screens at the sluice gates in the jack wells for arresting large
floating matters.
The work is on EPC basis and the offer of the tenderers shall be inclusive of all works
necessary for completing the Intake well-cum-pumping station complete in all aspects.
The HFL of Krishna River at Intake location is +21.5 m. Level of the Flood Bund is
+25.0m. Pump floor level shall be kept at +25.15 m.

3.2 Design Consideration

The Intake well-cum-pumping station structure and its sub-units shall be reinforced ce-
ment concrete and shall be designed for suction safely with the effect of the combination
of various loads, forces and stress that can possibly coexist. All calculations shall dis-
tinctly tabulate the various combinations of the loads and stresses covered by the design.
The loads, forces and stresses to be considered in designing the structure shall include
the following:
i. Dead Load – Dead weight of all structural elements, weight of intake pipes
including its supporting arrangements and probable silt deposits on the upper
surface.
ii. Live Load - Live load shall be considered as per relevant IS codes.
iii. Effect of bore and water current – The Maximum flood and ebb velocity when
high flood occurs is 3.07m/s. The Intake well are to be designed to withstand the
maximum of surge of bore current.
iv. Berthing forces from Vessels - For this, maximum capacity of Barge in National
Waterways with a velocity of 1.5 m/s shall be considered. The approach angle shall
be taken as 20 degrees.
v. Mooring forces.
vi. Forces due to wind.

vii. Temperature stress due to variation in temperature of 30 0 C.

viii. Seismic forces.
ix. Erection stresses.
x. Water hammer in Suction Mains.
xi. Any other forces that the Tenderers may consider.

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xii. Maximum anticipated scour depth at the Intake well-cum-pumping station shall be
designed by the Agency. The design shall be such that the entire structure is totally
safe with this scour depth.
xiii. Other than Intake well cum pump house, all major structures shall be supported on
direct mud circulation bored pile foundation.
xiv. Unless specified otherwise elsewhere, a factor of safety of 2.5 shall be applied to
the ultimate load to arrive at the safe load of the piles.
xv. Spacing of piles (centre-to-centre) in a pile group or between any two piles of
adjacent group shall not be less than 2.5-time diameter of the pile or the diameter
of the circumscribing circle in the structural area in case of non-circular sections.
xvi. Vertical load bearing capacity of pile under any combination of loads shall not be
allowed to exceed normal load bearing capacity under static condition.
xvii. In the case of R.C.C. bored piles, the main reinforced shall not in any case be less
than 0.80% of the gross sectional area and shall extended for the full length in all
piles made into cages and well wired lines/stirrups (8 mm dia at 150 mm c/c or
equivalent) and spot welded to make them stiff enough to withstand handling
without damage.

3.3 Screening around Bell-mouth of Suction Main & in front of Sluice Gate
Suitably designed screens shall be provided around the bell mouth of the Vertical Suc-
tion main. The screens shall be suspended from a suitable level of the Intake well-cum-
pump house platform and aligned accurately. The screen shall be made of SS 304 of
suitable size to prevent entry of large floating matters and shall be provided with all
arrangements and facilities for proper cleaning. The Agency shall also provide screen
arrangement at sluice gates of Intake well. The screen shall be made of SS 304 flat and
shall have provision for lifting and cleaning whenever necessary.
The Tenderers shall submit detailed drawing and design of the screening arrangement
for approval of the Engineer-in-Charge.

3.4 Specification for Work

The work shall be carried out, in general, according to the IS specifications applicable
for the respective items of the work. During execution, at any stage, if any variation is

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required to be made to suit the site condition; E.I.C shall be technically satisfied about it
and his decision will be regarded as final.
ALL load data are tentative. and if not found reasonable (this shall also be applicable for
data of Design Parameters), shall be given during Detailed Engineering submission. Ten-
derers therefore are advised to consult with manufacturer/experts at his own cost, if so
felt, to reach more Correct figure for Tendering purpose. The same is also advised for
any other data supplied/missing. But in no case, it shall be treated as a Fault of the Ten-
dering Authorities. If any data is found in Variance in same chapter/ section or anywhere
of the tender document, such matter shall be brought to the notice of the Tendering Au-
thority whose interpretation/decision shall be considered as final.
The depth of water table varies but while designing, the tenderer shall take into account
the probability of floatation and local flooding due to rains. The tenderers may assume
higher values since he would be responsible for establishing and ensuring safety against
possible floatation. The tenderers are to take adequate precautionary measure for the
safety of the adjacent existing structures (which, though dilapidated, is functionally im-
portant) during the entire period of execution, and as such vibration in any form are to be
kept to the minimum level. Therefore, driving of driving sheet piles, Z piles etc., are ruled
out.
The tenderers shall make all provisions for the safety of the structures. The Raw Water
Pump House will be functional mainly at floor level at (+) 23.0 M (operating platform
level). The pumps are Vertical Turbine Type (V.T) in vertical execution & thus motors
will be installed at an elevated level on the motor stool which shall be mounted on the
operating floor. Suitable walkways have to be provided as per requirement of site/ detail
design so as to reach every valve/ actuator on the pump delivery side. This will also help
for inspection and maintenance of the valve/ actuator and its accessories. The specific
levels will be finalized at per site requirement at Detailed Engineering stage. The bases
for the same, intermediate walkways and vertical support for suction main, valves, other
accessories, all other pipes are within the scope of the contract including hanging support.
Pedestal foundations/ cut outs for all pumps / motors & relevant items are within the
scope of contract.

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Cable trays/ Cable trenches insert plates, dowels chequred plates, M.S. gratings, pre-cast
slabs for cable trenches as required for the electrical/ mechanical equipment at both Raw
Water Pump House & Electrical Substations are within the purview of this contract.
The motor floor will also accommodate cable trench, cut out at different locations for the
pump motor sets. Capacitor and reactor, control and instrumentation panels and H.T.
switchgears whose weight need be considered within the live load as per relevant IRC
Code. The same is applicable for the elevated platform also.
On entry, the vehicle will negotiable a mild upward slope in the form of a range in the
passage. Trucks transporting materials and equipment shall reach the unloading bay of
the pump house through the approach road and shall be able to load and unload with the
help of an overhead E.O.T. crane. Unloading bay shall be constructed at the middle of
two Intake well cum pump house where truck will enter.

A 15 tonne EOT crane along with auxiliary crane hook of 3 tonne capacity shall be pro-
vided in the pump house. The Agency shall also provide suitable crane arrangement at
the unloading bay in between two Intake well cum pump house.
The Indoor substation cum Scada control room at Intake well cum pump house shall have
the following facilities:
a. HT Room (Switch Gear Room)
b. L.T. Room (Switch Gear Room)
c. Scada room
d. Store room
e. Service room
f. Three number of Transformers
The following dimensions (approx.) may be considered for tendering process.
i) Intake well cum Pump House of minimum internal diameter of 13.0 M with a canti-
lever walkway of width 1.5m wherever required.
ii) Indoor Substation cum SCADA Control Room including Electrical Panels, SCADA
room, Service room, Store room with an area of 32.50 m x 15.0m, Transformers (3
Nos), HT metering room with area of 8m x 15m,
iii) Security cabin 10 Sqm

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a) Each well of Intake well cum pump house shall accommodate three V.T. Pump Motor
sets, Valves, Specials, expansion joints, necessary valves with SCADA compatible
electrical actuators, one Flow Meter, one Dismantling Joint (D.J) on the common
delivery manifold, four delivery lines with its bends, PDVs, Valves etc. Loading and
Unloading Bay.
b) Sub-station Zone on the elevated platform to accommodate Control room, H.T.
room, Battery room., Store Room, Corridor, (U/B) Unloading bay and Platform.,
Stair etc. The tentative number & dimensions of the rooms under substation
zone is shown in the tender drawing. But the actual dimension and number of
rooms may vary during detailed Engineering stage as per the satisfaction of the
Directorate of Electricity (Govt. of A.P.) and the EIC keeping the total area con-
stant. No extra payment shall be made to the Agency for such addition/ altera-
tion.
c) RCC Approach road for the Intake well cum pump house & the Sub-station on the
elevated platform.
The water supply of entire pump house compound will be covered by a RCC tank of
capacity 10 m3 placed over administrative building.
The Agency shall use micro silica in RCC in all water retaining structure as specified
elsewhere in bid document. The Agency shall not take any advantage of using micro
silica in design of the water retaining structure. The Authority will not entertain any extra
claim at a later date of such provisions. The design must indicate that provisions are
being made in this regard.
The contract shall be on lump-sum basis including complete design together with con-
struction of all civil works as per specification and directions of the Engineer-in-Charge.
Before proceeding with any detailing and designing of various components of work un-
der this contract, the Agency shall first prepare a layout plan to a sufficiently large scale
and elevations of the pumping station and parts thereof. The entire work has to have a
suitable architectural treatment in conformity with the surroundings. For this purpose,
the services of a reputed architect shall be enlisted by the Agency at his cost. Economy
in construction, without sacrificing architectural and aesthetic get up of the work can
only be considered.

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For guidance of the tenderers we have enclosed Schematic drawings demarcating the
tentative. Tenderers shall strictly comply with the internal dimensions of the pumping
station.
i. The work shall be carried out in general according to IS specifications applicable for
the respective items of the work.
ii. The RCC design shall be based on IS:456 for plane and reinforced concrete for
general building construction and current IS:3370 for cement concrete structures for
storage of liquids for the underground part keeping water unit.
iii. All RCC works coming in contact with subsoil water shall be designed as per current
IS 3370, with concrete grade not less than M-30 and cement content not less as
stipulated in respective manual/I.S. Code. In case the tender adopts a richer concrete

mix, then in such case they must specify the cement content per M3 of concrete.
Tenderers/Agency will be given full liberty to opt for design mix as per
satisfaction of E.I.C. with minimum cement content as stipulated in I.S. code. It
is the responsibility of the Agency to make good or reconstruct the part or whole of
a structure if gets damaged or demolished/ crushed/ settled down due to water
hammer or similar external reasons or for faulty design at his own cost. Faulty
Design submitted by the contactor even if accepted by the department will not relieve
the Agency from above responsibility. Agency will be considered total responsible
for any accident caused due to negligence on his part/ poor workmanship/ faulty
design. Agency has liberty to go for design mix for achieving Rich concrete
having minimum cement content as stipulated in I.S. code or go for variation if
so required at site subject to the satisfaction & permission of E.I.C.
First class brick work in cement mortar of 1:6 shall be used for 250 mm thick super-
structure panel walls. Super structure panel walls of the building shall have 20 mm thick
cement plaster (1:6) inside and 15 cement plaster (1:6) faced outside. Internal and exter-
nal finishing of all the building shall be as per specification given elsewhere in this bid
document. Adequate number of 150 mm dia UPVC rainwater down pipes shall be pro-
vided of heavy duty type with fittings, as necessary.
Double chequered damp proof course of 25 mm thickness of 1:2:4 with stone chips will
have to be provided at plinth level of all brick walls. A 1.2 M wide plinth protection shall
be provided surrounding all building. The plinth protection shall be of 100 mm thick

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1:2:4 PCC over single layer brick flat soling. The plinth protection shall be finished with
35 mm thick IPS.
The roof slab of the Intake well-cum-pump house along with inter connecting platform
(unloading bay) shall be of architectural appearance.
The roof shall be of RCC construction of mix not leaner than Grade M-30 with minimum
cement content as specified in relevant I.S. Code.
The super structure of the pump house buildings shall be of RCC frame with brick panel
walls. The brick walls shall be of minimum 250mm thickness. All the buildings in the
Intake well cum pump house compound shall be RCC framed with brick panel wall.
The finishing of all buildings has been mentioned in general specification.
The building shall be of architectural design as per approval of EIC. Adequate skylights
and windows shall be and as approved provided to admit sufficient natural light. The
total shutter area of doors, windows & ventilators shall be not less than 20% of the total
carpet area of the buildings. All doors, windows and ventilators shall be of steel except
otherwise indicated in our drawings and their pattern shall be up-to-date and fitted with

floss of not less than 13 Kg/M 2. The external doors shall have a width of 1200 mm
except that of the unloading bay. All internal doors shall be not less than 1050 mm wide
where the application is only a pathway for persons and not less than 2500 mm where
Panels, Transformers etc. are to be installed. All exterior doors and windows shall have
RCC Chajja in a box type or any other approved architectural pattern so as to be useful
and effective in giving an architectural effect to the building in general. The main door
shall be 1500 mm. wide.
All fastenings and fixtures of doors, windows and ventilators shall be of heavy duty type
as per direction of EIC. The position of windows shall be such that these will open out-
side and close easily when necessary. One rolling shutters with a provision of ramp shall
be provided. The windows shall be provided with M.S grills of approved Design.
The Pump house would have one emergency exit.
ALL/many load data are tentative. & will be given during Detailed Engineering. Many
data/ design information being tentative may be verified with stipulated standards/site
information’s etc. Tenderers/Agency therefore are advised to consult with manufacturer/
experts at his own cost, if so felt, to reach more Correct figure for Tendering purpose.
The same is also advised for any other data supplied/missing. But in no case, It will be

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Treated as a Fault of Tendering Authorities. If any data is found in Variance in same

chapter/ section or anywhere of tender document, is to be brought to the notice of the
tendering Authority & his interpretation/ decision will be considered as final.
Agency shall supply necessary office furniture for SCADA room, pump house, substa-
tion, security room etc. as per direction of the EIC.

3.5 Guest House/Administrative Building

Agency shall design and construct office building cum guest house at raw water pump
house campus. The building shall be of RCC framed structure resting on pile foundation
with 250 mm thick external wall and 125 mm thick internal wall. This building shall be
of 300 sq.m built up area in each floor. Ground floor of the building shall be car parking
and one servant room with toilet and kitchen. First floor shall be office for administra-
tion staff which contains two cabins with air conditioned, ten cubical with necessary
furniture. Second floor shall be 4 bedrooms with attached bathroom, separate hall, com-
mon kitchen, common toilet and dining space in 250 sq.m area & 50 sq.m open terrace
with an ornamental parapet wall including all furniture. The first-floor level i.e. office
floor level shall be same as pump floor level. There shall be access from platform level
to the first-floor level/office floor level through gangway. The internal and external sur-
face of the building shall be plastered with cement mortar. The external and internal
surface shall be finished with 1.5 mm thick cement putty. The external surface will be
finished with two coats of premium quality Acrylic weather coat emulsion paint over a
coat of primer. Internal surface shall be finished with two coats premium quality Acrylic
emulsion paint (plastic paint) over a coat of cement primer. The finishing and flooring
in the guest house and office building has been given in general specification. The
ground floor i.e. car parking area shall be of anti-skid ceramic tiles flooring as approved
by EIC. The open terrace shall be provided with The Agency shall provide premium
quality furniture for office, guest house as per the requirement and direction of EIC. All
the rooms and drawing & dining room shall be provided with air conditioning system.

4. Raw Water Trunk Main:

Technical specification for SWMS pipe has been given elsewhere in bid document

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5. Water Treatment Plant

The scope of work for the Water Treatment Plant (WTP), to be located at Undavalli,
includes erection, testing, commissioning, trial run for 3 months, 2 years of DLP, 8
years of operation & maintenance and training of departmental Engineers and operators
and handing over the plant in full operational conditions after the O&M period.
5.1 Major Components
The WTP consists of following major components/units
1. Raw water Inlet pipe
2. Stilling chamber and Parshall flume with ultrasonic flow measuring device
3. Pre-chlorination with Alum/PAC
4. Chemical dozing with thorough mixing of raw water
5. Flash mixers
6. Flocculator
7. Sedimentation with plate settler technology
8. Rapid sand gravity filters with modern under drainage system.
9. Backwash arrangement with backwash sump cum pump house
10. Sludge drainage, sludge pump house
11. Sludge thickener with ZLD concept
12. Centrifuge
13. All pumps, motors, compressors, air blowers & other electro-mechanical equipment
related to water treatment process
14. Storage of disinfectant
15. Collecting & conveying channels of raw and filter water along with bypass channel
16. Weigh bridge of capacity 30 MT.
17. Chlorination
18. Chemical house
19. Recirculation sump cum pump house
20. Filter house annex building
21. Well-equipped laboratory
22. Semi underground reservoir
23. Clear water pump house
24. Substation building

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25. Transformer yard

26. MCC room
27. Administrative building (G+4) with G+5 foundation.
28. 2 No of Staff quarter building (G+4)
29. Chief Engineer-in-Charge bungalow (G+1)
30. Plant superintendent bungalow (G+1)
31. Instrumentation & control with SCADA & integration with main SCADA

5.2 Process Design Parameters

The plant shall be designed, constructed and installed considering site ambient condi-
tions, local conditions and location. For these, the Agency shall make due allowances
in his design for the increased temperatures which may be experienced by Plate Settler
clarifiers and filter plant exposed to direct sunlight.
The WTP shall be hydraulically designed to produce 190 MLD (23 hours operation) of
treated water to specified quality standards. The loss of water in terms of sludge bleed
from the clarifiers and filter backwash shall be kept to the minimum and not exceeding
3% of the raw water input.

5.2.1 Raw Water Quality

Available raw water quality of River Krishna (water source for the WTP) and required
treated water quality are given in Table 1 & 4. The treatment plant shall be designed to
treat water having the raw water quality as discussed subsequently.
However, the raw water quality given in Table - 1 & 2 are indicative, it is the Agency
responsibility to check the required details of raw water on their own and accordingly
design the treatment plant. The Agency shall, in addition, carry out the treatability tests
he considers necessary to deliver the guaranteed water quantity & quality. The Agency,
while designing the WTP. shall provide for treating raw water having maximum turbid-
ity up to 1000 - 1500 NTU.

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Table 1: Quality of Raw Water in Krishna River - Pre-monsoon

S. No Parameter Units Sample-1 Sample-2

O
1 pH at 25 C - 8.39 8.12
2 Color Hazen units 12 15
O
3 Conductivity at 25 C S/cm 698 654
4 Turbidity NTU 6.8 7.5
5 Dissolved Oxygen mg/L 5.3 5.6
6 BOD (3 days at 27oC) mg/L 07 05
7 Chemical Oxygen Demand mg/L 38 22
8 Total Dissolved Solids mg/L 446 418
9 Total Hardness as CaCo3 mg/L 150 150
10 Chloride as Cl mg/L 90.0 85.0
11 Fluorides as F- mg/L 0.6 0.6
12 Sulphate as SO4-- mg/L 70.3 66.5
13 Alkalinity as CaCo3 mg/L 140 130
14 Nitrates as NO3 mg/L 5.0 4.4
15 Calcium as Ca mg/L 32.0 32.0
16 Magnesium as Mg mg/L 16.8 16.8
17 Sodium as Na mg/L 87.4 77.2
18 Potassium as K mg/L 2.3 2.3
19 Residual Sodium Carbonate mg/L <0.1 <0.1
20 Iron as Fe mg/L 0.15 0.09
21 Zinc as Zn mg/L 0.069 0.072
22 Oil and grease mg/L <0.1 <0.1
23 Silica as SiO2 mg/L 4.1 4.0
24 Total Chromium as Cr mg/L <0.001 <0.001
25 Lead as Pb mg/L <0.001 <0.001
o
26 Temperature C 26.9 26.6
27 Total Suspended Solids mg/L 9.3 8.6
28 Phosphate as po4 mg/L <0.02 <0.02
29 Phenolic Compounds mg/L <0.001 <0.001
30 Mercury as Hg mg/L <0.0001 <0.0001
31 Total Arsenic as As mg/L <0.001 <0.001
32 Cadmium as Cd mg/L <0.001 <0.001
33 Hexavalent Chromium as cr-6 mg/L <0.05 <0.05
34 Copper as Cu mg/L 0.035 0.028
35 Total Plate Count MPN/250ml 750 680
36 Coli form Organisms cfu/ 100ml 18 12

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Table 2: Quality of Raw Water in Krishna River - Observed at Vijayawada Municipal Corpora-
tion Intake Headworks at Prakasam Barrage
Turbidity
pH
(NTU)
Max 320.0 7.90
Min 2.20 6.85

5.2.2 Process Guarantees

Apart from the quality of the treated water and the indicated water levels at the output
and input of the plant the Agency shall guarantee the following process performances:
Table 3: Quality of Treated Water Process guarantees
Turbidity of the effluent of the Clarifiers not more than 5 NTU
Suspended solids in the effluent of the Clarifiers not more than 8 mg/l
Total aluminum in the effluent of the clarifiers not more than 0.5 mg/l

Minimum free available chlorine residual content > 0.5 mg/l

in the treated water, after 10 minutes contact.

Minimum filter run period at any time of the year 48 hours

between successive backwashing
Maximum water losses (filter backwash, de- Less than 3 % of the raw water
sludging etc.) in the treatment plant during a pe-
input
riod of any 7 consecutive days.

Table 4: Treated Water Quality Parameters

Parameters with Units Output Standard
Turbidity (N.T.U.) Less than 1.0 NTU
Color (Units on Platinum Cobalt Scale)
Less than 5.00
TCU
Taste and Odor Unobjectionable
pH 6.5-8.5
Not detectable in any 100-ml sam-
Faecal coliforms number/100ml ple for required output and permis-
sible standards of faecal coliforms
Coliform organisms number/100ml
number/100 ml and Coliform or-
ganisms number/100ml
Residual Aluminum mg/l, Al <0.1
Residual Chlorine 0.8 to 1.0 ppm

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If, at any time during trial run period, any of the quality and process parameters cannot
be achieved, the Agency shall at his expenses carry out all necessary modifications to
the civil, mechanical, hydraulic, electrical and other components of the plant, or modify
the operation procedures and alter the chemicals / chemical dosing parameters to
achieve the required performance of the plant.

5.3 Preparatory Work

i. The details of the morphology shall be checked by the Agency before the final
layout of the units of the plant. He shall use the land earmarked to accommodate
for the siting of all the units of the final capacity treatment plant, semi-under-
ground clear water reservoir (SUGR), clear water pumping station and ancillary
civil structures along with existing structures (if any).
ii. The Agency shall provide RCC retaining wall wherever the filling is more than
1.0 m. The Agency may consider the retaining wall as a foundation of boundary
wall. Surplus earth, if any, shall be disposed of as per the direction of the Engi-
neer-in-Charge.
iii. The Agency shall construct approach roads connecting to all treatment units, clear
water pumping station and ancillary civil structures to be constructed within the
treatment plant campus as shown in the WTP layout plan. Approach Road to WTP
site is indicated in this plan. The Agency shall have to use the same for transport-
ing the materials to the site.
iv. The Agency shall establish a topographic benchmark at a suitable location within
the WTP campus by transferring level from the GTS benchmark as approved by
the Engineer-in-Charge. All levels shall be deemed to refer to that benchmark.
The Agency may establish other secondary benchmarks on the site. During all
stages of preparatory works, design and construction, the Agency shall cooperate
with other Agencies working in or near the same site. This is particularly im-
portant in the case of linkages such as incoming and outgoing pipes, cables, com-
munication lines, access roads, drainage pipes and channels.

5.4 Detailed Design

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The Agency shall design Water Treatment Plant i.e. Plate Settler Clarifiers for Clarifi-
cation and Rapid Gravity Sand Filters for filtration as mentioned in the scope of work.
These two processes are fixed and final and cannot be changed. The various design
parameters indicated in the following paras and elsewhere cover only the main param-
eters. All the detailed parameters laid down in the CPHEEO Manual of Water Supply
and Water Treatment or the relevant IS Codes however shall be applicable. The only
deviations permitted from those contained in the Manual or IS Standards are those con-
tained in the specifications detailed herein. Based on the Agency process design, ap-
proved by the Authority, the Agency shall prepare the final detailed design, according
to the latest Indian Standards (published up to date of submission of the Bid), the Man-
ual on Water Supply and Treatment, the tender documents and the instructions of the
Engineer-in-Charge.
The detailed design of the entire treatment plant including architectural, hydraulic and
structural designs shall be prepared in close coordination with the Engineer-in-Charge.
The WTP layout and hydraulic flow diagram along with elevation view and all levels
shall be submitted for approval of the Engineer-in-Charge. Placement of order, manu-
facturing or construction shall start only after the approval of all the related designs and
drawings. The procedures for the approval shall have to be followed as prescribed in
the Special Conditions of Contract. The Agency shall design all water retaining struc-
tures considering M30 grade concrete and Fe 500 grade steel based on IS: 3370 (latest
edition). The minimum free board shall be of 0.5 m for all components and conveying
channels.

5.5 Treatment Works - Plant Specifications

The intention is to automate all the treatment plant operations such as flow control,
distribution of flows to various units of the treatment plant, filter back wash operations,
chemical and chlorine dosing etc. The Agency shall propose the equipment of standard
and reputed manufacturers having the ISI or other relevant standards Mark/conform-
ance certificate for approval of the Engineer-in-Charge. The Engineer-in-Charge shall
examine the proposal based on the submitted documents and shall approve it or refuse
it if it does not correspond to the highest quality standards and to the specifications.

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The specifications deal herein with all treatment plant related works and equipment.
Detailed specifications for pipes and appurtenances, mechanical equipment, electrical
equipment, instrumentation and control systems and civil works are presented in differ-
ent sections of this volume which shall be read in conjunction with this Section. The
treatment plant and its unit components shall be designed for an input turbidity up to
1000 - 1500 NTU.
5.5.1 Raw water Inlet arrangement
The raw water will be delivered into a collecting well through a 1500 mm diameter
SWMS pumping main. Flow Control Valve of diameter not less than 1500 mm with
valve chamber shall be provided by the Agency to control the flow of raw water into
the collecting well. The valves (including bypass) shall be electrically operated butter-
fly type. There shall be a provision for remote operation of the valves from the central
control room as well as provision to control from its vicinity.

5.5.2 Stilling Chamber

The Stilling Chamber shall be a reinforced cement concrete structure of grade M30
concrete designed as per IS: 3370. The pipe from the raw water pumping main shall be
connected at a flange of a pipe which shall be cast in the wall at the lower part of the
chamber (puddle collar). The providing and fixing puddle collar is part of WTP. The
top of the chamber shall be accessible by the general walkway along the measuring
channel. The stilling chamber shall be connected to the drainage system by means of a
wall duct and a gate valve of minimum DN 300. A mild steel ladder shall be provided
in the chamber to access the bottom. The capacity of the settling chamber shall be in
accordance to the plant capacity of 8265 m3/hr (190 MLD with 23 hours operation)
output capacity and the required overloading.
The alum/primary coagulant and lime solutions (if & when required) shall be injected
into this chamber with feeder pipes. The outlets of feeder pipes shall be placed near the
raw water inlet pipe to ensure a thorough mixing. The chlorine solution (for pre-chlo-
rination) shall be injected by bottom mounted diffuser disks or pipes. The diffuser sys-
tem and baffle walls installed in the chamber shall be designed to guide the incoming
water and to ensure a complete diffusion of the chlorine solution before it leaves the
chamber. The chlorine solution feeding unit must be detachable for easy maintenance

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without interrupting the flow of the raw water into the measuring channel. There shall
be no smell of chlorine around 10 m radius from the chamber.
All inner surfaces of the inlet chamber shall be coated with food grade epoxy paint of
approved shade, resistive to the aggressive water to avoid corrosion in the acidic envi-
ronment.
Parameters:
Design Flow: Normal Corresponding to 190 MLD treated water + 20% overload-
ing
Top Level - To be arrived at by the Agency
Free Board - 50 cm.

5.5.3 Raw Water Measuring Channel and Flume

The raw water shall be measured in an open channel by means of a Parshall Flume.
Two Ultra-Sonic Flow Meters with flow integrator and electronic display unit shall be
provided at the flume. Two Nos of ultrasonic flow meters shall be connected with in-
strumentation and control panel of WTP. The Agency shall provide a table/ chart with
the calibrated values of the flume discharge. The measured discharge shall be indicated
in the main control room. The flume shall be designed according to the IS 6063. The
top of the channel shall be made accessible by a lateral walkway along the channel. The
freeboard shall be at least 50 cm.

5.5.4 Flash Mixer

The raw water from the venture-flume shall enter into the flash mixing units for thor-
ough dispersion of the coagulant chemicals added to the raw water. The flash mixing
unit will comprise of eight independent parallel flash mixing chambers, each designed

for a flow of 1380 m3/hr and to give a mixing time of not less than 60 seconds. Six of
the flash mixers shall be designed to work at full load and the other two remain as stand-
by. Each flash mixing chamber will be fitted with electricity driven turbine type motor
and with inlet and outlet penstock gates for isolation. Individual flash mixers shall be
provided with stainless steel impeller fitted at the bottom of stainless steel shaft under-
slung from driving gears mounted on the roof of each mixing chamber. The impeller,
its R.P.M. and the horse power of the electric motor be designed to give a value of G

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(Velocity Gradient) greater than 300 Sec -1 to ensure adequate turbulence for thorough
mixing. The electric motor shall be of weather proof type. Two sets of push button
starters shall be provided for each motor, one near the drive unit and the other in the
central control room. The flash mixing unit shall be provided with R.C.C. slab fitted
with SS hand railings partly covering the chamber for locating the driving unit of the
mixer and for approach to the same. Adequate arrangement for cleaning and desludging
the flash mixing chamber and finally disposing the same into the plant waste water
disposal system and towards the sludge pump house shall be made. The drain pipes
shall be of 250 mm diameter D.I. pipes fitted with 250 mm diameter D.I. sluice valve
(actuator controlled and SCADA compatible). The valve shall be placed in RCC valve
chamber.
After flash mixing, the total flow will be fed into the flocculator units. The raw water
flow can be fed into the flocculator units from the top or from the bottom. If the raw
water shall be fed into the flocculator from bottom, the stand wells shall be used for
delivery of raw water streams, feeding to each flocculator unit. These stand wells may
form an integral part of the flash mixing unit or may be constructed very close to the
flash mixing unit.
The raw water flow from flash mixer shall be divided into more than one division to
fed into stand wells (if more than one in number). Equal division of the flow shall be
effected by means of rectangular weirs built in to the wall of the tank. In this case, the
tank shall be designed to ensure a low velocity of approach, which will be achieved by
providing three chambers within the flash mixing unit. The rectangular weirs shall be
provided with arrangements for closing the openings to put the respective flocculation
unit out of action. Alternatively, equal division of flow can be achieved by means of
C.I. Sluice gates (actuator operated & SCADA compatible Penstocks) in two or more
individual channels leading from the flash mixing chambers to the two stand wells feed-
ing the flocculators. For operation of the sluice gates for exact distribution, each indi-
vidual channel will be provided with a venture-flume with necessary throat width. Local
flow indicators of a simple type to show the upper head in the flume will be provided
for manipulation of the control sluice gates. The sluice gates shall be single faced as per
I.S: 3042 and shall have square openings. The gates shall be fitted with geared operating

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head-stocks which shall be placed on top of the channels and shall be accessible from
the control room and the filter house.
Agency shall provide suitable bypass arrangements for diverting the raw water directly
into the filters to bypass any clarifier. The bypass arrangements shall be operated
through sluice gates or sluice valves.
The distribution channel and Flash Mixers (mixing chambers) shall be of reinforced
concrete. The inlet and the outlets to the flash mixer and channel shall be designed in
such a way so that any flash mixer can receive water from the stilling chamber and can
give output to any flocculator. The outlets to the Flash Mixers shall be provided with
electrically operated wall gates. Mixing chambers shall be adjacent to the distribution
chamber. The outlets to the pipes leading to the flocculators shall be provided with
electrically operated wall gates. The free board shall be at least 50 cm. A provision for
inlet from the supernatant of the recycling tank (used for storing filter backwash water)
shall also be in the raw water Distribution Channel but after the measuring flume. All
the sluice gates and valves shall be of electrical actuator controlled SCADA compatible
gates and shall be integrated with WTP SCADA.
Each chamber shall be equipped with an impeller type high-speed mixer. The driving
motor of suitable capacity and other accessories shall be totally enclosed but easily ac-
cessible for maintenance. The shaft with the impeller shall be freely suspended from
the driving gear mounted on a platform on top of the reservoir. No thrust or guide bear-
ing shall be located below the liquid level. The shaft of the mixer and the impeller shall
be of stainless steel-316.
The outlets of the chambers shall lead to common outlet channel from where it will
flow to the Flocculators. The pipes shall be flanged DI pipes. The top of the flash mix-
ing unit is to be made accessible by the general walkway along the measuring channel.
Each chamber shall be connected to the drainage system by means of a wall duct and a
gate valve of minimum DN 400.

5.5.5 Flocculation and Sedimentation/Clarification

Agency shall quote in its offer for two separate complete arrangement of flocculation
and clarification consisting of at least eighteen (18) flocculator units and at least eight-
een (18) inclined plate settler units to facilitate purification. Each flocculator unit shall

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be designed suitable to the flow requirement with an overload of 22.22% of the average
flow so that fourteen (14) units shall be running and four (4) units shall be standby. The
flocculators shall be mechanical type with power driven stainless steel shaft and pad-
dles. The flow through the flocculator units shall be either upward or downward ac-
cording to process design. The flow through the flocculator units shall be parallel. The
sludge from the flocculator units shall be delivered to the sludge pump house. While
calculating the surface loading or volume of the flocculator units, any area or volume
as may be made available by provision of a ledge or a diaphragm beneath the central
flocculating zone shall merely be omitted and treated as an advantage for dealing with
overloads. The process design and hydraulic design shall strictly be guided by the latest
CPHEEO norms. The inlet and the outlets to the flocculator shall be designed in such a
way so that it can receive water from any flash mixer and can give output to any inclined
plate settler.

Each plate settler unit shall be designed suitable to the flow requirement with an over-
load of 22.22% of the average flow so that fourteen (14) units shall be running and four
(4) units shall be standby. The flow through the plate settler units shall be upward. De-
sign shall be strictly guided by the CPHEEO norms. There shall be sufficient slope (55
degree) at the bottom of the flocculator so that sludge (if any) can be deposited at a
sump provided at bottom from where it can be discharged out through 250 mm diameter
DI pipe. The sludge pipe shall be provided with DI sluice valve. All the sluice gates and
valves shall be of electrical actuator controlled & SCADA compatible gates and shall
be integrated with the WTP - SCADA.

5.5.6 Inclined Plate Settlers

Depth of water below and above the Plate zone plays a crucial part in achieving overall
clarifier efficiency. Buffer Zone, i.e. zone immediately below the plate modules and
above sludge removal zone, may be anywhere between 1.0m to 2.50 m. The size of the
plates shall be as per design requirement. The angle of inclination of plates shall be

550in between. The plates shall be of rigid SS 316. Suitable no. of hose points to be
provided to facilitate cleaning of plates. The plates shall be at least 1 mm thick to with-
stand the thrust of water jet during cleaning. The size of the plates shall be such that it

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may be easily available at local market. At least 10% of the plates required for the plant
shall have to be supplied extra as spare. The depth of this zone (modules) shall be 0.5
m to 0.6 m to facilitate proper solid and liquid separation. The zone extended from top
of the plate modules up to settled water collection troughs/pipes is considered as col-
lection zone and settled water collectors shall be placed 0.6 to 1.0 m above the top of
the plate modules. The collector pipes or troughs shall be provided with collection ori-
fices or notches on both sides to ensure uniform surface loading over the plate modules.
The sludge collection zone below the buffer zone shall have an effective hydrostatic
head of at least 3.0 m to facilitate effective desludging operation. Electrically operated
mechanical scrapers shall be used for proper removal of sludge. The surface loading
rate may be considered as per CPHEEO manual. The detention time in the plate settling
zone shall be at least 10 minutes or more and the weir loading shall be less than stipu-
lation in CPHEEO manual. These parameters are simple guidelines and the Agency
may consider otherwise as per latest CPHEEO manual to suit the requirement of the
treatment plant.
Agency shall ensure that plate settling clarifiers offered by them shall be capable of
giving a turbidity of less than 5 NTU for average flow and less than 10 NTU when
running under overload conditions with raw water at its worst situations.
Arrangements shall be provided for rodding of the sludge main under the floor of the
tanks and for applying pressure water for loosening sludge that may consolidate in the
pipeline causing a choke. A sluice valve not less than 200 mm diameter shall be pro-
vided in the vertical pipe to the trumpet weir for isolating it when applying pressure
water. Arrangements for the pressure water shall be provided by the Agency through a
minimum 75 mm diameter G.I. pipeline from the proposed pressure main in the vicinity
(within 150 m) of the filter house/chemical house. There shall be a terminal point near
each sludge well for connecting the pressure line to the sludge pipe. The Sludge pits
shall be designed to permit the discharge of sludge from the blow down valve and the
trumpet weir to flow to the sump chamber of the sludge pump house. when necessary.
Agency shall provide necessary arrangements for diverting the clarified water into the
clear water reservoir to bypass the filters. The clarified water shall, however, be post-

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chlorinated with a higher dose before diverting into the clear water reservoir. The spec-
ification for mechanical equipment shall strictly conform as given in IS codes (latest)
& other sections of this tender document.
The electrical motors and other electrical equipment shall conform strictly to specifica-
tions for electrical works given in other Sections of these tender specifications. All the
M.S. structural members of the units in contact with water and up to 1.0 m above F.S.L.
shall be provided with two coats of epoxy lacquer with combination GY 257, HY 830
& HY 850 of M/s Ciba Giegy Ltd. or its equivalent, after sand blasting the members.
M.S. structural member beyond 1.0 m above F.S.L. shall be provided with two coats of
Epigard/Epilax or equivalent over a coat of suitable Epigard/Epilax primer.
All inlet of plate settler shall be provided with electrical actuator controlled & SCADA
compatible sluice gates and all outlets shall be provided with electrical actuator con-
trolled & SCADA compatible sluice valves and shall be integrated with WTP-SCADA.

5.5.7 Civil Works

The flocculator and plate settler clarifier tanks shall be of R.C.C. construction founded
on R.C.C. Piles. The peripheral wall and the base slab shall be designed based on un-
cracked section. The thickness of the base slab shall not in any case be less than 150
mm thick. The floor of the tanks shall be provided with a slope suitable to remove the
accumulated sludge by gravity. It shall be anticipated that a considerable quantity of
sludge shall be accumulated also below the flocculator units. The bottom of the floccu-
lator units shall be hopper-shaped with suitable slope so that the accumulated sludge, if
any, can be disposed of by gravity. Suitable valves shall be provided for desludging the
flocculator units. Suitable arrangement shall be provided to remove the accumulated
sludge regularly by gravity from the clarifier units and flocculator units and dispose
those into the sludge pump house. Suitable pneumatic operated valves shall be provided
at each of the sludge outlets of the flocculator and clarifier units which can be operated
from the walkway at the top of the units. There shall be a concrete walkway of at least
1200 mm width with proper handrail on each of the flocculator unit and flocculator
motor shall be supported from the walkway slab. The slab shall be suitably widened at
the place where the motor shall be installed to facilitate proper maintenance. A 1200

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mm wide walkway with handrail shall be provided all around the top of all the individ-
ual flocculator and plate settler tank walls and it would give access to all the units and
adjacent clarifiers, as well as to the chemical house and filter house. Hand railings shall
be provided on the walkways. Interconnecting walkways shall have railings on either
side. One M.S. step ladder of 900 mm wide with hand railing on one side shall be pro-
vided for each clarifier to give ready access to the top of the clarifier from ground level.
Proper facility shall be provided so that the plates can be taken apart from the clarifica-
tion units for washing or maintenance. There shall a be maintenance platform of at least
30 m2 which shall be an integral part of plate settler zone. The floor level of the platform
shall be same as the clarification zone platform level. The platform shall be enclosed
by brick wall/double layer aluminum sheet with proper openings as instructed by the
EIC. A hand operated travelling hoist of 1.0 MT capacity shall be hanged from the roof
of the platform along with RSJ. Two pumps of suitable capacity along with piping ar-
rangements, two brass nozzles and all necessary equipment shall be installed at a suit-
able position which shall be used for jet washing of the plates at the maintenance plat-
form or at its own position. If proper flow and head shall be available at this end, the
jet wash pumps for filter units can also be used instead of a new set of pumps. The water
for jet washing shall be drawn from filter water channel. There shall be proper drainage
system at the maintenance platform which shall convey all the wash water into the filter
waste channel. The waste water from the clarification units shall be conveyed into the
sludge pump house with an alternative arrangement to dispose into the surface drainage
channel in emergency. The entire maintenance platform shall be covered with RCC
slab. The sides of the maintenance platform shall be covered by brick wall with proper
openings as per instruction of the EIC.
Two 4 wheeled rubber tyre hand carts suitable to move on the walkway for transport of
the plates up to the maintenance platform shall be provided.
All the basic construction works and finishing works shall be carried out as per instruc-
tion of the Engineer-in-Charge, specifications relevant to latest IS codes and specifica-
tions contained in other Sections of this tender document.
Parameters
Flocculation Zone:
 Detention Time - 30 min.

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 Velocity Gradient - 40 to 60
 Tip Speed less than - 1 m/s
 Paddle Area* - 10 to 25% of vertical section
Plate Settler Clarifier:
 Surface Loading - Max 1.0 cum./sq.m./ hr. or as per manufacturer
specification whichever is lower

 Weir Loading < 12.50 cum./m./hr.

 Depth at outer edge (side water depth) - Minimum 4.0 m

5.5.8 Bypass of the plate settler Clarifiers; collecting channel; overflow

The clarifiers shall be bypassed by connecting the distribution chamber directly to the
collecting channel leading to the filters. The bypass can be used during periods of good
raw water quality with minimum of turbidity and suspended solids for direct loading of
the filters. There shall be an electrically operated bypass wall gate.
Overflow
An overflow shall be provided at the collecting channel to avoid uncontrolled flooding
of the plant. The weir of the overflow shall be designed for the design flow plus over-
load in a manner that the upstream head does not exceed the freeboard of the channels
and treatment units. The weir plate shall be adjustable. The starting chamber of the
overflow shall be adjacent to the channel and the overflow from the weir shall feed it.
It shall be suitably sized. Free board of the collecting channel shall be 30 cm and shall
be suitably connected through pipe / channel to the general drainage system of the plant.
5.5.9 Sludge Withdrawal
The underflow from the clarifiers shall be led through a DI pipe to the Sludge sump for
carrying out the Zero Liquid Discharge concept. Sludge collected in hoppers of each
clarifier shall be evacuated individually or in groups by hydrostatic pressure from the
bottom of the hoppers through a discharge pipe into a sludge collection channel com-
mon to all the clarifiers located between a pair of clarifiers or external to the clarifiers.
A gallery shall be provided to accommodate the sludge channel which shall be of suf-
ficient size to provide walkways along the side of the channel and to give access to all
sludge and drain valves and to house controls and associated equipment. Enclosed
sludge galleries shall be force-ventilated.

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All sludge valves shall be of the eccentric plug or ball type and shall be arranged for
pneumatic power operation with manual override. Each power operated valve shall be
of the spring-loaded type arranged to close on air supply failure and shall be provided
with a manually operated guard valve. The quantity of water discharged as sludge from
clarifiers averaged over 24 hours shall not exceed 2.5% of the works input averaged
over the same 24 hours.

5.6 Rapid Sand Filters

5.6.1 Filters
The filter beds shall be supplied, clarified or by-passed raw water from secondary chan-
nels through a main channel coming from the clarifiers. The filters shall be of the con-
stant flow and rising water level type (split flow). All filters shall be identical in internal
dimensions. The top level of the filters is the same as that of the feeding channels to
avoid overflow in the filter area. The thickness of filter wall shall not be less than 150
mm. A sound mechanism be adopted for water sealing from expansion joints, if pro-
vided.
The filter house shall have not less than thirty-six (36) filter beds with single bed. The

filter beds shall be designed to give the normal output of 8265 m3 /hour with a filtration
rate not exceeding 6 m/hour and with a filtered water turbidity less than 0.5 NTU. The
beds shall be capable of taking overloads up to 16.67% of the average flow to keep one
filter bed as standby, even at the time of worst tidal variations in the river without ad-
versely affecting the quality of the filtrate. The filters shall be arranged in two rows
with a space not less than 8 m between them to accommodate pipe galleries and a fil-
tered water channel. The filters shall be designed for a head loss not more than 2 m and
for cleansing by air followed by water. The minimum sizes of cast iron pipes, pipe fit-
tings, sluice valves and sluice gates shall be as follows:
Filter inlet pipe and sluice gate 600 mm dia
Filter outlet piping & sluice valve 450 mm dia
Filter waste piping & sluice gate 600 mm dia
Filter wash sluice valve 500 mm dia
Pipes and fittings for ring main for
backwash water 500 mm dia

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Pipes and fittings for wash main from

pumps to ring main 600 mm dia
Pipes and fittings for air scour 200 mm dia
Sluice valve for air scour 200 mm dia

A rectangular sharp-edged weir with gate shall control the flow to the filters. The weirs
shall be adjusted in a manner that all filters in operation receive the same flow consid-
ering the hydraulic conditions of the common feeder channel and fully opened gates.
The tolerance shall not exceed +/- 5 %. The gate shall be used for the isolation of a filter
in case of backwash or maintenance. It shall be electrically operated from the filter
control consoles. All gates shall be electrically operated.
All sluice gates and sluice valves on each filter shall be opened and closed by pneumatic
cylinders which shall be of double acting type with adjustable air cushions. The inside
surfaces of the cylinders shall be ground and honed to very fine tolerance for efficient
and positive operation. The pneumatic cylinders, pneumatic valves and other pneumatic
components shall be of reputed and approved make. All the pneumatic operated sluice
valves and gates shall be SCADA compatible and integrated with WTP-SCADA.
The cylinders and the operating air pressure system shall be designed to ensure positive
action and to overcome all forces due to friction and unbalanced head against the gates.
The cylinders shall either be mounted directly on the sluice valves or placed on the
operating platform with extended spindles to connect the pistons of the cylinders to the
valve spindles. Cylinders shall be designed for 100% over load after assuming com-
pressors to work at 60% of their rated capacity. Agency shall also include filter and
lubricator to be provided to the cylinder more than 8 m away (measured along the pneu-
matic pipeline) and a separate mounting with a solenoid valve would be necessary,
keeping the filter exposed. The power and control cables shall lead from the said mount-
ing to the main console. The cylinders shall be designed for an operating pressure of 5
bar. Speed controllers shall be provided to each cylinder - one for each direction of
operation, the time of travel in the downward direction being 10 sec. with 20% tolerance
either way.
The pneumatic cylinders shall also be actuated by solenoid valves as stated below which
shall be arranged on a console placed in front of each filter unit. Double coil solenoid

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operated two position valves shall be provided in the console to be able to open or close
the valves fully, except for the inlet sluice gate and back wash valves for both of which
the solenoid valve shall be of three position type which shall permit inching to hold the
valve or gate at any intermediate position. All air supply pipes to the individual valves
and sluice gates and from the filter consoles and electrical wiring for pilot lamps on the
consoles shall be neatly arranged on the walls in straight horizontal and vertical lines.
An air filter regulator and lubricator of approved design and make, shall be provided at
each filter console.
The filter consoles shall be of fiber glass reinforced plastic with a smooth finish and
shall be fitted with pilot lamps to indicate shut and open positions of the respective
valves or sluice gates actuated by limit switches mounted on the cylinders. The consoles
shall be provided with push button starters for each of the wash pump and air blower
motors with indicating pilot lamps. The consoles shall also be provided with arrange-
ments to give an audio-visual signal to the central control room and to the wash
pump/air blower room in case of emergency. The console board shall also be provided
with three analogue meters showing the rate of flow, loss of head and rate of wash water
flow.
Agency shall include in their offer two (2) electrically driven air compressors of reputed
make approved by the Authority mounted on a pressure storage tank for furnishing air
power for actuating the pneumatic cylinders. The displacement of the compressor and
the capacity of the storage vessel shall be so designed as will make available always
with one unit in operation, sufficient quantity of air under required pressure to actuate
the cylinders when the filters are washed one after the other at intervals of 30 minutes.
The compressors shall be fitted with a pressure switch to maintain the required pressure
in the storage vessel and a drier for dehumidifying to ensure dry air to the cylinders. An
audio-visual alarm shall be installed in the central control to indicate failure of the pres-
sure system. One compressor shall work at a time and the other one shall be stand by.
The compressors shall have a minimum capacity of 15 bar and provided with a pressure
switch each with both cut-in and cut-out facilities.
Each filter bed shall be provided with the complete set of underdrain system of latest
improved pattern, the system being designed for efficient application of compressed air
and wash water during filter cleaning. Agency shall have the option of providing in

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their offers underdrain system to suit their own designs, incorporating nozzles fixed on
precast slabs. Where nozzles are used these shall be of high density polyethylene noz-
zles and shall be spaced suitably on the filter floor to ensure uniform collection of the
filtrate and even distribution of the backwash air and water over the entire area of the
filter bed. The underdrain system shall be designed to ensure that there shall be no air
binding during either filtration or backwashing and shall prevent mud ball formation in
the sand bed. There shall be no loss of sand during filtration or backwashing and the
sand bed shall settle down uniformly. Agency shall submit with their offer detailed
specifications and description of the underdrain system with necessary sketches they
have incorporated in their design.

5.6.2 Filter Media

The filter media (sand and gravel) shall conform to IS:8419 (part I) amended up to date.
Each filter bed shall be complete with the filter media conforming to the following
specifications. The filter media shall consist of a sand bed supported on a bed of gravel.
The sand bed shall have a depth of not less than 635 mm while the depth of the gravel
bed shall be determined by the Agency to suit the type of filter floor offered by them.
The gravel bed shall incorporate layers of gravels of different sizes ranging from 6 mm
to 50 mm and the total depth of gravel bed shall be not less than 525 mm. Tenderer shall
ensure the stability of fine diameter & gravel of the filter bed.
The filter media shall be quartz sand of effective size of 0.55 mm to 0.70 mm with a
uniformity co-efficient not exceeding 1.50. The sand shall be granular, hard, and
screened through appropriate meshes and shall be thoroughly washed to the satisfaction
of the Engineer-in-Charge prior to loading in the filters. The sand shall be free from
clay, dust and other impurities and shall not contain more than 1% of micaceous matter.
The sand immersed in 40% hydrochloric acid for 24 hours shall not lose more than 5%
by weight. It shall not contain more than 1.5% of calcium and magnesium calculated as
CaCO3 and not more than 0.7% weight shall be lost after burning. The gravel support-

ing the sand bed shall be hard, durable and rounded and shall not disintegrate under the
action of water. The gravel shall be thoroughly washed to the satisfaction of the Engi-
neer-in-Charge prior to loading in the filters. The solubility of gravel in 40% hydro-
chloric acid after 24 hours at room temperatures shall not exceed 10% for 10 mm size

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gravel and 5% for smaller than 10 mm size gravel. Filter sand when immersed in 40%
hydrochloric acid for 24 hours, the soluble matter shall not be more than 5% by weight.
It shall not contain more than 1.5% of calcium and magnesium calculated as CaCO3.
Ignition loss shall not exceed 0.7% of the weight. The solubility of supporting gravel in
40% hydrochloric acid after 24 hours shall not exceed 10% for 10 mm or larger size
gravel and 5% for smaller than 10-mm size.
All filter media shall be supplied in polythene bags. Suitable care shall be taken to pro-
tect the media from spillage or contamination. Storage on site shall only be in an ap-
proved area, well drained and free of mud and silt. The filter media shall be carefully
placed in the filter beds and shall not be dropped or dumped or machine handled to be
detrimental to the media floor, nozzles or sealant. etc.
It shall be deemed that the Agency has investigated all potential sources and verified
that sufficient quantities of satisfactory filter sand can be obtained, packed and stored
on site.
The water level on the filter bed during filtration shall not be controlled. It shall serve
as the indicator for the filter head loss. The maximum water level (admissible filter loss)
must be such to allow free fall from the feeding channel / rectangular weir. Filters shall
be cleaned when the water has reached that upper level. There shall be proper arrange-
ments to avoid destruction of sand surface by freely falling water in case of a low water
level in the filters just after cleaning. The lip of the outlet weir shall be at least 100 mm
above the top of the sand bed to prevent media running dry.
 A filter false bottom floor with nozzles shall be provided for under drains conform-
ing to IS:8419 (Part 2) and contain polypropylene nozzles of reputed and approved
make.
 The under-drain system shall be designed to provide uniform draw-off of filtered
water and uniform distribution of wash water and air over the whole area of the
filter. Provisions have to be made for the handling of the high air velocities at the
inlet zone of the manifold.
 Before filling the supporting layers and the sand of the filter beds, the whole under-
drains system shall be thoroughly cleaned and tested for equal distribution of water.
The Agency shall take all necessary measures to ensure that false floor shall contain
polypropylene nozzles of reputed make and the water conveying system of pipes or

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channels connected to the floor are free from any debris, concrete, sand or other
material which could otherwise block or partially block nozzles. Uniform distribu-
tion of the nozzles of not less than 55 numbers per square metre shall be employed.
The nozzles shall:
- incorporate separate air and water entrances;
- be set at an exactly uniform level;
- be capable of replacement;
- be designed to avoid ingress of sand
- purge valve
It shall be the responsibility of the Agency to remove any such debris before the com-
missioning of laying filter floors or laterals and shall continue to remain his responsi-
bility for excluding unwanted materials which could block the filters until the O&M
period.
For twin bed filter, each filter shall have central and lateral wash water troughs that
shall be connected with adequate slope to the wash water outlet to prevent deposits of
silt. They shall allow an equal withdrawal of the wash water during backwashing the
filter. The filter backwash water shall ultimately be discharged to Recycling (Buffer)
Tanks.
A float switch shall be provided at the maximum admissible level of each filter to indi-
cate the need for back-washing.
The Agency shall provide a filter outlet controller which shall permit the filter to operate
at a fixed rate of desired output irrespective of the gradual increase in loss of head in
the filter bed. The outlet controller shall be designed to operate in the range of zero to
125% of the normal flow. The rate controller may be closed venturi type or open type
with double beat valves of not less than 600 mm diameter in outlet chambers in front
of the filters fitted with rectangular weirs made of brass for measurement of flow and
for controlling the double beat valves by means of floats in the outlet chamber and the
filter tank. The control valves for open type controllers shall be of cast iron with gun-
metal/S.S. facings to render them water tight in closed positions. The floats in the filter
tanks and outlet chamber shall be made of fiber glass. All levers operating the control-
lers shall be designed to move in ball bearings to ensure free movement. Where open
type controllers are offered the top of outlet chambers receiving the filtrate shall be

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provided with removable covers framed of aluminum alloy angles and of design to be
approved by the Engineer-in-Charge. The portion of the chamber receiving the filtrate
over the weir shall be provided with a minimum 6 mm thick framed transparent perplex
sheet. An underwater bulk head lighting fixture shall be fitted in the chamber below the
perplex sheet. Suitable arrangements shall be made for disposal of waste water from
the float chambers and outlet chamber irrespective of head loss in the filter bed or de-
signed on the principle of declining rate of filtration.
Agency shall submit with their offer the details of their designs and complete specifi-
cations for the equipment for the filter outlet arrangements.
The filters shall be provided with an automatic slow starting equipment so that after
each back wash the filter unit shall give an output at 10% of its rated capacity for a
minimum period of 15 minutes before reaching the rated loading. This slow start equip-
ment shall either form an integral part of the outlet controller or be independent of it.
In addition, Agency shall provide a rewash valve of at least 200 mm diameter. at the
outlet of each filter to operate the filter at a much-reduced rate immediately after back-
wash. Each filter shall be provided with Rate of Flow and Loss of Head indicators of a
diameter type in order to indicate the rate of flow from each filter and the progressive
loss of head in the filtration process. The rate of flow indicator shall be operated by a
differential head in the venturi controller and in the case of open type controllers by the
depth of flow over a rectangular weir in the outlet chamber. The loss of head indicator
shall be operated by means of a differential mercury pot or by water columns in which
case arrangements shall be provided in the indicator to compensate for fluctuations of
water levels in the filter box. The loss of head indicators shall incorporate an electrical
contact point to give a signal when the filter is due for washing. Agency shall also pro-
vide remote sensing for reading the rate of flow and loss of head indicators in the central
control room in the annexe building. The meters which shall be dial type or digital shall
be mounted on an instrumentation panel. All electrical wiring and/or air tubing from
the local indicators to the instrumentation panel shall be included in the offer.

5.6.3 Filter operation gallery and pipe gallery

The filters shall be operated and back-washed according to the instructions of the En-
gineer-in-Charge. Minimum guaranteed filter run shall be at least 23 hours under all

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conditions. Each filter shall be provided with necessary electrically driven butterfly
valves and push buttons provided on the filter operating console. The valves shall have
the possibility for manual operation from the pipe gallery in case of problems with the
drive. The following valves/gates shall be provided:
 filtered water outlet (electrical)
 backwash water inlet (electrical)
 air inlet (electrical)
 sludge water outlet (electrical)
 inlet gate (electrical)
 drainage of the filter (electrical)
The valves shall be connected to pipe branches coming out of the filter box. These outlet
and inlet pipes and inlets shall be provided with proper wall ducts without any leakage.
In line type DP transmitter type flow meter with 2% accuracy with 4-20 mA signal
output, flow transmitter with local display and a regulation valve shall be installed in
the backwash water pipe coming from the reservoir. There shall be a locking arrange-
ment in regulation valve that can be locked after adjustment of flow. The flow rate
(m³/hr) shall be transmitted to a wall mounted electronic digital meter of suitable size
so that it is visible and readable from each filter operating console.
The electrically driven valves and the inlet gates shall be operated from individual con-
trol consoles positioned adjacent to each filter in the operation gallery with visibility to
the respective filter bed. The control panel for the units shall be installed in the Machine
Room. The following control functions (-c) and indicators (-i) shall be provided:
-c operation of the inlet gate and the valves (open/closed/intermediate position)
-i indication of the status of the gate and the valves (open, closed, intermediate, motor
failure)
-c operation of the air blowers (on, off, failure)
-i signal lamp with acoustic signal if the water level in filter bed has reached the top
level and the backwash cycle shall be started
-i indication of adequate water level in the backwash reservoir (yes, no)
The washing cycle of the filter shall have all provisions for its manual operation, step
by step. The duration of the cycle shall be prescribed by the Agency, dependent on the

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raw water quality. Before back-washing, the filter water level shall be lowered to its
minimum in order to avoid wastage,
The pipe gallery shall have the following piping arrangement:
- backwash water pipe with connection to each filter
- air pipe with connection to each filter
The filtered water pipe of each filter shall be connected to a small chamber with an
adjustable rectangular weir to the central filtered water channel. This weir shall control
the minimum water level in the filter. The weir crest shall be 10 cm above the top sand
level of the filter. The length shall be designed to have less than 10 cm head. The com-
pletely covered channel shall lead directly to the chlorination chamber and lead to the
CWR.
The sludge water outlet and the evacuation outlet shall be directly draining into an open
channel in front of all the filters. This channel shall lead to a chamber that is connected
to the drainage system leading to the recycling tanks.
In the pipe gallery, easy access to all valves and drives, cables etc. shall be ensured. If
required, walkways and ladders shall be provided.

5.6.4 Filter operation gallery and pipe gallery

The filters shall be back-washed with water and air according to a cycle prescribed by
the Engineer-in-Charge. Therefore, the following capacity requirements are only tenta-
tive. However, one full filter bed / box (i.e. both the sections) shall be back-washed at
the same time (simultaneously) to reduce down time of filters.
The filters shall be designed for back washing with water at the rate of 600 litres per
square metre per minute proceeded by air scouring at the rate of 750 litres per square
metre per minute. Arrangements shall also be kept for suitable surface wash by water
jets to break up the surface of the sand bed prior to the application of back wash water.
The water for back washing of the filters shall be obtained by direct pumping, the
Agency shall include four pumps of identical capacity. Two of these pumps shall be in
normal use and shall be capable of delivering 300 litres per second each. The other two
pumps will remain as standby and of same capacity. The pumps shall be designed to
operate against a head which shall be adequate to overcome losses due to all causes
including friction in the wash main and the filter underdrain system when applying was

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water at a rate of 600 lpm/m2 and the pressure measured in the underdrains of filter
beds shall be equal to 5 M to 7 M head of water. The pumps shall be installed in a pump
room in the filter annexe building in such manner that it will provide positive suction
head to draw water from the filtered water channel or a sump connected with the filter
water channel. Each pump shall be complete with driving motors, necessary cast iron
sluice and reflux valves and cast-iron piping for suction, downward suitable bell mouth
and delivery including all fittings. The wash water from the pumps shall be delivered
at the wash valve of each filter through a cast iron main not less than 600 mm in diam-
eter. from the pump room to the filter house and through a cast iron ring main not less
than 500 mm in diameter. within the filter house.
Trenches with chequered plate covering shall be provided on the floor of the pump
house for placing all pipes and electrical cables. A 5 tonne capacity electrically operated
crane with travelling trolley complete with RSJ runners shall be provided in the back-
wash pump room for handling of the pumps, motors etc. and carrying the same at the
repairing bay at an elevated height.
Two units of Rotary Air Blowers of reputed make to the approval of the Authority each

capable of delivering at least 95 m3 of free air per minute at 0.35 to 0.50 kg/cm2 pres-
sure at the underdrains complete with motors etc., or of sufficient capacity as designed

by the agency whichever is higher, shall be provided to supply 0.75 m3 of free air per

minute per m2 of the filter bed. Out of two units one will be in operation and the other
will act as a standby. The header from the blower shall be at least 200 mm diameter
Double Flange Ductile Iron (DFDI) main and the piping leading the compressed air to
each filter unit shall be 200 mm diameter Double Flange Ductile Iron pipes only. Req-
uisite air filters shall be provided to control the air supply to the filter beds. Adequate
arrangements shall be made to ensure uniform application of air over the entire filter
bed. Measuring instrument for measuring quantity of air shall have to be provided of
approved make. The design of the blower and its silencer shall be such that the decibel
level in the blower room would be within permissible limit, and shall in no case exceed
80 dB at a point 3 m away.
Agency shall provide a flowmeter of the indicating, integrating and recording type for
the measurement of wash water flow rate and consumption. The meter shall be of a
reputed make to the approval of the Engineer-in-Charge and shall be operated by a
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pressure differential in an orifice plate in the 600-mm diameter. pumping main. The
loss of head in this orifice plate shall be taken into account for determining the duty of
the wash pumps. The indicating and integrating instruments shall be mounted on an
instrumentation panel in the central control room. A 100 or 150 mm diameter dial or
digital type wash water flow indicator shall also be provided on each filter console for
the guidance of the operator when applying backwash water. These secondary instru-
ments shall be actuated by the main wash water meter.
The filter waste water during backwashing shall be collected in waste troughs which
shall be provided sufficiently above the level of the sand bed to allows for expansion
of the sand bed. The spacings between the troughs shall be arranged to limit the hori-
zontal travel of the waste water to a maximum of 1 m. The waste trough shall be pro-
vided with horizontal inverts and shall be designed to discharge with a free fall into the
main waste gutter channel of the filter unit. Some arrangements shall be provided to
drain off during the washing process such light particles of impurities floating in the
water above the sand head which are unable to reach the lip of the waste toughs. Such
device shall ensure that the sand held in suspension during the application of wash water
is not drained off with the impurities. Agency shall submit with their offer a detailed
description with necessary sketches of the equipment offered by them for this and the
manner in which it will function.
Agency shall provide a pressure water system for each filter to break up the surface of

the sand bed by a pressure (not less than 3.5 kg/cm2) jet prior to the application of
backwash water. The equipment for this arrangement shall include a cast iron pipeline
in front of the two rows of filters and a hydrant at the centre of each filter with sufficient
length of flexible hose in reels fitted with a gunmetal/SS nozzle for the jets to reach all
corners of the filter bed. The pipeline for this pressure water shall be connected to the
pipeline specified earlier from the Authority's pressure main for supplying water in the
chemical house and pressure water to the clarifier sludge pipes of adequate capacity.
Separate high-pressure pumps (one acting and one standby) shall also be provided for
supplying water from the filter water channel for jet washing during non-supply hours
with suitable valve arrangement.
Pumps
The following control functions (-c) and indicators (-i) shall be provided:

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 Remote start, stop with manual override

 auto stop when sump (at filtered water channel) level low
 stop in case of failure of the motor
 on, off, failure (repeat indications at Main Control Panel)
 voltmeter, ampere meter, operation hours
 low level in the sump
 high, middle, low level in the backwash reservoir
 flow of the backwash water coming from the reservoir
Compressors / Blowers
The Agency shall provide compressors (minimum two numbers with 100 % standby
units) along with suitable induction motor coupled suitable for operating on 415V, 50
Hz frequency supply for the air delivery for scour of the filter beds.
Each unit shall be provided with a suction air filter and silencer, pressure relief valve
and delivery non-return valve. A non-return valve shall be provided on common air
main to each battery of filters.
The air pipe to the filter shall be laid with an apex above the maximum water level of
the filters and a vacuum breaker at the point to avoid back-flow and siphoning of water
in the compressor.
Pressure gauges with stop cock at the pressure side of the compressors shall also be
provided.
The air piping connecting the blowers to the filters shall be laid out on the ring main
principle. There shall be a provision for the release of air from the system at the end of
the scour before backwash commences.
The following control functions (-c) and indicators (-i) shall be provided:
 Remote start, stop with manual override
 local start, stop
 manual start, stop from each filter control console
 on, off, failure (repeat indications at Main Control Panel)
 voltmeter, ammeter, operation hours
The status of both the backwash pumps and the compressors are also to be indicated at
the main control panel of the treatment plant. The status of the compressors/blowers
shall be indicated on the filter control consoles also.
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Design Parameters for Backwashing Arrangements shall be followed:

Type of Filter Back- Sequential Back wash Conjunctive Air and

washing System Water Wash System
Configuration Minimum 1+1 Minimum 1+1
Vol. of free air 36-45 m/hr 45-50 m/hr
Vol. of water applied 24-36 m/hr 12-15 m/hr
Air pressure at under 0.35 Kg./sq.cm. 0.35 Kg./sq.cm.
drain
Speed < 1000 rpm < 1000 rpm
Air velocity in pipe and
< 25 m/sec. < 25 m/sec.
valves

5.6.5 Re-cycling of Backwashed Water

Waste water from filter backwashing process shall be re-used instead of being drained
to waste. For this, Agency shall provide a tank to recover the waste water from where
it will be pumped into the raw water channel upstream of the venuri throat and coagu-
lant dosing point for feeding it with the incoming raw water at a rate not exceeding
5%(five percent) of the raw water input. The capacity of this tank shall not be less than

50 m3 and the recirculation pump shall be capable of pumping continuously at the rate
of not less than 100 litres per second. The storage tank has to be provided with an over-
flow weir to discharge excess quantity of waste water into natural drainage or into the
sludge pump house sump through a pipeline. This overflow will come into use in the
event of breakdown of the recirculation pumps or at times when it becomes necessary
to wash the filters in rapid succession. The tank is to be provided at a convenient place
near the recirculation pump room. There shall be provision for suitable agitation system
for the deposited silts.
Alternatively, the space below the filter inlet channel around or on the two sides can be
used to give the necessary volume of storage of the waste water. In this case the floor
of the channel shall be provided with a slope from one end towards the pump sump to
give a scouring velocity between 1 to 1.2 m/sec. for a flow of at least 100 1/sec which
is the rate of recirculation. Provision shall be made for access to the bottom of the sump
by means of stair made of non-corrosive materials. The filter waste water channel would
be located outside the filter house, below the inlet channel but not below the pipe gal-
lery.

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For delivering the waste water from the channel into the raw water channel, Agency
shall install two electrically driven mixed flow centrifugal pumps each with a capacity
of at least 100 litres per second in a pump room on the ground floor of the filter annexe
building. One pump shall be in normal use while the other shall act as a standby. The
pumps shall be designed either for horizontal or vertical execution and shall be arranged
to start and stop automatically by means of a float/electrode in the channel at a preset
level near its floor. The pumps shall be complete with cast iron sluice valves, reflux
valves and piping which shall be arranged to deliver the waste water into the raw water
channel for reuse or to discharge into the sludge pumps house sump.
There shall be a provision for measurement of the filtered water output from the plant.
The measurement shall be by means of an open channel venturi-flume built in the fil-
tered water channel at the end of the filter house. Agency shall include in their offer an
open channel flow meter of reputed make to the approval of the Authority incorporating
an indicator, an integrator and a recorder which shall be mounted on an instrumentation
panel in the central control room. The instrumentation and control of filter console shall
have modern equipment with digital display and shall be SCADA compatible. All in-
strumentation and control in Filter house shall be SCADA compatible.
Design Parameters of RGF:
1. Design Flow: Normal corresponding to 190 MLD treated water + 20% overloading
2. Filters:
Normal Filtration rate - 5.0 m3/m2/hr

Water column - 1.0 - 2.0 m

Free board - 0.5 m
3. Filter media:
Depth of sand bed - 0.6 - 0.75 m
Effective size of filter media - 0.8 - 1.0 mm
Uniformity coefficient of sand - 1.3 - 1.5

Depth of gravel layer - 0.5 m

5.6.6 Civil Works: Filter House with Annex Building

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The filter house and annex building shall be of R.C.C. framed structure with brick panel
walls and shall be provided with pile foundation. The filter units and channels shall be
of R.C.C. construction only. The annexure building will also be used as administrative
purpose.
Total plinth area of the filter house excluding the areas covered by the inlet and waste
water channels shall satisfy the following two norms:
i) The distance between the two rows of filters shall be minimum 8 metres to

ii) accommodate filtered water channel and pipe galleries.

The total area of sand beds in the filter units (not less than sixteen in number) shall be

sufficient to give the normal output of 8265 m3 /hour of filtered water along with over-
loading at the filtration rate of 6 m./hr after deducting for backwash loss.
The filter tanks shall have a minimum free board of 500mm and operating platforms
walkways shall be provided at the level of the top of the tanks. The operating platforms
over the pipe gallery and the walkways connecting the two ends of these platforms shall
have a width not less than 2500 mm. The two operating platforms shall be intermedi-
ately connected at least at three points by 1200 mm wide walkways. The walkways at
the rear of the filters and on the cross walls shall be 1000 mm wide. Concrete platforms
of adequate size shall be provided outside the building on part of the filter inlet channel
to give access to the inlet sluice gates. Hand railings with as specified or directed by the
Engineer-in-Charge shall be provided on all walkway and operating platforms. Agency
shall also include for the supply of not less than three stairs (at least 1 m wide) of mild
steel construction to give access to the top of the filtered water channel from the oper-
ating platforms.
There shall be at least three manholes fitted with cast iron manhole cover and frame for
getting into the filtered water channel.
There shall be a 900-mm wide R.C.C. staircase at the rear end (end opposite to the
annex building and main entrance) of the filter house to give access to the filter house
from ground level to operating platform.
One door at least 1.0 m wide shall be provided at the entry to the operating platform.
The annex building shall be a two-storied building each floor having a minimum carpet

area of 250m2.

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The building shall have the following minimum areas:

On Ground Floor
Main entrance hall with staircase 100 m2
Wash Pump Room and Blower Room 120 m2
Waste Water Recirculation Pump Room 20 m2
Toilet 10 m2
On Frist Floor
Central Control Room & SCADA room for the Plant 130 m2
Operators Room 50 m2
Chemist's Room including office 30 m2
Store Room 30 m2

Toilet 10 m2
Adequate common passages shall be provided on each floor to give independent access
to individual room. Agency may make minor adjustments to the above-mentioned areas
in order to suit their own design, keeping the total area unchanging.
The staircase shall be of aesthetic architectural design and the width of steps shall be
1500 mm minimum with 300 m tread and 150 mm rise. The staircase shall provide an
access to the operating platform from the entrance hall. The staircase shall be provided
with decorative hand railings with wooden hand rest.
The main entrance to the annex building shall be designed in a consultation with an
architect to give an aesthetic appearance for which purpose the Agency shall provide a
porch of not less than 6 m with an entrance foyer in which decorative plants can be
placed. Agency shall submit preliminary sketches of this with the tender.
It is to be noted here that the chemical house and the annexe building shall be intercon-
nected with a covered gangway as specified elsewhere in the tender documents.
The clear height between the filter operating platforms and underside of the roof beams
shall not be less than 5.0 m. Similarly, the clear head room for each floor of the annexe
building shall not be less than 4.5 m.
Adequate skylights and windows shall be provided in the filter house and annexe build-
ing to admit sufficient natural light. The total shutter area of doors, windows and ven-
tilators shall not be less than 25% of the floor area. The windows and skylights shall be

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provided with grills of approved design. The position of windows and ventilators/sky-
lights shall be such that these can be opened and closed easily. All the windows and
ventilators/skylights except the main entrance door of the annexe building operator's
room and toilets shall be of mild steel and their pattern shall be up-to-date and approved
by the Engineer-in-Charge. The doors including frames to operator’s room and toilets
shall be of teakwood, size their thickness polished or painted as per direction of the
Engineer-in-Charge. The main entrance door shall be of aluminum alloy construction
photo-electric cell controlled sliding type of decorative design as per recommendation
of the Agency architect and approved by the Authority. All other doors shall be of 1st
class Teak Wood with Sal wood door frame.
The toilets block shall be provided in annex building and shall be connected with sew-
erage line of the vicinity.
The roof of the annexe building which is likely to be flat roof or shell shall be provided
with roof water proofing treatment with adequate arrangements for rain water drainage.
The roof of filter house shall be RCC shell roof and shall be provided with adequate
rain water drainage arrangement. There shall be a 250-mm thick parapet wall of 1000
mm height. A suitable access shall be provided to the roof from either within the filter
annexe building or outside it without such access being prominently visible from the
front of the building. The roof of the filter house may be a flat or shell roof accessible
from annexe building roof or separately and with proper water proofing treatment as
directed by the Engineer-in-Charge. While the flat roof shall be provided with a parapet
wall as mentioned above with roof water proofing treatment, the shell roof shall also be
provided with water proofing treatment. Adequate arrangements shall be made for rain
water drainage in either case. There shall be architectural blending of roof of the annexe
building and the roof of the filter house in order to provide an integrated and pleasant
look.
All external doors and windows shall be provided with R.C. Chajja in box type or any
other approved architectural design.
A 1200 mm wide apron of 75 mm thick 1:3:6 cement concrete laid on brick on-edge
soling and a surface drain shall be provided around the filter house and annexe building.
Adequate arrangements shall be provided to dispose of water from the rewash valves,
overflow from filter outlet control chambers, leakage water from glands of pumps and

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sluice valves in the filter house and annexe building and from all floor levels below
finished ground level to natural drainage through surface drains or into the filter waste
water sump, for which purpose sump pump shall be provided if necessary. Sufficient
number and capacity of pump shall be provided in all areas where leakage water may
be encountered to keep the areas free from water all the time. Each sump pump set
consists of two equal capacity pumps, one will be acting and the other will be standby.
Adequate number of lighting arresters shall be fixed on the top of the filter house annexe
building and chemical house and this arrangement shall conform to IS-2307-1969.
The flooring of pipe gallery shall be epoxy flooring over ironite flooring. All the Build-
ings and structures shall be provided with proper earthing arrangement as per IS-3043
with step & touch potential arrangements conforming to IE Rules as amended up to
date. All the basic construction works and finishing works shall be carried out as per
specifications.

5.6.7 Machine Room

The machine room of adequate size shall be provided in the ground floor of the Admin-
istration and Control building to house the required number of air blowers and pumps.
The number of pumps/ blowers shall not be less than two including 100% standby units
shall be provided. The area where the pumps are installed shall be lowered by 1.5 m
below the bottom level of the sump to provide positive suction head for the pumps. A
drainage sump shall be provided at the deepest point of the lower area. The pit is con-
nected to the drainage system leading to the re-circulation reservoirs.
A repair bay of 3 m shall be provided at the entrance of the room. A railing shall be
provided around the lower part of the hall. The partial accessibility to the repair bay for
a truck must be ensured by a wide and high gate minimum of 3 x 4 m. The room height
must be sufficient to allow loading and unloading of the pumps and the other equip-
ment.
Suitable ramps shall be provided to transfer the blowers / compressors from their re-
spective floor level to repair bay level by a hand driven trolley. An electrically operated
suitable capacity hoist of standard make shall also be provided in machine room for
handling of pump, motor & blower/compressor etc.

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5.7 Treated Water Measuring Channel and Flume

The treated water shall be measured in an open channel by means of a flume. An Ultra
Sonic Flow meter with flow integrator and electronic display units shall be provided at
the flume, to display the raw water flow in the control room. The measured discharge
shall be indicated in the main control room. Rated Flow Capacity shall be correspond-
ing to 190 MLD treated water.

5.8 Chemical House

5.8.1 General
The chemical house shall be planned, designed and constructed for the 190 MLD (23
hours operation) output capacity in one building and shall include space for fifteen (15)
days storage of alum and lime. The required number of chlorine tonners shall be stored
separately in that building too. The chemical house shall have sufficient space for un-
loading of the chemicals, wide corridors, office space, toilets etc. The ground floor shall
be used for the 15 days storage of alum and lime. The first floor shall house the alum/
Primary coagulant, lime preparation tanks, the dosing equipment for all chemicals re-
quired. Suitable staircases, platforms etc. shall be provided to have clear access to dif-
ferent units. The building shall be supplied with process water from the overhead tank.
The architectural layout of the chemical house shall be functional, adapted to the re-
gional climate conditions and shall give an aesthetic appearance bearing in mind the
local environment and culture in the campus. It shall be in harmony with the other
buildings in proximity and the treatment units.
The alum/ Primary coagulant and lime dosing room shall be equipped with desert cool-
ers. The cooler supports shall be integrated in the building and easily accessible. Water
points and 5 A sockets shall be provided at these locations.
The chemical house shall be supplied from the common manifold of clear water pump
house by minimum pipe size DN 150 to supply the solution tanks for alum and lime
solution. Branches of minimum of DN 100 - DN 25 shall be installed for supply the
sprinkler system of the chlorine cylinder storage area, the solution tanks for alum and
lime solution, the booster pumps for the injector system for the chlorinators and the
internal supply system.

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The regulation shall be made with the adjustable dosing metering devices/pumps. The
control over dosing rates shall be capable of being exercised from the control room
consoles. The solutions shall be conveyed through pipes to the injection points.
There shall be a single chemical house for the plant under this tender where provision
shall be made for alum, PAC or any other coagulant storage, alum tanks, dosing equip-
ment, etc. The coagulant solution shall be fed to the raw water before the venturi-flume
by gravity from the alum solution tanks in the chemical house. Provision shall also be
made for over the ground storage & pumping of liquid alum and PAC as per I.S. spec-
ification for a minimum capacity of storage of 5 Ton of liquid alum/PAC. There shall
be two suitable chemical pumps one in operation & the other standby for lifting liquid
alum or PAC of pH value of 1.18 at a rate of 4.0 MT/hr. Delivery pipeline shall be
capable to handle liquid of pH value 1.18 and requisite pressure to deliver the liquid to
the dosing tanks.
Alum dosing shall be done using pumps and shall be controlled through SCADA. Alum
dosing arrangement shall be designed to cater for a continuous dose of 50 mg/1 to an
average flow of 8265 m3/hr using a 5% strength solution. The solution shall be prepared
and stored in ten (10) tanks of sufficient capacity to store alum solution for 2 days. Out
of ten tanks, two tanks shall be reserve for PAC solution. The tank shall be planned in
such a way that any tank can be used for either PAC or alum dosing without affecting
the regular operation. The floor of the alum solution tanks shall be kept at a level which
will permit sufficient positive head to the feed pump. The coagulant solution shall be
dozed to the raw water by suitable pumping arrangement with 100% standby. The
chemical dosing shall be done through instrumentation and control (SCADA). The
agency shall provide one tank of same size of alum tank for lime solution. Similar ar-
rangement shall be made by the agency for lime dosing for adjustment of pH.
Provision shall be made in the alum solution tanks for providing timber slats to form
trays over which Stainless Steel cages shall be kept for alum blocks which will be
placed for preparation of the solution. Provision shall also be made for a jet spray of
water over the alum blocks to achieve rapid dissolution of alum. The alum solution
tanks shall be provided with fiber glass reinforced epoxy lining.
Electrically driven mechanical agitators shall be provided for continuous stirring of the
solution in the tanks. The agitators shall consist of FRP coated stainless steel paddles

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mounted on stainless steel shafts. The shafts shall be mounted on top of the tank and no
thrust or guide bearings shall be permitted below the liquid level. The paddles in the
tank shall be driven by an electric motor through a speed reduction gear of appropriate
ratio to provide gentle agitation of the liquid. The driving motor and the reduction gear
shall be totally enclosed and easily accessible for maintenance.
Agency shall also quote for providing water jetting and flushing the alum solution tank
when it is empty so that any settled insoluble material is flushed out. The drainage of
such flushing shall be conveyed into the intake well. Provision for water for the jetting
shall be made both from supply main as well as provision of high pressure pumps.
Agency shall include in their offer complete arrangements for chemical dosing through
instrumentation and SCADA control. The coagulant solution delivery and waste pipes
shall be of PVC inside and outside the chemical house. No bends shall be used in the
solution delivery pipeline and wherever a change in direction occurs cross pipes shall
be used to facilitate cleaning of chokes of the pipelines. All valves for solution delivery
and waste water from the tank shall be rubber lined cast iron diaphragm valves. The
entire pipe work including valves shall be easily accessible for maintenance for which
a walkway at the appropriate level shall be provided.
Agency shall provide two basket type strainers (one acting and other standby) in the
coagulant solution delivery pipeline to the dosing tank. The arrangement of the strainers
and the delivery pipeline shall permit isolation of any of the strainers for cleaning. The
strainer housing shall be of rubber coated Cast Iron construction and fitted with a stain-
less-steel mesh screen basket.
Agency shall also provide suitable level indicators operated either electrically or by
float. Gauges shall be provided for each tank placed at a convenient place easily visible
by the operators.
Owing to regular fluctuations in the quality of raw water/rate of flow of incoming raw
water, Agency shall provide arrangements to administer the coagulant solution strictly
in proportion to the incoming supply through instrumentation and SCADA control.
Agency shall also submit a detailed description of the proportioning device offered by
them. This include suitable device for measuring online turbidity as well as chemical
dosing. All dosing equipment and online turbidity meter shall be of 100% standby. The
piping for the ball valves shall be so arranged as will permit any one of them to be fed

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through either any one of the pump. The dosing tank shall be of R.C.C. construction,
lined with FRP or of mild steel lined internally with rubber or fiber glass. The ball valve,
orifice and the tapered needle shall be of stainless steel and the float for the valve shall
be of fiber glass. The entire coagulant dosing measuring device shall be capable to
withstand liquid of pH 1.8.
Water supply for the preparation of coagulant solution shall be obtained from a tapping
off the proposed clear water pressure main in the vicinity of the filter house/chemical
house. Agency shall include in their offer inter connection with the proposed main with
a C.I. sluice valve of required size and all pipes and fittings from this valve to the co-
agulant solution tanks. Agency shall also provide pumping arrangements for supplying
filtered water from the filtered water channel in the filter house. Agency shall include
in their offer the cost of all these arrangements including pipelines, valves, pumps, mo-
tors etc. There shall be a provision for 100% standby of pumps & motors for supplying
water to coagulant solution tanks. Agency shall include in their offer for the supply and
erection, where necessary, of the following ancillary equipment for use in the chemical
house.
i. Two electrically operated 2 - tonne capacity travelling hoists of reputed and ap-
proved make moving on rolled steel joists fixed on top of the coagulant tanks for
lifting alum or other coagulant in trays from ground floor to individual tanks.
There shall be sufficient head room for directly placing the SS cages in the dis-
solving trays of the solution tanks by the hoists. Both vertical and horizontal
movement of the hoist shall be controlled by a single hand control switch con-
nected by flexible cable of suitable length to control both vertical and horizontal
movements separately. Easy inter changeability shall have to be ensured. One
electrically operated 2.0 MT travelling hoist may also be provided instead of two,
if the arrangement of the alum/coagulant solution tanks permits.
ii. Necessary stainless-steel S.S. cages of suitable size of a suitable design approved
by the Engineer-in-Charge. The cages will be loaded with alum blocks or other
coagulants and placed directly on the dissolving trays of the coagulant tanks for
preparation of solution. The trays shall be of best quality teak wood and shall be
made with mortice and tenon joints and with timber nails. All the edges of the
trays shall be strengthened with stainless steel angles or straps. The S.S. cages

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shall be made of robust S.S. tube-frames and slotted S.S. sheet of approved design.
The top of cages shall be provided with hooks of stainless steel for lifting.
iii. Two 4 wheeled rubber tyred hand carts for transport of the cages containing alum
blocks or other coagulants.
One 1000 kg dial type platform weighing machine of reputed and approved make.

5.8.2 Civil Works

The chemical house shall be of R.C.C. framed structure with brick panel walls founded

on R.C.C. piles. Overall plinth area shall not be less than 320 m2. The minimum areas
to be provided for different purposes shall be as follows:
On Ground Floor
Coagulant storage, coagulant tanks

and dosing arrangements 320 M2

Operator's room 40 M2
Two batteries (one in operation
plus one in standby mode) of

chlorine drums 128 M2

Toilet block 12 M2

On First Floor
Chlorination Room 150 M2
Laboratory 100 M2
Office room 100 M2
Lobby 50 M2
Store room 20 M2

Toilet block 12 M2
The Agency shall be free to provide additional areas within their quoted price.
Agency may make minor adjustments to these areas to suit their own design require-
ments within the allowable minimum overall plinth area.
Adequate common passage and circulation space shall be provided on each floor to give
independent access to each individual room.

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An independent stair case of 1000 mm wide steps shall be provided from coagulant
dosing area in the ground floor to the first-floor lobby. A separate stair case of 1200 mm
wide steps shall be provided to access from the ground floor to the first floor for labor-
atory and chlorination room and the roof. The stairs shall be fitted with grilled hand
railings with timber hand-rest.
Any adjacent rooms shall be separated from the alum/coagulant storage space by a 375-
mm thick brick wall and shall be provided with a separate entrance.
The chlorine storage room also shall be separated from the coagulant storage space by
a 375-mm thick brick wall and shall be provided with independent 2400 mm wide en-
trance and exit. There shall be two ramps of mild slope of 2700 mm wide in front of the
entrance and exit to facilitate easy handling of chlorine drums. The clear head room
between the floor level and the bottom of the roof beam shall be 5.5m. Similar clear
head room shall be maintained for other appropriate areas of the chemical house except
for the mezzanine floor. Additional covered storage space for 6 tonner drums shall be
provided outside the chemical house in conformity with the statutory regulation of ex-
plosive departments.
The chlorine storage room shall be provided with one electrically operated travelling
hoist of 3.0 metric tons capacity complete with R.S.J. runners and two sets of drum
lifting tackles. The R.S.J. runner shall be extended suitably in both direction beyond
this room to facilitate the lifting of the chlorine tonners from carrier trucks and placing
directly on the trunnion base. Chlorine drum storage room shall be provided with ade-
quate chlorine neutralization pits including arrangements for neutralization. All the
chlorine tonner drums shall rest on a ball-bearing/roller bearing trunnion system so that
only one person is capable of rotating a completely filled chlorine drum in any direction
on the trunnion resting system. This shall be done in conformity with the explosive
department’s acts and regulations.
Both the chlorination room and chlorine storage room shall have adequate ventilation.
The total shutter area of doors, windows and ventilators shall not be less than 25% of
the floor area. Exhaust fans ensuring four air changes per hour shall be provided just
above the floor level. The chlorination room shall be provided with minimum two
wooden doors. Easy access to toilets are essential from chlorination room and chlorine

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storage room. The chlorination room shall preferably be placed above the chlorine stor-
age room to facilitate easy conveyance of chlorine gas.
For other parts of the chemical house the total shutter area of doors, windows and ven-
tilators shall not be less than 20% of the floor area.
The coagulant storage shall be provided with an entrance, 4500 mm wide fitted with
gear operated rolling shutter. Entrance of trucks into the store up to the stacking space
shall have to be provided to facilitate unloading of alum cakes or coagulants. For this
purpose, there shall be a 5000-mm wide ramp of suitable slope in front of the entrance.
Suitable storage tanks for 5 tons of liquid alum or PAC of pH 1.8 shall be provided over
the ground adjacent to the chemical house with suitable facilities for unloading from
tankers and pumping the liquid alum/PAC to the coagulant solution tank. The pumps
(one in action + one standby) and the pipelines from ground storage tank to the coagu-
lant/alum solution tanks shall be suitable to withstand pH value of 1.8.
The main entrance door to the stair block for laboratory and chlorination room and the
door of the laboratory shall be of 1st class C.P. teak wood all through including the
frame. The design of the doors shall be got approved by the Engineer-in-Charge. These
doors shall be polished as per standard practice as per direction of the Engineer-in-
Charge. All other doors and windows shall be of steel. The design of such steel doors
and windows shall be got approved by the Engineer-in-Charge.
There shall be a 2500 mm wide covered inter-connecting gangway between the chem-
ical house, the collecting well and filter house at the first-floor level. The gangway shall
be provided with SS grilled hand railings with wooden hand rest of approved design.
The roof of the chemical house shall be provided with approved water proofing treat-
ment with adequate arrangements for rainwater drainage. The roof shall be accessible
from the staircase of the laboratory, etc. and shall be provided with a 250-mm thick and
of 1000 mm height parapet wall. There shall be water tank of capacity 10 m3 over the
head room of staircase for use of water in the toilet.
A 1200 mm wide apron of 75 mm thick 1:3:6 cement concrete base laid under brick on
edge pavement with 25 mm thick IPS covering and a surface drain of adequate channel
width shall be provided all-round the chemical house.

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All the basic construction works and finishing works shall be carried out as per speci-
fications as contained elsewhere in the document or as per relevant and latest IS speci-
fication as directed by the Engineer-in-Charge.

5.9 Chlorination Chamber

Chlorination
5.9.1 General
In consideration of the quality of raw water from the river Krishna, the treatment pro-
cess would require both pre-& post chlorination. The chlorinating plant shall be de-
signed to administer a minimum dose of 6 mg/l for pre-chlorination and 2 mg/1 for
post-chlorination. Agency shall provide at least four chlorinators of design capacity for
pre-chlorination and four chlorinators each of design capacity for post-chlorination.
Two of each unit for pre-and post-chlorination shall be in normal operation and the rest
will act as standby. The chlorinators shall be of vacuum type with differential vacuum
regulator operated by water pressure. They shall be of reputed and approved make hav-
ing proven records of trouble free service for long periods of use. Vacuum Type Floor
Mounted Chlorinators shall be installed in a separate chlorinator room. The capacity of
chlorinators shall be sufficient to suit pre-chlorination of 5 PPM and post chlorination
of 2 PPM. The room shall be reasonably gas tight and shall be provided with a ventila-
tion system delivering to the roof level of the chlorine storage area. A set of continu-
ously running exhaust fans at floor level shall exchange the air three times per hour
with ventilators at 2.0m level. Emergency fans shall exchange it 20 times per hour. The
doors of the room shall open outward.
4 nos. (2W + 2S) vacuum type chlorinators of 40 kg/hr shall be provided for pre-chlo-
rination. Similarly, 4 nos. (2W + 2S) Chlorinators of 20 kg/hr shall also be provided for
post-chlorination. Each Chlorinator shall be provided with a dedicated injector. Chlo-
rinators shall be of Pivot or equivalent make.
An injector module to suit the capacity of the chlorinator shall be provided with each
chlorinator. A spring diaphragm check valves (to close injector suction port when the
injector is not operating) a ball check valve or both shall be incorporated in the injector
to prevent the back flow of water from the injector into the chlorinator. The injector
shall be designed with booster pump system of required capacity.

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All parts of the Chlorinators, the injector and its accessories shall be of suitable material
resistant to the chlorine (silver, silver plated Hastelloy C, PVC, Teflon, Borosilicate
glass, ebonite lined cast iron).
The Chlorinators and their injectors shall be wall mounted with suitable mounting
brackets with anchor bolts. All connections, valves and other parts of the Chlorinators
shall be easily accessible for cleaning, maintenance and repairs. Pipe connections shall
be flexible.
The complete chlorinator and injector units shall be piped and pre-tested as a system
with all necessary valves, inlet connections, gauges and orifice control.
There shall be neither reactor towers nor evaporators. The sets along with booster
pumps shall be provided for Stage I capacity but the space shall be for the Stage II
capacity. The process water for chlorine solution shall be drawn from the pipes coming
from the backwash water reservoir.
The Chlorinators shall be adjustable within a range of 1:10 according to the chlorine
requirements of the raw and treated water. The tolerance of adjustment is not more than
+/-4 %. Pressure gauges, indicating chlorine gas pressure and injector pressure shall be
mounted on the front of the chlorinator and calibrated in metric units.
An injector module to suit the capacity of the chlorinator shall be provided with each
chlorinator. A spring diaphragm check valves (to close injector suction part when the
injector is not operating) a ball check valve or both shall be incorporated in the injector
to prevent the back flow of water from the injector into the chlorinator. The injector
shall be designed according to the available pressure conditions, which are governed
by the available head in the backwash water reservoir at its lowest level. The flow of
the injectors shall be controlled with the help of rotameter. If the pressure is not suffi-
cient a booster pump system with small air vessel shall be provided to increase the
pressure to the required level.
All parts of the Chlorinators, the injector and its accessories shall be of suitable material
resistant to the chlorine (silver, silver plated Hastelloy C, PVC, Teflon, Borosilicate
glass, ebonite lined cast iron).
The Chlorinators and their injectors shall be floor mounted with suitable mounting
brackets with anchor bolts. All connections, valves and other parts of the Chlorinators

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shall be easily accessible for cleaning, maintenance and repairs. Pipe connections shall
be flexible.
The complete chlorinator and injector units shall be piped, and pre-tested as a system
with all necessary valves, inlet connections, gauges and orifice control. There shall be
neither reactor towers nor evaporators. The sets along with booster pumps shall be pro-
vided.
All the eight chlorinators shall be installed in the first floor of the chemical house while
the manifold of chlorine drums shall be located in ground floor of the same house. The
chlorine solution shall be delivered into the collecting well for pre-chlorination and into
the filtered water channel for post-chlorination. The two delivery pipe lines shall be
inter-connected and an arrangement of isolating valves shall be provided to permit the
use of any two of the four chlorinators independently for pre-and /or post chlorination.
Agency shall indicate this arrangement in drawings submitted with their tender. The
chlorine solution delivery pipe shall be of PVC pipe of approved thickness and the
chlorine resisting valves shall be rubber lined diaphragm type.
The pressure water required for the chlorinators shall be fed from the pure water chan-
nel in the filter house. Suitable separate pumping arrangement with necessary pipe line
and valves shall be provided for transporting water to chlorinators at the required pres-
sure. The velocity in the delivery pipe line shall not exceed 1 m per sec. Extra arrange-
ments shall also be made for obtaining the pressure water for operating the chlorinators
from proposed pressure main in the vicinity of the filter house/chemical house. Agency
shall include in their cost all pipes, specials and sluice valves from the pressure main to
the chlorinators. The chlorine dosing shall be instrumentation and SCADA controlled.
Agency shall provide necessary equipment, valves etc. accordingly.
Liquid chlorine shall be drawn from a battery of 1 tonner drums, the withdrawal rate
from each drum not exceeding 6 kg/hr. as per relevant rules & regulation and the chlo-
rine gas shall be delivered to the chlorinators through a gas grid. Liquid chlorine with-
drawal system shall be complete in all respects including connector valves, tubing and
liquid chlorine traps. There shall be two batteries of chlorine drums one for normal use
and the other as standby. An automatic changeover panel shall be provided to enable
the standby battery to come into service when the first one is nearing exhaustion. This

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changeover shall be signaled in the central SCADA control room (C3) and SCADA
control room at WTP by means of an audio-visual alarm.
Agency shall provide a duplicate set of gas grid from the chlorine drum room on the
ground floor to the chlorination room on the first floor of the chemical house. The two
grids shall be interconnected and shall be arranged to permit the use of any one or both.
The grids shall be laid above plinth level and shall be readily accessible for inspection
and servicing. The grids shall be made up from schedule seamless carbon steel pipe of
5 mm thickness and fittings and shall be provided with necessary valves for isolating
and for connecting to the four chlorinators.
Chlorine drum room shall be of adequate area to store 10 (ten) chlorine tonner drums
divided into two batteries. Chlorine drum room and chlorine store room shall be pro-
vided with adequate chlorine neutralization pit with arrangement of neutralization.
This shall be done in conformity with the explosive department's acts and regulations.
The chlorination room and the chlorine drum room shall each be provided with suffi-
cient number of exhaust fans which shall be fixed near floor levels. Each exhaust fan
shall be capable of giving four air changes per hour.
Agency shall also include for the supply of two sets of dry type chlorine gas masks, two
sets of self-contained air filled breathing apparatus type chlorine gas mask with two
protective suits and two chlorine kits as per standard norms. Chlorine leak detectors
with alarm shall be provided in both chlorine drum room and chlorination room. The
leak detector shall be SCADA compatible and shall send signal to the SCADA control
room. Agency shall supply spare parts that may be required (requirement being speci-
fied by the manufacturer) for the maintenance of the chlorinators for two years. They
shall also supply of 30 (thirty) chlorine tonner drums with necessary test certificates
and filling permissions etc. all complete as per statutory requirements. The Agency shall
obtain explosive license from Dept. of explosive, GOI.

5.9.2 Operation of Water and Booster Pumps for the Chlorinators

The water supply shall be made from the internal system. The pressure shall be boosted
by two centrifugal booster pumps to be installed in the Chlorine Building, adjoining to
the chlorination room.

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At least two pumps shall be supplied with isolating valves and the pressure gauges on
delivery and suction line and valves by pass with pressure release valve from delivery
to suction for each pump. The pump shall be connected to the common pipe fed from
the backwash water tank. The pumps shall be identical and suitable for single and par-
allel operation. The pumps shall be directly coupled to drive motor by flexible cou-
plings. The pump and the drive motor shall be mounted on a common base plate of
steel. Foundation or ground bolts shall be supplied for each base plate.
The drive motor shall be of horizontal spindle, totally enclosed fan cooled squirrel cage
motor and shall be manufactured, tested and provided with insulation to class E or bet-
ter. Starting device shall be as per clause 0. The rating of the motor shall be at least 20%
higher than the maximum power required by the pump over its operating range. The
operating voltage of drive motor shall be 415 volts, 3 phases, 50 Hz.

5.9.3 Chlorine and Solution Pipes

The gas and water piping system shall be designed according to the chlorine and injec-
tion water flows and the hydraulic/pressure conditions. The pipes shall be laid as
straight as possible on the shortest route from the drums to the Chlorinators. They shall
be fixed on well supported trays / brackets and adequately sloped to allow for drainage.
All steel supports shall be heavily painted in chlorinated rubber paint.
The connections of the chlorine gas pipes to the cylinders and the Chlorinators shall be
coiled for flexibility during operation and maintenance. Each connection shall have a
valve, a solenoid valve and a pressure gauge. All pipes and valves of the connection
shall be placed out of the reach of gas cylinders hanging on the hook during manipula-
tion. Not more than 4 gas drums shall be connected to a common withdrawal header.
Pipe material for the chlorine dosing plant shall be as given below:
Medium Construction material Test pressure
Chlorine gas Soft seamless copper tube with com- 25 kg/cm²
pressed fittings
Injector water (with Galvanised iron pipes and fittings, 10 kg/cm²
or without boosting) class C
Rigid PVC pipes and fittings, class 3, 10 kg/cm²
Chlorine solution
not exposed to open sunlight

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After installation, the chlorine gas piping system shall be cleaned and dried. After dry-
ing, the system shall be pressurized with dry air up to the test pressure and tested for
leaks by application of soapy water to the outside of all joints and connections. Leaking
joints shall be repaired, and only when all joints are made leak proof chlorine gas shall
be gradually introduced and the system shall again be tested for leaks.
The pipes for water and chlorine solution shall be tested with water with the respective
test pressure.

5.9.4 Neutralization Tank

One neutralization tank of reinforced concrete shall be provided in the maintenance bay.
The capacity shall be adequate to neutralize full two chlorine tonners. The tank shall be
suitably projected above the floor to prevent the entry of floor washings. It shall be
filled with suitable neutralizing agent such as caustic soda (NaOH). The opening of the
tank shall permit to place the chlorine tonner into it in any position. It’s top shall be
covered with some thin plywood type cover which can be broken up easily in the emer-
gency by the tonner itself. The tank shall be lined from inside with suitable material so
that the chemicals may not have any aggressive effect. The position of the tank shall be
such that the tonner can be dumped into the tank easily by using the OHT crane for
lifting the damaged tonner.
Alternatively, chlorine scrubber with suitably placed exhaust fan and piping can also be
provided with flow of water and caustic soda solution from the top of scrubber. The
capacity of exhaust fan shall be suitable for exhaust of full tonner chlorine in gaseous
form with chlorine air ratio of 1:3.

5.9.5 Chlorine Leakage Control System & Security Equipment

For the detection of excess concentrations of chlorine in the air of the chlorinator room
and the chlorine storage area leak detection devices are to be provided at suitable sites.
Two levels of detection are envisaged:
Level of detection of chlorine leakage shall be as given below:
Installation site &
Detection level Action
number

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Chlorine concentration at or be- Indicator lamp, acoustic

low the level of human percep- alarm at the chlorine plant 1 for drum storage
tion: and at the main control area
Concentration level 1mg/l, ad- room; automatic start of 2 for chlorinator room
justable between 1 and 5 mg/l emergency exhaust fans
Indicator lamp, acoustic
Abnormally high concentra- alarm at chlorine plant and
tions which could occur on at main control room; auto-
2 for drum storage
leakage or failure of the chlo- matic opening of valve of
area
rinating equipment: Concentra- sprinkler system; closing of
tion level 5 mg/l chlorine valves, closing of
injector water valve

The Agency shall provide following safety equipment in the works, as a minimum:

a) canister type respirators with full face coverage masks suitable for chlorine gaseous
atmosphere - min. 2 no.

b) spare canisters for the respirators - min. 2 no.

c) self-contained compressed air breathing apparatus complete with working whistle

and two spare air cylinders - min. 2 no.

d) a facility to recharge the compressed air cylinder or from a self-contained machine.

e) protective clothing such as PVC overall and gloves and rubber boots shall be
provided - min 2 sets.

This equipment shall be stored in glass fronted non-locking steel cabinets so that any
deficiency in the equipment shall be apparent. 15 m hoses DN 1" with jet and spray
nozzle and valve are provided near the chlorine drum storage area in non-locking steel
cabinets. They are connected to the process water system. The cabinets shall be located
at strategic places in the chemical house and near the storage area with view to easy and
safe accessibility in case of chlorine leakage.

The Agency shall provide visual and audible alarm system. Flashing warning lights
shall be provided over each door of the chlorination room store and near the chlorine
drum storage area. The lights shall be RED in color and shall be clearly visible at a

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distance of 20 m under normal daylight conditions. They shall be activated automati-

cally from the leak detection devices. Behind the lights a rear engraved perplex label
having red letters on a white back ground shall be mounted at each door and at visible
place. The lettering shall be a minimum of 50 mm high and one legend shall read in
English and the other in Telugu language.

5.9.6 Wear Breathing Apparatus Before Entering When Light Is Flashing

One emergency drum leakage repair kit shall be provided in the workshop or in the
chlorinator room.
Number & Location of Security Devices
Warn
Equipment Respi- Spare Breathing Protect. light
Hose
Location rators canister device Clothing with
hooter
Chlorination room 2 3 2 2 1
Chlorine drum
2 1
storage area
Chemical plant 3 2 5 1 1
Total 2 6 4 5 5 3

5.9.7 Operation and Control of The Chlorine Dosing Plant

A dedicated control panel shall be provided in the chlorination control room.
The operation of the chlorination plant is as follows:

Operation Pre-chlorination Post-chlorination

Automatic with manual over-

Automatic with manual override, ac-
ride, according to flow measur-
cording to flow measuring channel
regulation of the ing channel and instructions
and instructions passed from the con-
chlorine rate passed from the control room
trol room through PLC on the basis
through PLC on the basis of
of Raw Water quality
Raw Water quality
regulation of the Automatic, Automatic,
process water
Manual Manual
stop of chlorine Automatic when raw water flow is Automatic when raw water
gas flow zero flow is zero
Automatic when injector stops Automatic when injector stops

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Automatic when chlorine pressure Automatic when chlorine pres-

low (gas drums empty) sure low (gas drums empty)
Manual; automatic when chlorine Manual; automatic when chlo-
stop of injector
pressure low (gas drums empty) or in rine pressure low (gas drums
water
case of leaks empty) or in case of leaks
stop of chlorine Manual; automatic in case of
Manual; automatic in case of leaks;
flow at the chlo- leaks; automatic in case of stop
automatic in case of stop of injector
rine drums of injector
Automatic in case of leakage in
Automatic in case of leakage in the
the chlorinator room or in the
chlorinator room or in the chlorine
acoustic alarm chlorine
storage area; low chlorine level/ high
storage area; low chlorine
chlorine level
level/ high chlorine level
Continuous fans Manual; running continuously linked Manual; running continuously
in chlorinator to the emergency power supply sys- linked to the emergency power
room tem supply system
Automatic in case of leakage in
start of emer- Automatic in case of leakage in the
the chlorinator room; low chlo-
gency exhaust chlorinator room; low chlorine level
rine level
fans in chlorina- linked to the emergency power sup-
linked to the emergency power
tor room ply system
supply system
Automatic in case of leakage in the Automatic in case of leakage in
sprinkler system
chlorine storage area; high chlorine the chlorine storage area; high
storage area
level chlorine level
Automatic when raw water
Start chlorination Automatic when raw water flow start
flow start

* time to drain the filter after stop of supply.

** time required to build up full flow from filters

5.9.8 Civil Works

Civil works for chlorine drum rooms shall be as described above for the Chemical
House.
The laboratory shall be fully air conditioned without possibilities of opening of win-
dows. The access to the laboratory shall be from inside the building
A separate chlorine storage room with cradles having capacity for storage of 16 (six-
teen) chlorine tonner drums with adequate ventilation, neutralization pits and handling

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equipment like HOT crane etc. shall be provided outside the chemical house in con-
formity with the provision of Explosive Department.
The chlorination chamber shall be a reinforced concrete structure. It shall be fed from
the backwash reservoir/filtered water channel. The chlorine solution shall be injected
by bottom mounted diffuser disks. The diffuser system and baffle walls installed in the
chamber shall be designed to guide the incoming water and to ensure a complete diffu-
sion of the chlorine solution before it leaves the chamber. The outlet of chlorine solution
shall be at a depth of 2 m or more. The chlorine solution-feeding unit must be detachable
for easy maintenance. There shall be no smell of chlorine at a distance of 10 m from
the chamber. The minimum freeboard shall be 30 cm, but the walls shall be extended
up to a height so that its top is 60 cm above the general ground level there.
All inner surfaces of the chamber shall be coated with white or light blue glazed tiles
(lead free) laid in suitable cement mortar, resistive to the aggressive water. The project
logo/water works logo shall be provided on the bottom of the chamber using colored
tiles. A tight window with a tight shutter shall allow for the inspection. The chamber
shall be equipped with an underwater floodlight to be operated with a switch near the
window.
The outlet to the CWR is a wall duct with a flange (puddle collar) for the connection
through pipe / channel to the CWR. The chamber shall have a stainless-steel cover, a
stainless-steel ladder inside for the access and at least two stainless steel ventilation
pipes DN 150 with cowls and wire mesh.

5.10 Alum / Primary Coagulant Solution Dosing

The alum / Primary coagulant dosing shall be made by dosing metering pumps. The
solution tanks and dosing devices shall be installed at a level to be in a position to feed
into the inlet chamber. This must be also possible in the case of repair of the dosing
pipe for lime solution when both diameters are conveyed in one pipe. The diameter of
the pipes in the chemical plant and to the injection points shall be a reasonable compro-
mise between a sufficiently wide diameter to prevent clogging and a satisfactory high
flow velocity to prevent deposits.

5.11 Pipes and Valves in the Dosing Plant

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The pipes, fittings and valves shall be such that any of the alum / Primary coagulant
tanks can be used individually with any of the metering devices. The tanks shall be
filled from the process water pipe system. Each tank shall have an outlet with strainer
to the dosing unit, an outlet for complete drainage and an overflow. The service outlet
shall be at least 20 cm above the bottom level of the tank. The entire piping and the
fittings shall be in PVC/HDPE pipe 10 kg/cm2 rating of suitable diameter. All valves
for solution delivery up to the injection point and for waste water from the tank shall
be rubber lined diaphragm valves.
The solution pipe between the solution tank and the dosing device as well as the pipe
from the dosing device to the injection point shall be of PVC/HDPE pipe 10 kg/cm2
rating. They shall be connected to the process water circuit so that a rinsing of the pipes
between the solution tank and the dosing unit and downstream the dosing unit is possi-
ble after each stop of the plant. The valves in the solution pipes shall be installed ac-
cordingly.
The overflow and washout pipe shall be connected to the drainage system leading to
the recycling tanks.

5.12 Solution Pipes to the Injection Point

The solution pipes to the injection point in the inlet chamber shall be of PVC/HDPE
pipe 10 kg/cm2 rating. They shall be laid on pipe racks or trays to be fixed to walls of
tanks and buildings or in covered pipe channels so that they are always accessible. They
shall not be exposed to direct sunlight. The chemical pipes shall be fixed and jointed in
such way that individual runs can be changed without dismantling adjacent pipes. No
individual pipe run shall be longer than 5 m. A bypass with valves shall be provided
between the pipes for lime and alum solution so that the two diameters can be carried
by one pipeline in case of repair or maintenance of the other line. The pipe diameters
must correspond to the hydraulic conditions between the chemical house and the injec-
tion point.
In case of more than 30m between the dosing device and the injection point, duplicate
dosing lines shall be provided. In this case, no bypass shall be provided between the
pipes for alum and lime solution.

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There shall be washouts at suitable points of the chemical pipelines at distances not
exceeding 30 m. The pipes shall be clearly identified throughout the whole run as chem-
ical pipe for alum by means of plates every 20 m and by the color code which is used
on the display screen.

5.13 Alum / Primary Coagulant Solution Feeder

There shall be at least 4 (2 working + 2 standby) dosing metering pumps for the alum
solution. They shall be connected to both the tanks such that they can be operated indi-
vidually from each tank. They shall feed into the dosing line leading to the injection
point. The control of the flow (outlet) shall be regulated automatically through modu-
lation of stroke length on the basis of inflow rate and quality of raw water. It shall be
possible to modulate the dose manually as well. The outlet to the dosing line shall be
controlled by a solenoid valve. The inlet and the constant level shall be controlled by a
float valve.
The dosing devices and their components shall be fabricated of non-corrosive materials
(stainless steel, mild steel with rubber or ebonite coating, fibre glass, HDPE).

5.14 Operation & Control of Alum/ Primary Coagulant Dosing Unit

The operation of the alum/ Primary coagulant dosing unit shall be made from a wall
mounted control panel installed in the Chemical room.
Operation Activity

Filling of solution tanks water: automatic and float controlled alum bricks:
with electric hoist
Stirrers of the solution tanks Manual
Automatic at intervals according to timer settings
Manual
Outlet of the dosing device
Automatic when raw water pumps stop and start
Flushing of the dosing pipes af- Automatic
ter the stop of the dosing unit
Handling of chemicals with the Control unit suspended from the hoist; to be oper-
hoist ated from the dosing room

5.14.1 Lime solution dosing

Lime solution dosing facilities shall be provided in the chemical plant at the upper floor
opposite to the alum dosing units. The different components are similar to those of the
alum dosing plant.

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5.14.2 Tanks and agitators

The lime solution tanks shall be similar to those for alum solution but the tanks shall
not be lined. The stirrers and the pipes and valves are similar to those of the alum solu-
tion tanks except the paddles, which shall be of MS.

5.14.3 Pipes and valves

The pipes, fittings and valves shall be similar to those used for alum. The indication
and the colour code shall be different for lime.

5.14.4 Dosing device

Suitable dosing - metering device shall be provided.

5.14.5 Handling of the lime bags

The handling system to bring the lime bags from the ground floor to the troughs in the
solution tanks shall be the same as that for the alum bricks. Preferably one hole shall be
used and the monorail shall be provided with bends.

5.14.6 Operation and control

The operation shall be similar to the operation of the alum dosing device.

5.15 Weigh Bridges

A 30 MT electronic weigh bridge (SCADA compatible) with following features shall
be provided in the chlorination room:
 Heavy load cells for long life and reliable operation.
 Rugged construction to withstand hostile conditions such as high ambient
 chlorine gas.
 Robust and Sturdy Platform.
 Bright and large LED display.
 Minimal levers and knife edges to avoid frequent maintenance
 Computerised model for effective truck management and report generation.
 on a printer.
 RS 232 port for communication
 Weighing capacity minimum 15 tons

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Local digital indicator for controlling the changing/ replacement of tonners connected
to the chlorine dosing manifold shall be provided. The latter shall be calibrated in a
manner to indicate the net weight of the chlorine gas, without the weight of the drums
and the other dead weight.
A sprinkler system shall be installed above the whole storage area. It shall cover the
storage area and 1 m beyond. It shall be directly connected to the main supply pipe from
the backwash water reservoir. The sprinkler system shall have a motor driven valve,
which shall automatically open in case of chlorine leakage above a set limit. This valve
shall be installed at a place where it can be operated also manually in case of emergency.
Open drainage channels in the floor of the storage area shall be connected to the drain-
age system.

5.16 Laboratory and Sampling System

There shall be one Laboratory for the treatment plant suitably equipped for carrying out
physical, chemical and bacteriological tests. As already stated the laboratory shall be
located in the first floor of the chemical house. The layout and dimensions of the labor-
atory room shall be according to International Standards. Tenderers shall supply all the
furniture accordingly and all the equipment as listed hereinunder. A 2000 litre capacity
R.C.C./brick overhead water tank for water supply to the laboratory are to be provided.
The laboratory shall have a size of not less than 15 sq.m. It shall have the equipment,
storage space and chemicals for all the chemical and bacteriological routine analysis.
The laboratory shall have three metre of working platforms with minimum three sinks.
The sampling pipes shall end at one of the sinks. The taps shall be clearly labeled with
the type & provenience of the water. At least the following equipment and all required
laboratory chemicals / reagents except alum and chlorine are to be provided by the
Agency within the scope of work and shall be replenished by him till the end of the O
& M period.
The quality of the water entering, passing and leaving the treatment plant shall be mon-
itored via HDPE sampling pipes DN 25 from the following points leading to the labor-
atory:
 raw water pipe at the inlet chamber (raw water)
 end of the filtered water channel

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 outlet of the chlorination chamber (treated water)

The sampling pipes shall lead from the sampling point to small sampling pumps in-
stalled at a low area of the pipe gallery of the filters. From there, pressure pipes shall
lead to the laboratory to the outlet points.
A separate pipeline shall be provided from the measuring flume for continuous moni-
toring of turbidity and adjustment of chemical dosing through the online turbidity me-
ter.
A portable direct reading turbidity meter shall be provided for the measuring of the
turbidity at the individual measuring points.
The provision shall be kept for two nos. (one working + one standby) online continuous
turbidity meters with displays in the central control room and the laboratory of this 190
MLD WTP. Adequate digital/analogue signal shall be provided by these turbidity me-
ters so as to control the dosing of alum / lime and poly-electrolytes

5.16.1 Sampling Table

Agency shall provide and install one sampling table with a granite top. The sampling
table shall be provided with three clarity bowls to indicate the clarity of raw water,
clarified water and filtered water; a stainless-steel sink; and three faucets with swan
necks to give independently samples of raw water, clarified water and final filtered and
chlorinated water. Individual supply line of the sampling table shall be marked distinc-
tively as raw, clarified and filtered water. Independent electrically operated pumps shall
be provided for collection of samples of raw and clarified water and the third faucet for
the filtered and chlorinated water shall be connected to the proposed pressure main. In
addition, three similar clarity bowls shall also be provided in the entrance hall of the
annexe building at a prominent place and shall have decorative finish.

5.16.2 Laboratory Equipment

All the laboratory equipment shall be of reputed and approved make. Agency shall sub-
mit with their offer detailed specifications and catalogues of the equipment they have
proposed to supply. All the equipment are to be installed in position and commissioned
including supply of all accessories, stands, tables etc. The quoted rate shall be inclusive

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of all such installations, supply of all accessories, stands, tables with complete air con-
ditioning arrangements where necessary, excluding laboratory glass apparatus and
chemical reagents.
i. One set of Electrical Mono-Pan balance of 100 g. capacity having sensitivity of
1/100 mg. complete with weight box and digital display.
ii. One Distilling Apparatus, electrically heated, with low water cut off and
automatic shut off, 1.0 gph. complete.
iii. One Muffle furnace made of high sillimanite Muffle and sillimanite Bricks. The
outer body is made of heavy gauge mild steel sheet finished in heat proof and rust
proof silver ash hammer stone painting fitted with swing type hinged door with

peep holes, temperature up to 12000C provided with excess temperature

protection and accessories for direct connection to laboratory AC main 220/230
volt, single phase, 50 cycles. Size of the Muffle Chamber 6" x 6" x 12" (150 mm
x 150 mm x 300 mm) or close to this size.
iv. One pH Meter of digital display type with a range 0 to 14 in 0.01 PH subdivisions.
It shall be compact direct reading type with a built-in voltage stabilizer, a
temperature compensator and an anti-parallax mirror. Electrode assemblies shall
comprise a glass electrode, calomel reference electrode and a resistance
thermometer for temperature compensation housed in an immersion type housing.
Operation shall preferably be push button type and the instrument shall be suitable
for operating in a temperature range of 0 to 660C - complete.
v. Two Jar Test Apparatus. Each shall be provided with six transparent glass jars,
each containing a paddle mixer hanging from a long horizontal shaft through a
level gear. The horizontal shaft shall be run by a variable speed motor with the
provision of measuring rpm. of paddle mixer R.P.M. of paddle shall be in the
range of 0-150 rpm. - complete.
vi. Two Hot Plates, operating on 230W, single phase, 50 cycles, AC, capable of
adjusting at different range of 750, 1000 and 1200 watt beating elements -
complete.
vii. One Magnetic Stirrer - Complete.
viii. One Dissolved Oxygen Meter - Complete with necessary electrodes.
ix. One frost free Refrigerators, 165 litres (approx) - capacity.

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x. Twelve Crucible, Gooch, F 30 ml.

xi. One Water Bath with 8 nos. of hole, electrically operated SS made - complete.
xii. One thermometer general lab engraved stem - 100 to 2600c subdivision.
xiii. One Thermometer, precision - 10 to 1010 C, 1/100 subdivision.
xiv. One Interval Timer, Spring wound.
xv. One stop watch.
xvi. One Chloroscope for measurement of residual chlorine with necessary reagents -
complete.
xvii. One electronic turbidity meter (nephelometric method) capable of measuring
turbidity in the range of 0-2000 NTU - complete.
xviii. One spectrophotometer, specifications as per instruction of the Engineer-in-
Charge along with all necessary testing kit as directed by the Engineer-in-Charge.
xix. All necessary furniture (eg. tables, drawers, sinks, tools etc.) and plumbing (eg.
wash basins, water connections at different points etc.) as required in a standard
laboratory.
Apart from the above instruments, the agency shall provide laboratory instruments as
per the list given below. The total number shall not exceed the number given in the
table.

Lab Equipment/ Instruments

1 pH Meter (Portable) (Digital, Range 0-14pH) Nos 2
2 Continuous Nephew Turbidity Meter (Range: 0-2000 NTU) Nos 2
3 Portable Nephew Turbidity Meter (Range: 0-4000 NTU) Nos 1
4 Dissolved Oxygen meter (Range: 0 - 20 mg/l) Nos 2
Chlorine compactor with accessories- (0.1 to 2.0 PPm/6-8 to
5 Set 1
8.4 p)
6 Conductivity Meter(Portable) (1Khz/50Hz) Nos 2
7 Jar Test Apparatus Set 2
8 Colony counter Nos 2
9 Binocular Microscope Nos 1
10 Water Still (Distilled water plant - Cap. 4lits/Hr)-1.5Kw Nos 1
11 Water Bath (serological-45x45x45 cm)- 1.5Kw Nos 1
12 Laboratory Electric Oven (45x45x45 cm) Nos 2
13 Autoclave Vertical-(300x500 mm) Nos 1
14 Incubator Bacteriological Test Nos 1
15 B.O.D. INCUBATOR - (87x57x55 cm) Nos 1
16 Magnetic Stirrer with Hot Plate- 2Lit cap. Set 1

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17 Analytical Balance - (200 gm capacity) Nos 1

18 Precision Balance - (60 to 360 gm capacity) Nos 1
Electrically Operated Vacuum Pump (single stage with suction
19 Nos 1
flask 1 lit. capacity)
20 Membrane Filtration Assembly Set 1
21 Frost free Refrigerators, 165 litres (approx) Nos 1
Thermometer general lab engraved stem - 10 to 260 deg C
22 Nos 1
subdivision
23 Thermometer, precision - 10 to 1010 C, 1/100 subdivision Nos 1
24 Interval Timer, Spring wound Nos 1
25 Stop watch Nos 1
Chloroscope for measurement of residual chlorine with neces-
26 Nos 1
sary reagents
27 Spectrophotometer Nos 1
28 Crucible, Gooch, F 30 ml. Nos 12
Muffle furnace made of high sillimanite Muffle and sillima-
29 Nos 1
nite Bricks
30 Wire Basket Nos 6

5.16.3 Specifications for Laboratory Equipment

Analytical Instruments
a) pH Meter (Digital)
pH range 0-14 pH
Milli volt range 0 to + 1999 mV.
Accuracy 0.01 pH + 1 digit
Reproducibility 0.01 pH
Temperature compensation 0 to 1000c manual or automatic
Power supply 230 V + 10% 50 HZ
Accessories 2 No. of combined electrodes, electrode stand.

b) Continuous Nephelo turbidity meter

The on-line monitoring system shall be designed for the continuous measurement of
Turbidity in water.
The full-scale operating range of the system may be selected by the user from 0- 4.000
to 0-4,000 NTU or from 0-10.00 to 0-10,000 PPM (mg/l) of SiO2, and the sensing
system shall be capable to operate on water streams with temperature from 0 to 50 °C.

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The measured Turbidity shall be displayed on a backlit liquid crystal display on the
front of the instrument. The Turbidity monitor shall be suitable for water treatment
plants.
The measuring method Shall be Nephelometric.
A light source and a photocell shall be positioned with their optical axes 90° from each
other. The emitted light is scattered by particles in the process and received by the pho-
tocell, in accordance to standard ISO 7027.
The assembly automatically shall deliver high pressure air to the tip of the sensor to
effectively blast accumulated growth from the optical lens.
The Turbidity monitor shall be supplied with the cleaner with arrangement to provide
the pressure air to the sensor.
Submersible sensors shall be designed for direct immersion in the tank or flowing
stream.
A Suitable length cable shall be potted into the top section of the sensor assembly, and
connect directly to the Turbidity monitor.
A separate tubing connection located at the top of the sensor assembly shall be provided
for connection of a 10 mt length of plastic tubing between the sensor and the monitor.
The Turbidity sensor assembling shall be mounted to a 1" pipe using a special mounting
adapter.
The 1" pipe shall be provided with a bracket assembly to attach it to the tank handrail
that holds the sensor at a slight angle in the tank.
Once installed and placed into operation, the Autoclean Turbidity sensor shall provide
months of reliable Turbidity measurement in almost any application.
The sensor cleaning frequency shall be user programmable, and units shall be supplied
with a default cleaning frequency of once every 24 hours.
The sensor shall have facility to increase this frequency if needed for a specific appli-
cation.
The installation of the Auto-Clean Turbidity system shall be quick and simple.
It shall be designed to operate with either a retro-scatter (180°) probe or an 90° probe.
The turbidity meter shall allow the user to set up measurement parameters through a
user-friendly menu system displayed on the in-built 2 line alphanumeric display.

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Measurements can be read directly from the display at any time or downloaded to a
computer/printer through the optional RS232 output at user selectable periodic inter-
vals.
The necessary power up arrangement shall be provided to automatically power up tur-
bidity meter to its last settings whenever external power is available.
Specifications
Range 0.0 to 20,000NTU
2 line, 16-character dot matrix alphanumeric liquid
Display
crystal display.
Display language English standard
Turbidity (NTU) – default
Relative Turbidity Reference (NTU)
Parameters displayed
Relative Turbidity (Turbidity - Relative Turbidity
Reference NTU)
Date/Time default
Reading updated every 1 second
Averaging period 0.5 second or 10 seconds nominal - user selectable
1 <0.1 to 20NTU
2 <1 to 200NTU
Range Steps
3 <10 to 2,000NTU
4 <100 to 20,000NTU
1 0.02NTU
2 0.1NTU
Resolution
3 1NTU
4 10NTU
Repeatability 2% ± digit on all ranges
User set for one reading every 1 to 90 seconds or
Data Logging
minutes. All readings stored in the Notepad.
Notepad 100 readings each with time and date
Menu driven, including
- Calibration
- Automatic Logging
Setup procedures
- Analogue output range selection
- Reference Turbidity value
- Setting date and time.
Setup memory Non-volatile EEPROM
Calendar clock displays date and time. Year 2000
Clock
compliant.
0 - 2 volts full scale corresponding to preset measure-
Analogue Output
ment range. Output impedance 600 ohms nominal.
All readings as well as calibration constants are
Good Laboratory
stored together with the Time and Date and can be
Practice
recalled at and time
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Power:
Internal 6V NiMH rechargeable battery
External 230V AC, 50 Hz Supply (with Adapter if necessary)
Automatic power down when operating from batter-
ies after approx. 5 minutes may be selected. Auto-
Power management
matic power up when powered externally. Low bat-
tery indication prior to shut down.
Inbuilt LCD, analogue output and optional RS232
Measurement outputs
port
The RS232 port can output readings on request or at
preset intervals of time from 1 to 90 seconds or
RS232 Port minutes. The Notepad memory can also be down-
loaded on request. 9600 baud rate, 8 bits, no parity, 1
stop bit, Xon/Xoff protocol
Operating tempera-
0 to 50°C
ture
Operating humidity 0 to 90% RH
Storage temperature -10 to 60°C
Case rating IP65
c) Portable Nephelo turbidity meter
The instrument shall be based on the principle of Tyndall effect. The meter shall be direct read-
ing instrument between 0-5000 Turbidity in 4 ranges for accuracy.
1) 0 - 1 NTU
2) 0 - 10 NTU
Range 3) 0 - 100 NTU
4) 0 - 1000 NTU
5) 0 - 5000 NTU
Display 4 - digit Digital display
Within + 2% of FSD in 0-1 & 0 - 1000 NTU
Accuracy & reproducibil-
(up to 500 NTU) range, + 1 % of FSD in 0-10
ity
and 0-100 NTU ranges.
Detector Visible range photo cell
Power Supply 230 V AC + 10%, 50 Hz.
a) Flat Bottom test tubes -25 mm dia - 4
Nos.
Accessories
b) Cell riser
c) Height shield
d) Dissolved Oxygen Meter

The instrument shall be capable of DO and temperature measurement in raw and treated
water.
Range : 0-20 mg/l

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Temperature : 0-60o C
Resolution : DO - 0.1 ppm
Temp : 0.10C
Accuracy : DO - +/- 0.2 ppm
Temp : +/- 0.20C
Temperature compensation: 0 to 500C
Sensor : DO - Amperometric (gold/silver)
Temp : RTD (PT –100)
Power : 220 V +/- 10 %, 50 Hz AC
Dimensions : 76 x 275 x 175 mm
Accessories : Operation Manual, Dust cover, stirrer etc.

e) Chlorine Comparator

Specifications:
Comparator shall have capacity to measure the residual chlorine from 0.1 to 2.0 PPM.
& pH from 6-8 to 8.4 (Phenol red indicator disc) by movable disc arrangement.
Accessories:
Orthtolidine solution, test tubes, brush & cover etc. & separate movable discs, stand-
ardized for measuring Residual chlorine & pH by orthotolidine method and phenol red
indicator method, respectively, shall be supplied with the Comparator.

f) Conductivity meter

Shall be a handy instrument for measuring conductivity of various solvents coupled to

an amplifier –null detector with a meter used for balancing the bridge circuit.
Specifications
Bridge source : 1 kHz / 50 Hz
Null detection : meter pointer
Conductivity Range : 1 Micro-mhos to 106 Micro mhos 6 ranges.
Accuracy : + 2%
Accessories : unbreakable PVC cell and stand with clamp
Conductivity cell : Approx. 1 cell constant
Power requirement : 230 v, 50 Hz or Battery
Jar test apparatus

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Jar testing machine with electrically operated 6 stainless steel paddles, equipped with
suitable motor to give rotation from 10 to 100 rpm in all peddles. it shall be provided
with gear system of rotation and a speedometer to not the speed. The equipment shall
hold 6 glass beakers of 1 litre capacity each at a time. The arrangement of peddles shall
be such that they can be lifted to remove the beakers without disturbing the test liquid.
Colony counter
Colony counter with digital display electrically operated suitable for bacterial plate
count complete with counting plates and lens etc.
Binocular Microscope
Binocular Research Microscope with built in illumination with variable transformer.
Two pair eye pieces 5x10 and four objectives 5x, 10x, 45x and 100x, oil (springs).
Heating Appliances
Water Still (Distilled Water Plant)
Electrically heated with boiling chamber, lid and cooling jacket, made of stainless steel,
provided with two automatic ejection type heaters, constant water level device, stout
wall hanging brackets, complete with plug, cord & adapter.
Power : 220 - 230 V AC
Capacity : Approx. 4.0 litres per hour
Rating of elements : 1.5 kW each
Water bath (Serologcal)
Rectangular water bath, shall be completely made of copper, heavily tinned inside and
outside finished in enamel.
The cover shall be chrome plated & shall have 12 holes of 7.5 cm Dia. concentric rings
(3 sizes of each hole) with lid. The water bath shall have built in constant level arrange-
ment and fitted with Swan type ejection electric heaters.
Dimensions 40 cm x 30 cm x 9 cm
Rating 1.5 kW
Power 230 Volt A C
2-Meter-long cord with 3 pin and adopter
Accessories
for power
Electric Oven
Shall be doubled walled with inner chamber of Aluminium sheets and outer body made
of MS sheets. The gap shall be filled with good quality glasswool for proper insulation.
space for inserting thermometer control system of the accuracy of +/-10C.
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Temperature range room temperature to 2500C+/-10C

Power 220-250 V AC
Chamber size 45x45x45 cm

Autoclave

Autoclave shall be vertical type, sturdy double walled construction with boiler made of
stainless steel 18SWG. Sheet & easy to operate. Outer shell shall be made of mild steel
finished with enamel point. The boiler & outer shall shall have air insulation. Lid shall
be made of stainless steel plate and tightened all-round by wing nuts. Moulded, Jointless
gaskets shall be made of Neoprene rubber. It shall be fitted with water level arrange-
ments to indicate water position inside the boiler, pressure gauge, Air /Steam release
cock, spring loaded safety valve which can be set at any selected point from 10 psi to
25 PSI +/-3 PSI and drain. ISI marked immersion type heating element heats the water
steam to desired temperature & pressure, supplied complete with SS basket, cord &
plug to work in 220 volts 50 cycles AC supply.
chamber size (Dia x depth) 300 x 500 mm
Load 2 kW
Incubator 2 Nos. (For Bacteriological Tests)
Incubator made of Aluminium sheet, inner door of glass with 3 adjustable shelves with
temperature control system with accuracy of +/- 0.50C. Double wall shall have proper
glass wool insulation system. Thermostatically controlled.
size(WxDxH) 61x45x45 cm
operating temperature. 50C above ambient to 600C
Power 220-250 V AC
BOD Incubator
Suitable to work at 230 V with automatic control heating or cooling circuits according
to environmental temperature, made of mild steel wall with enamel paint, inside cham-
ber shall be anodized, adjustable shelves made of Aluminium and full inner view glass
doors. Chamber capacity shall be 245 litres. Temperature control device German ther-
mostat.
Chamber size 87x57x55 cm
Temperature range 5 to 500C
Operating Sensitivity +/-0.50C
Forced air circulation to maintain uniform temperature with dial thermometer.
Magnetic Stirrer with Hot Plate

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Magnetic stirrer with hot plate of 2-liter capacity with separate stirring & temperature
control regulator for setting stirring rate & temperature complete with plug, 2-meter-
long cord. Adapter and Teflon paddle 1" long (Rotor 3 No) cap. 2 liters, max. speed
1200 rpm.
General
Analytical Balance

Analytical Balance complete with case, weight box, and beam of gun metal. Flat beam
sprayed with colorless cellulose lacquer, edges are of best selected agates ground to
optical precision case finely polished with two side doors and counterpoised front slide.
Case made of teak wood having sunmica base.
Capacity 200 gm
Sensitivity 1/10 mg
Diameter of pan 3 inches slightly concave Nickel Chromium plated
Length of Beam 5 inches
Watch Glasses 2 Nos. light wt. to be provided on each of the pan
Graduation Graduated into 100 divisions with 0 in centre
Electronic Balance

Readability 1 mg/10 mg
Weighing capacity 60 gm/310 gm
Repeatability(s) 0.2 mg/0.5 mg
Linearity +/-2 mg/+/-10 mg.
Stabilisation time 5 secs
Power supply 230 V AC +/- 10%, 50 Hz
Facility of piece counting, % weighing, display various weighing units, provision for
attachment of printer.

Vacuum Pump Single Stage (With Suction Flask/Litre Capacity).

Electrically operated shall be compact and smooth in operation with effective cooling,
high water vapour tolerance and guaranteed ultimate vacuum.
Air Displacement 150 litre per minute
Ultimate vacuum 10 microns Mcleod
HP of motor 0.5 or 1/3
Pump speed 375 rpm approx.
Power supply 220/230 Volt AC

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Refrigerator
Minimum 300 litres capacity, of reputed make.
Notes: All the aforesaid instrument shall be supplied along with operation and circuit
diagram manual, dust cover, 2 m long cord and plug & related accessories required for
the satisfactory working of the instruments.

Miscellaneous

Nuts, Bolts, Studs and Washers

Nuts and bolts shall be of the best quality bright steel, machined on the shank and under
the head and nut. Studs, bolts and nuts shall be electro-galvanized. Bolts shall be of
accurate length so that only one thread shall show through the nut in the fully tightened
conditions. Nuts and bolts shall conform to IS:1363 and IS:1367.
Washers, locking devices and anti-vibration arrangements shall be provided where nec-
essary.
Where there is a risk of corrosion, bolts, nuts and studs shall be designed so that the
maximum stress does not exceed half the yield stress of the material under any condi-
tions. All bolts, nuts and screws which are subject to frequent adjustment or removal in
the course of maintenance and repair shall be made of nickel bearing stainless steel.
The Agency shall supply all holding down, alignment levelling bolts complete with
anchorages, nuts, washers and packing required to fix the plant to its foundations, bed
plates, frames and other structural parts.
The Agency shall procure and keep at site, reasonable excess quantities to cover wast-
age of those materials, which shall be normally subject to waste during erection, com-
missioning and setting to work.

Laboratory glass apparatus and chemical reagents shall be separately collected by the
purpose and supply of them does not come under the scope of this tender. Approxi-
mately 40% of the carpet area of the laboratory are to be covered by tables, fitted with
necessary drawers and sinks. The height and top width of the tables shall be 900 mm.
and 750 mm. respectively. All the furniture shall have a decorative finish. The furniture
shall be of best quality teak wood/NUWUD of approved quality and the top of the tables

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shall be acid/alkali & heat resistant and the drawer units shall be provided with SUN-
MICA DECOLAM or equivalent make laminate sheets. The laboratory sinks shall be
of best quality porcelain make.

5.16.4 Tool Box and Tools

Tenderers shall supply three tool boxes (overall dimensions 1200 mm x 900 mm x 750
mm) made of best quality wood/NUWUD and polished or painted as per direction of
the Engineer-in-Charge. The box shall be compartmentalized inside suitable to hold
different types of tools separately. The edges of the box shall be protected by aluminum
angles and the box shall be fitted with lock and key arrangement. Tenderers shall supply
all the tools listed in O&M section.
In addition, Tenderers shall quote separately on their own letter heads for supply of one
set special tools and tackles that they feel shall be necessary for maintenance, overhaul
or replacement of the electrical and mechanical equipment under this contract. The quo-
tation shall be attached with the Schedule of Prices.

5.17 Color Code for Pipes

All visible pipes in the different units of the plant shall be painted according to a distinct
color code. This color code shall also be used for the presentation of the pipes on the
mimic panel.
Raw water dark green
settled/filtered water light green
treated potable water light blue
backwash water Blue
air yellow
sludge, sludge water Brown
Chlorine solution Red
Alum, lime pink

5.18 SLUDGE TREATMENT

A wastewater recovery system shall be provided to handle sludge from the clarifiers.
The sludge handling system shall be designed considering 100 mg/l TSS in raw water
at plant Design Net Output capacity. However, design of centrifuge decanter dewatering

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machine (including feed pumps and poly dosing system) shall be based on 50 mg/l TSS
in the raw water. The calculations of the total sludge production for the design of sludge
treatment system shall also include the sludge produced by the coagulant at design raw
water TSS and by plant waste water recycled back to the clarifiers.
The sludge treatment process shall comprise:
 clarifier sludge sump;
 thickener feed pumps
 polyelectrolyte dosing;
 continuous thickening;
 thickened sludge pump and sump;
 centrifuge feed pumps;
 polyelectrolyte addition;
 sludge dewatering in centrifuges;
 centrate
 Sludge drying
The sludge from the clarifiers shall drain into the Clarifier sludge sump. From the
sludge sump, the sludge shall be pumped to the sludge thickeners, with in-line dosing
of a solution of thickener polyelectrolyte to assist the thickening process.
The thickener polyelectrolyte dosing pumps shall be linked to the thickener feed pumps
on a one to one basis to simplify the dosing controls. The supernatant from the thicken-
ers shall be returned to the works inlet.
The Thickened sludge from the thickener shall be extracted in a controlled manner with
the help of Thickened Sludge Pump which shall discharge the sludge into the Thickened
Sludge Sump from where it shall be further pumped to centrifuges machines for de-
watering.
The dewatered sludge shall be disposed of at the sludge disposal land provided by the
Authority. The centrate shall be discharged to the plant drain for disposal outside the
plant.
Provision shall be provided throughout the installation to clear sludge blockage without
the removal of pipework sections.

5.19 Sludge Sump cum pump house

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Sludge Pump House

5.19.1 General
Notwithstanding the arrangements provided for natural drainage of the plant waste wa-
ter, there shall be a sludge pump house primarily meant for dealing with the clarifier
sludge and in addition, when necessary, dealing with the overflow of filter waste water
from the overflow weir at the time of backwashing, and wash water from the collecting
well and all the units during emptying in case natural drainage is not feasible. The
sludge collected in the sludge well of this pump house shall be pumped to the sludge
thickener. A separate arrangement shall be provided in the sludge pump house so that
is case of emergency, the accumulated sludge water shall be overflown into the surface
drainage system.
The sludge collecting sump of the pump house shall have sufficient capacity not less

than 150 m3. However, the Agency shall design the sump and pump capacity required
for proper treatment and disposal of sludge. There shall be 100% standby of the pumps.
The pump house shall be operated remotely through SCADA control and locally.
Adequate provisions shall be made to scour sludge accumulated in the sludge pump
sump by air and water jet. Water for water jetting may be obtained by pumping clear
water from the clear water duct or the proposed underground reservoir. For this arrange-
ment, at least two pumps of adequate capacity shall be provided of which one will be
in operation and the other will be a standby. An extra arrangement of the clear water
supply may also be made from the proposed clear water main available within 150 M.
The offer shall include all piping, fixed jets valves & nozzles etc. For air, two nos. of
air blowers of sufficient capacity with fixed air nozzles at the bottom of the sludge pump
sump shall be provided. The agency shall design and install sufficient capacity of air
blowers with 100% standby along with necessary piping arrangements and nozzles for
agitating sludge at the bottom of sludge sump to keep solid particles in suspension.
Each sludge pump shall be completed with driving motors, necessary cast iron sluice
and reflux valves and cast-iron piping for suction and delivery including all fittings.
Agency shall include for delivery and laying sludge line up to a suitable point of the
existing sludge line indicated by the Engineer-in-Charge. The connection of the sludge
line with the existing one is also within the scope of this contract. The sludge delivery
line of design diameter shall be of SWMS of wall thickness at least 12 mm. The outer

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surface of the SWMS pipe shall be covered with 3 LPE/polyolefin coating as instructed
by the Engineer-in-Charge. The arrangement of the valves etc., shall be as per direction
of the Engineer-in-Charge. The impeller and the casing of the sludge pumps shall be of
stainless steel or other similar metal of sufficient strength to withstand the continuous
abrasion and other wear & tear for a considerable time of running.
A manually operated chain pulley block of 3 tonne capacity shall be provided for han-
dling the pumps and motors in the pump room.
The specification for pumps and other equipment shall strictly conform to specification
of equipment of these tender specifications.
The electric motors, switch gears and other electrical equipment provided in the sludge
pump house shall conform strictly to specifications for electrical work given in relevant
Section of these tender specifications.
The sump shall be complete with all necessary controls and a set of level electrodes to
provide the necessary controls and alarms. Controls shall be provided to prohibit the
desludging of a clarifier if there is insufficient storage.

5.19.2 Civil Works

The sludge pump house shall be of R.C.C. underground structure with brick panel walls
in the superstructure and shall be provided with pile foundation.
The sludge sump shall be circular in shape and shall be provided with a dry pit at the
centre for accommodating sludge pumps and air blowers. The diameter of the pump
area shall not be less than 8 m and the volume in the annular space shall be not less than

120 m3. The floor of the pump shall be placed at a sufficiently low level to receive the
discharge of clarifier sludge coming out at the lowest level of the clarifier sludge pipe.
The floor of the wet sump around the dry pit shall be given a slope not less than 1 in 12
towards the dry pit where a channel 600mm wide and 400 mm deep shall also be pro-
vided. A 2000 mm wide walkway shall be provided to give access to the pump room
and R.C.C. steps 1000 mm wide shall be provided from the walkway to floor level of
the dry pit. An annular platform of 1000 mm width shall be provided on the outer wall
at plinth level excepting the portion over part of the steps. Steps shall be provided to
give access to the walkway from ground level. Hand railing, as specified, shall be pro-
vided on the walkway platform and one side of the steps.

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Adequate skylight and windows shall be provided in the sludge pump house building
to admit sufficient natural light. The total shutter area of doors windows and skylights
shall not be less than 25% of the plinth area. The windows and skylights shall be pro-
vided with grills of approved design. The main entrance door shall be a 1.75 m wide
mild steel gear operated rolling shutter.
The roof of the pump house shall be provided with roof water proofing treatment with
adequate arrangements for rain water drainage.
Hand railing, shall be of stainless steel SS 316 and walkways, access steps etc. shall be
galvanized. Hand railing, shall be of stainless steel SS 316 and walkways, access steps
etc. shall be galvanized. The mixer shall be provided with motor protection panel
against heating, moisture, etc.
All the basic construction works and finishing works shall be carried out as per speci-
fications of these tender specifications.

5.20 Thickener Feed Pumps

2 (1W+1S) submersible type thickener feed pumps shall be provided. The pumps shall
operate at a speed not greater than 1500 rpm. The Agency shall select the rating of the
pump to ensure as far as is practical the continuity of flow to the thickener installation.
Duty pump shall be manually selected at the wastewater control panel. The action of
selecting the duty thickener feed pump shall automatically select the corresponding
duty polyelectrolyte dosing pump. The duty status shall not be accepted unless the pump
and its corresponding dosing pump are both available.
The pumps shall be automatically controlled by the water level in the Clarifier Sludge
Sump and shall deliver wastewater to the thickener.
An orifice plate, or equivalent device, shall be installed in the thickener feed pump
delivery line. This device shall be mounted inside the pumping station and shall ensure
adequate mixing of the injected polyelectrolyte within the bulk of the wastewater.
A manually operated chain pulley block and running beam shall be supplied for removal
of the pumps.

5.21 Thickener Polyelectrolyte/PAC Dosing System

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Thickener Polyelectrolyte/PAC solution is needed to be prepared and dosed for aiding

sludge thickening. The minimum dosage of polyelectrolyte required for thickening shall
be worked out by the Agency, however, for the design, it shall not be less than 5 kg dry
polyelectrolyte /ton dry solids.
1 unit of Automatic Polyelectrolyte Solution Preparation system shall be provided, with
capacity not be less than 6 kg dry polymer per hour.
Hand railing, shall be of stainless steel SS 316 and walkways, access steps etc. shall be
galvanized. The mixer shall be provided with motor protection panel against heating,
moisture, etc.
The sump shall be complete with all necessary controls and a set of level electrodes to
provide the necessary controls and alarms. Controls shall be provided to prohibit the
desludging of a clarifier if there is insufficient storage.

5.22 Continuous Thickener

One picket fence type continuous sludge thickener, with thickened sludge pumps shall
be provided to accommodate the variable quantity of sludge and solids loads produced
during the different seasons during the year. The thickener shall thicken the sludge to a
average concentration of 4 % solids prior to dewatering in the centrifuges.
The sludge thickener shall have a sloping bottom and shall be fitted with a rotating
sludge scraper to transfer thickened sludge to a central removal hopper.
The volume in the thickener shall provide a minimum of two hours retention time and
storage for one day’s sludge production at at design Net Output during the period of
100 mg/l TSS in raw water.
The thickeners shall have a full diameter fixed bridge complete with walkway for per-
sonnel access to the centre, access stairs to ground level and handrailing, a motor driven
sludge scraper complete with all necessary controls, delivery pipework, a stilling well
and overflow steel weir plates. Walkways, access steps etc. shall be galvanized. Hand-
railing shall be of SS316 material. Underwater Fastener shall be SS316 material.
The scraping gear shall be supported from the tank base and from a fixed bridge carry-
ing the central electrical drive for the rotating gear. The equipment including driving
motor, gears, shafting and scrapers shall be designed for continuous operation and sized

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for the most arduous operating condition including starting from rest with an accumu-
lation of sludge in the thickeners.
The electric motor, gearbox etc., shall be provided with proper shade. The fixed bridge,
and the stilling chamber shall be steel coated with Polyurethane, including scrapper
mechanism. Suitable overload protection for the drive shall be provided to ensure that
the sludge shall not overload the equipment and emergency stop push button shall be
provided. The scrapers shall be fitted with rotation monitors and over torque protection
to alarm in the event of a failure.
A set of 2 No (1W + 1S) Thickened sludge pumps of fixed speed positive displacement
type shall be provided. shall be fixed speed positive displacement pumps. Sludge blan-
ket monitoring shall be provided to control the pumps in an approved manner. Each
pump shall be rated to pump the volume of thickened sludge produced by thickener at
plant design Net Output during the period of 100 mg/l TSS in raw water.
The Thickener supernatant shall overflow a peripheral weir into a Supernatant sump of
HRT not less than 60 minutes. From there it shall be pumped to the raw water channel
at the plant inlet with a set of 2 No (1W + 1S) submersible type pumps.
An electromagnetic flow meter shall be provided in the supernatant return pipe to
stilling chamber. The supernatant pipework shall be arranged to ensure that the pipe-
work in the region of the flow meter always remains full. Flows shall be indicated,
totalized and recorded at the local control panel and at the central HMI.

5.23 Thickened Sludge Storage Tank

One tank shall be provided to store thickened sludge and to act as a sump for the cen-
trifuge feed pumps. The capacity of the tank shall be sufficient to hold 12 hours thick-
ened sludge production at plant design Net Output during the period of 100 mg/l TSS
in raw water. The tank shall be fitted with continuous level measurement equipment.
A mechanical submersible mixer shall be provided in the tank, with mixing power not
less than 10 w/m3, sized to maintain solids in suspension. Handrailing, shall be of stain-
less steel SS 316 and walkways, access steps etc. shall be galvanized. The mixer shall
be provided with motor protection panel against heating, moisture, etc.
The centrifuge feed pumps shall be fixed speed positive displacement pumps. Each
pump shall be rated to pump in 12 hours the volume of thickened sludge to be dewatered

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by one centrifuge at a plant design Net Output during the period of 50 mg/l TSS in raw
water.

5.24 Dewatering Polyelectrolyte/PAC Dosing System

Dewatering Polyelectrolyte solution is needed to be prepared and dosed for aiding
sludge dewatering. The minimum dosage of polyelectrolyte/PAC required for dewater-
ing shall be worked out by the Agency, however, for the design, it shall not be less than
5 kg dry polyelectrolyte /ton dry solids.
1 unit of Automatic Polyelectrolyte/PAC Solution Preparation system shall be provided,
with capacity not be less than 6 kg dry polymer per hour.
The Volumetric dry powder feeders (SCADA compatible) shall comprise of powder
hopper, screw feeder and pneumatic conveyance system mounted on a galvanized mild
steel base. The dosing of polyelectrolyte/PAC shall be controlled through SCADA. The
hopper shall be manufactured in 316L stainless steel and shall be fitted with high and
low-level probes, anti-bridging mechanism, covers designed for ease of access and iso-
lation valves on the hopper discharge. Screw feeders shall ensure free flowing dis-
charge, avoid compaction and be self-cleaning. Screw feeders shall include anti-con-
densation heater and be variable speed motor driven. Heated pneumatic conveyance
system shall comprise blower, venture educator and heated educator cone. Suction and
discharge hoses shall be anti-static.
The dispersion unit shall wet the polymer dry powder and comprise dry powder con-
nection, make-up water connection, dispersion head, solenoid valves and makeup water
flow regulator. Dry powder and make-up water connections shall be an integral part of
the dispersion head. The dispersion head shall provide clear sight to the operator of the
wetting process, be self-cleaning and easily removable. Solenoid valves shall control
make-up water supply to both dispersion head and polymer dilution.
Valves shall be controlled by level probes in the solution preparation/ageing tank. The
make-up water flow regulator shall be operator set.
The solution preparation/ageing tank shall be manufactured in Plastic (LDPE/
HDPE/GRP), and include holding down points, overflow, drain, inlet and outlet con-
nections, high and low-level probes, outlet pipe work, isolation and solenoid valves.

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Agitators shall comprise rotating blades mounted on a vertical shaft coupled to the gear-
box output shaft through rigid coupling and driven through a 1,500-continuous duty
motor (TEFC) with IP 55 protection coupled to the gearbox by a flexible coupling.
Materials of construction for the shaft shall be 316L stainless steel, code of practice IS
9522:1980 and the impeller shall be 316L stainless steel / CF8M, turbine type. The shaft
length shall be as required for easy dismantling and installation. The drive unit shall be
mounted on girders. The safety factor for the gear box shall be a minimum of 1.5.
A set of 2 (1W+1S) polyelectrolyte dosing pump shall be provided. Polymer dosing
pumps shall be hydraulically actuated diaphragm pumps simplex or 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 1,000 RPM.
The Pumps shall incorporate sensors that monitor the dosing flow and the diaphragm
and provide process stability. The pumps shall be designed to have separation of hy-
draulics and electronics, to protected process from equipment failure.
The metering pump shall be selected as duty along with its corresponding centrifuge
decanter feed pump. The dosing pump shall start and stop simultaneously with the as-
sociated duty centrifuge decanter feed pump.

5.25 Centrifuge Decanter

The design of centrifuge decanter dewatering machine shall be based on sludge produc-
tion at plant design Net Output with 50 mg/l TSS in the raw water. Solid bowl centri-
fuges decanter shall be used for the sludge dewatering operations. There shall be 4
(2W+2S) centrifuge machines. The dewatering capacity of the centrifuge shall be based
on max. 12 hours operation per day. The centrifuges shall produce a dewatered sludge
cake of no less than 20% dried solids. At least 97% of the solids shall be in the de-
watered cake and less than 3% of the solids shall be in the centrate.
In the event sludge production is more that the design capacity of dewatering machine,
the dewatering machine shall be operated for more than 12 hours to compete the de-
watering of the sludge production during the day. In the rare situation of sludge produc-
tion beyond the capacity of 1 machine in 24 hours, due to increase in the TSS in the raw
water especially during rainy season, all the dewatering machines may be used.

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Operation of each centrifuge and its associated dedicated sludge feed pumps, polyelec-
trolyte dosing system, and flushing system and other plant shall be automatic once the
start-up procedure has been initiated by the operator.
The polyelectrolyte and sludge feed pumps shall not start until the centrifuge has
reached its full speed.
The shutdown sequence shall be a reversal of the above-mentioned procedure. After
stopping the sludge and polyelectrolyte pumps, the centrifuge shall be flushed out with
clean water. This shall be carried out while the centrifuge is still running. Means shall
be provided to divert the flushing water to the centrate drain.
The operation of a low-level sensor in the thickened storage tank shall automatically
stop the flow of sludge to the centrifuge Polyelectrolyte shall be dosed to the sludge
flow via an in-line injection system and mixer designed to achieve rapid and even dis-
tribution throughout the sludge. The conditioned sludge shall be delivered into the inlet
chamber of the centrifuge.
The pond depth, drum speed and differential scroll speed shall be pre-set at optimum
values determined during commissioning trials. The differential scroll speed shall be
operator adjustable to allow further optimization of the dewatering process.
 The dewatered sludge shall be taken to the Drying Bed for conversion to sludge
cakes and later taken by a truck for disposal as fertilizers / fuel.
 The centrate from dewatering machine shall be drained to the waste water sump
from which it shall be pumped to Flash Mixer as a measure of ZLD by re-cycling/re-
use.
The centrifuge shall comprise the following components:
- sludge feed system;
- collecting vessel and support frame;
- variable speed drive;
- differential scroll drive;
- centrifuge washing;
- concentrate collection;
- control system.
The centrifuge shall be mounted on heavy-duty vibration isolators, located between the
machine and the supporting steelwork or foundations, to damp vibrations and prevent

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vibration transmission. Two axis vibration monitors shall be provided to stop the cen-
trifuge automatically when excessive vibration is detected. Flexible connections shall
be provided on the sludge fed system and the centrate system at the centrifuge. The
dewatered sludge discharge system shall incorporate flexible chutes.

5.26 Sludge Treatment and Disposal Power and Control

A combined MCC and control panel shall be provided and located in a suitable location
protected from the weather and the effects of the process. The control panel shall pro-
vide facilities for the:
 display status and values associated with the sludge treatment systems;
 duty pump selection;
 annunciate alarms associated with the sludge treatment systems;
 all necessary controls for centrifuge installation.
 The centrifuge manufacturers proprietary control panel/s may be provided in addi-
tion to the above providing the requirements for centrifuge status and alarm annun-
ciation is fulfilled locally and at the central HMI.

5.27 Filter Backwash Water Recovery

5.27.1 Backwash water Collection & Pumping
A Filter Backwash Water Collection Sump for holding a total volume of dirty backwash
water produced during the washing of two filters, shall be provided to receive the dirty
backwash from filters. A set of submersible mixers shall be provided to deliver at least
10 W/m3 mixing power to keep the sludge in suspension in the sump.
A set of four no. of pumps, two duty and two standby, shall be provided to pump out
the dirty backwash water and transfer to stilling chamber. An electromagnetic flow me-
ter shall be provided on the common discharge line to measure the flow rate and total
flow returned back to the plant.
The Agency shall adequately size the pumps to ensure that filters are not queuing-up
for an excessive time for backwash water sump capacity availability for the for the plant
operator to complete the filter backwashing in a single shift of eight hours. However,
the minimum capacity of each pump shall be such that it shall not take more than 30
minutes to evacuate the 100% of the dirty wash water produced in one filter washing.

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The backwash flows shall be set using preset butterfly setting valves in series with iso-
lation valves.
The tank shall be provided with continuous level measurement and a digital high-level
alarm.

5.27.2 Backwash Water Handling Power and Control

A combined MCC and control panel shall be provided and located in a suitable location
protected from the weather and the effects of the process. The control panel shall pro-
vide facilities for the:
 display status associated with the backwash water handling system;
 duty pump selection;
 control mode selection;
 annunciate alarms associated with the backwash water handling systems

5.28 Administration and Control Building

The agency shall design, Detailed Engineering and construct Administrative building
(G+4 with provision of G+5 foundations) in WTP compound separated by boundary
wall from WTP main area and quarter compound. The built-up area of administrative
building of each floor shall be 600 sq.m. The ground floor shall consist of SCADA
control room (C3) of area 180 sq.m, reception of area 50 sq.m and building section 100
sq.m. common toilet block at ground floor of area 20 sq.m. Rest area at ground floor
shall be car parking.

First floor shall have a conference room of area 100 sq.m and balance area for office
of Executive Engineer (EE). EE office shall consist of EEs chamber with attached toilet
and anti-chamber of area not less than 60 sq.m. It shall consist of 3 Dy. EE chambers,
6 AEE cabins and cabins for 10 supporting staff. It shall also consist of toilet block of
size 25 sq.m and a store room 15 sq.m.

Second floor shall be of 2 EEs office similar to the first floor EEs office.

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Third floor shall have a conference room of area 150 sq.m and balance area for office
of the two Chief Engineers (CE). CE office shall consist of CEs chamber, with attached
toilet and anti-chamber of area not less than 75 sq.m. and additional CEs chamber at-
tached with toilet and anti-chamber of area not less than 65 sq.m. It shall also consist
of the visitors’ lobby of area 40 sq.m, toilet block of area 25 sq.m, store room of area
15 sq.m and rest of the area for supporting staff.

Fourth floor shall have an office of the two Superintending Engineers (SE). Each SE
office shall consist of SEs chamber, with attached toilet and anti-chamber of area not
less than 65 sq.m. Each SE office shall have Technical Assistant (TA) to SEs chamber
with attached toilet of area 40 sq.m. It shall also consist of the visitor’s lobby of area
40 sq.m, toilet block of area 25 sq.m, store room of area 15 sq.m and rest of the area for
supporting staff. There shall be two Dy. EEs chamber, two AEEs cabins & cabins for
ten supporting staff in each SEs office.

The supply and installation of office furniture is also under the scope of this tender. The
detail layout plan of office shall be finalized in consultation and as per approval of EIC.

The building shall be designed as RCC framed structure resting over DMC bored RCC
pile foundation. The agency shall design the building for G+5 construction but they will
construct up to G+4 with a provision for pile foundation for G+5 building under this
tender. Administrative building shall have lift facility for carrying capacity of 15 per-
sons and shall have two staircases, one main and other for emergency exit. The height
of each floor shall not be less than 4.0 m. In the Administrative building, the agency
shall provide false ceiling, air conditioning, firefighting.

The roof terrace shall be accessible through main and emergency staircase. The machine
room and stair head room shall be minimum 2.7 m height. All windows shall be of
anodized aluminum window of approved shade with 4 mm glass.

The finishing of the building shall be as per specification given in this bid document.

Supply of office furniture in all water supply installations as per approval of EIC is
under the scope of this tender.

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5.29 Electric Substation

The agency shall construct two substations with area of 607.50 sq.m and 649.25 sq.m
at Intake well and WTP premises respectively. The substation building shall consist of
operator room including SCADA, battery room, switch gear room, toilet block. The
height of the building shall be minimum 4.0 m.

The floor level of the substation building at Intake well shall be at the same level of
pump floor level of Intake pump house. The substation building shall be of RCC framed
structure resting on DMC bored RCC pile foundation. The flooring of substation build-
ing shall be of Kota stone. Finishing of the building shall be as per specification given
in this bid document.

The floor level of the substation building at WTP shall be 0.5 m above FGL. The sub-
station building shall be of RCC framed structure resting on DMC bored RCC pile
foundation. The flooring of substation building shall be of Kota stone. Finishing of the
building shall be as per specification given in this bid document.

5.30 Staff Quarter

Two No staff quarter (G+4) building with lift (5 persons) each having 8 No quarters,
one for Group C employee and one for Group A&B employees. The built-up area of
group C employee shall be of 100 sq.m and for group A&B shall be of 120 sq.m.

The floor level of the staff quarter building at WTP shall be 0.5 m above FGL. The staff
quarter building shall be of RCC framed structure resting on DMC bored RCC pile
foundation. Each quarter shall have two bedrooms, one attached toilet and one common
toilet, kitchen, drawing cum dining, balcony. The Agency shall submit detailed plan for
approval to EIC. Finishing of the building shall be as per specification given in this bid
document.

5.31 Transformer Yard

The agency shall construct two transformer yards of built-up area 160 sq.m and 200
sq.m at Intake well and WTP premises respectively. The transformer yard at Intake well
will be at same level 0.5 m above the substation floor level. The floor level of the trans-
former yard at WTP shall be 1.0 m above FGL.

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The details of the yard shall be finalized at the time of Detailed Engineering in consul-
tation with EIC.

5.32 Chief Engineer Bungalow

The agency shall design, Detailed Engineering, construct (G+1 storied) bungalow for
Chief Engineer of built-up area of 150 sq.m in each floor with boundary wall, gate,
internal lighting, storm water drainage, internal roads etc. The building shall be of RCC
with M20 grade framed structure 250 mm thick brick fill wall. At ground floor, there
shall be a covered car parking facility, servant quarter, kitchen, hall, toilet. The rise and
thread shall be of 150 mm and 250 mm. The height of the room shall be minimum 3.3
m. At first floor, there shall be three bed rooms with attached washroom, lobby. There
shall be a staircase up to the roof. The finishing work of the building shall be of pre-
mium quality. The agency shall provide false ceiling in all rooms and halls.

5.33 Plant Superintendent Bungalow

The agency shall design, Detailed Engineering, construct (G+1 storied) bungalow for
Plant superintendent of built-up area of 120 sq.m in each floor with boundary wall, gate,
internal lighting, storm water drainage, internal roads etc. The building shall be of RCC
with M20 grade framed structure 250 mm thick brick fill wall. At ground floor, there
shall be a covered car parking facility, servant quarter, kitchen, hall, toilet. There shall
be a staircase up to the roof. The rise and thread shall be of 150 mm and 250 mm. The
height of the room shall be minimum 3.3 m. At first floor, there shall be three bed rooms
with attached washroom, lobby. The finishing work of the building shall be of premium
quality. The agency shall provide false ceiling in all rooms and halls.

5.34 Miscellaneous
a) Cable glands and lugs
All cable glands shall be made from brass and shall be of double compression type.
All cable lugs shall be of tinned copper, crimping type.
b) Cable trays
Cable carrier system shall comprise of site fabricated ladder type cable trays made from
structural steel and painted duly with two coats of red oxide and a final coat of enamel

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paint. The construction of the cable trays shall be as per the site requirement and gen-
erally in line with the drawing enclosed.
c) Civil works
All civil / structural works, required for electrical installation is included in the Agency
scope. However, some of the major items are listed below
 Foundations for Lighting Masts / poles.
 Road Crossings by RCC Pipes
 Excavation, cable protection tiles, sand filling, back filling etc. for directly
 buried cables and earthing conductors.
 Any other minor civil works required such as making openings in wall, floor etc.
 Built up trenches for indoor cabling.
All openings made by the Agency for laying of conduit / cable / earthing strip etc. shall
be made good at no extra cost.
d) Local PB Stations
a) Construction Outdoor type weatherproofs
b) Push Buttons On, Off

Instrumentation and Control Systems

The requirements of the Instrumentation, Automation and Control for the Treatment
Plant are stipulated in separate chapter. The requirement of works and their specifica-
tions shall be in accordance to the stipulations in the Chapter.
Signal and Control Cables
All digital signal cables, control cables and 240V AC power supply cables shall be of
1.5 sq.mm. solid copper conductor, single or multi core, armored type (CYWY) of
650/1100V grade.
All analog signal cables shall be of 1.5 sq.mm. stranded copper conductor, single or
multi twisted pairs, screened type.
All instrumentation cables viz. power, digital signal and analog signal shall be laid in
GI conduit. The cross- sectional area of the conduit shall be minimum 2.5 to 3 times
the cross-sectional area of cables to laid through.
Minimum clearance of 300 mm shall be kept between signal cables and electrical power
cables when running parallel. Crossing or overlaying of the cables shall be avoided.

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Sharp bends or zig zag laying of the cables shall be avoided at all the places. All signal
cables shall have shield earthing at control panel end only.
Double compression type brass cable glands shall be provided for all the cables while
terminating at instrument, junction box and control panel.
Wherever there are cable trays, they shall be provided with proper supports and cables
shall. be clamped in the trays properly and no cable shall be kept loose or hanging.
Junction Box (JB)
Weather proof junction boxes shall be provided for all signal. and control cables wher-
ever required. All junction boxes shall be mounted properly and shall have chrome
plated rail mounting type terminal block arrangement. Wherever possible use of instru-
ment power supply junction boxes as well as signal junction boxes shall be made to
enable use of multicore as well as multipair cables respectively between the control
panel to JBS. From JB onward the individual cables to field equipment shall be laid
through flexible GI conduit. The general arrangement of power supply JB and signal
JB shall be like the sketch enclosed. Minimum 3 circuits in case of power JB and 20%
terminals in case of power shall be provided for future use, if required.
All junction boxes shall be of weather proof type (IP65) as per IS:2147.
Filter Operating Consoles:
It shall be a Panel mounted with instrumentation elaborated in the section on Filter
Beds. All instruments shall be of flush mounting. It shall be constructed in MS Sheet of
minimum 2 mm thickness painted with Epoxy Paint of approved color. The panel shall
have instruments mounted for viewing and operation at an appropriate level. The Panel
shall have no sharp edges and the drawing of same shall be got approved from PHED
before manufacture.
Local control panels
Local control panels wherever required shall be provided standard vertical or slanted
panel type only depending upon the number of components viz. control switches, indi-
cating lamps, metres etc.
Sheet of local panel shall be of MS and thickness not less than 2 mm.
Local control panel after having the pre-painting treatment and two coats of red oxide,
shall be painted with final paint shed of 631 as per IS:5. The control panel shall have
bottom entry for cables, hinged type lockable door arrangement and easy access for

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wiring. Mounting arrangement for the control panel shall be suitable for the application
and location and easily accessible for the operator.
Site Calibration
All field instruments shall be calibrated at site under supervision of supplier’s Engineer.
Standard calibration procedures shall be followed for calibration. All reference equip-
ment such as pressure gauges, scales etc. shall be certified from authorized / approved
agency. All such certification shall be in the scope of Agency.
For all instruments, standard calibration documentation shall be prepared at the time of
calibration.
All Calibration and recalibration shall be performed in the presence of the Engineer-in-
Charge or his representative till handing over of the plant shall be done by the Agency.
Loop Drawings
Loop drawings shall be prepared for all control loops and field instruments. Any change
in the loop drawings at the time of installation as per requirement at site shall be docu-
mented and approved by the Engineer-in-Charge before execution.
Checks and Loop Checking
Cable continuity shall be checked before cable laying and after cable termination for
all the instruments. Loop checking shall be conducted for all the analogue and digital
loops before system testing. Any damage or fault shall be immediately located and rec-
tified. All the instruments and control panel shall be isolated from the power supply
while cable laying and termination. Each instrument shall be checked for its functions
before putting them into operation. All control loops shall be checked in manual mode
first and then they shall be put in to the auto loops. All instruments shall be provided
with proper earthing.

5.35 Documentation
Agency shall provide following set of documents and drawings
i. Instrumentation Schedule
ii. Instrument schedule
iii. Instrumentation Cable schedule
iv. Loop drawings
v. Technical Parameters for each instrument (Data Sheet)

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vi. Control panel drawings (GA Drawing & Control room layout) and control panel
wiring
vii. P&I Diagram for Water Treatment Plant
viii. Equipment layout and plant layout indicating location of each instrument
ix. Calibration and test reports for each instrument (shop and site)
x. Pre-commissioning check list for equipment and instruments

5.36 Civil Works

5.36.1 General
The civil works shall be carried out as per specifications defined in Chapter of “Speci-
fications for Civil Works” in accordance with the Indian Standard. In case of any vari-
ation between the specifications, the specifications given in document shall prevail.
The Agency shall use sulphate resistant cement for all RCC works below ground level.
The main building and the chemical house shall be designed as a RCC framed structure.
All masonry shall be either in stone or bricks of class designation 100 in 1:4 cement
sand mortar. For all masonry walls RR or CR stone masonry in mud mortar thickness
not less than 60 cm shall be provided in place of PCC at km-4 head works. Above the
mud mortar layers, the RR/CR masonry shall be provided with a DPC course at plinth
level.
The thickness of the external walls and load bearing walls shall not be less than 30 cm
for stone masonry and 25 cm for finished brick masonry. The partition walls shall not
be less than half brick thickness.
The general requirement of material, specifications, sampling of materials, standards to
be followed & testing criteria shall be as per provisions laid down in the Section of
“Technical Specifications for Civil Works”.

5.36.2 Doors & Windows:

As a general guideline, the total area of doors and windows shall be not less than about
25 % of the floor area. Doors to the pump and compressor room and to the chemical
storage room shall be of the rolling shutter type with manual operation from inside.
They shall be 4 m wide and 3.5 m high so that a truck can enter, (backside first). A
standard door shall be provided for entry of the operators. Doors in dangerous areas

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(chemical house, main distribution panel room) shall open to the outside. The chlorin-
ator room shall have two doors.
All outer doors and those of dangerous areas shall have a self-closing device.
The types and locations of the doors and windows shall be approved by the Engineer-
in-Charge.
All the external walls shall have aluminum section glazed window as per specification
provided in Chapter of specifications of civil works. The other walls may have steel
glazed windows shutters of standard rolled steel section joints mired and welded with
steel lugs 13 * 3 mm, 10 cm, long with fixed wire gauge of 14 mesh * 24 gauge to the
metal frame of rolled section by metal beading 20 * 3 with suitable screw at not ex-
ceeding 150 mm distance and square bars or other flat welded, embedded in cement
concrete block 15 *10* 10 cm of 1:3:6 (1 cement :3 coarse sand :6 graded stone aggre-
gate 20 mm nominal size) or with wooden plugs and screws or with fixing clips or with
bolts and nuts as required including providing and fixing of plain glass panes 4 mm
thick with glazing clips and special metal sash putty of approved make or metal beading
with screws complete including priming coat of approved steel primer, partly fixed and
partly openable [ Fixed area not to exceed 33%].

5.36.4 Sanitation Facilities:

A lavatory shall be provided near the laboratory and control room. It shall have an area
of about 5.00 sq.m. It shall be equipped with Indian type water closet, urinal, flushing
cistern for WC, wash basin, mirror, toilet shelf etc. The disposal (in septic tank soak pit
etc.) shall be made at least 15m away from the main building. The disposal system is
part of the contract.

5.36.5 Walkways and Access Stairs

Unless otherwise specified all individual units shall have concrete walkways of a width
of 1.0 m surrounding it. The walkways shall have railings of 1.0 m of stainless steel
tubes of diameter 32 (pillars and upper railing) and 25 mm (lower railing). The walk-
ways shall be accessible from the upper floor of the control building and by means of
1m wide stairs at suitable places (filters, mixing chamber). Walkways shall link the
following units:

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5.36.6 Internal water supply

The water supply of the whole treatment plant shall have two circuits:
a) Process water
The agency shall make necessary arrangements for process water supply by providing
pumps at suitable location in filter house. The pump shall draw water from filter water
channel.
 preparation of the chemical solutions

 injectors of the chlorinators

 sprinkler system in the chlorine drum storage area

 supply points for desert coolers and cooling system

 flush toilets

b) Drinking water
The Agency shall provide the drinking water facilities with cooler within the campus in
all buildings in all floors.

5.36.7 Finishing
a. Painting of metallic surfaces

If not otherwise stated metallic surfaces shall receive one initial coat in the manufac-
turer's workshop. After arrival of the equipment on site, the same shall be inspected and
damaged portions shall be cleaned and given the primer and under coat of similar paint.
After erection, all metal work shall be painted as follows:
Painting of metallic surfaces
Galvanization, chromate primer, and
All mild steel railing, mild steel lad-
two coats of approved oil paints, fin-
ders, pipes for water supply, grit iron
ishing coat of approved oil based paint
plates
of approved shades.
Submerged metallic parts and their
Two coats of bituminous paint
projections above water level

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Primer of red oxide, two under coats

Metal parts above water level or in dry
and one finishing coat of an approved
places
oil based paint and of approved shades
All indoor fixtures, instruments and
Chromium or copper nickel plating
similar equipment on panels etc

Coating of the pipes and the plant equipment is to be provided according to the speci-
fications and following the color code.
b. Final Finishing:
The Agency shall ensure that the entire building along with all its installations are in a
finished and in new and fully operative condition when handed over. He shall have
repaired and remove all signs of damage that might have been done during installation
and fixing of equipment. He shall also see that the entire exterior has been finished
properly and the entire site is cleared of all extra construction material, debris and ex-
cavated soil. This shall have to be done to the satisfaction of the Engineer-in-Charge.

5.37 Miscellaneous Requirements

Name Plates, Signboards, Nomenclature
Each item of the plant shall have permanently attached to it in a conspicuous position a
name plate, on which shall be engraved or stamped the manufacturer's name, type and
serial number, manufacturing year, details of the design capacity etc. Such labels shall
be of non-hygroscopic material to be approved by the Engineer-in-Charge- in -Charge.
Near or on each item of the plant a plate with the name and nomenclature (code) of the
item according to the project nomenclature shall be fixed. It shall be visible from a
distance of several metres.
The Agency shall also provide bilingual signboards and instruction tables of durable
material throughout the plant for the purposes of operation, maintenance and security:
- Danger and caution signs (English and local language)
- Preventive maintenance schedules (local language)
- Operation instructions (local language)
- Unit names (English and local language)
- Name plates at the doors to the units (English and local language)
Signboards and plates shall be appropriately sized in relation to the relevant item and
its surroundings. Details of the proposed inscription, size, material and colors shall be

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submitted to the Engineer-in-Charge for approval before any tables are manufactured.
They shall be compatible with the instructions in the operation manual.
All cables shall be provided with clip-on identification numbers on both ends and at all
terminations in between, for identification. The nomenclature shall correspond to the
electrical as-built drawings.

5.38 Ancillary Works

The Ancillary Works in connection to the Water Treatment Plant are as follows:
i) Raw Water Supply
ii) Roads Inside the Plant Boundary
iii) Electric Supply
iv) Drainage System of Plant
v) Area Drainage System
vi) Treated water outlet up to filter water reservoir.
vii) Building work.
Raw water supply connection has been elaborated in the specification
1. Roads
Plant internal roads as required shall be provided. Minimum road width shall be 6 m &
4 m with 1 m wide shellers on both sides of the road. Adequate provision shall be made
for Guard Rails, retaining walls, cross drainage structures and Crash Barriers based on
the site requirements. The schematic arrangement of the minimum length of proposed
road is shown. Actual road arrangement shall be decided by Engineer-in-Charge during
Detailed Engineering.

6 Semi Underground Reservoir

The specification is given in Chapter on General Requirements, para under SUGR.

7 Clear water Pump house

The specification is given in Chapter on General Requirements, para under CWPS.

8 Cushion Tanks (Elevated Service Reservoirs)

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The agency shall design, detail engineering and construct ELSRs with unique aesthetic
view. The ELSR shall have unique architectural design with decorative artefacts outside
camouflaged with surroundings which gives a pleasant look and resembles a signature
structure of the Amaravati capital city. The ELSR with complete architectural design
shall be prepared and submitted along with 3D view to the Authority for apprecia-
tion/modification and approval from the Engineer in charge.

All the RCC Water Retaining structures shall be designed as per IS: 3370 -2009.
The concrete grade for the water retaining members shall be M30. The steel used for
reinforcement shall be Corrosion resistance high yield strength deformed bars confirm-
ing to IS: 1786 (with latest revision).
i. Capacity of the reservoir shall be the volume of water stored between the full
supply level and the invert of the outlet pipe. Due allowance shall be made for
any dome or obstructive structure inside the reservoir and floor, while calculating
the net capacity of the reservoir.
ii. Free board shall be minimum 500 mm.
iii. Design shall be based on accepted norms and methods of design and the provision
contained in the latest versions of IS: 456, IS:3370, IS:1893, IS:875 and all other
relevant codes etc.
iv. Grade of RC concrete: RCC M-30
v. The design calculations and drawing shall be worked out in either metric or in S.I.
unit.
vi. The water retaining component/ member including member subject to condensa-
tion like Roof Slab shall be designed as un-cracked section with M-30 grade con-
crete.
vii. Foundation of the structures should be with Pile foundations
viii. For access into the overhead tank there shall be RCC stair case with RCC landings
at suitable intervals. The width of the stair and landing shall not be less than 800
mm. The stairs shall be provided with SS railings of approved design for a mini-
mum height at 800 mm with two rows of horizontal runners at each side holding
the vertical posts. Inlet & outlet pipe shall be as per pump motor & field require-
ment. Overflow pipe dia shall be more than inlet dia. 150mm dia wash out pipe
shall be provided. Each pipeline shall be provided with required puddle collars,
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expansion joint, duck foot bend, DI/DF valves, valve chambers etc., as required
for completeness. The limit of contract of each pipeline for Tank is up to founda-
tion trench from outer face of staging shaft/column.
ix. The roof of the overhead tank shall be provided with hand rail at the edges by
means of Stainless Steel posts and railings for a minimum height of 800 mm with
two rows of horizontal runners holding the vertical posts.
x. The overhead tank shall be provided with suitable ventilation arrangement at the
roof. The openings of the ventilators shall be protected with mosquito proof wire
net of SS wire net of SS wire mesh.
xi. One lightening arrestor shall be provided on the roof of the elevated tank as per
IS: 2309. The same shall be suitable earthed with aluminium tape conductor as
per I.S. specifications.
xii. Reservoir Management System (RMS) shall be provided at the inlet of ELSR and
Bypass management system (BMS) shall be provided with in the WDC compound
at suitable location.
xiii. There shall be one electromagnetic flow meter within the WDC compound at suit-
able location.
xiv. Two Nos. of S.S lockable hinge type manhole covers of minimum 600mm dia.
with frame shall be provided on the roof of the elevated reservoir.

9 Clear water pipelines

The specification for all pipeline under this package is given in Schedule<<<<<<

10 SURGE PROTECTION DEVICES

10.1 Surge Analysis
The Agency shall undertake surge analysis to determine the extent of surge pressures
or other adverse hydraulic conditions that may occur during the operation of rising
mains.
The Agency shall undertake the following tasks as an integral part of the surge analysis
for each system:
 Construct a mathematical model of the system using internationally recognized
transient simulation computer software. The network model shall be as detailed as
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Amaravati Development Corporation Limited

possible incorporating high and low elevation points along the pipeline and detailed
piping manifold in pump station area.
 List all the steady state scenarios under which the system will operate;
 List, with reasons, the most adverse surge conditions under which the system will
operate;
 Determine maximum and minimum surge pressures along the system that can occur
due to system operation with and without cavitation conditions. The case with cav-
itation conditions must capture high and low surge pressures by simultaneously lim-
iting low pressures to vapor pressure at all nodes considered in the mathematical
model.
 Add surge protection system to the network model and determine the maximum and
minimum surge pressures for the most adverse surge conditions. The network model
used for studying the effectiveness of surge protection system shall also include all
air venting valves, though they are not normally considered as part of the surge
protection system.
 Verify the adequacy of the surge protection system for other important operating
scenarios such as new pipe roughness condition, power failure during single pump
operation, and pump start up conditions.
 The surge simulations must be carried out for at least 10 times 2L/c value where L
is the total length (m) of the pipeline and c is the average celerity (wave speed) in
m/s. Results presented shall indicate the total simulation time, e.g., pressure varia-
tion graph w.r.t. time at some specific locations along the pipeline.
 Computational time shall be at a minimum of 0.005 seconds to capture all the pres-
sure spikes arising from air valve slam conditions, NRV Slam Conditions and any
other rapidly varying slam pressures. The report generated by the surge analysis
software shall be attached to demonstrate the use of all small computational time
steps.
 Surge Protection System shall be suitable for the Thickness of Pipeline used for the
Project. Thickness of the pipeline must be capable of withstanding both highest and
lowest negative pressures in accordance with the appropriate Indian or AWWA
standards.

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 Prepare a Surge Analysis Report providing full details of tasks as mentioned above,
including sufficient data sheets, figures, and analysis output etc. from the transient
simulation computer software to allow the vetting authority to undertake a detailed
review of the Surge Analysis Report.
The Report shall be Vetted by Competent Authority such as any NIT/any IIT/IISC Ban-
galore and if they suggest additional simulations and/or changes to the protection meth-
ods, the Agency shall incorporate all the necessary changes as agreed mutually by client
and Agency and resubmit the report.
Surge protection system shall comprise of bladder vessels only or along with any or all
of the following equipment depending on the recommendation of surge analysis to pre-
vent the positive and negative surges in the pipeline.
Surge protection system comprises of bladder vessel and surge suppression valve must
be in working condition for projects in India.
The work done certificate shall be signed by an officer not below the rank of Executive
Engineer-in-Charge of the concerned division and in case of Sub Contract the Certifi-
cate shall be counter signed by the Engineer-in-Charge of the Concerned Division.
Surge Monitoring System comprises of Data Logger, Pressure Transmitter to be sup-
plied to enable to study the surge effect.

10.2 TECHNICAL SPECIFICATIONS OF SURGE PROETECTION EQUIPMENT

Supplying erecting commissioning of Three Stage Surge Suppression Valve oper-
ation:
The Valve shall be able to take high air intake capacity and Discharge the Air in Con-
trolled Way by predesigned Small Orifice to allow the re-joining of columns slowly.

SPECIFICATION:
 Air Intake:

The Valves shall offer very high air intake capacity with nominal orifice size for ex. 6”
valve shall have a large orifice of 6” along with better aerodynamic design to reduce
the obstruction of air flow through the valve.

 Sealing:

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The models shall be equipped with a two-stage sealing, a soft EPDM seal and Bronze
seat. As float approaches the orifice it meets first the rubber seal and as pressure in-
creases the seal is pushed and the float seats on the Bronze seat. This ensures low min-
imum sealing pressure of 2 meters and long-life maintenance and leakage free opera-
tion.

 Float design:

Floats shall be made of polycarbonate, and shall be tested for 100 bar bursting pressure
for all pressure ratings of the valves. The float design shall offer long term maintenance
free operation and resistance against drowning effect of float against orifice. The float
design and the air valve body design shall offer better protection against pre-mature
closing of the valve. The spherical hollow design of the float will offer less resistance
which leads to high flow capacities and also avoids accumulation of debris.

 Air discharge and surge suppression:

The Surge Suppression Disc shall be used in Surge Suppression Air Valve. The follow-
ing parameters are emphasized for the purpose of simulation:
Air Intake Orifice:
Both the models offer nominal size of orifice for ex. 6” valve has a large orifice of 6”
offering very high intake capacity due to less frictional losses.

Air Outlet Orifice (Surge Suppression orifice):

Manufacturer shall develop standard Surge Suppression orifice sizes for each size for
Customization of specific requirement as per the hydraulic analysis.

 Switching pressure:
This denotes differential pressure required to switch from large orifice to Surge Sup-
pression orifice during air release. The Valve Shall have Surge Suppression Disc op-
erating from a differential pressure less than 2 KPA (20cm) of water column.

Technical Specification for ARI surge suppression High Flow Combination Air Release
Valve Material of Construction
 Body & Cover : Ductile Iron ASTM A 536/EN 1563
 Float (Kinetic) : Polycarbonate/Polypropylene
 Float (Automatic) : Polypropylene
 Seal : Rubber E.P.D.M.

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 O-Ring : Buna-N
 Bolt and Nut : Galvanized Steel
 Working Pressure : 16 Kg/cm2

Design, manufacture, Supply, erection, commissioning & Testing at site and supply
of Bladder type air vessels
The surge tank shall be vertical, Bladder type vessel suitable for use of with water. The
tank, supports & anchor bolts shall be designed & with stand confirm to Indian / inter-
national standards.
Surge Tank
The surge tank shall be vertical, bladder type vessel suitable for use with raw Water.
Nitrogen shall be used to avoid the corrosion. Nitrogen pressure shall measure and com-
municated to SCADA. Each Surge tank weight shall be measured through weighting
sensor installed at surge tank leg and the same signal shall be transferred to SCADA

Tank Sizing.
Surge Tank Design and Materials
1. Materials for the tank, design, and shop fabrication and inspection shall comply
with pressure equipment standards (IS/ASME/BS 5500/CODAP)
2. Minimum design pressure shall be as stated in this section of the Specifications,
Perform hydrostatic testing in shop. Test pressure shall be 150% of the design pres-
sure of the tank.
3. Provide a ½ inch threaded connection at the top of the tank to contain a gas charging
valve and pressure gauge. Tank shell will be constructed of deep drawn carbon steel
double welded domes and side shells with double welded seams. Tank shall be
equipped with a heavy-duty butyl rubber bladder. The Precharge pressure will be
located between the shell of the tank and the bladder. The side manhole shall be
removable to allow inspection and maintenance of the bladder. The bladder shall be
sized to conform to the inner shape of the vessel. Bladder surge tank shall be of the
vertical configuration.

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Bladder tank shall be equipped with a Hydro Control Level Gauge Equipment
with Output 4/20MA.
Bladder Manufacturing
Service Conditions
Surge tank hydraulic performance conditions and design data shall be as shown below.
Minimum Capacity: As per Scope of work mentioned elsewhere in the bid document

Minimum Design Pressure: 16 Bar

Minimum Test pressure: 1.5 times of * test pressure
Tank Installation
The surge tank shall be installed in accordance with the manufacturers/Suppliers sug-
gested procedures. All supports, piping, valves, and related appurtenances shall be pro-
vided and installed by the Agency at no additional cost to the Owner. Surge tank con-
nected through flexible or expansion joint.
Painting and Coating
All painting and coating shall be completed at the factory. Field painting and coating
will not be accepted. The tank interior shall be painted with anti-corrosion epoxy paint
with a uniform layer thickness of no less than 100 microns, the tank exterior shall be
painted with 3 coat zinc based epoxy to a minimum thickness of 406 microns.

MATERIAL SPECIFICATIONS FOR BLADDER TYPE SURGE VESSEL

SHELL : Carbon Steel SA 516 Gr 70/Equivalent

ELLIPTIC CAP : Carbon Steel SA 516 Gr 70/ Equivalent

BLADDER : BUTYL

COATING INSIDE : Sand Blasting SA 2.5

1 Coat Food Epoxy Thickness of 200 micron

COATING OUTSIDE: Sand Blasting SA 2.5

Zinc Epoxy Dressing

Lacquer RAL 2002

Total thickness 406 microns

LIFTING PAD : Carbon Steel SA 516 Gr 70/ Equivalent

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OUTLET : Carbon Steel SA 516 Gr 70/ Equivalent

DESIGN TEMP. : 600C

POSITION : Vertical

LOAD CELL : Hydro Control Level Gauge Equipment with output 4/20

MA

Supplying, erecting and commissioning of Pressure Relief Valve Specification:

Valve shall be able to relieve the excess pressure than the set pressure.
The Valve Shall be with Rapid-action piston for Fast Opening/Closing action to facili-
tate stable and accurate control of pressure.

Valve shall have Low head loss at high flow rates,

Valve shall be strong, lightweight and corrosion proof surfaces, which resist cavitation
damage, thus increasing service life and reducing operation & maintenance cost.

Valve shall have Linear flow, Low turbulence to minimize cavitation, and allow high
flow velocities with low noise and vibration.

Valve shall have “Soft closure” feature to prevent water hammer.

Multi-Valve modular configuration Full redundancy enabled. Individual valves can be

possible to separately removed for maintenance or replacement which reduces down-
time and maintenance costs & allows maintenance work to be done without halting
water flow.

MATERIAL OF CONSTRUCTION:
Valve Body : Reinforced fiberglass nylon or Polypropylene

Pistons, Bushing, Front and Rear Cups: Reinforced fiberglass nylon or Polypropylene

Main seal : NBR, VITON or EPDM rubber, Shore index: 80

O-rings : NBR or EPDM rubber, Shore index: 70

Clamps, bolts : Stainless steel

Multi-Valve manifolds: Spheroid iron with polyester or epoxy coating/Coated Steel

Pressure Rating : PN 16

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Inspection and Testing of all equipment will be done as per the approved Quality As-
surance Plan from Engineer-in-Charge.

11 Site development
The agency shall develop all the sites for installation of water supply infrastructure as
per specification given hereunder. Existing GL and FGL of different sites are given in
table below:
Description of Existing Finished
WDC Location
WS infrastruc- Area Ground Ground Remarks
No (LPS village)
ture Level Level
1 Cushion Tank Penumaka 6737.50 19.94 20.21
2 Cushion Tank Undavalli 18.69 20.88 2 & 3 in
9071.93 one cam-
3 Cushion Tank Undavalli 18.69 20.88
pus
4 Cushion Tank 5305.55 19.42 21.80
5 Cushion Tank Venkatapalem 5485.81 19.69 21.57
6 Cushion Tank Venkatapalem 5013.45 19.77 20.44
7 Cushion Tank Mandadam 3834.53 21.63 21.60
8 Cushion Tank Mandadam 5355.49 19.88 21.36
Tapping point to
9
startup area
10 & 12 in
10 Cushion Tank 11091.23 20.45 21.42 one cam-
pus
11 Cushion Tank Lingayapalem 7103.33 20.67 21.81
10 & 12 in
12 Cushion Tank 20.45 21.39 one cam-
pus
13 Cushion Tank 2355.55 21.54 22.06
14 Cushion Tank Rayapudi 3300.00 21.77 22.81
15 Cushion Tank Borupalem 4800.00 22.23 24.35
16 Cushion Tank 4800.00 22.63 23.18
17 Cushion Tank Borupalem 5184.15 23.14 26.50
18 SUGR 5055.50 33.50 33.50
Abbarajupa-
19 Cushion Tank 5209.75 23.01 23.71
lem
20 Cushion Tank Rayapudi 6095.50 22.22 22.86
21 Cushion Tank 5929.00 24.25 25.03
22 & 24 in
22 Cushion Tank Thulluru 10268.61 29.50 30.50 one cam-
pus
23 SUGR Ananthavaram 5234.72 40.50 41.00
22 & 24 in
24 SUGR Thulluru 29.50 30.50 one cam-
pus
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Amaravati Development Corporation Limited

25 Cushion Tank Thulluru 6120.00 25.77 26.36

26 Cushion Tank Nelapadu 3925.62 22.29 23.21
27 Cushion Tank 6132.84 20.47 22.13
28 Cushion Tank Velagapudi 5398.00 20.96 21.12
29 Cushion Tank Mandadam 6339.15 20.02 21.00
30 Cushion Tank 7218.01 19.71 20.62
31 Cushion Tank Yerrabalem 6303.00 18.86 19.51
32 Cushion Tank 5044.46 19.09 19.82
33 Cushion Tank Venkatapalem 5089.66 19.11 19.41
34 Cushion Tank 5400.00 19.21 19.55
35 Cushion Tank Mandadam 3806.21 19.54 21.12
36 Cushion Tank Mandadam 6417.09 19.89 21.20
37 Cushion Tank 4181.25 20.72 20.65
38 Cushion Tank 6003.32 20.37 21.22
39 Cushion Tank 7034.93 22.45 23.14
40 Cushion Tank Shakamuru 4344.89 23.40 23.90
41 Cushion Tank 5702.26 26.55 27.50
42 SUGR Nekkallu 3825.99 33.00 33.50
43 SUGR Ananthavaram 6670.42 39.00 39.50
44 SUGR 5930.88 40.00 41.00
45 SUGR 5948.35 32.00 32.50
46 SUGR Nekkallu 6217.54 31.50 32.00
47 Cushion Tank Nekkallu 4726.35 26.09 27.27
48 Cushion Tank Kuragallu 7567.23 22.19 22.69
49 Cushion Tank Yerrabalem 4457.74 18.36 19.30
50 Cushion Tank Navuluru 4911.86 22.32 22.91
51 Cushion Tank 5360.20 28.28 28.20
52 Cushion Tank Navuluru 6362.50 18.71 19.50
53 Cushion Tank Kuragallu 8789.37 18.63 19.25
54 Cushion Tank 7274.40 19.52 20.24
55 Cushion Tank Nidamarru 6595.06 22.99 24.50
56 Cushion Tank 8140.67 21.20 22.13
57 Cushion Tank 5679.99 20.15 20.59
58 Cushion Tank Nidamarru 6600.00 25.43 26.09
59 Cushion Tank Nidamarru 3438.97 29.41 29.40
60 Cushion Tank Nidamarru 4724.35 25.40 25.50

11.1 Site Clearance

The building areas in the sites shall be cleared of all trees, shrubs or other vegetation,
rubbish, slush etc. and other objectionable matters. If any roots or stumps of trees are
met during excavation, they shall also be removed. Where earth fill is intended, the area
shall be stripped of all loose / soft patches or top soil containing objectionable matter

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before filling commences. Any structure or services existing at the site shall be removed
/ rerouted with the permission of the Engineer-in-Charge. Existing wells, pits, marshy
areas etc. shall be filled up with earth of approved quality.

The Agency shall be deemed to have visited and carefully examined the sites and sur-
roundings and to have satisfied himself about the nature of the existing structures, un-
derground services, general site conditions, and the site for disposal of surplus materi-
als, debris etc and all other items affecting the work.

Green Building Requirements like preserving top soil; erosion control etc shall be
followed.

Claims due to ignorance of site conditions will not be considered after submission of
Bid.

11.2 Site Grading

The table given above is indicating grade levels based on the preliminary survey work.
The Agency shall conduct a study on the site grading to fix the grade levels at various
locations of the plot based on the detailed topographical survey conducted at site by
him, and the information given by Engineer-in-Charge to match the overall master
plan and infrastructure master plan.

The Agency site grading proposal may consider optimum use of locally available earth
in addition to achieving the above objective. Fills shall normally be made up of CNS
material capable of being compacted up to 95% Modified Proctor density. In case
earth has to be borrowed from outside the plot boundary, the same shall be arranged
by the Agency himself. The Agency shall fill earth in layers not exceeding 150 mm
and each layer shall be consolidated properly to get optimum dry density.

Earth from Swamps, marshy as well as bogs, expansive type of clays, peat, organic
material, material susceptible for combustion, material which will react with other
material already used in work shall not be used as borrow material.

12 Boundary wall & Security cabins

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The Agency shall design and construct RCC framed 250 mm thick brick filled deco-
rated boundary wall with ornamental gates made of MS angle, flat, square bar, sheet.
Security cabins of floor space 10 sq.m shall be provided in all the water work sites like
Intake well, WTP, WDC compounds.
The height of the boundary wall shall be 1.8 m above the finished ground level. Height
of the MS gates shall be of 1.8 m. There shall be atleast two ornamental covered gates
sufficient to provide access to heavy vehicular trucks in Intake well & WTP compound.
There shall be atleast one ornamental covered gates sufficient to provide access to
heavy vehicular trucks in WDC compound. The gates shall preferably be made of MS
bars, flats and plates welded together. The design of the entire work shall be submitted
to the Engineer-in-Charge for approval. The location of the gates shall be as instructed
by the Engineer-in-Charge. The Agency shall also provide plaster finish over both the
sides of boundary wall and two coats of decorative weather coat exterior paint on the
surface of the entire boundary wall. The entire WTP compound shall be divided in three
premises (one for main WTP premises, second one for staff quarters premises and third
for administrative building premises) by boundary walls. All the above three premises
shall have boundary walls and separate access gate from main road. All gates shall be
provided with MS gates. The MS gates at WTP site and Intake well site shall be elec-
trically operated and access control gate. In addition to MS gate, the gate of main WTP
premises and administrative building premises shall provide with electrically operated
remote-control boom barrier.

13 Internal road network

All internal roads shall be of cement concrete (M30) with minimum reinforcement as
per relevant IS codes.

13.1 Internal drainage

The Agency shall design, make detailed Engineer-in-Charge and construct storm water
drains for disposal of rain water from the compound of all water work sites like Intake
well, WTP & WDCs. The Agency shall also connect the internal drains with the city
storm water drain outside the premises at suitable location. The storm frequency shall
be one in five years. The Agency shall submit layout and design of storm water drainage

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network to the Engineer-in-Charge for approval. The storm water drainage system shall
consist of underground RCC NP3 pipelines, manholes, gully pits/catch pits etc. The
storm water drainage system shall be so designed so as to make the discharge of the
water into the outlet channel by gravity alone. The Agency shall make proper arrange-
ment to discharge the water into the existing drainage system of the vicinity. Necessary
permissions have to be obtained from the competent authority by the Agency to dis-
charge the same into the existing drainage system. He shall also satisfy himself about
the adequacy of the existing drains. The Agency shall design, make detailed Engineer-
in-Charge and construct proper sewerage system for disposal of sewage from toi-
let/wash room provided inside the different buildings of WTP, Intake well cum pump
house, WDCs etc. Sewer line shall be of DWC HDPE pipeline and manholes shall be
RCC. The specification for Storm water drain and sewerage system are given elsewhere
in the bid document.

14 Landscaping
Providing Landscape architecture in this project includes intake well-cum-raw water
pumping station campus, WTP campus and WDCs/GLSR - 8 No. Other than the build-
ings and built-up areas in these campuses, landscaping shall be provided to the rest of
the spaces available for landscape development.

14.1 Specific Objectives

The landscape component in this project shall be designed to achieve the following
specific objectives:
 Landscape shall add to the beautification of the space.
 Ample landscaping, using low maintenance, low water use native plantings that
evoke the visual character of the surrounding area and the city landscape.
 Wide landscape buffers to mitigate impacts to the proposed planned development
activities around the buildings and built-up areas in each campus.
Landscaping practices that shall integrate and go beyond the conservation and effi-
cient use of water, soil and vegetation.

14.2 Provisions
For landscaping, Agency shall provide the following in planning and construction:
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a) Given Amaravati capital city’s climatic conditions of high rainfall during south-
west monsoon, heat wave during summer, variable humidity and wind factors, as
well as varying soil characteristics, etc., plants including ornamental plants, mos-
quito repellent plants, dust and pollution- arrest plants shall be selected with an un-
derstanding of the microclimate conditions and they shall be grouped in appropriate
hydro and plants variety zones.
b) A Grading Plan for the available space shall be prepared which shall include main-
taining land slope towards the natural drainage and no erosion of soils.
c) Grass turf with soft grass variety shall cover the entire landscape areas. Before
placement of grass turfs and plants, good soils shall be provided with appropriate
bio-fertilizers and other nutrients.
d) Landscape area shall be covered with flower gardens at suitable places. Flower
plants which sustain year-round shall be selected.
e) Landscape areas shall be covered with sprinkler irrigation. Depending on the land-
scape area of the campuses, one or more water fountains shall be provided.
f) Walkway/inner roads in the campus shall be curvilinear and aesthetically designed
with colorful inter-locking tiles.
g) A few sit-outs, waste bins, few artifects, signs mentioning interesting plants’ name
shall be provided
h) Entire landscape architectural plan shall be prepared and such drawings, 3-D view
and detailed specification shall be submitted to the Engineer-in-Charge for ap-
proval.

Daily maintenance of the landscaped areas shall continue through the 2-year DLP and
8-year O&M period.

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SECTION – IV
Technical Specification for Electrical Works

1.1. LIST OF DRAWINGS TO BE SUBMITTED AFTER AWARD OF CONTRACT

Following drawings, calculations & schedules shall be submitted for approval before
procurement, fabrication and Installation of equipment at site.

(A) Drawings

1.0 Single Line Diagram of Complete and individual Electrical System

2.0 Electrical Substation Layout of Intake well, WTP and clear water pumping station
showing Panel locations, Transformer locations, 33kV Centralised Switchgear
Panel location, 6.6kV Centralised Switchgear/MCC Panel location, LT Main
PMCC Panel Location and Trench Layout.

3.0 33kV Centralised Switchgear Panel / 6.6kV Centralised Switchgear/MCC Panel

a. General arrangement drawing shall indicate the overall dimensions, net weights,
and the general constructional features.
b. Certificates of type tests carried out on Switchgear Panel of similar rating in the
last three years.
c. General arrangement drawing of the Switchgear Panel showing plan, front ele-
vation and side elevation complete with all accessories and fittings, detailed di-
mensions, net weights etc.
d. Foundation drawing with position of foundation bolts and depth.
e. Schematic power and control wiring diagrams with control, interlocks, instru-
ments, space heaters, bus bar rating with material, Current transformers, potential
transformers etc.

4.0 33kV/6.6kV, 6.6kV/0.415kV, 33/0.415KV Oil Filled/dry type transformers

a. General arrangement drawing shall indicate the overall dimensions, net weights,
quantity of oil, crane requirements for assembly and dismantling of transformers
and the general constructional features.
b. General arrangement drawing of the transformer, showing plan, front elevation
and side elevation complete with all accessories and fittings, detailed dimensions,
net weights, quantity of, crane lift for un tanking, size of lifting lugs and eyes,
clearances between HV terminals, between LV terminals, between HV and LV
terminals, between HV & LV terminals and ground etc.
c. Rating, diagram and terminal marking plates, complete with polarity and vector
group.

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d. Control wiring diagram for marshalling box.

e. Foundation drawing with position of foundation bolts and depth.

5.0 Neutral Earthing Resistor

a. General outline drawing but with binding dimensions and weights.
b. Detailed outline drawing showing plan, front elevation, end elevation, inner
view, locating dimensions of cable entries, terminal details, structure/floor fixing
details and weight of the neutral earthing resistor.
c. Schematic diagram of resistor with taps, terminal box connections, terminal de-
tails, ohms, current and voltage rating, voltage class of the stand insulators.
d. Details of Temperature coefficient of resistance.

6.0 Main LT PMCC/MCC’s, UPS/Lighting DB’s

a. Dimensional layout drawing
b. Complete assembly drawings of the switchboard/distribution board showing
plan, elevation and typical sectional views and location of cable boxes and control
cable terminal blocks for external wiring connections, etc.
c. Foundation plan showing the location of channel sills, foundation, anchor bolts
and anchors, floor plans and openings.
d. Schematic power and control wiring diagrams with control, interlocks, relays,
instruments, space heaters, starters with Bi-metallic relay ratings and contactor rat-
ings, busbar rating with material etc.
e. Feeder operation logic

7.0 LT Capacitor bank with Automatic power Factor Correction Relay

a. Dimensioned general arrangement drawings of capacitor and capacitor control
panel
b. Justification for number of steps for switching
c. Fully dimensioned general arrangement drawings of capacitor and capacitor
control panel with elevation, side view, sectional view and foundation details
d. Complete schematic and wiring diagrams for capacitor control panel

8.0 Variable Frequency Drives

a. Dimensional details with mounting Arrangement
b. Schematic power and control wiring diagrams with control, interlocks, relays,
instruments, space heaters, starting time and current, relay ratings, contactor rat-
ings, bus bar rating with material etc.

9.0 Battery & Battery charger with DC Distribution Board

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a. Dimensioned general arrangement drawings

b. Fully dimensioned general arrangement drawings of battery and battery charger
with elevation, side view, sectional view and foundation d
c. Complete schematic and wiring diagrams

10.0 Cabling system

a. Details of Installation of Cables in Trenches/Tunnels, on cable trays, racks di-
rectly buried etc., at all locations inside the Chiller plant.
b. Cable routing layout inside and outside the plant.
c. Bill of quantities of cables, lugs and glands.
d. 33kV & 6.6kV Cable termination and mounting Kit Layout drawing.

11.0 Earthing & Lightning Protection system

a. Details such as material, sizes, etc. of the earth conductor and electrode pits
b. Earthing layout drawing showing routing of main grid inside and outside the
plant with interconnection of equipment earthing to the grid and earth pits

12.0 Lighting System

a. Detailed Room wise Lighting Layout with Type of fixture details and Circuit
diagram showing phase wise load distribution and interconnection between
switches, fixtures, Lighting panel, receptacles etc & Detailed lux level calcula-
tions.
b. Conduit layout showing room wise routing of wires from lighting panel to light-
ing fixtures, receptacles etc.
c. Internal road Lighting and Area lighting layout with type of mounting details
and fixture details.
d. Street Light pole details with Foundation details.

(B) Calculations
a. Transformer Sizing Calculations
b. Fault level and Voltage Dip Calculations
c. Neutral Earthing Resistor sizing Calculations
d. Co-ordinated protection study.
e. Sizing of capacitor banks
f. HT & LT cable sizing
g. UPS & Battery Sizing Calculations
h. Building Lightning Protection and Earthing Sizing Calculations

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i. Room wise Lighting Calculation as per Lux level given in IS 3036 Part-I.
j. Protection matrix with supporting calculations for all electrical equipment

(C) Schedules
a. Cable Schedule
b. Load & Power Consumption Schedule
c. Protection Relay Setting Schedule
d. Junction Box Schedule

1.2. PRIMARY POWER SOURCE

The Power supply for Intake, WTP will be arranged by laying 33kV underground cables
from 220KV GIS substation nearest. The incoming 33kV cables will be terminated on
the 33kV RMU inside Intake and WTP premises.

1.3. POWER SUPPLY ARRANGEMENT INSIDE THE PLANT

The overall power supply arrangement for intake and WTP shall be as per Single line
diagram.

1.4. GENERAL DESIGN CRITERIA

The 33kV Substation at Intake well is going to be developed in modules as per the
growth of water supply load. There shall be a 33kV Centralised Switchgear Panel, in-
comers sized for the total load Requirement of all the Phases of intake well. All the
Outgoings of the 33kV Centralised Switchgear Panel & respective Transformers are
added according to the Phase wise growth Requirement of the Plant.

33kV System
a) Nominal voltage 33kV
b) Number of phases 3
c) Frequency 50 Hz

d) Connection 3 Wire
e) Maximum Fault Level 1600 MVA

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6.6kV System

a) Nominal voltage 6.6kV

b) Number of phases 3
c) Frequency 50 Hz

d) Connection 3 Wire

e) Maximum Fault Level 500 MVA

LV System

Voltage : 415V Nominal

Frequency : 50 Hz
Connection : 4 wire
No load transformer voltage : 433 V
System earthing : Solidly earthed
Maximum fault level : 36 MVA

All Plant shall, unless otherwise specified, be capable of continuous operation at a volt-
age level in the range of 90% to 110% of the relevant nominal voltage and a frequency
variation of plus 3 % to minus 3% with a maximum combined tolerance of 10%.
AC Control, Lighting and Space Heating
Voltage : 240 V
Phases : 1
Frequency : 50 Hz
Connection : 2 wire (Phase & Neutral)

Power Transformers
 The 33kV substation will have of 33kV / 6.6kV Transformers.
 The transformers shall be sized considering 20% contingency of total working load
while arriving at the final capacity of transformers. Two nos. of transformers are
provided in substation such that under normal condition one transformer will be
standby. Under fault on one transformer, the healthy transformer shall have capacity to
take entire load so as to have 100 % standby. The transformer shall be designed such
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that at any point of time maximum loading on any single transformer shall not exceed
80% of full load capacity.
Distribution Transformers
 There will be 1nos of 6.6kV / 0.415kV Transformers.
 The transformers shall be sized considering 20% Contingency of total working load
while arriving at the final capacity of transformers. The transformer shall be designed
such that at any point of time maximum loading on transformer shall not exceed 80%
of full load capacity.
33kV & 6.6kV Switchgear
 33kV & 6.6kV switchgear will be sheet metal enclosed with draw out type vacuum
circuit breakers for incoming and outgoing feeders, for the HV motors and auxiliary
transformers.
 The switchgear degree of protection will be IP 4X.
LV Switchgear
The 415V switchgear will be of compartmentalized and modular construction. Fuse
switches and starters will be of a fixed construction whilst main air circuit breakers will be
withdrawable type. The degree of protection will be IP 54 for indoor installation and IP55
for outdoor installations. The switchgear will be designed for a fault level of not less than
25 MVA at 415 V.
System Protection
A microprocessor based protection system for the various parts of the power supply system
is proposed.
The following protection systems will be used:
33kV & 6.6kV Transformer feeder
HV Side
 transformer differential relay;
 inverse definite minimum time overcurrent relay with instantaneous over current
element;
 instantaneous earth fault;
 Bucholz/ gas pressure relay with alarm and trip contacts;
 winding temperature indicator with alarm and trip contacts;
 oil temperature indicator with alarm and trip contacts;
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 magnetic oil level with alarm contact.

LV Side
 inverse definite minimum time earth fault relay;
 restricted earth fault relay and Stand by earth fault.
33kV & 6.6kV Incoming Outgoing Feeders
 inverse definite minimum time phase overcurrent relay;
 inverse definite minimum time earth fault relay;
 potential transformer fuse failure relay;
 under voltage relay.
6.6 kV Feeder to Distribution Transformer
 inverse definite minimum time overcurrent with instantaneous over current element;
 instantaneous earth fault relay and standby earth fault.
415 V Incomer Feeder
 Overload, Earth fault and short circuit protection;
LV Motors
Motors less than 15 kW
 overload protection by three phase thermal (bimetal) relay.
 Single phasing preventer.
Motors 15 kW up to 132kW
Electronic motor protection relay providing the following protection for
 Overload;
 Earth fault;
 Phase currents out of balance.
 Single phasing preventer.

Motors 132kW and above

Comprehensive motor protection relay providing the following protection for
 Overload;
 locked rotor;
 Over current;
 Earth fault;

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 Phase currents out of balance.

 Over voltage & under voltage;
 phase loss/reversal;
 Negative sequence;
 Protection for repeated and prolonged starts;
 restart inhibition;
 No load running;
 Single phasing preventer.
Switchgear Equipment / Instruments
33 kV Incoming & Outgoing Feeders, 6.6kV Feeders Incomers
 ammeter on all 3 phases;
 voltmeter with selector switch;
 kW meter;
 kWh meter;
 power factor meter.
6.6kV Outgoing Feeders
 ammeter on all 3 phases;
 kWh meter;
 power factor meter.
6.6 kV Feeders to Distribution Transformers
 ammeter on all 3 phases;
415V Incomer Feeders
 Ammeter on all 3 phases;
 Voltmeter with selector switch;
6.6KV Motor Starters
VFD Starters for all HT and LT pumping motors.
Each motor shall be provided with a press to lock and twist to release type local emer-
gency stop button with mushroom head.
Pump Drives
Where practical all pumps shall be provided with the following additional protection:
 run dry protection,

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 over pressure
L.T Capacitor Bank and Power Factor Correction
 The capacitor banks provided shall be of bus connected type with Automatic Power
factor correction, the system shall be designed such that a power factor of not less than
0.95 is maintained.
 Automatically controlled multistage power factor correction shall be provided. 2 Nos.
PFC panels providing no less than 8 No PFC stages per panel shall be provided each
connected to one bus section of the distribution board. The PF on each half of the board
shall be monitored and corresponding PFC capacitors switched in and out automatically
in discrete stages in order to maintain a set point PF value.
 The breakers and cables in capacitor circuit shall be designed for taking extra loading
of 35%.
H.T Capacitor Bank and Power Factor Correction
 The 6.6kV capacitor banks provided if any shall be of 6.6kV Motor connected type with
Automatic Power factor correction, the system shall be designed such that a power
factor of not less than 0.95 is maintained.
 The breakers and cables in capacitor circuit shall be designed for taking extra loading
of 35%.
Cabling
 HV Power Cables
 HV cables for use on 33kV & 6.6kV shall be XLPE insulated aluminium conductors.
 LV Power Cables
 LV multicore cables for use on 415 V and 240 V power supply system shall be XLPE /
PVC type with aluminium conductors for sizes 6 sqmm and above and Copper
Conductors for sizes below 6sqmm.
Cable Rating
 All power cables shall be sized for continuous current carrying capacity and permissible
voltage drop at an ambient temperature of 50 degrees C. Due consideration shall be
taken of cable grouping, method of installation and local variations in ambient
conditions. Further, for cables controlled by circuit breakers, due consideration shall be
given to the fault level.

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 LV cables shall be sized for a minimum fault clearance time of 0.5 second for incoming
feeders and 0.16 second for equipment feeders & HV Power cables shall be sized for
fault clearing time of 1 sec.
In general power cables will be sized to limit the maximum voltage drop of 5 % from
transformer secondary to motor terminal.
Cable Installations
Heavy duty galvanized iron cable tray and ladder racking shall be used for cable support
systems. These shall be used to route cables along walls, below beams and within cable
trenches. Cables shall be securely fixed to the support systems. Bundling of cables shall be
permitted where allowance for this practice has been made while sizing the cables.
Building Services
Lighting
All internal and external areas shall be provided with lighting. The illumination levels to
be achieved shall be as follows:
Area Illumination Level (Lux)
Pump house 200 Lux
Machinery service area 200 Lux
Offices 300 Lux
Control rooms 300 Lux
Cable basement 100 Lux
All other indoor areas 100 Lux
Outdoor platforms and walk ways 50 Lux
Building entrance 100 Lux
Outdoor plant areas 30 Lux
Outdoor transformer yards
- General 30 Lux
- On equipment 40 Lux
Roads (secondary) 40 Lux

 Luminaires for internal lighting shall comprise LED type only. Assure that minimum
illumination levels are maintained following momentary power dips which could
extinguish the discharge lights for several minutes.

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 Ceiling fans shall be provided in offices, control rooms and they shall be connected to
local lighting circuit.
 The internal lighting installation shall be installed using single core, PVC insulated
copper cable enclosed in galvanized iron conduit. Lighting in external areas shall be
installed using multicore armoured cable.
Ventilation Fans
 Variable speed ventilation ceiling fans shall be provided in offices, control rooms,
control areas and switchgear rooms. One fan shall be provided for each 10 m2 or part
thereof of the area concerned.
 Where fitted, ceiling fans shall be connected to the local lighting circuit.
 Small Power Outlets
 Switched single phase three pin 5 A and 15A receptacles shall be provided throughout.
In offices and control rooms they shall be the decorative type and industrial type in all
other areas.
 Unless required to be provided in greater numbers to power specific Plant items the
number of
Such outlets shall be as follows ;
 5 A type one outlet per 5 m or part thereof of perimeter in offices;
 5 A type one outlet per 20 m or part thereof of perimeter in all other areas;
 15 A type one outlet per 20 m or part thereof of perimeter in offices;
 15 A type one outlet per 20 m or part thereof of perimeter in all other areas.
 32 A switched three phase and neutral receptacles shall be provided in plant areas where
appropriate i.e. adjacent to areas where flooding is likely to permit the use of portable
sump pumps. The Agency shall install ten such outlets at various locations throughout
the plant.
 The location of outlets shall be approved by the Engineer-in-Charge. The spacing of 5
A and 15 A outlets shall be arranged to suit the intended location of equipment, desks
etc.
 Receptacles for outside areas shall have a degree of protection of IP 55.
System Earthing
 An earthing system comprising earth electrodes and conductors shall be established at
each substation and transformer. The two networks will be interconnected.
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 The earthing system will be designed to give a combined earth resistance value of not
greater than 1 ohm. In order to be sure of obtaining suitable final values, soil resistivity
shall be measured at the various sites during the detailed design phase of the work.
 In outdoor substation areas the main earth electrode conductors shall be located, to
ensure potential gradients occurring at the surface during fault conditions are kept
within allowable limits.
 Materials used for earth electrodes shall be designed to suit the ground conditions and
shall either be plain mild steel or Galvanised steel.
 The fault clearing time will initially be taken one second for the 33kV, 6.6kV and 415V
systems.
 The maximum temperature allowed for steel welded joints will be taken as 500oC with
an ambient of 50oC. Main Equipotential bonding conductors shall be galvanized steel.
 Circuit protective conductors will comprise either the armouring of the supply cable or,
for major loads such as main switchboards and large drives the supply cabling plus an
additional suitably sized single core copper cable.
 The neutral point of the 33kV/6.6kV transformer secondary windings shall be earthed
through Neutral Earthing Resistor.
 The neutral point of the 6.6kV/0.433kV transformer secondary windings shall be
solidly earthed.
For Transformer Neutral Earthing, Copper conductors shall be used.

TECHNICAL SPECIFICATION FOR 36kV RING MAIN UNIT

General
 The RMU for the compact substation shall be 5 way/7 way, 36kV, extendable type, free
standing, outdoor, metal clad SF6 insulated Ring Main Unit (RMU) along with
metering, PTs, CTs etc.
 The outdoor type RMU shall be extendable type and stand alone.
 Two numbers, fault making / load breaking, motor operated, line side switches, fitted
with indications for phase and earth fault along with associated CTs. The load break
switches shall be connected via underground XLPE Cables.
 Outgoing feeder of RMU shall have, Tee-off, spring operated, Circuit breaker with
sealed for life vacuum interrupter complete with meters, CTs, Protective and auxiliary
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relays to control desired number of transformers or equipment with complete

arrangement to connect the tee-off circuit breaker to the 33kV side of the power
transformer.
 The springs for closing the load break switches & tee-off circuit breaker shall be motor
operated.
 The opening & closing for the load break switches as well as tee-off circuit breaker
shall be carried out electrically from remote via SCADA, besides local / hand operation.
Built in compact battery [with no maintenance of any type] with charger shall be part
of supply for this purpose.
 The breaker shall have necessary over current and low sensitivity earth fault protection
on the delta connected, 33kV side of the transformer. Further the protections on
distribution transformer shall operate this breaker with required alarms. It shall have
basic metering features also to monitor these in RMU.
 RMU shall also be equipped with necessary Remote Terminal Units, transducer’s etc.
complete in all respects, since these RMU’s shall be having provision for SCADA with
remote control. The provision for requisite control & indications shall be provided in
the RMU’s & substations.
 Fault passage indicators, Feeder Remote Terminal Units, with self-healing feature,
communicating with each other in the Ring circuit shall ensure automatic isolation of
faulty cable and restoration of supply in case of cable fault in the system, using Fibre-
Optic based communication.
 There shall be continuous monitoring of supply on 36kV cables via capacitive voltage
indicators.
 The RMU shall be complete in all respects including elbow type cable termination
arrangement [with shrouds] in air from bottom, gland plate, double compression glands,
foundation channels, bolts, inter connection arrangement etc.
 The external dimensions shall be identical throughout the length of the board.
 The operation of any of the switching functions shall be simple with only three possible
positions viz. closed, open and earthed. The earthing switch shall be placed on cable
side. The earthing of cable is to be done by an independent fault making switch.
 All the necessary safety interlocks between switching devices, earthing switch and
cable box covers shall be integrated.
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 The accessories and LV auxiliaries (i.e. motor mechanism, coils, auxiliary switches etc.)
shall be the same for the entire range of switching functions, load break switches or
circuit breakers. They can be installed on site without any dedicated tool and training.
 Any other item not included above but required to complete the works shall be deemed
to be included in RMU, without any financial liability to the purchaser.

Standards
Unless otherwise specified, all equipment and material covered in this specification shall
conform to the latest applicable Indian / IEC Standards. Equipment complying with any
other international standards will also be considered if it ensures performance of equipment
equal to or superior to Indian Standards. Copy of such a standard shall also be supplied.
S. No Standard Number Description
High-voltage switchgear and control gear – Part 1: Common spec-
1 IEC 62271-1
ifications
High-voltage switchgear and control gear - A.C. metal-enclosed
2 IEC 62271-200 switchgear and control gear for rated voltage above 1 kV and up to
and including 52 kV.
3 IEC 62271-103 Switches for rated voltages above 1 kV and less than 52 kV
High-voltage switchgear and control gear – Part 100: High-voltage
4 IEC 62271-100
alternating current circuit breakers.
High-voltage switchgear and control gear – Part 102: High-voltage
5 IEC 62271-102
alternating current disconnectors and earthing switches
High-voltage prefabricated switchgear and control gear assemblies
6 IEC 61958
– Voltage presence indicating systems.
7 IEC 60529 Degrees of protection provided by enclosures (IP Code)
8 IS:722 A.C. electricity meters
9 IEC 60044-8 Instrument transformers – Part 8: Low Power Current Transducers
10 IEC 60044-1 Instrument transformer – Part 1: Curent transformer
11 IEC 60044-2 Instrument transformer – Part 2: Voltage transformer
12 IEC 60255 Electrical relays
13 IS: 5 Colours for ready mixed paints and enamels
14 IS:1248 Electrical Indicating Instruments
15 IS:1554 PVC insulated cables up to and including 1100 volts
16 IS:4794 Push Button Switches
17 IS:6005 Code of practice for phosphate coatings of iron and steel
18 IS:2099 Bushings for alternating voltages above 1000 V
19 IEC:62271-202 Pre-Fabricated Substation
IS:13118, IS:3427,
20 Switchgear cubicles
IEC:60694.
21 IS:9920, IEC:60265 Ring main unit

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S. No Standard Number Description

Code of practice for selection, installation and maintenance of
22 IS:10118
Switchgear
23 IS: 1180 Distribution Transformer
24 Indian Electricity Rules
25 Indian Electricity Act
26 IS:13072 Sulphur hexafluoride for electrical purposes

Technical Particulars (Standard Values)

The Ring Main Unit (RMU) shall consist of three phase, two load break switches and one
or two (depending type no. of outgoings) tee-off VCB, Circuit Breaker Compact Unit, SF6
insulated and sealed for life complying to latest version of IEC 622-71-200
a. Rated system voltage (kV) 36
 Rated current for load break switch [A] up to 630 Amps
 Rated current for tee-off Breaker [A] up to 630 Amps
 Nominal system voltage [kV] 33
 System Earthing Solid
b. Basic Insulated level
 Lightning Impulse withstand voltage (kV) As per Indian Standard
 Power frequency withstand voltage for As per Indian Standard
One minute (kV rms)
c. Frequency (Hz) 50
d. Bus bar rated current (A) upto 630 Amp
e. Rated short time symmetrical three phase current 20
(kA for 3 sec for load break switches & tee-off breaker)
f. Earth switch for load break switches (kA for 3 sec) 20
g. Earth switch for tee-off breaker (kA for 3 sec) 20
h. Rated making current (kA peak) 65
i. Rated breaking current for circuit Breaker [kA for 3 s] 20
j. Rated breaking current for circuit Breaker [kA for 1s] 25
k. Filling & rated gas pressure <1 bar, gauge
l. Internal arc test [kA for 1 sec] 20
m. Interrupting time in millisecond less than 40
n. Operating Duty: O-0.3s-CO-3min-CO

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o. Degree of protection for enclosure IP 54

p. Paint thickness (micron) 60
Notes:
 Type, routine, internal arc test reports shall be supplied by the Agency along with
tender.
 RMU for CSS shall be non-extendable type and RMU for outdoor distribution shall be
extendable type.
Storage [without heaters, in humid environment]: from 0°C to +50°C
 Operation : 0°C to +50°C
 Partition class : PM
 Main HV circuit : IP67
 Front connection in cable box, suitable for armored, XLPE insulated Aluminium cable,
as per calculated & specified size. Termination with elbow type plugs in bushings with
insulating boots.
Load Break Switch
 The switch shall be combining the functions of a load break switch, disconnector and
associated earthing switch. It shall have three positions (closed, open / disconnected,
earthed) earthing to be on cable side.
 The mechanism shall be anti-reflex, lever-operated type, with intuitive operation and
clear mimic panel indications.
 Switch shall have built-in fail safe interlocks between main switch and earthing switch.
Standard built-in padlocking facility for main switch, earthing switch and interlock shall
be provided.
 Switch shall have a provision for remote opening and closing through SCADA also.
Earthing switch operation shall be locally.
 It shall carry rated current continuously and short circuit current for the duration
specified without exceeding the permitted temperature rise as per relevant IEC / Indian
standard. Switch shall not be damaged even when closed on a dead short circuit for the
permitted period of short circuit.
 Each load break switch shall be of the triple pole, gang operated, with quick break
contacts.
Circuit breaker for Transformer

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 The Circuit Breaker shall have a switch disconnecting the circuit breaker with an
associated earthing switch. It shall have three positions (closed, open / disconnected,
earthed) earthing to be on transformer side. Circuit Breaker shall have a provision for
remote opening and closing through SCADA. Earthing switch operation shall be locally.
 It shall carry rated current continuously and short circuit current for the duration
specified without exceeding the permitted temperature rise as per relevant IEC / Indian
standard.
 Circuit breaker shall be opened with a push button and closed with the “closing lever”.
The mechanism shall be anti-reflex, lever-operated type, with intuitive operation and
clear mimic panel indications. Switch shall have built-in fail safe interlocks between
main switch and earthing switch. Standard built-in padlocking facility for main switch,
earthing switch and interlock shall be provided. The circuit breaker and load break
switch can be locked in the open, close or earth position by 1 to 3 padlocks of ESI size.
 Breaker shall not be closed when cable cover is open.
 In case of fault the breaker shall be tripped through a self-powered relay.
 Circuit Breaker Interrupting Unit:
 Tee-off Circuit breaker shall have Vacuum interrupting arrangement.
 The design & construction of the Vacuum circuit breaker shall be compatible with the
latest Vacuum circuit breaker technology.
 The Vacuum interrupter bottles shall be completely maintenance free & mechanically
strong for 30 years life. Test certificate to be provided.
 Suitable interlock shall be provided against breaker operation in the event of loss of
Vacuum.
 Circuit breaker shall allow low chopping current level.
 Graph showing short circuit Vs tripping permitted for Circuit Breaker.
 Duty Requirement:
 The circuit breaker shall be totally restrike free under all duty conditions and shall be
capable of performing the duties satisfactorily.
 The circuit breaker shall meet duty requirement for any type of fault location, also for
line charging current. The operating duty of the circuit breaker shall be as follows:
 O-0.3s-CO-3min-CO

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 The circuit breaker shall be suitable to break the required induction current in accordance
with the BIS / IEC standard. The value thereof shall be clearly specified at the time of
offer.
 The circuit breaker shall meet its duty requirement in case of application for controlling
U/G cables, power transformer.
 The rated transient recovery voltage for terminal fault and short line faults shall be as
provided in the relevant IEC / BIS.
 Constructional Details:
 Complete switchgear including bus bars shall be contained in an earth screened stainless
steel tank, filled with SF6 gas, degree of protection not less than IP-67, as per
requirement of IEC standards. To prevent gas leakage the gas pressure shall be
maintained low within one atmospheric gauge. The filled gas shall provide the required
insulation and also current breaking for load break switches.
 There shall not be any condensation of SF6 gas on internal insulating surface of the
circuit breaker and Load Break Switches. Temperature compensation shall be provided
and the system shall be an integral part of breaker.
 SF6 gas shall be sealed for life in the compartment so as to satisfy “Sealed Pressure
Systems” requirement of IEC-60694 (Clause 5.15.3). Throughout the life of the
equipment there shall not be any “topping up” of SF6 gas. The rated life of the equipment
must not be less than 30 years as per IEC-60694. During this operational life of the
switchgear, absolutely no gas filling is required. The container shall be evacuated before
gas filling and it shall be diffusion-tight. The design of the RMU housing shall be such
that in the event of an internal arc fault, the safety of the operator shall be ensured. All
the safety requirements as required in IEC 62271-200 shall be provided.
 The switchboard when charged must not have any access to live parts so as to endanger
the life of operating personnel.
 The RMU shall be so designed that the position of different devices is visible to the
operator in front of the switchboard. The operating switches, handles etc. shall be at a
height at which these or easy to operate, without any extra effort. All the items in the
equipment shall be identified with long life labelling, cautions etc. The labelling must
clearly indicate the required function.

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 All the items in the equipment shall be identified with long life labelling, precautions
etc. The labelling must clearly indicate the required function.
 There shall be operation counters for Load Break Switches and breaker with a provision
to sound an alarm when the permitted operations are approaching.
 It shall be possible to lock the operating mechanism in any of the three positions when
the contacts have fully homed and also to independently lock the “ON” and “EARTH”
positions. The position “ON”, “OFF” and “EARTH” of the switch shall be clearly
indicated such that the direction of movement of the operating handle(s) from one
position to another is readily apparent.
 The operating mechanism shall be maintenance free without the need of any lubrication
during its life time of 30 years. The operating mechanism shall undergo a mechanical
endurance test as specified in IS/ IEC 62271-200.
 The ring main shall be dust, moisture & vermin proof and suitable for indoor or outdoor
installation. All the cabinets shall be free standing floor mounting type and shall be
provided with double hinged doors with padlocking arrangements.
 All door panels, removable covers shall be gasketed all round with neoprene gaskets.
All louvers shall have screen and filters. Vent opening shall be covered with mesh and
so arranged that hot gases or other material shall not be discharged, injuring operating
personnel or surrounding apparatus and cables.
 Metal enclosure unit shall comprise of rigid welded structure frame enclosed completely
by metal sheet of thickness not less than 2 mm. The sheet shall be cold rolled with
smooth finish, levelled & free from flaws. However, the structural frame & all load
bearing members of the enclosures shall have a minimum thickness of 2.5 mm or more.
All members shall be properly braced to prevent webbing.
 Ring main design shall comprise full compartmental execution having separate vertical
sections for each circuit having internal barriers. Compartment with doors for access to
operating mechanism shall be so arranged as not to expose high voltage circuit. The ring
main cubical compartment shall be provided with hinged doors on the front with facility
for padlocking door handles.
 All corresponding components of circuit breaker / load break switch cubicles of same
ratings shall be interchangeable with one another.

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 The board shall be wired with the connection brought on to the terminal boards for
remote operation.
 The equipment shall also be as compact as possible so as to occupy minimum space in
the sub-station room. Such type of equipment will have preference.
 Temperature rise in the unit shall not exceed as prescribed in IS/IEC.
 Minimum clearance between the phases and between live parts & grounded objects in
the switchgear/ load break panels shall be in accordance with IEC.
 Operating Mechanism:
 Circuit breaker as well as load break switches shall be provided with suitably designed
spring charged motor operated mechanism. It shall be possible to charge the spring
manually, if required. The closing/ opening shall be through remote or through locally
operated push button or operating switch.
 It shall be “trip free” mechanically under every method of closing (except during closing
for maintenance).
 The operating mechanism shall be such that the failure or any auxiliary spring will not
prevent tripping. When the circuit breaker is already closed it shall not cause damage to
the breaker or endanger the operator.
 The breaker / load break switch shall also be hand operated, if so required.
 Electrical as well as mechanical indicator shall be provided to show open & close
positions of the breaker / load break switches. It shall be located in a position where it
will be visible to a man standing on the ground with the mechanism housing closed. An
operation counter shall also be provided with each breaker / load break switch.
 Working parts of the mechanism shall be of corrosion resisting material. Bearings, which
require grease, shall be equipped with pressure type grease fittings. Bearing pin, bolts,
nuts and other parts shall be adequately pinned or locked to prevent loosening or required
adjustment with repeated operation of the breaker / load break switch. The mechanism
shall be maintenance free.
 The closing mechanism shall be able to be operated by one man standing on the ground
& direction of rotation of the handle for charging / closing shall be clearly defined.
 Arrangement shall be made to de-couple/ trip the motor in case of failure of limit switch
to cut out motor when the springs are fully charged and annunciation for this shall be
provided.
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 The mechanism shall be complete with opening spring, closing spring, auxiliary contacts
& all other necessary accessories to make mechanism a complete operating unit. A
continuous sequence of closing and opening operation shall be possible.
 Besides the requirements of auxiliary switches used by the manufacturer, at least 4 NO
+ 4 NC shall be provided for the use of the purchaser.

RMU to be Maintenance free

 The RMU’s life and its operation must not be affected by environmental conditions such
as foggy atmosphere, extremes of cold, seismic conditions such as corrosive / winds,
100% relative humidity (condensing type) with hot and humid environment, temporary
flooding etc.
 The equipment shall be of “fit & forget” type requiring little maintenance, (practically
no maintenance), during its life.
 RMU shall have reliable switching devices and maintenance free drives.

Insulating Medium
 The RMU shall comply with the requirements of IEC standard for “Sealed Pressure
System”, for which no filling of gas is to be carried out during the life span of the
switchgear. The SF6 gas shall be as per IEC-60376 / IS:13072 and shall be suitable for
its application in the switchgear. It shall continue to have high insulating and arc
quenching properties throughout the switchgear life of 30 years.
 The SF6 gas shall be self-regenerating after the interruption of arc due to breaking load
currents. The gas tank shall have material in the tank to absorb the moisture from SF6
gas.
 The use of organic seals on the equipment, grease and oil in the drives requiring periodic
maintenance are not to be used.

SF6 Gas Monitoring & Pressure Relieving

 SF6 gas in the RMU tank shall be constantly monitored through a gas pressure indicator,
which shall be duly temperature compensated. In case the pressure is not adequate it
shall block its operation and give a warning to isolate the RMU.

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 The pressure sensors shall feed a microprocessor based analysing unit. By this system
the gas pressure (temperature compensated) shall be recorded to measure the dielectric
strength of the gas in the compartment.
 A loss of gas shall be signaled via two contacts one to initiate the low alarm of gas and
second to trip the whole system.
 If the gas pressure exceeds the permissible limit, such as during short circuit clearing,
the pressure relief device shall operate in the underside of the module. This area must be
partitioned from the cable connection apartment.

Voltage indicator lamps, phase comparators and Monitoring of RMU Bus Voltage
 It shall be possible for each of the functions on the RMU to be equipped with a
continuous voltage indication, to indicate whether or not there is voltage on the cables.
The capacitive dividers will supply low voltage power to sockets at the front of the unit,
an external lamp shall be provided to indicate live cables. Three outlets can be used to
check the synchronization of phases with the use of an external device. This device shall
be in compliance with IEC 1958 standard. Besides this the voltage monitoring of bus bar
shall be provided continuously.

Earthing of RMU Circuits

 The cables in the RMU on the load break switch sides shall be earthed (only when these
are dead) through integral earthing switch having the short circuit capacity of the RMU.
 The earthing switch shall be mechanically interlocked so that it can only be operated
when the main switch is in open condition and circuit is fully de-energized. Necessary
voltage monitoring device in such a case shall be provided.
 The earthing switch shall be operated through the main circuit mechanism and manual
closing shall be through a fast-acting mechanism.
 Mechanical interlocking system shall be provided to ensure that the switch is turned to
‘OFF’ position before being turned from ‘ON’ to ‘EARTH’ condition.
 Cable box interlocking is to be provided to ensure that before the removal of the unit
cable box cover, the unit earth is applied.

General Earthing Requirement:

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 All metal parts not intended for carrying current shall be connected to duplicate earthing
system and suitable terminals shall be provided on each equipment or part of equipment
in conformity with the relevant standards.
 The earth continuity conductor shall be of tinned copper and shall have sufficient cross-
sectional area so as to afford a low resistance path for the full fault current corresponding
to the circuit breaker ratings.
 The size of earth continuity conductor shall be adequate, so as to restrict the temperature
rise to the limit without causing any damage to the earth connection, while short circuit
current flows through it for the short time rating of the equipment.
 The size of earth continuity conductor shall be as large as possible to reduce to the barest
minimum the potential rise of the metal frame of the circuit breaker.
 No sweated / riveted joints in current conducting path shall be permitted.
 Cable end Termination box
 Cable-end termination box shall form an integral part of the equipment. The cables shall
be convenient to install.
 There shall be elbow type connection for cable termination with insulating boots. The
boots shall form part of supply.
 Each Cable compartment shall be provided with three bushings to terminate the
incoming and outgoing 33kV or 6.6kv, 3 Core or single core cables as the case may be.
There shall be minimum 700 mm height from the base of the mounted switchgear so that
the cables can be bent and taken vertically up to the bushings. The Cable termination
shall be done by Heat Shrinkable Termination method so that adequate clearances shall
be maintained between phases for Termination.
 The arrangement for earthing the termination point of cables shall form a part of supply
and shall be of adequate rating. The standard size of 33kV XLPE cable being used is as
specified for load break switches as well as for the tee-off transformer.
 The cable mounting arrangement on the load break switches shall be over the trench and
no special arrangement is required for installation of the cables and their terminations.
These shall enter directly from the cable trench through cable glands in gland plate to
the load break switches. The ring type air insulated CTs shall be provided.
 All of the cable boxes shall be air insulated suitable for dry type cable terminations.
Compound filled cable boxes are not acceptable.
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 The cable boxes at each of the two ring switches suitable for accepting H.V. cables
approaching from below or as per site requirement. The tee-off circuit breaker shall be
suitable for either of the following termination arrangements:
 Direct coupling to a transformer flange
 Cable entry from below via a tee-off cable box
 Cable entry from above via a tee-off cable box
 The extended function shall be suitable for cable entry from either above or below only.
 Double compression type, chrome, plated cable brass glands shall be provided in the
gland plate, with necessary cable clamping and earthing arrangement.
 Support frames shall be provided whose height shall be such that cable connections can
be conveniently made after allowing for bending radius of cables.
Note: The XLPE, outgoing & incoming 33kV power cables to LBS are not in the scope of
the RMU manufacturer. However, elbow type termination kits for these cables (including
two sets, of new cable termination tools) are included in the scope of supply.

Testing of Cables:
 It shall be possible to test the core or the sheath insulation of the network cables while
the RMU remains energized at rated voltage. It shall be preferable to carry out the phase
by phase testing through a built-in-facility without necessity to have access to cable
compartment. The maximum test voltage shall be less than 38 kV DC for 10 minutes.
 Any cable test access facility which requires the use of an additional loose devise shall
not be acceptable.
 Any switching unit, load-break switch or circuit breaker, shall be able to receive a
dedicated device for cable testing, allowing the cable test bench to be connected from
the front of the cell without opening the cable compartment. This cable test device must
be fully interlocked with the earthing switch.

Bushings:
 Bushing shall be homogeneous, free from laminations, cavities & other flaws or
imperfection that might affect the mechanical or di-electric quality & shall be tough and
impervious to moisture.
 Silicon type bushings shall be used.
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 Bushings shall be designed to have ample insulation, mechanical strength and rigidity
for the conditions under which they will be subjected.
 When operating at normal rated voltage there shall be no electric discharge between the
conductors & bushings, which could cause corrosion or injury to the conductors,
insulators or supports by the formation of substances produced by chemical action.
 All iron parts shall be hot dip galvanised (not less than 75 micron) & all joints shall be
airtight. Surfaces of the joints shall be smoothened up. Bushing design shall be such as
to ensure a uniform compressive pressure on the joints.
 All current carrying contact surfaces shall be sliver plated; silver plating shall not be less
than 1 mil in thickness.
 The creepage distance of the bushings shall be suitable for condensing type humidity
atmosphere atmosphere.
 Bushings shall be tested for type tests & routine tests in accordance with stipulation of
IS: 2099. Routine as well as type test reports in conformity with above IS shall be
furnished to the purchaser.

Caution Notice:
 Caution name plates shall be provided at all points where such safety requirements are
to be met as per Indian Electricity Rules.

Safety Interlocks:
 Disengagement of a circuit breaker or switch shall not be possible unless it is in open
position. Suitable interlocks shall be provided.
 The position of the circuit breaker, whether in open or close position shall be indicted
through suitably designed fail-safe mechanical indicators.
 The operating position of circuit breakers or isolators, either on bus-bar side or for
earthing, shall be clearly indicted by a reliable indicating device.
 Integral earthing facility, when provided, shall be suitable to make earthing connections
only when the associated circuit breaker is in tripped position. The current rating of
earthing facility shall be commensurate with the short circuit rating of the circuit breaker.
 Metering, Protection, Indication & Auxiliary Switches

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General Requirements for Instruments:

 Multifunctional Measuring instruments, with an accuracy of 0.5S or better shall be of
digital type, with minimum 3 line LED display and conforming to relevant IS / IEC &
shall be of an approved type & design suitable for tropical climate and condensing type
humidity. Measurement shall include voltage, current, pf, kW, kVA, kVAR and neutral
current. It shall have RS 485 communication port.
 All instruments shall be back connected and instruments cases shall be earthed.
 The instruments safety factor shall be equal to or less than 5.

Protection:
 The protection on the circuit breaker shall comprise the following arrangement:
 The Tee-off, Circuit breaker unit fitted with 3 protection CTS of suitable ratio and burden
[considering power transformer rating], a low burden trip coil and auxiliary switch
assembly allowing the use of a self -powered, numerical relay with an open protocol
having three over current and one sensitive earth fault elements. The relay shall be
housed within a cubicle box, accessible from the front. This relay shall also communicate
with Feeder Remote Terminal Unit.
 The protection curves and all other settings shall be adjustable in software through lap
top, which when viewed from the front clearly show the unit settings. (Note DIL type
switches are not acceptable). The protection setting range and minimum pick up current
shall be in accordance with the protection of transformer rating.
 Typically, the primary settings may be in the following range:
 Overcurrent : 20A to 200A
 Earth Fault : 2A to 50A
 The relay shall give local indication of a fault operation and shall differentiate between
overcurrent and earth fault.
 It shall be possible for the relay to perform a self-check.
 Other auxiliary relays to give trip / alarm [local as well as remote] in case of operation
of transformer protections, gas leakage, ON, OFF & Earth status of RMU load break /
breaker, spring charged etc. shall be provided.
 Besides the requirements of auxiliary switches used by the manufacturer, at least 4 NO
+ 4 NC shall be provided for the use of the purchaser.
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Instrument Transformers:
The instrument transformers required for the switchgear shall conform with the respective
standards specification.

Voltage Transformers
The Voltage Transformers (VT) shall be of dry compound epoxy insulated. The VT shall be
protected on their primary sides by current limiting fuses. On the secondary side, the circuit
shall be protected by MCB’s. Provision shall be so made that the primary fuses can be han-
dled only in the drawn-out position. The particulars of the voltage transformer are:
Type : Cast Resin.
Rated Voltage : 33000 110 110 Volts
3 3 3
Accuracy Class : 1.0
Burden : 50 VA or as per system requirement.
Note: Agency shall design the voltage transformer as per system requirements, and alternate
arrangement, if any, shall also be considered.

Current Transformers:
 The CT’s shall be cast resin ring type, suitable for metering and protection requirements,
air insulated and shall be able to withstand the thermal, dynamic and mechanical stresses
resulting from the maximum short circuit and short time current rating of the switchgear.
CT shall be suitable for continuous operation at 130% of its rated current.
 CT’s shall have polarity marks engraved on each transformer and at the associated
terminal blocks. Facility shall be provided for short circuiting and earthing the CT
secondary at the terminal blocks by the use of shorting type terminals.
 CT ratio, burden, accuracy [1.0 for metering and 5P for protection] and other requisite
parameters shall be suitable for the self-powered relay. CT calculations in this regard
shall be submitted.
 Control of the RMU
 Remote & local operation of the RMU’s line switches and Circuit breaker shall be
provided using motors fitted to the operating mechanism.

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 The provision of the motors to the mechanism must not in any way impede or interfere
with the manual operation of the switches or Circuit breaker.
 The Agency shall provide all necessary equipment for remote control and monitoring of
the RMU
 Feeder Remote Terminal Unit (FRTU) For RMU
 Make of FRTU shall be same as that of the RMU manufacturer. It shall have peer to peer
communication and with the remote switchgear / SCADA at the controlling substation
through fiber optic cable to initiate the required switching operations.

Main Requirements:
 FRTU cubicle shall be equipped to meet the following main requirements for compact
substation. It shall be possible to mount it on wall if required.
 Monitoring and control of 33kV LBS and VCB feeders
 In conjunction with FCI, detection and isolation of faulty cable for phase to phase and
phase to earth cable short circuits and automatically ensure supply restoration in less
than 60 seconds.
 Multifunction measurements.
 Transmit data to the remote control centre.
 The system shall have necessary redundancy in communication.
 To incorporate self-healing grid logic for faster restoration of supply even in the absence
of control centre SCADA.
 Data storage.
 Provision for Maintenance
 FRTU shall be capable to monitor and control 5 ways RMU.
 Chronological time stamped event recording.
 Data storage, in the event of mains failure, shall be for at least 8 hours. The minimum
storage shall be for about 40000 events.
Control unit:
 Control Unit shall perform all the required control and monitoring functions as isolated
unit or as part of Compact Substation and shall be equipped with a remote and local
control mode switch on its front panel.
 Operation in Local Mode:
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 Transmission of data for remote measurements and time-stamped events shall not be
disturbed.
 Opening and closing operation after validation.
 Inhibition of opening / closing from remote.
 Operation in Remote Mode:
 Transmission of measurements and time stamped events.
 Local electrical control shall get blocked.
 Opening and closing operation from remote control centre.
 All data shall be available locally on the front panel of the enclosure and remotely from
the control centres. LBS / breaker open and close status can be had from the front mimic
of FRTU respectively with the green / red LED indication. It shall be possible to retrieve
and display the time-stamped events recorded at the enclosure locally as well as at the
remote-control Centre on a lap top computer.

Power Supply:
Compact, built in sealed for life 12V battery with a long life and no maintenance of any kind
for 5 to 7 years or more along with charger [to be supplied 230 V, 50 Hz from CSS and in
case of stand-alone RMU supply arrangements shall be made by manufacturer] is to be pro-
vided in the unit. The supply shall be conditioned to provide power at required voltage for
motor operation and communication for local and remote SCADA. The transmission output
shall be able to supply a conventional radio [without battery power of RTU] to inform the
remote control centre of a battery failure. Power from the unit shall be sufficient to supply
control power to all the switch cubicles in the CSS, radio and the electronics in the enclosure.
The standby power unit shall be with a minimum autonomy of at least 8 hours for 10 opening
and closing cycles. The battery shall be checked at regular intervals by the slave station and
an alarm shall be generated and transmitted to the remote control centre in the event of a
fault. The unit shall be protected against overvoltage and over loads.
Time-tagged data archiving:
 All the archived data shall be retrieved locally and remotely by means of the
configuration and operating software supplied with the control unit. The data shall also
be downloaded locally or remotely to a PC as a .CSV file.

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 Event and measurement time-stamping shall be accurate to one millisecond [ms] and the
discrimination between two events shall be 10 ms.
 Communication with the remote control centre
 FRTU shall have IEC 870-5-101 / 104 protocol to transfer information to control center
SCADA and Modbus protocol to communicate with field MFM [Multifunction Meters]
on RS485. The Modbus protocol shall be open. Security & communication package
provider shall only lay the fibre optic cable for the same and further connections,
repeaters, boosters and any other communication equipment shall be included in the
scope of supply.
 It shall be possible to configure each measurement to be transmitted spontaneously to
the remote control centre with 100% redundancy. Failure of one channel shall have an
automatic changeover to second channel.
 Data shall be configured using a PC connected to the control unit via an Ethernet and /
or USB port. It shall also be possible to configure data remotely.

Software
The software shall not require a special license and it can be used and copied freely.

Indications
The slave stations shall process at least the following information for remote indication and
for local display purposes:
 Open / closed position of each LBS
 Earth status
 Absence of AC voltage,
 Local / remote control operating mode,
 Detection of phase-to-phase or earth fault current flow,
 Load current measurement
 Charger fault
 Battery fault
 motor drive DC supply fault
 Internal fault
 Detailed diagnosis of the status of the uninterruptible power supply (charger, batteries).
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 Indications for LT side status of switches, alarms as required.

 Erection / construction / Operating Tools and Tackles
 Each RMU will be provided with operating lever and other such equipment which are
necessary for the normal operation of the equipment. It shall also include any spring
charging handles for the manual charging of closing springs. The tenderer shall
separately list out in the tender in the given schedule, sets of tools required for initial
erection/construction and subsequent maintenance. The price of those shall be included
in the cost of equipment.
 An anti-reflex mechanism on the operating lever shall prevent any attempts to re-open
immediately after closing of the switch or earthing switch.
 All manual operations will be carried out on the front of the switchboard.
 The effort exerted on the lever by the operator shall not be more than 250 N for the
switch and circuit breaker.
 The overall dimensions of the RMU shall not be increased due to the use of the operation
handle. The operating handle shall have two workable positions 180o apart.

Mimic Diagram:
 The front shall include a clear mimic diagram which indicates the different functions.
The position indicators shall give a true reflection of the position of the main contacts.
They shall be clearly visible to the operator. The lever operating direction shall be clearly
indicted in the mimic diagram. The manufacturer’s plate shall include the switchboard’s
main electrical characteristics.

Labels and Marking of Connections:

All apparatus, control gear and the apparatus mounted thereon shall be clearly labelled, in-
dicating where necessary, their purpose and the ‘ON’ ‘OFF’ and ‘EARTH’ position. The
labels shall be clearly lettered on enamelled surface or other approved materials. Brass shall
not be used for labels. Each phase of alternating current and connections shall be coloured
to distinguish phases, neutral and earth. The colouring shall be red, yellow, blue, black and
green respectively.

Bus Bars:
 Bus bars shall be of uncoated tinned conductor grade electrolytic copper.

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 The tenderer shall furnish calculations establishing thermal and dynamic adequacy of
bus bar sizes with reference to its short circuit ability. The bus bar shall be integrated
completely into the gas filled compartment including the coupling chambers between
two adjacent modules.
 The insulating ability of the entire bus bar system shall be monitored along with the gas
filled cladded compartment of the module. The bus bar size shall be so chosen so as to
limit the current density to within permissible limit and if the fault current restricts the
current density less than that, then lesser density shall be used. Calculations shall be
submitted for this purpose.

Temperature rise:
The temperature rise and the maximum temperature on any part of the equipment when in
service at site under continuous full load condition or under short circuit shall not exceed
the permissible limit as per relevant IEC or IS: 13947. This shall not be exceeded when
corrected for the difference between the ambient temperature at site and the ambient tem-
perature specified in the relevant standard.
RMU Indications
Indication of spring charge, ON, OFF trip etc shall be provided by means of LED which
shall be fed from control supply arrangement designed by Agency If LED’s are provided,
the indicating lamps shall have covers of following colours.
Red closed position of breaker/ load break switch
Green open position of breaker /load break switch
Blue spring charge condition of breaker / load break switch
Amber auto tripped position of breaker
Yellow Earth position

Terminal boards and Secondary Wiring

 Connection to switchgear, operating mechanism indicating relays and all instruments
shall be deemed to form a portion of equipment of panel.
 Panel connections shall be insulated and shall be healthy and securely fixed to back of
the panel. The wiring must run on porcelain or non-rusting metal cleats or metal flexible
tubes as may be approved by Engineer-in-Charge. All wiring in the vicinity shall be

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insulated and shall run in non-rusting flexible tubes from terminal boards conveniently
situated. All control connections instruments and relay wires shall be provided with
numbered ferrules at each terminal and the numbering shall be in accordance with an
approved system. All wiring diagrams shall be clearly marked with the numbers
corresponding with those on the ferrules of the individual cores. Each set of current and
voltage transformer secondary connection shall be complete and shall be earthed at one
point only. Each such earthing shall be made through links which can be opened for
insulation testing.
 All the internal control wiring shall be through fire-resistant tinned stranded copper
wires of 1.5 mm2 and for CT circuits these shall be with 2.5 mm2. The strands in the
copper wire shall not be less than 48.
 The CT circuits shall be provided with isolating type of links, to check the current in the
CT circuits during testing. Similar it shall be possible to isolate PT’s without
disconnecting wires to check & test the meters. All CTs must have provision for shorting
through link.
 The air insulated control cabinet shall have provision for lighting.
 As the equipment is to be installed in a tropical and humidity zone, the air insulated
control cabin shall be provided with suitable space heater of PTC type.

Type and routine tests

All the routine and type tests shall be carried out as per relevant IEC / Indian Standard. For
type test certificates Engineer-in-Charge may consider test certificates at its absolute discre-
tion.
All the routine tests on the switchboard shall be witnessed by the Site Engineer-in-Charge
or its authorized representative.
The following type & routine test certificates shall be supplied / carried out on the RMU:
 Impulse withstand test
 Temperature-rise test
 Short-time withstand current test
 Mechanical operation test
 Checking of degree of protection
 Switch, circuit breaker, earthing switch making capacity.
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 Switch, circuit breaker breaking capacity.

 Internal arc withstand test.
 Checking of partial discharge on individual components.
In addition, for switches, test reports on rated breaking and making capacity shall be sup-
plied.
For earthing switches, test reports on making capacity, short-time withstand current and peak
short circuit current shall be supplied.
The routine tests carried out by the manufacturer shall be backed by test reports signed by
the factory’s quality control department. They shall include the following:
 Conformity with drawings and diagrams,
 Measurement of closing and opening speeds & times
 Measurement of operating torque
 Checking of filling pressure
 Checking of gas tightness
 Checking of partial discharges on individual components
 Dielectric testing and main circuit resistance measurement
All of the major type tests shall be certified by an independent authority and an internation-
ally acceptable test house for the tests carried outside the country of manufacture.
Configuration of Ring Main Unit
 Each non / extendable ring main unit shall comprise of three or four configurations, with
a continuous bus bar, SF6 insulated, sealed for life, CTs and PTs as per requirement, pad
locks for locking with a universal key, complete in all respects.
 The main items of RMU are given below any other item not specifically mentioned but
required for the successful operation of the equipment shall be deemed to be included
without any financial liability to purchaser.
 Each load break switch panel shall be equipped with rating of 36kV, 630 Amps. 25kA /
3s, Gang operated, SF6 insulated, manual / motor operated, fault making, load breaking
switch, along with associated bus bars, CTs, PTs [as required] and the same shall consist
of the following main items:
 Metal clad in door type weather proof housing.
 36 kV, 630 Amps, fault making, load breaking, manually/motor operated, self-
aligning, gang operated.
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 One set of 630 Amp, bus bar as specified.

 Isolating plug & socket for main & auxiliary contacts if required.
 Mechanical interlocks to prevent switching on with cable in earthed position.
 One set of triple pole gang operated cable earthing contacts.
 Load Current measurement.
 Air Insulated cable box for Cable end termination suitable for 3 core, 36kV or 12 kV,
XLPE armored cable of specified size, with AL conductor, along with glands,
suitable Gland plate and Cable support.
 Mechanical On/Off/Earth/Test Indicators.
 Cable Testing Sockets
 Capacitive Voltage indicator lamps.
 Cable clamps
 Feeder Remote Terminal Unit [FRTU]
 Fault Circuit Indicator along with CTs.
 Indicating lamps & auxiliary contacts.
 Auxiliary relays (if required).
 Interlocked earthing arrangement.
 Tee-off Circuit Breaker Panel, with SF6 insulation, suitable for transformer feeder shall
be equipped with minimum 36kV, upto 630 Amps, 25 kA, for 3 sec rated circuit breaker
with associated C.Ts, PTs, spring operated mechanism, bus bars, compete with
instruments, relays, terminal blocks. It shall comprise of the following main items:
 Metal clad / indoor type weather proof housing
 Vacuum circuit breaker, trip free
 One set of 630 Amps. Bus bars (integral part with load break bus bar).
 CTs for protection & Metering to match the transformer – 3 Nos.
 3-overcurrent & one earth fault IDMT relays, direct operating.
 Termination suitable for connection to 11/0.433 kV transformer of specified rating.
 Multifunction meter
 P.T. 33000/3 - 110/ 3 - 110/3, as required.
 On/Off indicator
 Mechanical interlocks
 Tripping, closing coils.

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 Indication lamp & spare auxiliary NO/NC contacts.

 Auxiliary relays for alarm and trip for transformer protections
 Earthing arrangement duly interlocked.
 Mechanism with spring charging motor.
 The common system for the above shall consist mainly of:
 Channels, nuts, bolts, glands, gland plates, inter connecting arrangement of tee-off
breaker with transformer, cable termination kits & supporting arrangement of cable,
with the load break switches etc.
 Cable termination kits to be included for each RMU.
 Gas monitoring device for sealed gas unit.
 Pad locks for locking the panels.
 Handles for normal operation, spring charging & other tools required for normal
operation.
 Arrangement of control supply for breaker / load break closing / tripping, motor
charging indications etc.
 All the necessary indicating lamps.
 SF6 pressure monitoring unit.
 Analysis unit for dielectric monitoring of SF6 gas.
 Any other item not included above but required for the operation shall be deemed to
be included though specifically not mentioned, without any financial liability to
purchaser.
Two sets of cable termination and jointing tools for all the substations at various locations.
Any other item mentioned in text or any other item required for successful operation but
not included here shall be deemed to be included.

TECHNICAL SPECIFICATIONS FOR POWER AND AUXILIARY TRANSFORM-

ERS
These specifications are intended to cover design, manufacture, testing/inspection before
dispatch, packing, and transportation to site, erection supervision, testing and commission-
ing of 33/6.6kv & 33/0.415KV Step-down outdoor/indoor type ONAN transformers com-
plete with all accessories / fittings and spare parts as specified herein.

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Applicable Standards
The power and Auxiliary transformers shall conform to the latest applicable standards spec-
ified below. In case of conflict between standards and this specification, this specification
shall govern.
Power Transformer IS:1180/BS:171/IEC:76
Fittings and Accessories IS:3639
Auxiliary Transformer IS:1180
Loading of oil immersed transformer IS:6600/BS: CP.1010/IEC: 54
Oil IS:335/BS 148/IEC:296
Bushings for > 1000V, AC IS:2099/BS:223/IEC:137
Bushings for ≤ 1000V, AC IS:7421
Degree of Protection IS:13947 (Part 1) / IEC:947-1
Buchholz Relay IS:3637
Electrical insulation classified by thermal stability IS 1271/BS:2757/IEC:85
Climate Proofing BS: CP1014
Features of Construction
The transformer tank shall be made from high grade plate steel, suitably reinforced by
means of stiffeners made of structural steel sections. All seams, flanges, lifting lugs, braces
and other parts attached to the tank shall be welded. The interior of the tank shall be cleaned
by shot blasting and painted with two coats of heat resistant and oil insoluble paint. Ade-
quately sized manholes shall be provided for easy inspection and maintenance. All joints
which may have to be opened from time to time in the course of operation shall be of a
design to permit them to be made easily oil tight in reassembly. Steel bolts and nuts exposed
to atmosphere, shall be galvanised. The tank cover shall be suitably sloped so that it does
not retain rain water.
Lifting lugs and eyebolts shall be so located that a safe clearance is obtained between sling
and transformer bushings, without the use of a spreader. Transformer of rating above 500
KVA shall be equipped with detachable or separately mounted radiator banks. Transformers
of rating 500 KVA and below shall be provided with fixed type radiators.
When transformers are provided with separately mounted radiators, flexible joints shall be
provided on the main oil pipes connecting the transformer tank to the radiator banks to

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reduce vibration and facilitate erection and dismantling. The interconnecting pipes shall be
provided with drain plug and air release vents.
The transformer tank, radiators and conservator shall be designed taking into account the
loss of thickness due to shot blasting. The transformer core shall be constructed from high
grade, non-ageing, cold-rolled, grain oriented, silicon steel laminations coated with insula-
tion varnish. The steel laminations shall be of “core” type.
Each lamination shall be coated with insulation which is unaffected by the temperature
attained by the transformer during service.
Core laminations shall be annealed and burrs removed after cutting. Cut edges shall be
insulated.
The frame work and clamping arrangements of core and coil shall be securely earthed in-
side the tank by copper strap connection to the tank. Windings shall be of suitably insulated
copper wire or copper strip. The Windings shall be fully shrunk under vacuum before as-
sembly. High voltage end windings shall be suitably braced to withstand short circuit
stresses and stresses set up by surges. All taps shall be provided on the HV winding. The
core and coil assembly shall be dried out and impregnated under vacuum.
Cable boxes shall have sufficient space for segregating the cable cores and to give adequate
clearance in air between bare conductors at the terminals. Cable boxes shall be complete
with necessary cable lugs and armour grips. All auxiliary wiring from current transformers,
buchholz relays, winding temperature indicators, etc., shall be marshalled to a separate
weatherproof and verminproof marshalling box with an independent access cover. The mar-
shalling box shall be complete with necessary cable glands and cable lugs. The marshalling
box and components shall comply with the requirements specified for control cabinets in-
dicated elsewhere in this specification.
Painting
The interior of all transformer tanks and other oil filled chambers and internal structural
steel work shall be cleaned (seven tank process) of all scale and rust by shot-blasting. These
surfaces shall be painted with not less than two coats of heat resistant, oil insoluble and
insulating varnish. Steel surfaces exposed to the weather shall be thoroughly cleaned and
have a priming coat of zinc chromate applied. The second coat shall be of a glossy oil and
weather resisting non-fading, paint of shade No. 631 as per IS:5.
Metal parts not accessible for painting shall be made of corrosion resistant material.

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Interior surfaces of mechanism chambers and marshalling kiosks shall receive three coats
of paint after proper cleaning. The final coat shall be of a light coloured anti-corrosion
paint.
All paints shall be carefully selected to withstand heat, rain and extremes of weather. The
paint shall not scale off or crinkle or be removed by abrasion due to normal handling.
In case finish paint chips off or crinkle during transit or installation, the supplier / Agency
shall arrange for repainting transformer at site at his cost. The paint for repainting shall be
supplied by the supplier / Agency.
The following treatments shall be applied:
External surfaces
All steel surfaces shall be sand-blasted in accordance with DIN 55928 Part 4 (equivalent to
SIS 055900), and shall then be painted in the following sequence:
One (1) primer coat 60 µm
Two-component epoxy zinc-phosphate
One (1) intermediate coat 60 µm
Two-component epoxy micaceous iron oxide
One (1) top coat 40 µm
Two-component polyurethane
Total coating thickness (dry-film incl. tolerances) min. 160 µm
The final coat of painting shall be of pore-free and homogeneous quality and shall be of
uniform shade of colour.

DETAILED DESCRIPTION
Tank:
The Transformer tank and cover shall be fabricated from high grade low carbon plate steel
of tested quality. The tank and the cover shall be of welded construction.
Tank shall be designed to permit lifting by crane or jacks of the complete transformer as-
sembly filled with oil. Suitable lugs and bosses shall be provided for this purpose.
All beams, flanges, lifting lugs, braces and permanent parts attached to the tank, shall be
welded and where practicable, they shall be double welded.
The main tank body of the transformer, excluding tap changing compartments and radia-
tors, shall be capable of withstanding pressure of 760 mm of Hg. Inspection hole(s) with

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welded flange(s) and bolted cover(s) shall be provided on the tank cover. The inspection
hole(s) shall be of sufficient size to afford easy access to the lower ends of the bushings,
terminals etc. The weight of cover shall be easily lifted by a single person, whenever re-
quired. All bolted connections to the tank shall be fitted with suitable oil-tight gaskets
which shall give satisfactory service under the operating conditions. Special attention shall
be given to the methods of making the hot oil-tight joints between the tank and the cover
as also between the tank cover and the bushings and all outlets to ensure that the joint can
be remade satisfactorily and with ease, with the help of semi-skilled labour. Where com-
pressible gaskets are used, steps shall be provided to prevent over-compression.
Suitable guides shall be provided for positioning the various parts during assembly or dis-
mantling. Adequate space shall be provided between the cores and windings and the bottom
of the tank for collection of any sediment. The completely assembled tank shall be fully
vacuum proof.

Tank Cover
The transformer top shall be provided with a detachable tank cover with bolted flanged,
gasket joint. Lifting lugs shall be provided for removing the cover. The surface of the cover
shall be suitably sloped so that it does not retain rain water. Neoprene/cork/hemp type gas-
kets are not acceptable.

UNDER CARRIAGE
The transformer tank shall be supported on steel structure with detachable forged steel
flanged wheels suitable for moving the transformer completely filled with oil. Rail gauge
shall be 1676 mm in both directions. Flanged wheels shall be spaced accordingly. Wheels
shall be provided with suitable bearings which will resist rust and corrosion and shall be
equipped with fittings for lubrication. It shall be possible to swivel the wheels in two direc-
tions, at right angle to or parallel to the main axis of the transformer.
Jacking pads shall be provided on the transformer. It shall be possible to change the direc-
tion of the wheels through 90 degree when the transformer is lifted on jacks to permit
movement of the transformer both in longitudinal and transverse directions.
Suitable hydraulic jacks (4 nos.) for lifting the transformer shall be supplied by the supplier
/ Agency, for each rating.

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CORE
The magnetic circuit shall be constructed from high grade cold rolled non-ageing grain
oriented silicon steel lamination with low loss, such as of W17/50; max 1.05W/Kg. The
laminations shall be free of all burns and sharp projections. Each sheet shall have an insu-
lating coating resistant to the action of hot oil. The insulation structure for the core to bolts
and core to clamp plates shall be such as to withstand a voltage of 2000 V for one minute.
The completed core and coil shall be so assembled that the axis and the plane of the outer
surface of the core stack shall not deviate from the vertical plane by more than 25 mm.
All steel sections used for supporting the core shall be thoroughly shot or sand blasted, after
cutting, drilling and welding. The finally assembled core with all the clamping structures
shall be free from deformation and shall not vibrate during operation. The core clamping
structure shall be designed to minimize eddy current loss.
The framework and clamping arrangements shall be securely earthed. The core shall be
carefully assembled and rigidly clamped to ensure adequate mechanical strength.
Oil ducts shall be provided where necessary to ensure adequate cooling. The welding struc-
ture and major insulation shall not obstruct the free flow of oil through such ducts.
The design of magnetic circuit shall be such as to avoid static discharge, development of
short circuit paths within itself or to the earthed clamping structure and production of flux
component at right angle to the plane of the lamination which may cause local heating. The
supporting frame work of the cores shall be so designed as to avoid the presence of pockets
which would prevent complete emptying of the tank through the drain valve or cause trap-
ping of air during filling.
The construction is to be of ‘core’ type. The core shall be provided with lugs suitable for
lifting the complete core and coil assembly. The core and coil assembly shall be so fixed in
the tank that shifting will not occur during transport or short circuits.
The earthing of core shall be done at the top of the cover, with removable link so as to test
the same.

INTERNAL EARTHING
All internal metal parts of the transformer, with the exception of individual laminations,
core bolts and their individual clamping plates shall be earthed.

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The top clamping structure shall be connected to the tank by a copper strap. The bottom
clamping structure shall be earthed by one or more of the following methods:
 By connection through vertical tie-rods to the top structure.
 By direct metal to metal contact with the tank base.
 By a connection to the top structure on the same side of the core as the main earth
connection to the tank.
The magnetic circuit shall be connected to the clamping structure at one point only and this
shall be brought out of the top cover of the transformer tank through a suitably rated insu-
lator. A dis-connecting link shall be provided on transformer tank to facilitate disconnec-
tions from ground for IR measurement purpose.
Coil clamping rings of metal at earth potential shall be connected to the adjacent core
clamping structure on the same side as the main earth connections.

WINDING
Winding shall be subjected to a shrinking and seasoning process, so that no further shrink-
age occurs during service. Adjustable devices shall be provided for taking up possible
shrinkage in service.
All low voltage windings for use in the circular coil concentric winding shall be would on
a performed insulating cylinder for mechanical protection of the winding in handling and
placing around the core.
Winding shall not contain sharp bends which might damage the insulation or produce high
dielectric stresses. No strip conductor wound on edge shall have width exceeding six times
the thickness.
Materials used in the insulation and assembly of the windings shall be insoluble, non cata-
lytic and chemically inactive in the hot transformer oil and shall not soften or the otherwise
affected under the operating conditions.
Varnish application on coil windings may be given only for mechanical protection and hot
for improvement in dielectric properties. In no case varnish or other adhesive be used which
will seal coil and prevent evacuation of air and moisture and impregnation by oil.
Winding and connections shall be braced to withstand shocks during transport or short cir-
cuit

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Permanent current carrying joints in the windings and leads shall be welded or brazed.
Clamping bolts for current carrying parts inside oil shall be made of oil resistant material
which shall not be affected by acidity in the oil. Steel bolts, if used, shall be suitably treated.
Terminals of all windings shall be brought out of the tank through bushings for external
connections.
The completed core and coil assembly shall be dried in vacuum at not more than 0.5mm of
mercury absolute pressure and shall be immediately impregnated with oil after the drying
process to ensure the elimination of air and moisture within the insulation. Vacuum may be
applied in either vacuum over or in the transformer tank.
The winding shall be so designed that all coil assemblies of identical voltage ratings shall
be interchangeable and field repairs to the winding can be made readily without special
equipment. The coils shall have high dielectric strength.
Coils shall be made of continuous smooth high grade electrolytic copper conductor, shaped
and braced to provide for expansion and contraction due to temperature changes.
Adequate barriers shall be provided between coils and core and between high and low volt-
age coil. End turns shall have additional protection against abnormal line disturbances.
The insulation of winding shall be designed to withstand voltage stress arising from surge
in transmission lines due to atmospheric or transient conditions caused by switching etc.
Tappings shall not be brought out from inside the coil or from intermediate turns and shall
be so arranged as to preserve as far as possible magnetic balance of the transformer at all
voltage ratios.
Magnitude of impulse surges transferred from HV to LV windings by induction and capac-
itance coupling shall be limited to B.I.L. of LV winding.

INSULATING OIL
The insulating oil for the transformers shall be of LHV / MHV grade, generally conforming
to IS:335.
The quantity of oil required for the first filling of the transformer and its full specification
shall be stated in the bid. The bidder shall quote the price of transformer complete with first
filling of oil plus 10% extra. However, the rate of transformer oil in Rupee per litre shall be
quoted separately also. The transformer oil shall be supplied in non-returnable containers /
drums.

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The design and materials used in the construction of the transformer shall be such as to
reduce the risk of the development of acidity in the oil.
The gaskets of neoprene or similar type such as cork, which can be damaged by over-press-
ing or not acceptable.

VALVES
Valves shall be of forged carbon steel upto 50 mm size and of gun metal or of cast iron
bodies with gun metal fittings for sizes above 50 mm. They shall be of full way type with
screwed ends and shall be opened by turning counter clockwise when facing the hand
wheel. There shall be no oil leakage when the valves are in closed position.
Each valve shall be provided with an indicator to show the open and closed positions and
shall be provided with facility for padlocking in either open or closed position. All screwed
valves shall be furnished with pipe plugs for protection. Padlocks with duplicate keys shall
be supplied along with the valves.
All valves except screwed valves shall be provided with flanges having machined faced
drilled to suit the applicable requirements. Oil tight blanking plates shall be provided for
each connection for use when any radiator is detached and for all valves opening to atmos-
phere. If any special radiator valve tools are required, the supplier / Agency shall supply
the same.
Each transformer shall be provided with following valves on the tank:
 Drain valves so located as to completely drain the tank.
 Two filter valves on diagonally opposite corners, of 50 mm size.
 Oil sampling valves not less than 8 mm at top and bottom of main tank.
 One 15 mm air release plug.
 Valves between radiators and tank.
Drain and filter valves shall be suitable for applying vacuum as specified in the specifica-
tions.

BUSHING
All porcelain used in bushings shall be homogeneous, non-porous, uniformly glazed to
brown colour and free from blisters, burns and other defects.

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Stress due to expansion and contraction in any part of the bushing shall not lead to deteri-
oration.
Bushing shall be designed and tested to comply with the applicable standards.
Liquid / oil-filled bushings shall be equipped with liquid level indicators and means for
sampling and draining the liquid. The angle of inclination to vertical shall not exceed 30
degree.
Oil in oil-filled bushings shall meet the requirements of the transformer oil standards.
Bushing rated for 400A and above shall have non-ferrous flanges and hardware.
Fittings made of steel or malleable iron shall be galvanised.
Bushing shall be so located on the transformers that full flashover strength will be utilised.
Minimum clearances as required for the BIL shall be realised between live parts and live
parts to earthed structures.
All applicable routine and type tests certificates of the bushings shall be furnished for ap-
proval.
Bushing shall be supplied with bimetallic / terminal connector / clamp suitable for fixing
to bushing terminal and the PURCHASER’S specified conductors. The connector /clamp
shall be rated to carry the bushing rated current without exceeding a temperature rise of 45°
degree centigrade over an ambient of 50°C. The connector / clamp shall be designed to be
corona free at the maximum rated line to ground voltage.
Bushing of identical voltage rating shall be interchangeable.
The insulation class of high voltage neutral bushing shall be properly coordinated with the
insulation class of the neutral of the low voltage winding.
Each bushing shall be so coordinated with the transformer insulation that all flashover will
occur outside the tank.

CURRENT TRANSFORMER
The current transformer shall comply with the requirements of latest issue of IS:2705. The
reports of all type and routine tests as stipulated in the Indian Standards shall be furnished
for approval to the purchaser. Each current transformer shall be subjected to routine tests
as specified in the Indian Standards.

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All technical particulars of current transformers as called for in bidding schedule shall be
furnished with the bid. The parameters given for the current transformers in the specifica-
tion may be modified before final approval of drawings but these changes shall not affect
the cost of the transformers.
All secondary leads, including tappings shall be brought out to a weather proof outlet box
near on the current transformer. The supplier / Agency shall carry out conduit wiring from
this outlet box upto the transformer marshalling box or control cabinet.CT shorting termi-
nals shall also be provided in the marshalling box.
Current transformer name plate shall be mounted on the equipment adjacent to the terminal
box.

CABLE BOX AND CABLE BOX BUSHINGS

Cable boxes are to be suitable for operating outdoor and suitable for vertical arrangements
of cables ascending to the box from below. Cable boxes for the transformers shall be with
the disconnecting chambers so that the transformers with accessories can be removed for
servicing for repair without disconnecting the cable connections.
Boxes shall be suitable for aluminium conductor, XLPE insulated armoured and PVC
sheathed cables of sizes approved by Purchaser.
Compression glands and lugs shall be provided suitable for PVC cables.
The design and construction of the cable box shall be such as not to permit the entry of
moisture into the box.
Supports for cable boxes shall be provided by the tenderer.
Suitable draining plug shall be provided with each cable box.
Suitable earthing arrangement for cable armouring shall be provided.

MARSHALLING BOX
Sheet steel vermin proof, well ventilated and weather proof marshalling box with water-
tight hinged and padlocked door of a suitable construction shall be provided for the trans-
former ancillary apparatus. The box shall have slopping roof and the interior and exterior
painting shall be in accordance with the specification. Padlock along with duplicate keys
shall be supplied for marshalling box. The degree of protection shall be IP-55. The sheet
thickness shall not be less than 2mm.

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The schematic diagram of the circuitry inside the marshalling box be prepared and fixed
inside the door under a propone sheet.

AUXILIARY POWER SUPPLIES

The following power supplies shall be available at site
 AC, 3 phase 433 volts 50 Hz earthed.
 AC, 1 phase 240 volts 50 Hz earthed.
 220 volts DC ungrounded.

ON LOAD TAP CHANGER

The transformers shall be provided with an On-Load Tap Changer (OLTC) of well reputed
such as Easun MR and of proven make as per technical requirement for varying the effec-
tive transformation ratio while the transformer is ON Load and without providing phase
displacement. The salient features of the OLTC shall be as under:
The tap changing mechanism shall be suitable for automatic, remote control operation from
remote control panel in the control room in addition to being capable of local manual as
well as local electrical operation.
The On Load Tap Changer (OLTC) shall include the following:
An oil immersed tap selector and arcing switch on arc suppressing tap selector provided
with ohmic or resistor type high speed diverter switch, for reduction of make and break
arcing voltages, overloads and short circuits.
Diverter switch shall be with snap action mechanism with energy accumulator mounted
directly on the diverter switch.
Separate oil compartment
Easy removable diverter switch unit.
Motor driven mechanism
Control and Protection devices
Local tap changer position indicator
Manual operation device
Make of OLTC – Esun MR Indigenous make (type test certificates from (CPRI).
voltage rating -36 KV (as appropriate)
Current rating – 300 A

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Control voltage – 110 Volt (AC)

The on-load tap changer shall be designed so that the contacts do not interrupt arc within
the main tank of transformer. The tap changer selector and arcing switch on arc suppressing
tap selector switch shall be located in one or more oil filled compartments. The diverter
switch shall be provided with gas vent and buchholz relay. It shall be designed so as to
prevent the oil in tap selector and diverter switch compartments from mixing with the oil
in transformer. The barrier board between OLTC and the transformer tank shall be made of
silicon bonded rasin paper (SBRP).
The tap changer shall be capable of permitting parallel operation with other transformers
of the same type. The transformer shall give full load output on all taps without exceeding
the limit of permissible temperature rise in oil and winding. The manual operating device
shall be so located on the transformer that it can be operated by a man standing at the level
of transformer track. It shall be of robust construction and shall be capable of frequent
operations. It shall not be possible to operate the electric drive when the manual operating
gear is in use.
Necessary interlocks blocking independent control when the units are in parallel shall be
provided.
The controls shall be so arranged as to ensure that when a tap change operation has com-
menced, it shall be completed independently of the operation of control relays or switches.
Local or remote-control switch shall cause one tap movement only, until the control switch
has returned to the off position between successive operations. Under abnormal conditions
such as may occur when the Agency controlling one tap change sticks, the arrangement
must be such as to switch off supply to the motor so that an out of step condition is limited
to one tap difference between the units. Limit switches shall be provided to prevent over
running of mechanism.
The transformer and the tap changing equipment shall be designed to permit full rated op-
eration with tap changing equipment temporarily installed in any intermediate position.
Details of out of step protection provided for the taps shall be furnished in the tender.
The control scheme for the tap changer shall be provided for independent auto/non-auto
control of the tap changer when the transformers are in independent service. Voltage regu-

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lating relay shall be designed for maximum operational simplicity for regulating the sec-
ondary voltage of power transformer with OLTC. The required dead band settings are set
by setting the nominal value and lower and upper levels independently.
In addition, provisions shall be made to enable non-auto/automatic parallel control also so
that the tap changers of two or more transformers will be operated simultaneously when
one unit is in parallel with another so that under normal conditions the tap changer will not
become out of step and this will eliminate circulating current. Additional features like
“Master/Follower” and visual indication, during the operation of motor shall also be incor-
porated.
A mechanical tap position indicator shall be provided on the tap changer in addition to
remote indication equipment in the control room on remote control cubicle of OLTC. Nec-
essary interlocks, for independent control when the units are in parallel shall be provided.
The whole of motor drive unit comprising the motor and its control gear including Agency,
indicators, local electrical push buttons, five-digit operation counter, handle for manual
control etc. as well as terminals for the control and indication wiring shall be housed in a
dust proof kiosk mounted on a tap changer. A heating element with thermostat and MCB
shall also be provided in kiosk. Arrangement shall be made for padlocking the kiosk. Tap
position indication shall be visible by a number appearing in a small glass window on the
front of the kiosk. For remote indication, digital type instrument shall be provided on the
panel.
Any enclosed compartment not oil filled shall be adequately ventilated. All Agency, relay
coils or other parts shall be suitably protected against corrosion or deterioration due to con-
densation, fungi etc.
The oil in the compartments of the main tap changing apparatus which do not contain con-
tacts used for making or breaking current shall be maintained under conservator head by
means of a pipe connection from the highest point of the chamber to the conservator. This
connection shall be controlled by a suitable valve and shall be arranged so that any gas
leaving the chamber will pass into the gas and oil actuated relay. A separate oil buchholz
relay with trip contacts shall be provided for the On-Load Tap Changer chamber. Each tap
changer shall also be provided with a Pressure Relief Valve outside OLTC to protect against
sudden pressure development in OLTC.

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Each compartment in which the oil is not maintained under conservator head shall be pro-
vided with a suitable direct reading oil level gauge.
A permanently legible lubrication chart shall be fitted with the driving mechanism chamber.
Local electrical control switches and the local operating gear shall be clearly labelled in
suitable manner to indicate the direction of operation of tap changer.
The remote-control panel of OLTC gear to be installed in the control room shall match in
colour and dimensions sheet steel size etc. with the purchaser’s transformer control panel
for which details would be furnished to the successful tenderer.
In addition to the fittings, auxiliaries and accessories considered necessary by the tenderer
the following shall be provided.

FOR LOCAL ELECTRICAL CONTROL

Raise lower selector switch with an intermediate ‘OFF’ position.
Auxiliary transformer (if necessary) along with MCB’s and links.
Step by step contactor
Thermal over-load relay for the motor
Reversing contactor
ON/OFF automatic trip air circuit breaker for motor supply
Local / Remote change-over selector switch.

FOR REMOTE ELECTRICAL INDEPENDENT CONTROL

All equipment listed in (I) above.
Tap position indicator for mounting on control panel in the control room.
Signal lamp and buzzer, for indicating “Tap Change in Progress”.
Raise lower switch push button type with intermediate off/position for remote control.
Emergency stop button (push button type) with visual indication.
Visual and alarm indication for non-completion of operation within pre-set time.
Provision of interlocking system for blocking independent control when the units are to run
in parallel by providing interlocking phase sequence selector switch.
All audio-visual indications shall be brought to the Remote Tap Changer Cubicle (RTCC)
panel.
DC supply isolators, DC supply ‘ON’ indicator & DC failure, booth along with cancellation.

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All equipment and their connections in RTCC panel shall be properly marked. The buzzer
/ bell (industrial type) shall be provided.
Voltage regulating relay for automatic operation.
HV side and LV side digital voltmeters.

VOLTAGE REGULATOR RELAY FOR OLTC

Voltage Regulator Relay for OLTC shall have the following characteristics:
Input Voltage (nominal value) 95 to 130 V
Rated Frequency 50 Hz
Band width +0.6 to +6% of nominal value
Time delay circuit 10 to 180 seconds
Integral response to be switched on
Under Voltage blocking 70 to 90%
Line drop compensator 0 to 25 V
Current path of LDC 1A
Note: If OLTC built-in feature is available in the main relay, separate voltage regulating
feature may not be provided.
Circuit Tap Changer
The off-circuit Tap changer (wherever specified and required) shall be operable by means
of an operating handle brought outside the tank and operable from ground level. It shall be
equipped with an indicating device to show the tap in use and shall be provided with a
locking arrangement to lock the switch in position. The tap changer contacts and connec-
tions shall be accessible through an access hole having bolted gasketed cover.

FITTINGS
The following fittings shall be provided on the transformers:
 Conservator with isolating valves, oil filling hole with cap and drain valve. The
conservator vessel shall be fitted with constant oil pressure diaphragm oil sealing
system.
 Magnetic type oil level gauge (150 mm dia.) with low oil level alarm contacts.
 Prismatic/toughned glass oil level gauge.

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 Silica gel breather with oil seal and connecting pipe complete with first fill of activated
silica gel or Alumina mounted at a level of 1300 mm above ground level.
 A double float type Buchholz relay with isolating valve, bleeding pipe and a testing
cock, the test cock shall be suitable for a flexible (pipe connection for checking its
operation). A 5-mm dia. cooper pipe shall be connected from the relay test cock to a
valve located about 1.25 meters above ground level to facilitate sampling of gas with
the transformer in service. Interconnection between gas collection box and relay shall
also be provided. The device shall be provided with two electrically independent
ungrounded contacts, one for alarm on gas accumulation and the other for tripping on
sudden oil surge. These contacts shall be wired upto transformer marshalling box. The
relay shall be provided with shut off valve on the conservator side as well as on the tank
side.
 Pressure relief device the necessary air equilizer connection between this and the
conservator with necessary alarm contacts.
 Air release plugs in the top cover.
 Inspection cover, access holes with bolted covers for access to inner ends of bushing,
etc.
 Winding temperature (hot spot) indicating device for local mounting complete in all
respects. Winding temperature indicator shall have two sets. of contacts to operate at
different settings:
 To provide winding temperature ‘high alarm’.
 To provide temperature too high ‘trip’.
 Dial thermometer with pocket for oil temperature indicator with one set of alarm and
one set of trip contacts and maximum reading pointer.
 Lifting eyes or lugs for the top cover, core and coils and for the complete transformer.
 Jacking pads
 Haulage lugs
 Protected type mercury / alcohol in glass thermometer and a pocket to house the same.
 Top and bottom filter valves on diagonally opposite ends with pad locking arrangement
on both valves.
 Top and bottom sampling valves.
 Drain valve with pad locking arrangement.
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 Rating and connection diagram plate.

 Two numbers tank earthing terminals with associated nuts and bolts for connections to
purchaser’s grounding strip.
 Bi-directional flagged rollers with locking and bolting device.
 Marshalling Box (MB)
 Shut off valve on both sides of flexible pipe connections between radiator bank and
transformer tank.
 Cooling Accessories:
 Requisite number of radiators provided with:
 One shut off valve on top
 One shut off valve at bottom
 Air release device on top
 Drain and sampling device at bottom
 Lifting lugs.
 Air release device and oil drain plug on oil pipe connectors:
 Terminal marking plates for Current Transformers and Main Transformer.
 Neutral earthing to be brought down through tinned copper strip to purchaser’s earthing
grid via support insulators on tank.
 On load tap changer (OLTC), motor operated, complete in all respects, with separate
oil chamber from main tank and provided with:
 Operating handle (for manual operation).
 Surge relay.
 PRV.
 Silica gel breather.
 Conservator.
 Magnetic level gauge for low level alarm.
 Motor, terminals, heater with thermostat, lighting etc complete in all respects.

CONTROL CONNECTIONS AND INSTRUMENT AND WIRING TERMINAL,

BOARD AND FUSES

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 Normally no fuses shall be used anywhere instead of fuse MCB’s (both in AC & DC
circuits) shall be used. Only in cases where a MCB cannot replace a fuse due to system
requirements, a HRC fuse can be accepted.
 All wiring connections, terminal boards, fuses MCB’s and links shall be suitable for
tropical atmosphere. Any wiring liable to be in contact with oil shall have oil resisting
insulation and the bare ends of stranded wire shall be sweated together to prevent
seepage of oil along with wire.
 Panel connections shall be neatly and squarely fixed to the panel. All instruments and
panel wiring shall be run in PVC or non-rusting metal cleats of the compression type.
All wiring to a panel shall be taken from suitable terminal boards.
 Where conduits are used, the runs shall be laid with suitable falls, and the lowest parts
of the run shall be external to the boxes. All conduit runs shall be adequately drained
and ventilated. Conduits shall not be run at or below ground level.
 When 415-volt connections are taken through junction boxes or marshalling boxes, they
shall be adequately screened and 415 volts Danger Notice must be affixed to the outside
of the junction boxes or marshalling box. Proper colour code for Red, Yellow, Blue
wirers shall be followed.
 All box wiring shall be in accordance with relevant IS. All wiring shall be of stranded
copper (48 strands) of 1100-volt grade and size not less than 2.5 sq.mm.
 All wires on panels and all multicore cables shall have ferrules which bear the same
number at both ends, as indicated in the relevant drawing.
 At those points of interconnection between the wiring carried out by separate Agency,
where a change of number cannot be avoided double ferrules shall be provided on each
wire. The change of numbering shall be shown on the appropriate diagram of the
equipment.
 The same ferrule number shall not be used on wires in different circuits on the same
panels.
 Ferrules shall be of white insulating material and shall be provided with glossy finish
to prevent the adhesion of dirt. They shall be clearly and durably marked in black and
shall not be affected by dampness or oil.
 Stranded wires shall be terminated with tinned Ross Courtney terminals, claw washers
or crimped tubular lugs. Separate washers shall be suited to the size of the wire
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terminated. Wiring shall, in general, be accommodated on the sides of the box and the
wires for each circuit shall be separately grouped. Back of panel wiring shall be
arranged so that access to the connecting items of relays and other apparatus is not
impeded.
 All circuits in which the voltage exceeds 125 volts, shall be kept physically separated
from the remaining wiring. The function of each circuit shall be marked on the
associated terminal boards.
 Where apparatus is mounted on panels, all metal cases shall be separately earthed by
means of stranded (48 No.) copper wire of strip having a cross section of not less than
2 sq.mm where strip is used, the joints shall be sweated. The copper wire shall have
green coloured insulation for earth connections.
 All wiring diagram for control and relay panel shall preferably be drawn as viewed from
the back and shall show the terminal boards arranged as in services.
 Terminal board rows shall be spaced adequately not less than 100 mm apart to permit
convenient access to external cables and terminations.
 Terminal boards shall be placed with respect to the cable gland (at a minimum distance
of 200 mm) as to permit satisfactory arrangement of multicore cable tails.
 Terminal boards shall have pairs to terminals for incoming and outgoing wires.
Insulating barriers shall be provided between adjacent connections. The height of the
barriers and the spacing between terminals shall be such as to give adequate protection
while allowing easy access to terminals. The terminals shall adequately protected with
insulating dust proof covers. No live metal shall be exposed at the back of the terminal
boards. CT terminals shall have shorting facilities. The terminals for CTs shall have
provision to insert banana plugs and with isolating links.
 All fuses shall be of the HRC cartridge type and these shall be properly labelled,
wherever these cannot be replaced by MCB as normally only MCB’s shall be used.
 All interconnecting wiring, as per the final approved scheme between accessories of
transformer and marshalling box is included in the scope of this specification and shall
be done by the Transformer supplier.
 The schematic diagram shall be drawn and fixed under a transparent prispane sheet on
the inner side of the marshalling box cover.

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 As a rule, the fuses shall be replaced by Miniature Circuit Breakers (MCBs) in the
control and other supplies.
 To avoid condensation in the MB, a space heater shall be provided with an MCB and
thermostat.
 Suitable 11 W, CFL light shall be provided in the Marshalling Box for lightning
purpose.

RADIO INTERFERENCE AND NOISE LEVEL

Transformers shall be designed with particulars care to suppress at least the third and fifth
harmonic voltages so as to minimise interference with communication circuits. Transformer
noise level, when energised at normal voltage and frequency shall be as per NEMA stipu-
lations.
Performance Requirements
Transformers shall operate without injurious heating at the rated KVA at any voltage within
± 10 percent of the rated voltage of that particular tap.
Transformers shall be capable of delivering the rated current at a voltage equal to 105 per-
cent of the rated voltage without exceeding the limiting temperature rise.
Transformer for two or more limits of voltage or frequency or both shall deliver its rated
KVA under all the rated conditions of voltage or frequency or both; provided an increase in
voltage is not accompanied by a decrease in frequency.
Transformers shall operate below the knee of the saturation curve at 110 percent voltage to
preclude ferro-resonance and non-linear oscillations.
Transformers shall be capable of operation continuously, in accordance with the applicable
standard loading guide at their rated KVA and at any of the specified voltage ratios. Under
these conditions, no limitations by terminal bushings, on-load tap changers or other auxil-
iary equipment shall apply.
The neutral terminal of windings with star connection shall be designed for the highest over
current that can flow through this winding.
The transformers shall be designed with particular attention to the suppression of harmonic
voltage, especially the third and fifth, so as to eliminate wave form distortion and any pos-
sibility of high frequency disturbances reaching a magnitude as to cause interference with
communication circuits.

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The Engineer-in-Charge reserves the right to reject the transformer if the same does not
meet the specification requirement subject to tolerances as per IS:2062. The rejected trans-
formers shall be replaced by transformers complying with the requirements to this specifi-
cation at the Agency cost.
If the commissioning of the project is likely to be delayed by the rejection of a transformer,
as mentioned under (h) above, the Engineer-in-Charge reserves the right to accept the re-
jected transformer until the replacement transformer is made available. Transporting the
rejected and replacement transformers as well as installation and commissioning of both
the transformers shall be at the Agency cost.
The permissible tolerances on the guaranteed values of transformer losses shall be as per
IS 2025. The values of load- losses and No-load losses shall be within the values given in
latest edition of CBIP manual for transformer ratings less than or equal to 2000kVA.
Cost loading shall be done for capitalization of losses at time bid evaluation for all trans-
former rating above 2000kVA as per Formula given in CBIP manual.

On Load Tap Changing Gear for Power Transformer

The OLTC gear shall be designed to complete successfully tap changes for the maximum
current to which transformer can be loaded i.e., 150% of the rated current. Devices shall be
incorporated to prevent tap change when the through current is in excess of the safe current
that the tap changer can handle. The OLTC gear shall withstand through fault currents with-
out injury.
When a tap change has been commenced it shall be completed independently of the opera-
tion of the control relays and switches. Necessary safeguard shall be provided to allow for
failure of auxiliary power supply or any other contingency which may result in the tap
changer movement not being completed once it is commenced.
Oil in compartments which contain the making and breaking contacts of the OLTC shall
not mix with oil in other compartments of the OLTC or with transformer oil. Gases released
from these compartments shall be conveyed by a pipe to a separate oil conservator or to a
segregated compartment within the main transformer conservator. A Buchholz relay shall
be installed in the above pipe. The conservator shall be provided with a prismatic oil level
gauge.

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Oil, in compartments of OLTC which do not contain the make and break contacts, shall be
maintained under conservator head by valved pipe connections. Any gas leaving these com-
partments, shall pass through the Buchholz relay before entering the conservator.
Oil filled compartments shall be provided with filling plug, drain valve with plug, air re-
lease vent, oil sampling device, inspection opening with gasketed and bolted cover with
lifting handles.
OLTC driving mechanism and its associated control equipment (Local) shall be mounted
in an outdoor, weather-proof cabinet with IP55 protection which shall include:
Driving motor (415V, 3-phase, 50 Hz. AC squirrel cage).
Motor starting contactor with thermal overload relays, isolating switch and HRC fuses.
Duplicate sources of power supply with automatic changeover from the running source to
the standby source and vice versa.
Control switch: Raise/off/lower (spring return to normal type).
Remote/local selector switch (maintained contact type).
Mechanical tap position indicator showing rated tap voltage against each position and re-
settable maximum and minimum indicators.
Limit switches to prevent motor over-travel in either direction and final mechanical stops.
Brake or clutch to permit only one tap change at a time on manual operation.
Emergency manual operating device (hand crank or hand wheel).
A five-digit operation counter.
Electrically interlocked reversing contactors (preferably also mechanically interlocked).
240V, 50 Hz. AC space heater with switch and HRC fuses.
Interior lighting fixture with lamp door switch and HRC fuses.
Gasketted and hinged door with locking arrangement.
Terminal blocks, internal wiring, earthing terminals and cable glands for power and control
cables.
Necessary relays, contactors, current transformers etc.

Control Requirements for OLTC

The following electrical control features shall be provided:
Positive completion of load current transfer, once a tap change has been initiated, without
stopping on any intermediate position, even in case of failure of external power supply.

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Only one tap change from each tap change impulse even if the control switches or push
button is maintained in the operated position.
Cut-off of electrical control when manual control is resorted to. Cut-off of a counter impulse
for a reverse tap change until the mechanism comes to rest and resets the circuits for a fresh
operation.
Cut-off of electrical control when it tends to operate the tap beyond its extreme position.

Automatic Control of OLTC

Automatic OLTC control shall include the following items:
Voltage setting device
Voltage sensing and voltage regulating devices.
Line drop compensator with adjustable R and X elements.
Timer 5-25 seconds for delaying the operation of the tap changer in the first step for every
tap change operation.
Adjustable dead band for voltage variation

OLTC Panel
The OLTC remote control equipment shall be suitable for 110V DC supply and shall be
housed in an indoor sheet steel cubicle to be located in a remote-control room. The OLTC
control panel shall comprise of rigid welded structural frames made of structural steel sec-
tion or of pressed and formed cold rolled steel and frame enclosures, doors and partitions
shall be of cold rolled steel of thickness 2 mm. Stiffeners shall be provided wherever nec-
essary. All doors, removable covers and plate shall be gasketed all around with neoprene
gaskets. Panel shall be dust, weather and vermin proof providing degree of protection of
IP54, colour of finish shade for interior and exterior shall be glassy white and light grey
semi glossy shade 631 of IS-5 respectively. Earthing bus shall be of 25 x 6 mm copper.
Control switch : Raise/Off/Lower(spring return to normal type)
Auto/manual selector switch (maintained contact type)
Tap position indicator
Facia type alarm annunciators with “accept” and “lamp test” facilities.
A.C. supply failure
Drive motor auto tripped

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Tap change delayed

Necessary auxiliary relays
Lamp indications for:
Tap change in progress
Lower limit reached
Upper limit reached
Cable glands for power and control cables
240V rated panel space heater with ON-OFF switch
Fluorescent type interior lighting fixture with lamp and door switch
HRC fuses
Terminal blocks
Internal wiring
Earthing terminal

Off Load Tap Changing Mechanism for Auxiliary Transformer

Off circuit tap changing mechanism shall comprise the following
Operating handle of wheel, accessible from ground level
Tap position indicator
Pad locking arrangement
The tap-changer connections and contacts shall be accessible through an access hole having
a bolted gasketted cover

Fittings and Accessories

The following fittings and accessories shall be provided with transformer
Inspection manhole in the cover.
Lifting lugs for both the transformer and the core.
Two earthing terminals on opposite ends of the transformer tank.
Name plate, rating plate and diagram plate.
Detachable radiator banks, complete with top and bottom shutt-off valves, air release plug,
drain valve and lifting lugs, suitably located thermometer pockets for measuring inlet and
outlet oil temperature and one grounding terminal for connection of grounding conductor.
Fins of the radiators shall not have sharp edges but shall be rounded shape.

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Conservator, complete with filling plug, sump and drain valve, and a shut-off valve on the
pipe connection between transformer tank and conservator, to permit removal of the con-
servator. The conservator shall be designed to maintain an oil seal through a temperature
range of 100 Deg C.
Oil level indicator with minimum marking.
Weather proof dehydrating breather with activated alumina or silica gel as the dehydrating
agent.
Magnetic type oil level gauge with low oil level alarm contact, mounted on the conservators
with waterproof and dustproof terminal box.
Gas detector relays with separate alarm and trip contacts complete with shut-off valves.
Separate drain valve, oil sampling valve with plug and top filter valve shall be provided on
the tank.
Explosion vent with diaphragm for relieving pressure inside the transformer. The device
shall be rain proof after operation. For transformers of 500 KVA and above an equaliser
pipe connecting the pressure relief device to the conservator shall be supplied.
Separately mounted, water proof and dustproof marshalling box housing the oil tempera-
ture indicator and winding temperature indicator with alarm and trip contacts and mar-
shalling facilities for electrical devices mounted on transformer.
For transformers rated 500 KVA and above. Adequate number of air vents for relieving
trapped air during oil filling and during maintenance.
Thermometer pockets and sensing element mounted on the transformer tank cover for
measuring top oil temperature.
Four jacking pads for lifting the transformer with jacks.
Pulling eyes and skids for the movement of the transformer.
Bidirectional wheels for movement of the transformers.
Accessories for clamping the wheel mounted transformer to the foundation in order to with-
stand earthquake forces with a seismic acceleration of 0.2g.
Noise level of transformers shall be less than 80 dB.
Transformer shall be supplied complete with insulating oil required for first filling plus
10% excess oil.

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Drawings and Data

The following drawings shall be submitted for the Authority’s Approval:
General outline drawing as submitted at the Biding stage but with binding dimensions and
weights within 2 months of award of contract.
General outline drawings showing plan, front elevation, and side elevation, with all fittings
and accessories, locating dimensions of cable entries, earthing terminals, foundation/floor
fixing details, jacking pads and weights of the following within 4 months of award of Con-
tract.
OLTC (Local and Remote) cabinets
Marshalling box
Cable boxes
Disconnecting chambers
Maintenance and Operating Instructions
 Height of centre line of HV and LV connectors of transformers from the rail top level
 Painting procedure.
 Complete CT details including VA, class, ALF, resistance, magnetization characteristic
curves, dimensions fixing arrangement etc. of neutral and phase side current
transformers (as applicable).
 Specification of the insulating oil.
 GA drawings / details of bushing and terminal connectors.
 Name plate drawing with terminal marking and connection diagrams.
 Wheel locking arrangement drawing.
 Transportation dimensions drawings.
 Magnetization characteristics curves of PS class neutral and phase side current
transformers, if applicable.
 Interconnection diagrams.
 Over fluxing withstand time characteristics of transformer.
 GA drawing of marshalling box.
 Control scheme / wiring diagram of marshalling box.
 Technical leaflets of major components and fittings.
 As built drawings of schematics, wiring diagram etc.
 Setting of oil temperature indicator, winding temperature indicator.
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 Completed technical data sheets.

 Details including write-up of tap changing gear.
 H.V. cond. bushing.
 Bushing Assembly.
 GA of HV & LV cable Box.
 Radiator type Assembly.
 Detailed wiring/schematic drawings for ONAF operation of the transformer.
 Motor Drive (circuit diagram plus parts list etc.)
 Earthing and Insulation of Core
 Locking Facilities and Accessories for Valves
 Construction of Globe Valves and Gate Valves
 Factory Test Procedure and Test Schedules for Factory Tests
 Commissioning Test Procedure and Report
 Operation and Maintenance Manual including Test Reports
 Outline of Radiator
 Outline of Fan Unit
 Mechanical Protection of Auxiliary Wiring and Capillaries
All drawings/documents, technical data sheets and test certificates / results / calculations
shall be furnished.
Bushings Plan, elevation, terminal details, mounting details, make and type number, current
and voltage rating, creepage distances and principal characteristics.
Rating and diagram plates
OLTC cabinets: schematic circuit diagram and actual detailed wiring diagram giving ter-
minal numbers within 5 months of award of Contract.
Marshalling box terminal connections wiring diagram.

TESTS
The Transformers shall be completely factory tested before despatch in accordance with
the standards and with such other tests as may be necessary to ensure that the equipment is
satisfactory and is in accordance with this specification.

ROUTINE TESTS
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Transformer routine tests shall include tests stated in latest issue of IS:1180. These tests
shall also include but shall not be limited to the following:
 Measurement of winding resistance.
 Voltage ratio on each tapping and check of voltage vector relationship.
 Impedance voltage at all tappings
 Magnetic circuit test.
After routine tests, each core shall be tested for 1 minute at 2 KV between all bolts, side
plates and structural steel work. Immediately prior to the dispatch of the transformer, the
magnetic circuit shall be pressure tested for 1 minute at 2 kV A.C. between the core and the
earth.
 Load losses.
 No load losses and no-load current
 Absorption index i.e. insulation resistance for 15 seconds and 60 seconds (R60/R15)
and polarization index i.e. Insulation Resistance for 10 minutes and one minute (R10
mt/R1 mt)
 Induced over voltage withstand test.
 Separate source voltage withstand test (applied potential).
 Tan delta measurement and capacitance of each winding to earth (with all other
windings earthed) & between all windings connected together to earth.
 Dissolved gas analysis test
 Measurement of acoustic noise level
 Measurement of Zero sequence impedance.
All routine & type tests shall be done free of cost. If it is to be done on the cost basis, the
same may be indicated in the schedule of prices and delivery and this will be taken into
account for evaluation of prices.
TYPE TESTS
Moreover, in addition to the routine tests, the transformer shall be subjected to the following
type tests:
 Lightning Impulse Test
This test shall be carried out in accordance with clause 12 of the latest issue of IS: 1180.
The bidder shall quote separate price for lightning impulse test on HV and LV windings.
(One limb only).
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 Temperature Rise Test

The temperature rise test shall be carried out in accordance with IS:1180. The Temperature
rise shall not exceed the values stated elsewhere in the specification.

TEST WAIVAL, PROCEDURES AND COSTS

The purchaser, at his option, may waive impulse tests provided type test reports of impulse
tests carried out on essentially identical units in their factory in India are furnished by the
manufacture.
No load losses and exciting current shall be measured at rated voltage, rated frequency and
at 90% and 110% of rated voltage, both before and after the lightning impulse tests.
The method of test loading shall be described in the test report for determination of both
average and hottest spot temperature. Where the winding temperature equipment is speci-
fied, data shall also be included for calibration of hottest spot temperature indicator.
Resistance of each winding of each phase shall be measured at principal and at all the taps
and corrected to 75°C.
Impedance voltage shall be measured at principal and at all taps.
No load Loss Measurement at 415 Volt.
The bidder shall indicate separately the cost of each of the following types tests:
Lightning impulse test separately for HV and LV winding
Temperature rise test

TESTS ON TRANSFORMER TANK

Vacuum Test: One transformer tank of each size shall be subjected to the vacuum pressure
of 760 mm of mercury. The tanks designed for full vacuum shall be tested at an internal
pressure of 3.33 KN/m2 (25 mm of mercury) for one hour. The permanent deflection of flat
plates after the vacuum has been released shall not exceed the value specified in C.B.I.P.
Manual on Transformers (Revised 1999) without affecting the performance of the trans-
former.
Pressure Test: One transformer tank of each size together with its radiators, conservator
vessel and other fittings shall be subjected to pressure corresponding to twice the normal
head of oil or to the normal pressure plus 35 kN/m2 (5 1b/sq.in) whichever is lower meas-
ured at the base of the tank and will be maintained for one hour. The permanent deflection

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of flat plates after the excess pressure has been released shall not exceed the value specified
in C.B.I.P. Manual on Transformers (Revised 1999).
The pressure relief device shall be subjected to increasing oil pressure. It shall operate be-
fore reaching the test pressure specified above. The operating pressure shall be recorded.
The device shall seal off after the pressure in excess has been relieved (routine test).
Oil leakage test: All tanks and oil filled compartments shall be tested for oil tightness by
oil of a viscosity not greater than that of insulating oil to IS: 335, at the specified ambient
temperature and subjected to a pressure equal to the normal pressure plus 35 KN/m2 square
(5 1b/sq.in) measured at the base of the tank. This pressure shall be maintained for a period
of not less than 12 hours, during which time to leakage shall occur.

TEST ON ASSOCIATED EQUIPMENT

Porcelain bushings, bushing current transformers, wherever provided, winding temperature
indicating devices, dial thermometers, buchholz relays, ON LOAD tap changer, coolers,
control devices, insulating oil and other associated equipment shall be tested by the supplier
/Agency in accordance with relevant IS. If such equipment are purchased by the supplier/
Agency on a sub-contract, he shall have them tested to comply with these requirements.

SEQUENCE OF TESTING ON ASSEMBLED TRANSFORMER

Unless otherwise agreed, the sequence of testing shall be as follows:
 Ratio and vector group
 Winding resistance measurement
 Tan Delta & Insulation resistance measurement
 Separate source voltage withstand test
 Measurement of Iron losses
 Load losses and impedance voltage measurement
 Lightning impulse test
 Temperature rise test
 Induced voltage withstand test
 Tests on OLTC
TEST MEASUREMENTS

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The zero-sequence impedance, insulation power factor and capacitance for each winding
and between windings shall be measured and recorded.
Certified test report and oscillograms shall be furnished to the Purchaser / Consultants for
evaluation as per the schedule of distribution of documents. The Contactor shall also eval-
uate the test results and rectify the defects in the equipment based on his and the Purchaser’s
evaluations of the tests without any extra charges to the Purchaser. Manufacturer’s Test
Certificates in respect of all associated auxiliary and ancillary equipment shall be furnished.
The bidder shall state in his proposal the testing facilities available at his works. In case
full testing facilities are not available, the bidder shall state the method proposed to be
adopted so as to ascertain the transformer characteristics corresponding to full capacity
testings.

WITNESSING OF TESTS AND EXCESSIVE LOSSES

The Purchaser and / or his representative reserves the right to witness any or all tests, or to
accord waival at its sole discretion.
The Purchaser reserves the right to reject the Transformer it losses exceed the declared
losses beyond tolerance limits as per IS or if temperature rise of oil and winding exceed the
values specified elsewhere. (See clause 3.5.0).

SITE TESTS
After the transformer is installed, the following pre-commissioning tests and checks shall
be done before putting the transformer in service.
 Dry out test
 Megger test
 Resistance measurement of windings
 Ratio test
 Phase relationship test
 Tap changer test
 Buchholz relay alarm & surge operation test
 Low oil level alarm
 Temperature Indicators
 Marshalling kiosk

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 Protective relays
 Magnetising current
 Tests on OLTC
 The following additional checks shall be made:
 All oil valves are in correct position closed or opened as required.
 All air pockets are cleared.
 Thermometer pockets are filled with oil.
 Oil is at correct level in the bushing, conservator, divertor switch, tank etc.
 Earthing connections are made
 Colour silica gel is blue.
 Bushing arcing horn is set correctly and gap distance is recorded.
 CT polarity and ratio is correct.

LOSSES AND DAMAGES

LOSSES
Transformers with lower losses shall be preferred. The bidder shall indicate the values of
load and no-load losses of the transformer in his bid. Losses quoted shall be firm, without
any tolerance. If nothing is indicated regarding tolerance on losses, it will be considered
that losses are subject to tolerance. In case no ceiling is specified, these will be taken as per
IS and the offer shall be loaded as per Table 7 of latest issue of IS: 1180 or Table 1 of IEC
660076-1.

Capitalization of losses
For total cost evaluation, the capitalized cost of losses will be taken into account as per the
following:
Capitalized Cost of transformer = Initial cost of Cost of transformer + Rs. 564.53 x Wi +
Rs. 312.03 x Wc
Where: Wi = Iron loss in Watt
Wc =Copper loss in watt
The no load loss in Watts at rated voltage & frequency and the load loss in kW at rated
voltage, rated frequency, rated output and 75 Deg C shall be quoted and these shall be
guaranteed.
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Liquidated damages for increase in losses:

Penalty shall be applied to the successful bidder in case he is unable to achieve the quoted
guarantee figures at the following rates:
For each Watt of excess of no-load loss Rs. 565/-
For each Watt of excess of load loss Rs. 312/-
REJECTION
The Purchaser may reject any transformer if during tests or service any of the following
conditions arise:
No load loss exceeds the guaranteed value by 15% or more.
Load loss exceeds the guaranteed value by 10% or more.
Impedance value exceeds the guaranteed value by + 10% or more.
The difference in impedance values or any two phases during single phase short circuit
impedance test exceeds 2% of the average value guaranteed by the vendor.
Oil or winding temperature rise exceeds the specified value.
Transformer fails on impulse test
Transformer fails on power frequency voltage withstand test.
Transformer is proved to have been manufactured not in accordance with the agreed spec-
ification.

INSTRUCTIONS MANUAL
Eight sets of the instruction manuals shall be supplied atleast four (4) weeks before the
actual dispatch of equipment. The manuals shall be in bound volumes and shall contain all
the drawings and information required for erection, operation and maintenance of the trans-
former. The manuals shall include amongst others, the followings particulars:
 Marked erection prints identifying the components, parts of the transformer as
despatched with assembly drawings.
 Detailed dimensions, assembly and description of all auxiliaries.
 Detailed views of the core and winding assembly, winding connections and tappings,
tap changer construction etc. These drawings are required for carrying out overhauling
operation at site.
 Salient technical particulars of the transformer.
 Copies of all final approve drawings.

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 Detailed O&M instructions with periodical check lists and proforma etc.
COMPLETENESS OF EQUIPMENT
All fittings and accessories, which may not be specifically mentioned in the specification
but which are necessary for the satisfactory operation of the plant, shall be deemed to be
included in the specification and shall be furnished by the supplier /Agency without extra
charges. The equipment shall be complete in all details, whether such details are mentioned
in the specification or not, without any financial liability to the Purchaser under any cir-
cumstances.
All deviations from this specification shall be separately listed under the requisite sched-
ules, in the absence of which it will be presumed that all the provisions of the specification
are complied with by the bidder.

TOOLS & TACKLES

All the necessary tools and tackles required for normal operation shall be supplied by the
supplier / Agency.

COMMISSIONING
The equipment shall be commissioned as per CBIP manual, IS 10028 and manufacturer’s
recommendations. All the as built drawings / manuals shall be pre-requisite for release of
payment for final payment.
Specific Technical Particulars of 33kV/6.6kV Transformers shall be as follows:

Description Unit Technical Particulars

As per Preferred Makes/Manufactur-
Make
ers
Type As per Specification
Applicable Standards As per Specification
Rated output KVA (*)

Description Unit Technical Particulars

Quantity required Nos. 2
Transformer location Outdoor

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No load transformer ra-

kV/kV 33kV / 6.6kV
tio
Number of phases 3
Rated frequency Hz 50
Impedance at all taps % Value as per IS 1180
Number of winding /
material of Two/Copper
conductor
Type of cooling ONAN
Full capacity, OLTC on HV side
with local
Tap changer marshalling box and Remote Tap
Changing
panel
Tap range % + 5 % to -15 %
Tap step % 1.25 %

Terminal connection Cable box suitable for 33kV XLPE,

HV terminals Primary Al.
Conductor armoured cables (*)
HV terminals Second- Cable box suitable for 6.6kV (UE),
ary XLPE, Al
Conductor armoured cables (*)
Current Transformer
(*)
On HV Secondary

Description Unit Technical Particulars

On HV Secondary Neutral Class PS Ac-
i. Restricted Earth Fault curacy
ii. Over current earth fault Class 5P20
backup protection Accuracy
HV Secondary Neutral shall be
brought out the cable box for
forming the 3 Ph, 4-wire system
HV Secondary Neutral earth- and outside the cable box by
ing 6.6kV Single core Unearthed ca-
ble upto Neutral Earthing Resis-
tor & from Neutral Earthing Re-
sistor for direct connections to

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earth by means of 6.6kV (UE),

1C, XLPE, Cable (*)

Insulation of Windings H.V.(Primary) H.V.(Secondary)

One-minute power frequency
withstand voltage (dry and kV (rms) 70 20
wet)
1.2/50 microsecond full wave
170 60
impulse withstand voltage
Insulation of bushings H.V.(Primary) H.V.(Secondary)
Rated Voltage of bushing kV 36 7.2
One-minute power frequency
withstand voltage (dry and kV (rms) 70 20 20
wet)
1.2/50 microsecond full wave
kV (peak) 170 60
impulse withstand voltage
25mm/kV on 25mm/kV on
Minimum creepage distance Mm
36kV 36kV
Vacuum withstand capability
of transformer main tank with 250mm of 250mm of mer-
bushings, radiations, fitting mercury cury
and accessories

Specific Technical Particulars of 6.6kV/0.415kV Transformers shall be as follows:

Description Unit Technical Particulars

As per Preferred Makes/Manufac-
Make
turers
Type As per Specification
Applicable Standards As per Specification
Rated output KVA (*)
Quantity required Nos. 3
Transformer location Indoor
No load transformer ratio kV/kV 6.6/0.415kV
Number of phases 3
Rated frequency Hz 50
Impedance at all taps % Value as per IS 1180
Number of winding / material of
Two/Copper
conductor

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Type of cooling ONAN

Full capacity, Off-Circuit type on
HV side
Tap changer with local marshalling box and Re-
mote Tap
Changing panel
Tap range % + 5 % to -5 %
Tap step % 2.5 %

Cable box suitable for 6.6kV

Terminal connection
XLPE, Al.
HV terminals
Conductor armoured cables (*)
LV terminals
Cable box suitable for 650/1100 V
XLPE,Al.
Conductor armoured cables (*)
Current Transformer
On LV (*)
On LV Neutral (*)
LV Neutral shall be brought out
through a 1.1 kV rated bushing,
both inside the cable box for form-
LV Neutral earthing ing the 3 Ph, 4-wire system and out-
side the cable box for direct con-
nections to earth by means of Cop-
per Earthing conductor (*)
One-minute power frequency 3.0
One-minute power frequency 3.0
kV
withstand voltage (dry and wet)
(r.m.s)
1.2/50 micro second full wave kV
-
impulse withstand voltage (peak)
L.V.
Insulation of bushings H.V. (Line and Neu-
tral)
Rated Voltage of bushing kV 7.2 1.1
One-minute power frequency with-
kV (r.m.s) 70 3.0
stand voltage

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1.2/50 microsecond full wave im-

kV (peak) 60 -
pulse withstand voltage

Description Unit Technical Particulars

25mm/kV on
Minimum creepage distance Mm 25mm/kV on 1.1 kV
7.2kV
Vacuum withstand transformer
main
Tank with bushings, radiations, 250mm of mer-
250mm of mercury
fitting cury
And accessories.

NEUTRAL EARTHING RESISTOR

Applicable Standards
Neutral earthing resistor shall conform to latest applicable standards specified below. In
case of conflict between Standards and this specification, this specification shall govern.
Neutral Earthing Resistors : IEEE32
Degree of Protection for enclosures : IS 13947 (Part I) / IEC 947-1 / BSEN
60529
Design Features
Resistor Element
The element material shall possess a balanced combination of properties, uniformity of
resistance and mechanical stability over the intended temperature range, without any inju-
rious effects on the elements and its associated insulation.
The resistor assembly shall be designed for a maximum temperature rise as per IEEE 32,
Table 6, Column 7. The maximum operating temperature shall not be higher than 80% of
the maximum design temperature.
Degree of Protection
The minimum degree of protection for the resistor element shall be IP 34.
Construction
The construction of the resistor assembly shall be such that the minimum required insula-
tion resistance is maintained under all atmospheric conditions, without a space heater.
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The front and back covers shall be removable for access to internal resistor connection and
for removal of resistor banks.
The resistor shall be housed in a free standing and self-supporting metal enclosure suitable
for installation in outdoor, humid atmospheric condition with IP-55 protection. For outdoor
installation, the top of the enclosure shall be protected against direct sun radiation.
The enclosure shall be suitable for installation on a concrete foundation.
Terminations
The connection box and terminals shall be suitable for the cable specified and adequate
space shall be provided for termination of cable.
All conductor terminations shall be bolted welded or brazed. Low melting alloys used to
join connectors, which would be adversely affected by the resistor operating temperatures,
shall not be used. All conductor terminations must be mechanically secured to provide con-
tinuous electrical continuity and shall be rated for the full system voltage.
Terminal box protection shall be minimum IP 55 for outdoor installation.
Cable gland plate shall be made of non-magnetic metal.
Specific Technical Particulars of 6.6kV Neutral Earthing Resistor shall be as follows:

Description Unit Technical Particulars

GENERAL
Transformer Neutral Earth-
Application/Designation
ing
Quantity Nos. 2
Type Material
A) Wire Wound (Stainless Steel) Nos. Stainless Steel
B) Strip Type Element
Installation Outdoor
Enclosure Totally Enclosed Dust and
A) Sheet Steel Thickness Vermin Proof.
B) Tank Type Weather Proof 2 Mm

Description Unit Technical Particulars

With Aluminium Covers
IP 55
C) Tank Type with Galvanised
Epoxy paint
Screen Covers

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D) Safety Screened Enclosure for

Personnel Protection
E) Degree of Protection
F) Colour Shade
Cooling Naturally Air Cooled
Site Conditions
A) Area Classification
B) Gas Group
C) Temperature Class
RATINGS
Rating kW (*)
Ohmic Value Ohms (*)
Taps % As per Specification
Rated Current A (*)
Duration of Rating
10 Sec.
Continuous / 60 Secs.
Line to Neutral Voltage kV 3.15
Insulation Class kV 6.6
Voltage Class of Stand Insula-
kV 6.6
tors
CURRENT TRANSFORMER
2 Core
a) Required and Part of Supply
(*)/(*)
b) Ct Details

Description Unit Technical Particulars

(*)
C) Ratio A
5P20 – Both Cores Have
D) Rating VA
Same Accuracy
E) Class
Class
TERMINAL CONNECTIONS
Incoming to Terminal Box MM2
A) Cable Type MM 6.6kV (UE), 1C, XLPE,
B) Size Al, Armoured cable

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C) Overall Diameter (*)

D) Gland or Entry Type & Size (*)

All Taps of Resistors

Outgoing from Resistor Shall Be Brought to Ter-
minal Box

Outgoing from Terminal Box

6.6kV (UE), 1C, XLPE,
A) Cable Type
MM2 Al, Armoured
B) Size
MM (*)
C)Overall Diameter
(*)
D) Gland or Entry Type & Size

Resistor Earthing Bushing Suita-

ble for Conductor Of
A) Material
B) Size
APPLICABLE STANDARDS
Neutral Grounding Resistor IEEE 32
Current Transformer IEC 185
Degree Of Protection IS 2147
Provided by Enclosures

TECHNICAL SPECIFICATION FOR COMPACT SUBSTATION (33/0.415KV)

1. Scope
This specification covers the design, Engineer-in-Charge manufacture, Shop testing pack-
ing, transportation to site, site storage, installation, testing and commissioning of a SCADA
operated, prefabricated, factory assembled and fitted. 8 nos of required capacity in WDC
areas and 1 no required capacity at WTP plant are to be installed at respective locations.
Compact Sub Station [CSS] consisting of following main components.
 36kV, non-extendable, metal clad SF6 insulated switchgear, sealed for life, Ring Main
Unit (RMU)
 Dry type 33/0.433kV distribution transformer
 LV switch board.
 Prefabricated weather proof enclosure.
 SCADA connection for remote control and monitoring.

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All termination and connections to high voltage and low voltage side of distribution trans-
former, earthing and any other work to complete the works in all respects whether specifi-
cally mentioned or not in this specification.
Portable Fire extinguishers for electrical fires
Complete Documentation
Training to Owners personnel
The CSS is to be totally free from any external deposit (dust, condensation etc.) and suitable
to operate in highly humid, hot environment without any preventive maintenance, cleaning
etc. It shall be of “fit and forget” type. All nut bolts, frames etc. shall be rust proof, typically
of stainless steel or materials not prone to rusting, in site environmental conditions.
CSS can be placed indoor or outdoor as per detail design and requirement. Scope shall also
include design, Engineer-in-Charge of all the civil and all other related site works so as to
complete the works in all respects.
The prefabricated substation unit is required for fast installation, to be maintenance free
and with life expectancy of thirty years under site conditions.
Climate and Isocerunic Conditions
For AURIC BIA Project, the electrical equipment selected shall be such so as to give trouble
free operation during the life of the equipment, under the most stringent atmospheric con-
ditions prevailing at site.
Basic Design Criteria
The CSS shall be designed with the following design criteria:
 For design purpose maximum, ambient temperature of 50° C shall be considered.
 It shall be factory built and tested and preferably transported as such so that it is ready
for site installation. Only external connections need to be done at site.
 Design to comply with latest version of IEC 62271-202.
 Maintenance free Ring Main Unit [RMU] with SF6 insulation sealed for life as per IEC
standard.
 Dry type, epoxy insulated transformer with HV side metering.
 LV Switchboard with Capacitor bank for automatic power factor correction [APFC].
 Enclosure to have independent compartments for RMU, transformer and LV Board with
suitable entry doors.

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The electrical equipment including the enclosure, its supporting structure etc. is to be rust
and corrosion proof throughout its life. In case there is no alternative to items such as mild
steel sheet, and other structural items, the same shall be hot dip galvanized [minimum 610
gm zinc /m2] and epoxy painted. Nut, bolts, washers and other similar items shall be of rust
proof material such as stainless steel.
Cables shall be mostly in trenches of concrete, as per site conditions.
The Enclosure consisting of High Voltage switchgear, Low Voltage switchgear & Trans-
former of the Unitized substation shall be designed to be used under Indoor or outdoor
service condition.
Quality of Material:
All material used shall be new and of best quality and of class most suitable for working
under the conditions specified herein without distortion or deterioration.
Galvanization of steel shall only be done by hot dip process after the parts are ready for the
purpose of assembly. Alternatively stainless steel of the quality suitable for site shall be
used.
Design and Standardization
The equipment shall be designed to ensure satisfactory operation in which continuity of
service is the first consideration and shall also be designed to withstand sudden load varia-
tions due to short circuits and other fault conditions.
The design shall incorporate every reasonable precaution and shall have necessary provi-
sion for the safety of all those concerned in the operation and maintenance of the switch-
gear.
All mechanism shall be made of such materials as to prevent sluggishness due to rust or
corrosion. All Connections and contacts shall be of ample section and surface for carrying
continuously the specified current without undue heating and shall be secured rigidly and
locked in position.
Standard sizes of bolts, screws, pipes and other fittings are to be used and number of sizes
is to be kept to the minimum. Cast iron shall not be used for any part of the equipment
which may be subjected to mechanical stresses. All apparatus shall be so designed and con-
structed as to obviate the risk of short circuits of the live parts by reptiles, rodents etc. Metal
cubicles, housings and covers shall be 100% weather / vermin proof.

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All parts shall be manufactured in accordance with relevant standard specifications. Corre-
sponding parts of similar equipment and apparatus shall be mutually interchangeable.
All apparatus, connections and cabling [FRLS type] shall be designed and arranged to min-
imize the risk of fire and any damage, which might be caused in the event of fire.
Design shall take into consideration that equipment is to be operated under rainy, hot and
humid atmospheric conditions, and surroundings with reptiles and rodents. Certification
offering evidence for the satisfactory operation under such environmental conditions shall
be provided.
 Technical Data for CSS
S. No. Description Technical Data
1 Applicable Standard IEC 62271-202
2 Design Ambient Temperature 50 C
Type of Ventilation for
3 Normal Condition Natural
Hot Condition Natural
4 Compartmentalized Yes
5 Rated temperature enclosure class 10
Degree of protection for external enclo-
IP34
sure for Transformer compartment
6 Degree of protection for external enclo-
IP54
sure for HV compartment
Degree of protection for external enclo- IP54
sure for LV compartment
7 Location Indoor / Outdoor
8 Rated HV 36kV, RMU, with metering
9 Transformer 100,160,250,1000 KVA, Dry Type
10 Nominal rated voltage rating on LV 415V

11 LV Board Incomer ACB + Outgoing MCCB

12 Enclosure material Resistant to rusting

13 Thickness of sheet (minimum) 2mm for enclosure.
14 Base 4mm hot-dip galvanized
14 Enclosure Paint Epoxy, RAL 7032
15 SCADA system / Remote Control Yes

Painting

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Since the local environment is harsh, even galvanized steel will rust after a few years.
Therefore, paint of suitable quality to protect the equipment is of utmost importance.
All sheet steel work shall be phosphated in accordance with IS: 6005 'Code of practice for
phosphating iron and steel, through seven tank processes. Oil, grease, dirt shall be thor-
oughly removed by emulsion cleaning. Rust and scale shall be removed by pickling with
dilute acid followed by washing with running water, rinsing with slightly alkaline hot water
and drying. After phosphating, thorough rinsing shall be carried out with clean water fol-
lowed by final rinsing with dilute dichromate solution and oven drying.
The phosphate coating shall be sealed with the application of two coats of ready mixed zinc
chromate primer. The first coat may be air dried while the second coat shall be stove dried.
Panels shall be painted with epoxy paint of superior quality. ALTERNATIVELY, the panels
shall be painted with electrostatic epoxy powder coating process to have paint of hard coat-
ing. Necessary details shall be provided to Engineer-in-Charge in this regard for prior ap-
proval.
 Paint Thickness
The final finished thickness of paint film on sheet shall be approximately 60 to 80 micron.
The finished painted surface of panels shall present aesthetically pleasing appearance free
form dents and uneven surfaces. Paints shall not scale off or wrinkle or be removed by
abrasion due to normal handling. The colour for finishing paint shall be Siemens grey as
per RAL 7032. Unless otherwise desired the same shall be got confirmed from the Engi-
neer-in-Charge before taking up painting. Each coat of primer and finishing paint shall be
of slightly different shade to enable inspection of the painting.
 Spare Paint
A small quantity (one litre per board) of finishing paint shall be supplied for minor touching
up required at site after installation of the panel.
Drawings and Manuals
The Agency shall furnish all drawings & manuals as called for and given below and also
those which are not specifically included but are necessary for proper operation and mainte-
nance.
 Complete assembly drawing of the Packaged & Ring Main Unit showing plan,
elevations, side & typical sectional views giving complete dimensions.
 Assembly drawings & weight of main component parts.

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 Foundation drawings showing the load on the foundations.

 Schematic control & wiring diagram in accordance with BIS / IEC practice.
 Bushing drawings & their specification.
 Cable termination details & drawings along with terminal connection drawings.
 General arrangement drawing of the complete panels showing CTs, PTs together with
dimensions.
 Maintenance Manual.
 Graph indicating short circuit Vs number of tripping for Vacuum Circuit Breaker.
 Permitted mechanical opening and closing operations.
 Besides above drawings, the Agency shall submit type test certificates, leaflets &
instruction manuals.
 Within 60 days after contract award, the Agency shall furnish to the Engineer-in-Charge
three sets of following drawings for approval. No manufacture of equipment shall
commence untill the drawings are approved:
 General arrangement drawing of complete assembly of packaged & individual RMU
including giving dimensions & their salient features.
 Schematic wiring diagram.
 Foundation drawings.
 Locations of cables slots, cable terminations, CTs, PTs & terminal connections.
 Any other necessary detail.
 Instruction manuals for erection/construction, maintenance and operation.
 Height of centre line of HV and LV connectors of transformers from the rail top level
as well as from the roof of enclosure.
Quality Control
All material shall be new and of best quality and of class, most suitable for working under
the environmental conditions specified herein without distortion or deterioration of equip-
ment during the lifetime of not less than twenty-five years.
1. Quality Assurance
Manufacturer shall submit its quality assurance plan for the approval of Engineer-in-Charge
prior to fabrication.
2. 36kV RING MAIN UNIT

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Specifications same as mentioned in Section 3 “Technical Specifications for Ring Main

Unit”
3. DRY TYPE TRANSFORMER
 General
The distribution transformer in CSS shall be indoor Dry Type Transformer, complete with
all accessories / fittings and spare parts as specified herein.
Three-phase transformers shall be with cast resin type, class F insulation system with nat-
ural (AN) cooling for indoor installation, for use in three-phase HV/LV distribution sys-
tems.
 Specific Technical Requirements (Standard Value)
Rated KVA : up to 1600KVA
Number of phases : Three
Type of installation : Indoor
Frequency : 50 Hz
Cooling medium : AN
Rated Voltage
High voltage winding : 33 kV (DELTA)
Low voltage : 0.433 kV (STAR) with Neutral
Highest Continuous System Voltage:
High Voltage : 36kV
Low Voltage : 0.450 kV
Method of System Earthing :
High Voltage : Unearthed
Low Voltage : Solidly grounded
Type of tap changer : OFF CIRCUIT GANG OPERATED
Range of tapping : +5% to -5% with 5 steps of 2.5% on 33 kv side
Impedance at rated KVA : As per relevant IS
at 75oC
Insulation and level : HV LV
Type of insulation : Uniform Uniform
One-minute power : 28 3
frequency withstands

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test voltage (kV)

Impulse withstand : 75 8
test voltage (kVp)
Winding
Connection : Delta (HV) Star (LV)
Material : Aluminium
Vector group : Dyn-11
Terminal details
HV Termination : Suitable for tee-off Breaker of RMU
LV Termination : Suitable for phase and neutral connection
between transformer and LT board through an insulated
copper bus bar or a sand witched copper bus bar enclosed
in a non-segregated bus duct. The size of the neutral bus
shall be same as phase bus.
LT Neutral earthing : A separate Neutral point to be provided for earthing.
Minimum Clearance in Air: 33 kV 0.433 kV
Phase to phase (mm) : As per IEC
Phase to earth (mm) : As per IEC
Design Ambient temperature: 50 degrees C Maximum Temperature Rise of winding
over an ambient of 50°C and 1000m altitude, not to ex-
ceed 90°C.
Maximum Temp of insulation: 150°C
Over load capacity : As per IEC
Noise level at rated voltage & frequency: As per NEMA Pub. Tr-1
 Transformer Losses
The guaranteed losses of the transformer shall not exceed as given in the Energy Conser-
vation Building Code [ECBC], as per latest guidelines of the Bureau of Energy Efficiency
[BEE] for the required rating of distribution transformer or as per the Bureau of Indian
Standards [BIS] for transformers having energy efficiency level-3. Transformers not com-
plying with BEE / BIS loss guidelines shall not be accepted. The guaranteed values of no
load losses and load losses shall be stated in the bid and these shall be firm.
 Performance

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Transformer shall be capable of withstanding for two seconds the short circuit at its termi-
nals as per requirements of IS-1180 without any damage. Source short circuit power on the
primary of the 33 or 11/0.433 kV transformer shall be assumed as 500 MVA for the short
circuit capability of the transformer. The thermal ability withstand due to short circuit shall
be demonstrated by calculation.
The maximum flux density in any part of the core and yoke at normal voltage and Fre-
quency shall be such that the flux density under 10% over voltage condition shall not ex-
ceed 1.9 Tesla.
Transformer shall, under exceptional circumstances, due to sudden disconnection of the
load, be capable of operating at the voltage approximately 25% above normal rated voltage
for a period of not exceeding one minute and 40% above normal for a period of 5 seconds.
The transformer may be operated continuously without danger on any particular tapping at
the rated KVA ±10% of the voltage corresponding to the tapping.
 Miscellaneous
Complete hardware for fixing the transformer as a part of packaged RMU substation shall
be provided whether specifically mentioned or not.
 Delivery
The equipment shall be delivered, erected and commissioned at site as a part of the pack-
aged RMU substation.
 Conflict in Clause
In case of any conflict between the Specific Technical Requirements and General Technical
Requirements, the requirements indicated as Specific Technical Requirement shall prevail
over the General Technical Requirements.

Environment: Climatic, Environmental and fire-resistant Requirements

As the equipment is to be installed in humid atmosphere the equipment and material pro-
vided must resist the corrosion likely to occur in any case.
Further the transformer must comply to the following class requirements of clause 13 of IS
1180/ IEC 60076- 11.
Class C1: Operation, transportation and storage at ambient temperature as low as -5ºC
Class E2: Frequent condensation combined with high pollution.

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Fire Class F1: Limited flammability, Self-extinguishing of the fire and to be free from hal-
ogens, emission of toxic gases, and minimum of thick smoke.
The above classes will be indicated on the rating plate.
Note: The manufacturer must produce a test report, complying to above clauses as per test
procedure of IEC-60076-11. Test report shall be from an accredited laboratory acceptable
to Engineer-in-Charge, for a transformer of the same design.
Name Plate
Transformer rating plate in English and Hindi language shall contain the information as
given in Clause 15 of IS: 1180 / IEC 60076-11. The details on rating plate shall be finalised
during the detailed Engineer-in-Charge.
General Technical Requirements
Dry type transformer will be manufactured in accordance with a quality system in conform-
ity with ISO 9001 and complying to latest version of IEC 60076-11
Environmental management system is to be in conformity with ISO 14001, which shall be
certified by an independent recognized organization acceptable to Engineer-in-Charge.
Codes & Standards
The design, material, fabrication, inspection, testing before dispatch, erection/construction,
testing, commissioning and performance of distribution transformers shall comply with all
currently applicable statutory regulations and safety codes in the locality where the equip-
ment will be installed. Nothing in this specification shall be construed to relieve the Agency
of this responsibility.
Transformers shall conform to the latest applicable standards and codes of practice as given
below.

S.No. Standard Number Description

1 IS: 5 Colour for ready mixed paints and enamels.
Ready mixed paint, brushing, zinc chrome
2 IS: 104
Priming
3 IS: 1180 Transformers
Thermal evaluation and classification of
4 IS: 1271
Electrical Insulation
Hexagon head bolts, screws and nuts of
5 IS: 1363
Product grade C
6 IEC: 60076-11 Dry Type Transformers
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Amaravati Development Corporation Limited

S.No. Standard Number Description

7 IS: 2016 Plain washers
8 IS: 2071 Method of high voltage test techniques
Ready mixed paint, air drying, red oxide-zinc
9 IS: 2074
chrome, primary
High voltage bushing for alternating voltage
10 IS: 2099
above 1000 V.
Methods for testing uniformity of coating of
11 IS: 2633
zinc coated articles
Enamel, synthetic, exterior (a) undercoating
12 IS: 2932
(b) finishing
13 IS: 3043 Code of practice for earthing
14 IS: 3347 Dimensions for transformer Bushings
Fittings and accessories for power transform-
15 IS: 3639
ers
Dimension for clamping arrangements for
16 IS: 4257
porcelain transformer bushings
Guide for safety procedures and practices in
17 IS: 5216
electrical work
18 IS: 5561 Electric power connectors
bushing for alternating voltage upto & in-
19 IS: 7421
cluding 1000 V
Code of practice for selection, installation
20 IS: 10028
and maintenance of transformers.
Voltage bands for electrical installation in-
21 IS: 12360
cluding preferred voltages and frequency.
22 C.B.I.P. Publication Manual on Transformers

The equipment complying with other internationally accepted standard may also be con-
sidered if they ensure performance superior to the Indian Standards.
Drawings
The Agency shall furnish, within fifteen days after issuing of Letter of Intent, the following
drawings / documents incorporating name of project and transformer rating for approval.
Detailed overall general arrangement drawing showing front and side elevations and plan
of the transformer and all accessories including external features with details of dimen-
sions, spacing of wheels in either direction of motion, net weights and shipping weights,
crane lift for un-tanking, size of lugs and eyes, bushing lifting dimensions, clearances be-
tween HV and LV terminals and ground etc.

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 Foundation plan showing loading on each wheel and lifting lugs.

 GA drawings / details of bushing and terminal connectors.
 Name plate drawing with terminal marking and connection diagrams.
 Wheel locking arrangement drawing.
 Transportation dimensions drawings.
 Interconnection diagrams both on HV & LV sides.
 Over fluxing withstand time characteristic of transformer.
 Technical leaflets of major components and fittings.
 As built drawings of schematics, wiring diagram etc.
 Setting of winding temperature indicator.
 Completed technical data sheets.
 Details including write-up of tap changing gear.
 H.V. bushing.
 Bushing Assembly.
 B-metallic connector for connection to specified conductor / bus-bar /in bus-duct.
 Assembly.
 Two earthing terminals & core earthing
 Thermometer pockets
 Inspection cover
All drawings / documents, technical data sheets and test certificates / results / calculations
shall be furnished.
Any approval given to the detailed drawings by the Engineer-in-Charge shall not relieve
the Agency of the responsibility for correctness of the drawing and in the manufacture of
the equipment for the packaged substation.
General Constructional Features
All material used shall be of best quality and of the class most suitable for working under
the conditions specified and shall withstand the variations of temperature and atmospheric
conditions without distortion or deterioration or the setting up of undue stresses which may
impair suitability of the various parts for the work which they have to perform.
Similar parts, particularly removable ones, shall be interchangeable.

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Screws, studs, nuts and bolts used for external connections shall be as per the relevant
standards. Bolts and nuts exposed to atmosphere shall be of stainless steel.
Exposed parts shall not have pockets where water can collect due to moisture or otherwise.
Labels, indelibly marked, shall be provided for all identifiable accessories. All label plates
shall be of in-corrodible material.
All internal connections and fastenings shall be capable of operating under overloads al-
lowed as per specified standards without injury.
Transformer and accessories shall be designed to facilitate proper operation, inspection,
maintenance and repairs.
No patching, plugging, shimming or other such means of overcoming defects, discrepan-
cies or errors will be accepted.
The galvanizing if required shall be of minimum 610 gm zinc per square meter and it shall
be hot dip galvanized.
Painting [as applicable]
The structural steel work shall be cleaned of all scale and rust by shot-blasting. Steel sur-
faces exposed to the weather shall be thoroughly cleaning and have a priming coat of zinc
chromate applied. The second coat shall be of a glossy oil and weather resisting non- fading,
paint of shade No. 631 as per IS: 5.
Metal parts not accessible for painting shall be made of corrosion resistant material.
All paints shall be carefully selected to withstand heat, rain, hot humid atmosphere and
extremes of weather. The paint shall not scale off or crinkle or be removed by abrasion due
to normal handling.
In case finish paint chips off or crinkle during transit or installation, the Agency shall ar-
range for repainting transformer at site at his cost. The paint for repainting shall be supplied
by the Agency.
Under Carriage
The transformer shall be supported on non- corrosive steel structure with forged steel
flanged wheels suitable for moving the transformer completely. Wheels shall be provided
with suitable bearings which will resist rust and corrosion and shall be equipped with fit-
tings for lubrication.
Magnetic Core

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The magnetic circuit shall be constructed from prime quality high grade cold rolled, non-
ageing, grain oriented silicon steel lamination. The manufacture shall submit the following
documents to prove only Prime Quality Core are used:
Invoice of the supplier
Mill’s test Certificate
Packing list
Bill of loading
Bill of entry certificate to custom
The manufacturers shall indicate whether they have in-house core cutting facilities or not,
if not, they shall indicate place of cutting.
To reduce the noise produced by the magnetic core, it is to be equipped with noise-damping
devices.
To reduce the no-load losses, the magnetic core is to be stacked using overlapping-inter-
locking technology.
The laminations shall be free of all burns and sharp projections. Each sheet shall have an
insulating coating.
The insulation structure for the core to bolts and core to clamp plate shall be such as to
withstand a voltage of 2000 V for one minute.
The completed core and coil shall be so assembled that the axis and the plane of the outer
surface of the core stack shall not deviate from the vertical plane by more than 25 mm.
All steel sections used for supporting the core shall be thoroughly shot or sand blasted, after
cutting, drilling and welding.
The finally assembled core with all the clamping structures shall be free from deformation
and shall not vibrate during operation.
The core clamping structure shall be designed to minimise eddy current loss.
The core shall be carefully assembled and rigidly clamped to ensure adequate mechanical
strength.
The core shall be provided with lugs suitable for lifting the complete core and coil assembly
The design of magnetic circuit shall be such as to avoid static discharges, development of
short circuit paths within itself or to the earthed clamping structure and production of flux
component at right angle to the plane of the lamination which may cause local heating. The
construction is to be of ‘core’ type.

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Internal Earthing
All internal metal parts of the transformer, with the exception of individual laminations,
core bolts and their individual clamping plates shall be earthed.
The magnetic circuit shall be connected to the clamping structure at one point only and this
shall be brought out. A dis-connecting link shall be provided on transformer to facilitate
disconnections from ground for IR measurement purpose.
Coil clamping rings of metal at earth potential shall be connected to the adjacent core
clamping structure on the same side as the main earth connections.
Winding
LV windings
The LV winding shall be of Aluminium foils in order to cancel out axial stress during short
circuit. This foil will be insulated between each layer using a heat-reactivated class F pre-
impregnated epoxy resin film including the ends of the winding. The whole winding as-
sembly is to be polymerized at suitable temperature to ensure high level of resistance envi-
ronment and to have excellent dielectric strength.
HV windings
HV winding shall be separated from the LV winding to give an air gap between the MV
and LV circuits for easy maintenance.
HV winding shall have linear potential gradient from top to bottom to have low stress be-
tween adjacent conductors, with high dielectric strength and low partial discharge.
HV winding shall be of Aluminium wire with class F insulation cast in vacuum with fire
proof / flame retardant epoxy resin.
The interior and exterior of the windings will be reinforced with a combination of glass
fibre or similar material to provide thermal shock withstand.
HV winding support spacers
Winding support spacers are meant to provide sufficient support in transport, operation,
short circuit and earthquake conditions.
These spacers will be circular in shape for easy cleaning. They will give an extended track-
ing line to give better dielectric withstand under humid or high dust conditions.
These spacers will include an Elastomer cushion that will allow it to absorb expansion as
peer load conditions. This Elastomer cushion will be incorporated in the spacer to prevent
it being deteriorated by air or UV.

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HV Connections
The connections shall be of copper and made from the top to give a safe and neat connec-
tion. A terminal plate shall be provided.
The HV connections will be made from the top connection bars. Each bar will be drilled
with a hole for connection of cable lugs on terminal plates.
The HV connection bars will be in rigid copper bars protected by heat shrinkable tubing.
HV connections in cables are not allowed, in order to avoid all risk of contact, due to cables
flapping.
Depending upon the design of the manufacturer the arrangement shall be approved by the
Engineer-in-Charge.
LV Connections
The LV connections with copper bars will be made from top of coils on the opposite side
to the HV connections.
Connection of the LV neutral will be directly made to the LV terminals between the LV
phase bars. There shall be a separate earth point connected to neutral.
Depending upon the design of the manufacturer the arrangement shall be approved by the
Engineer-in-Charge.
Transformer Thermal and Overload Protection
PTC type sensors [minimum 6] shall be placed in the winding to measure the winding tem-
perature.
The transformer shall be equipped with an overload and thermal protection device with
sensors to continuously monitor the LV and HV winding temperature for each phase.
Digital monitoring thermometers shall be installed locally in the CSS on LV Board, with a
provision for monitoring the temperatures at remote SCADA. Necessary alarms and trip
contacts along with warning LEDs shall be provided to protect the transformers from high
temperature.
Sensors shall be so placed that it shall be possible to replace the same very easily. All sen-
sors along with enclosures, digital thermometers, transducers, sensing relays, connecting
leads, etc. complete in all respects shall be in the scope of supply. For this purpose, Security
& Communication Agency shall lay a fibre optic cable from CSS to SCADA control Centre,
termination of which to such devices shall be in the scope of Agency.
Provision shall be made that in case of fire the transformer circuit breaker shall be tripped.

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Off Circuit Tap Changer

There shall not be a bolting arrangement for selecting the taps and shifting the copper bars.
Instead the off circuit tap changer shall be operatable by means of an operating handle /
ring brought out-side the tank operable from ground level. It shall be equipped with an
indicating device to show the tap in use and shall be provided with a locking arrangement
to lock the switch in position. The arrangement shall be such that an operator can change
the tap while standing at ground level with complete ease. There shall be separate cover for
tap changer.
Safety of Personnel
Transformer shall be properly fenced/protected in case the maintenance personnel are likely
to come near the live parts while carrying out normal maintenance or monitoring activities
near the transformer.
Fittings
The following fittings shall be provided on the transformers:
Separate LV neutral point, with two joined points for double earthing of neutral along with
tinned copper strip compatible to transformer short circuit current rating for earthing.
One danger Plate
Temperature indicating device, sensors etc. complete in all respects with contacts for re-
mote / local indication.
Lifting eyes or lugs for the top cover, core and coils and for the complete transformer.
Platform lugs / haulage lugs on under carriage.
Marshalling box.
Rating and connection diagram plate.
Two numbers earthing terminals on opposite sides, associated nuts, bolts and tinned copper
earth strip of suitable section for connections to purchaser’s grounding strip.
4 bidirectional rollers.
Thermal and overload protection devices and equipment, along with necessary transducers,
sensors etc. for local and remote SCADA indication, Alarm / trip contacts, LED indicators
complete in all respects
Note: The fittings listed above are indicative and any other fittings which are generally
required for satisfactory operation of the transformer are deemed to be included in the
quoted price of the transformer.

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Radio Interference and Noise Level

Transformers shall be designed with particular care to suppress at least the third and fifth
harmonic voltages so as to minimise interference with communication circuits. Transformer
noise level, when energised at normal voltage and frequency shall be as per NEMA stipu-
lations.
Mandatory Spare Parts
The mandatory spare parts shall be included in the bid along with costs. These shall be
considered in evaluation.
Recommended Spare Parts
Agency shall provide a list of recommended spare parts for 5 years operations. The cost of
these spare parts shall not form part of Agency proposal.
Tests
The Transformers shall be completely factory tested before dispatch in accordance with the
standards and with such other tests as may be necessary to ensure that the equipment is
satisfactory and is in accordance with this specification.
 Routine Tests
Transformer routine tests shall include tests stated in latest issue of IS: 1180 / IEC 60076-
11. These tests shall also include but shall not be limited to the following:
Measurement of winding resistance.
 Voltage ratio on each tapping and check of voltage vector relationship.
 Impedance voltage at all tapping.
 Magnetic circuit test
 (After routine tests, each core shall be tested for 1 minute at 2 kV between all bolts,
side plates and structural steel work. Immediately prior to the dispatch of the
transformer, the magnetic circuit shall be pressure tested for 1 minute at 2 kV A.C.
between the core and the earth).
 Load losses.
 No load losses and no load current.
 Absorption index i.e. insulation resistance for 15 seconds and 60 seconds (R60/R15)
and polarization index i.e. Insulation Resistance for 10 minutes and one minute (R10
mt/R1 mt).
 Separate source voltage withstand test (applied potential).

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 Induced voltage test.

 Measurement of partial discharges.
Partial discharges less than or equal to 10 pC at 1.30 Un, or
Partial discharges less than or equal to 5 pC at 1.30 Un (Special test)
 Measurement of acoustic noise level.
 Measurement of Zero sequence impedance.
All routine and type tests shall be done free of cost. If it is to be done on the cost basis, the
same may be indicated in the schedule of price and delivery and this will be taken into
account for evaluation of prices.
When transformers are equipped with a protection enclosure, these shall be tested in their
enclosure.
Moreover, in addition to the routine tests, the transformer shall be subjected to the following
type tests:
 Lightning Impulse Test
This test shall be carried in accordance with clause 12 of the latest issue of IS: 1180. The
Agency shall quote separate price for lighting impulse test on HV and LV windings. (one
limb only).
 Temperature Rise Test
The temperature rise test shall be carried out in accordance with IS: 1180 /IEC-60076. The
Temperature rise shall not exceed the values as in the IS: 1180 / IEC 60076-11
 Noise Level Test:
It shall be carried out as per IEC-60076-10
 Environmental and Firefighting tests
Certificates for tests carried out for Compliance to Class C1, E2 and F1 as per IEC 60076-
11.
 Short Circuit Test
It shall be carried out as per IEC 60076-5. Alternatively, Authority at its discretion can ask
for calculations instead of actual test.
 Test Waiver, Procedures and Costs
Certified test report and oscillograms shall be furnished to the Engineer-in-Charge for eval-
uation as per the schedule of distribution of documents. Manufacturer’s Test Certificates in
respect of all associated auxiliary and ancillary equipment shall be furnished.

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The Agency shall state in his proposal the testing facilities available at his works. In case
full testing facilities are not available, the Agency shall state the method proposed to be
adopted so as to ascertain the transformer characteristics corresponding to full capacity
testing.
 Witnessing of Tests
The Clients’ Engineer-in-Charge reserves the right to witness any or all tests. If required,
visits can be made to the works of manufacturer to ensure that the approved quality ensuring
programme is being followed. In this regard all the necessary facilities shall be arranged by
manufacturer at his end and cost borne by the Agency.
 Site Tests
After the transformer is installed, the following pre-commissioning tests and checks shall
be done before putting the transformer in service.
 Visual checks for connections etc.
 Dry out test
 PI / Resistance measurement of windings
 Ratio test
 Tap changer test
 Temperature Indicators & alarms
 Magnetizing current
 Earth connections are made.
 Rejection
The Engineer-in-Charge can reject any transformer if during tests or service any of the
following conditions arise:
 No load loss exceeds the guaranteed value.
 Load loss exceeds the guaranteed value.
 Impedance value exceeds the guaranteed value by  10% or more.
 The difference in impedance values of any two phases during single phase short
circuit impedance test exceeds 2% of the average value guaranteed by the vendor.
 Winding temperature rise exceeds the specified value.
 Transformer fails on impulse test.
 Transformer fails on power frequency voltage withstand test.

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 Transformer is proved to have been manufactured not in accordance with the agreed
specification.
Instructions Manual
Six sets of the instruction manuals shall be supplied at least four (4) weeks before the actual
dispatch of equipment. The manuals shall be in bound volumes and shall contain all the
drawings and information required for erection/construction, testing, operation and mainte-
nance of the transformer. The manuals shall include amongst others, the following particu-
lars:
Marked erection/construction prints identifying the components, parts of the transformer
as dispatched with assembly drawings.
Detailed dimensions, assembly and description of all auxiliaries.
Detailed views of the core and winding assembly, winding, connections and tapping’s, tap
changer construction etc. These drawings are required for carrying out overhauling opera-
tion at site.
Salient technical particulars of the transformer.
Copies of all final approved drawings.
Detailed O&M instructions with periodical check lists etc.
Completeness of Equipment
All fittings and accessories, which may not be specifically mentioned in the specification
but are necessary for the satisfactory operation of the equipment, shall be deemed to be
included in the specification. These shall be furnished by the Agency without extra charges.
The equipment shall be complete in all details, whether such details are mentioned in the
specification or not.
All deviations from this specification shall be separately listed under the requisite sched-
ules, in the absence of which it shall be presumed that all the provisions of the specifications
are accepted by the Agency.
Tools & Tackles
All the necessary tools and tackles required for the normal operation shall be supplied by
the bidder.
LV Switchboard for Compact Sub-Stations
General

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Amaravati Development Corporation Limited

The LV switchboard for CSS shall be indoor 3-Phase, 4-wire, 440 V, 50 HZ, neutral solidly
grounded, complete in all respects including base channels, foundation bolts and other
hardware for various packaged RMU distribution sub-stations.
Standards
The equipment covered in these specifications shall conform to the latest revisions / re-
placements of the following Indian Standard Specifications.
The equipment complying with other internationally accepted standards shall also be con-
sidered, if they ensure performance equivalent to or superior to Indian Standards.
S. No. Standard Number Description
1 IS: 5 Colours for ready mixed paints & enamels
2 IS: 722 AC Electricity Meters
3 IS: 1554 PVC insulated (heavy duty) electric cables
Degrees of protection provided by enclosures for Low-volt-
4 IS: 2147
age switchgear and control gear
Dimensions for panel mounted electrical indicating & re-
5 IS: 2419
cording electrical instrument
6 IS: 2551 Danger notice plates
Methods for testing uniformity of coating of Zinc coated ar-
7 IS: 2633
ticles
8 IS: 2705 Current Transformers
9 IS: 3156 Voltage Transformers
Specification for electrical relays for power system protec-
10 IS: 3231
tion
General requirements for Switchgear & Control gear for
11 IS: 4237
voltage not exceeding1000 volts.
12 IS: 4794 Push buttons
Wrought aluminium and aluminium alloy bars rods, tubes,
13 IS: 5082
sections plates, sheets for electrical application
14 IS: 5578 Guide for making of insulated conductors
Code of practice for phosphate coatings of iron and steel
15 IS: 6005
(First Revision)
Control switches (switching devices for control and auxil-
16 IS: 6875 iary circuit including Agency relays) for voltages up to and
including 1000 V AC and 1200 V DC
17 IS: 8623 Low voltage Switchgear and Control gear assemblies
Electrical accessories circuit breakers for over current pro-
18 IS: 8828
tection for home load and similar installations.
Basic environmental testing procedures for electronic and
19 IS: 9000
electrical items
20 IS: 10580 Service conditions for electrical equipment

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Amaravati Development Corporation Limited

S. No. Standard Number Description

Guide for uniform system of marking and identification of
21 IS: 11353
conductors & apparatus terminals
Low voltage fuses for voltages not exceeding 1000 V AC or
22 IS: 13703
1500 V DC
23 IS: 13942 Low voltage switchgear and control gear
Guide for insulation coordination within low voltage sys-
24 SP: 39
tem
Low Voltage Electrical Installations [All applicable series
IEC -60364
of IEC-60364]
25
Insulation coordination within low voltage system including
IEC: 60664
clearance and creepage distance for equipment.

System Details
The L.V. Distribution Board shall be a part of a packaged RMU substation having trans-
former rating as in the single line diagram for that location and technical data as given under
Specific Technical Requirements. Only the standard size of transformer shall be selected.
Broadly the LV distribution board shall have the following configuration:
 Connection to LV side of Transformer
Connection to LV side of distribution transformer shall be through insulated, three phase,
four wire tinned Copper bars. Alternatively tinned Copper bars may be considered with a
non-segregated three phase four wire bus duct, or with sand-witched bus bars, conforming
to relevant IS Standard as per current requirements.
 Incomer and Board Bus bar
Incomer shall be Air Circuit Breaker, draw out type, electrically operated, equipped with
microprocessor based electronic trip units, complete with CTs & metering. It shall be pos-
sible to operate this breaker from remote through SCADA also. Transformer incomer rating
shall be same as that of bus rating. LV Bus bars shall be three phase, 4wire, and of tinned
copper. Size of neutral conductor shall be same as of phase bars. The LV Board shall be
designed for fault level as given in the Specific Technical Requirements.
 Outgoing Feeders
No HRC fuses are envisaged. All the outgoing feeders shall be equipped with Moulded
Case Circuit Breakers of appropriate rating.
 External Cabling

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The external, three phase, four core, LV cables of required size shall be terminated to the
outgoing terminals of LV switch board. Necessary cable supports shall be provided in the
cable alley of the board
Design and Standardization
General
The equipment shall be designed to ensure satisfactory operation of the system in which
continuity and quality of service is the first consideration. It shall also be designed to with-
stand sudden load variations due to short circuits and fault conditions or for any other rea-
son.
All mechanism shall be made of such materials as to prevent sluggishness due to rust or
corrosion. All connections and contacts shall be of ample section and have sufficient sur-
face area for carrying continuously the specified current without undue heating and shall
be secured rigidly and locked in position. Standard sizes of stainless steel bolts, screws,
pipes and other fittings are to be used and number of sizes is to be kept to the minimum.
Cast Iron shall not be used for any part of the equipment which may be subjected to me-
chanical stresses.
All apparatus shall be so designed and constructed as to obviate the risks of short circuits
of the live parts by lizards, vermin’s etc. Metal cubicles, housing and covers shall be 100%
weather / vermin proof and shall be able to provide the degree of protection IP-54 in ac-
cordance with latest version of IS-2147.
All parts shall be manufactured in accordance with relevant standard specifications of IEC
/ I.S. Corresponding parts of similar equipment and apparatus shall be mutually inter-
changeable.
All apparatus, connections and cabling shall be designed and arranged to minimize the risk
of fire and any damage which might be caused in the event of such an eventuality.
Specific Technical Particulars
The standard technical particulars (which must be modified considering the climatic con-
ditions as given in relevant standards) for the LV Switchboard, are given below:
AC System : 3 phase, 4 wire, solidly earthed
Transformer secondary Voltage : 433V
System Nominal Voltage : 415 volts 6%
Frequency : 50 Hz  5%

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Combined variation in : 10% absolute sum of Voltage & frequency

Bus bar Electrolytic Copper, tinned, Continuous
rating [as per transformer rating]
150KVA : 400 A
250 Circuit Performance : P2
Short Circuit Capability : 50 kA (rms) for 1 Sec.
Making capacity : 62.5 kAp
Operating Mechanism : Manual, trip free
Temperature rise : As per IS: 2516
Mechanical : As per IS: 2516
Auxiliary contacts : 4 No., 4 NC
Current Rating : As per Single Line Drawing
Multi-function Meters
Accuracy class : 1
One Minute Power : 2 kV (rms)
Frequency Withstand Voltage
Current Transformers
Type : Cast resin, Bar primary
Secondary circuit : 1 Amp.
Voltage class and Frequency : 1100 v, 50 Hz
Class of insulation : E or better
Accuracy :
Accuracy class &VA : Class 1, 10 VA
of metering CT
Accuracy class of VA : 5 P 15, 10 VA
of protection CT
Short time current rating : 50 kA (rms) for 1 sec.
Dynamic rating : 120 kA (peak)
One Minute Power : 2.5 kV (rms)
Frequency Withstand Voltage
Voltage Transformers
Type : Cast resin

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Rated voltage :
Primary : 415 V / √3
Secondary : 110 V / √3
Accuracy class and VA burden
Metering : 1.0, 25 VA
Protection : 3 P, 25 VA
Method of connection
Primary : Star
Secondary : Star
Rated voltage factor : 1.1 continuous, 1.5 for 3 sec.
Class of insulation : E or better
One-minute power : 2.5 kV (rms)
Frequency withstand voltage
Relay
One Minute Power : 2.0 kV (rms)
Frequency withstand Voltage
Cubicle Colour Finish
Interior : Glossy White
Exterior : Grey shade No. 631 of IS: 5
Accessories
Plug point with MCB.
Space heater PTC type.
Name plate on front & rear
Danger plates.
Cubicle
Minimum thickness of CRCA sheet steel: 2 mm
Base Frame channel : 100mmx50mmx6mm
Degree of protection : IP-54
Rubber mat between Panel & base: 15mm
Clearance and Creepage Distances
The clearances and creepage distances shall be in accordance with Indian Standard for con-
densing humidity and highly polluted environment.

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Labels and Marking of Connections

All equipment, control gear and the apparatus mounted thereon shall be clearly labelled
indicating, their purpose and the ‘ON’ ‘OFF’ and “EARTH’ positions. The labels shall be
clearly lettered on enameled surface or other approved materials. Brass shall not be used
for labels. Each phase of alternating current and connections shall be coloured to distin-
guish phase, neutral and earth. The colouring shall be respectively for red, yellow, blue for
phases black for neutral and green for earth.
Each phase of alternating current and connections shall be coloured heat shrinkable sleeve.
The LT switchboards shall be labelled as per designation shown in the single lien diagram.
The labelling shall be finalised after the arrangement for the same, is got approved by the
successful Agency during detailed Engineer-in-Charge.
Drawings and Literature
Four sets of tentative G.A., Schematic drawings and detailed literature of equipment shall
be submitted with the tender clearly giving the scope of supply and bill of material to enable
the Engineer-in-Charge to scrutinize all aspects of design including arrangement and sup-
port of cable accessibility for maintenance work and future additions, cable connections,
general appearance etc. In addition, the Agency shall submit drawings & literature are to
be furnished by successful tenderer / bidder within 2 weeks after the award of contract,
which shall include the following:
Complete assembly drawings of the boards, showing plan, elevation, typical section, loca-
tion of terminal blocks for external wiring connections and mounting details of various
devices with dimension.
Foundation plan, embedment channel frame with associated holes and suitable size of bolts
for fixing to channel frame.
Wiring diagrams including terminal wiring design and cable schedule.
Schematic control diagram, details of relays, instruments, space heaters, cubicle illumina-
tion and receptacle etc.
Bill of material of each LV board.
Layout plan of each LV board.
Bought out Items
All bought out items such as switches, MCCBs, MCB’s meters, terminal blocks, cables etc.
shall be of reputed make. Engineer-in-Charge reserves the right to accept only materials of

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proven make at its sole discretion. The list of recommended make for major items is given
in the specification volume.
Details of L.V. Switchboard
 Constructional Details
The Switchboard shall be made of cold rolled sheet steel of 2 mm thick having different
compartments for bus-bars, cable alley and instrumentation. The board shall be floor
mounted, self-supporting.
The bus-bars shall be rectangular, of tinned electrolytic copper and of approved size for
current rating for phases as well as for neutral. The bus bars shall be suitably supported on
non-hygroscopic insulators to withstand forces arising from short circuits in the system.
These shall be suitable for harsh environmental conditions.
The switch boards shall be of compact design. All doors and covers shall be fully gasketed.
Individual feeder compartments shall be provided with stainless steel hinged doors, bolted
type doors shall not be acceptable. Indicating instruments shall be of 96x96 mm.
The interconnections between bus-bars and MCCBs unit shall be solid insulated, tinned
copper strip permanently bolted with the bus-bars and MCCBs. The bus-bar joints shall be
given a thin coating of conducting grease after fully cleaning both the surfaces. The termi-
nals shall be of substantial mechanical strength & shall provide adequate electrical contact
area and the contact pressure is maintained permanently. The bus-bars / tee off shall be
insulated with heat shrinkable sleeve tapes with red, yellow, blue colours for 3 phases and
black for neutral. All the bus-bar tapping & markings shall be in accordance with relevant
IS.
The gland plate shall be of Aluminium minimum thickness of 3 mm and detachable type.
A strong supporting channel of 100 x 50 x 6 mm shall be provided beneath the switchboard
shell besides anti-vibration rubber gasket of 15 mm thickness.
The connection from 11/0.433 kV transformers to the LV switchboard shall be through a
LV non-segregated bus duct [alternatively sandwiched bus duct] or through insulated cop-
per bus bars as per requirement.
The bus-bars shall have non-hygroscopic support insulators. The bus bar shall be insulated
with heat shrinkable insulating kits.
The short circuits withstand capacity of all the bus-bars and tap-connection shall be 50 KA
for one second.

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 Details of Circuits
Each switchboard shall have the following circuit arrangement.
 Incoming
1 no. 3 phase, 4 wire incomer four pole air circuit breaker, electrically operated with mi-
croprocessor based trip circuit release. The breaker shall conform to IEC 61439.
It shall be withdrawal type. The control supply can be provided from a line connected PT
from the LV connection from the transformer or any other arrangement given by Agency
can also be considered during detailed Engineer-in-Charge.
3 Nos. – Metering CTs of required ratio, 10 VA Class 1, with ISF less than 5.
3 Nos. – Protection CTs
The incomer breaker shall have numerical relay having three over currents of setting 50%
to 100% of 1A rating with IDMTL; current Vs time characteristics. Short circuit instanta-
neous trip shall be included. Alternatively, the built in microprocessor based trip units hav-
ing Overload protection [IDMTL, IEC characteristics], short circuit trip [time delayed],
Instantaneous short circuit protection, Ground Fault Protection can also be considered.
1 no. 96 x 96 mm flush mounted multi-function meter. Meter shall measure unbalanced
neutral current also along with three phase currents simultaneously.
1 no. digital bus voltmeter scale 0-500 V with three-line reading.
If required, 1 no. Automatic Power factor controller [APFC], connected to y-phase meter-
ing CT, with SCADA communication, and five steps to switch on capacitor banks for power
factor improvement to 0.95.
Note: Number of steps is tentative and shall be finalised during detailed Engineer-in-
Charge.
LED type lamps to indicate breaker closed, open, auto trip, protection operation, spring
charged etc. indications.
 Outgoing feeders
3 phase, 4 wire, outgoing cable circuits are envisaged from the switchboard and each circuit
shall have the following items, indicating instruments, terminal connectors etc.
4 pole withdrawable type Moulded Case Circuit Breakers of appropriate, rating as indicated
in the single line diagrams.
 Earth leakage relay

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3 nos. metering current transformers of secondary rating 1A & 1.0 accuracy class having
primary current as per SLD.
1 no. 96x96mm flush mounted multifunction meter as per CT rating.
Termination points for 4C XLPE, Al. Armoured cables with lugs.
The LV board must have sufficient space of not less than 100 mm between two termination
points for external cables.
Cable alley along with necessary clamping arrangement for the outgoing feeder cables.
Indicating LED lights – red, yellow and blue for the supply.
Capacitor Bank & Automatic Power Factor Controller [APFC] (If Required)
Considering the transformer capacity and load power factor as 0.8, a suitable size of
switched capacitor bank shall be mounted inside the LT compartment to improve the power
factor to 0.95. Necessary calculations, number of steps and switching details shall be pro-
vided for approval.
Capacitor units shall be fuse-less, with loss not exceeding 0.5W / kVAR, with metallised
polypropylene film, double casing insulation, self-healing feature, non-flammable and with
nontoxic material. Reactors shall be non- resonance, dry type resin embedded. Capacitor
unit shall with automatic operation steps as required, built in discharge resistor and mounted
on stainless steel frame. APFC shall also be supplied by the same manufacturer. APFC shall
have LCD display, programmable, with monitoring of all parameters locally as well as at
remote SCADA on mod bus via fibre optic cable. It shall be with built in cabinet placed in
the cubicle of LV board with easy access doors.
Earthing
The LV switchboard shall be provided with two separate earthing terminals at the ends.
With minimum rated for 50kA for 3 sec running in the board. All metal parts, enclosure,
transformer and neutral have to be interconnected and ready for connection to the external
earthing arrangement.
The earthing terminals shall be identified by means of proper embossed sign marks adjacent
to the terminals.
In the cable gland area provision shall be made at cable gland for armour earthing and then
connecting it to main earth bar in a proper way. There shall be a continuous tinned copper
earth bus bar in the board. The size of the earth bus bar shall be suitable to carry 50 kA for
3 second. The bus bar shall not be visible or removable from outside the switchboard. The

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earth bus bar shall have necessary holes, nuts & bolts including washers for making earth
connection of cable glands / armouring of the cables.
Switchboard Lighting & Heating
A lamp holder with a 11 W LED lamp and operated by an internal SP-MCB shall be fitted
for internal illumination. In addition, a 3 pin 6A/25A socket shall also be provided with a
separate SP-MCB. Space heater of suitable rating of PTC type, and with SP MCB shall also
be provided to avoid any moisture condensation inside the switchboard.
Danger Notice Plates
An enameled sheet steel danger plate of approved design as per IS: 2551 shall be fixed on
the middle upper front of the switchboard.
Tests
All tests as required in relevant Indian standard shall be carried out on the LV switchgear.
Engineer-in-Charge shall witness the tests at the works of the manufacturer.
 Type Tests
The purchaser may ask the manufacturer to conduct the following type tests on one of the
AC Boards.
Verification of temperature rise limits test
Verification of rain test to determine the degree of protection against rain.
Verification of dielectric properties.
Necessary type tests as per IS on all the individual items such as ACB’s, MCB’s, MCCB’s,
instruments, links etc.
 Short circuit test.
The Engineer-in-Charge, at its option, may waive the above type tests provided type test
reports of the above type tests carried out on essentially identical unit in their factory /
approved testing laboratory are furnished by the manufacturer.
 Routine Tests
The switchboard shall be subjected to all the routine tests as per Indian Standard [IS] and
witnessed by the Engineer-in-Charge. For power frequency voltage the test voltage to be
applied shall be for a period of one minute. Insulation tests with 500 volts megger before
and after the high voltage test shall be carried out on the switchboard.
Routine tests, as per IS shall be carried out on the bought out items viz. MCCB’s, MCBs,
meters etc.

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 Verification of wiring & earth continuity

Voltage test on auxiliary circuits.
Tests for mechanical operation, control & interlocks.
 Commissioning Site Tests
Necessary site tests at site shall be carried out to ensure its satisfactory operation after in-
stallation at site.
Terminations of Incoming and Outgoing Circuits
The cable termination arrangements shall be located at the lowest point above the cable
clamps, for ease of termination.
Cable support shall be provided by a suitable clamp at the bottom of the panel. These cable
supports shall be adequate to support the outgoing cable in normal service and when sub-
jected to the short circuit current specified. The distance between these cable supports and
the gland plate shall be at least 200 mm.
The outgoing cables to be terminated in the switchboard shall be XLPE insulated PVC
sheathed armoured and with aluminium conductors. The cables shall have bottom entry to
the switchboard.
Air Circuit Breaker (ACB)
415 V four pole air circuit breakers shall be withdrawal type with manually / electrically
operated mechanism. It shall be supplied for controlling the LV side of the 33/0.433kV,
distribution transformer. Air circuit breakers shall have symmetrical short circuit rating of
50 kA for 1 sec. The circuit breaker shall be fitted with direct acting microprocessor based
electronic release. It shall be provided with instantaneous and adjustable short circuit trip.
The adjustment of the setting shall be possible without disrupting the supply. The releases
shall be ambient temperature compensated type. The release shall have IEC IDMTL char-
acteristics. The breaker mechanism shall be robust, quick making quick breaking and trip
free. It shall be possible to close and trip the breaker without opening the compartment &
door. It shall have auxiliary contacts for indications along with spare contacts.
The detailed specifications of Air Circuit Breaker shall be as under:
No. of poles Four
Service voltage 415 Volts
Normal current As per design calculation
Frequency 50 Hz

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Rated Symmetrical Breaking 50 kA for 1 Sec.

Capacity at 415 V AC/50 Hz
Making current 120 kA
Rated insulation voltage 1000 V
Max Breaking time 30 ms
Max Making time 80 ms
 ACB Connection to Transformer
The air circuit breakers shall be suitably earthed with the main earth bus. The air circuit
breakers of the LV board shall be connected to the LV side of the distribution transformer
as specified. In case bus duct is provided the connections at both the ends shall be through
proper clamps preferably bimetallic. Suitable arrangement shall be provided in the bus duct
to take care of the expansion.
 LV Moulded Case Circuit Breaker
All the LV outgoing underground feeders from the sub-station shall be controlled by 4 pole
draw out type moulded case circuit breakers, provided in the LV switchboard.
The moulded case circuit breakers shall be of robust construction and shall comprise of
switching mechanism, contact system, arc extinguishing device and a tripping unit con-
tained in a compact moulded case and cover. The insulating case and cover shall be made
of high strength, heat-resistance and flame-retardant thermo-setting insulating material.
The switching mechanism shall be quick-make / quick break type, and shall be trip-free.
The arc extinguishing device shall comprise of a series of grid plates mounted in parallel
between supports of insulating material. The arc shall be drawn from the moving contact
into the divide chamber and extinguished.
The moulded case circuit breakers shall have a thermo-magnetic type tripping mechanism,
where the heating effect and the electromagnetic effect of current are made use of to provide
protection against overload and short-circuit conditions respectively. The heated-bimetal
strip in each phase of the MCCB shall actuate the tripping system following on inverse-
time-current characteristics depending upon the severity of the overload current. During
short-circuits, the system shall trip instantaneously. The tripping element provided on each
pole of the MCCB shall operate on a common trip bar, thereby preventing single phasing
in the event of fault occurring on any of the phases. The tripping device shall be ambient
temperature compensated type.

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The MCCB shall have a minimum Ics rupturing capacity of 50 kA. Positive indication
about the position of the MCCB i.e. whether ‘ON’ ‘OFF’ or TRIPPED shall be provided.
The short circuit breaking capacity and operation mechanism of the MCCB shall be sup-
ported by test certificates.
All the MCCBs used in LV switchboards for controlling the outgoing feeders shall have a
Thermal current setting of 50 to 100% of its rated current and magnetic setting of 500% to
1000%
The rated currents given are provisional and shall be finalised during detailed Engineer-in-
Charge.
The detailed specifications of the MCCBs shall be as under:
No. of poles 4 pole
Service voltage 415 Volts
Normal current [In] As per SLD
Frequency 50 Hz
Service [Ics] Breaking capacity at 415V AC, 50 Hz 50 kA
Making current 120 kA
MCCB shall be provided with rotary handle for manual operation.
 Internal Wiring
The LV AC distribution boards shall be supplied with complete internal wiring. The central
wiring shall be of 1100 V grade, FRLS, PVC insulated. Stranded tinned (not less than 48
strands) copper conductor cables of 1.5 mm2 size shall be used for control circuits and 2.5
mm2 for CT circuits. Engraved identification ferrules, marked to correspond with the wir-
ing diagram shall be fitted at both ends of each wire. All wiring shall be terminated on
terminal blocks. Terminal blocks shall be one piece moulded and suitable for 500 V and of
recommended make. Terminals shall be adequately rated for the short circuit current. Typ-
ically, terminals of ‘Phoenix’ make shall be provided which shall be approved by Engineer-
in-Charge during detailed Engineer-in-Charge.
For CT circuits, shorting type terminals shall be provided. It shall be possible to measure
the CT current through clip-on-ammeters.
Pre-fabricated Enclosure for Packaged RMU Substations
General

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The enclosure for the compact substation also includes the base frame/ channels and all the
necessary fixing hardware accessories required at site. The enclosure shall be compart-
mentalized and house RMU, dry distribution transformer, LV distribution board with ca-
pacitor bank and their interconnections both external and internal. Engineer-in-Charge at
its sole discretion may also consider the alternate designs given by the Agency, if the same
are found to be better or equivalent to the ones given hereunder.
Standards
The equipment shall conform (but shall not be limited) to IEC 6227-202 standard. The
requirements of standards for necessary clearances, ventilation etc. shall also be complied
with.
Specific Technical Requirements
Typical size : 2 x 2.5 m (5 m2) with 2 m height [Agency may
quote its own size, if different
Construction : Self- standing on concrete base
Steel base frame : 4mm thick base [hot dip electro-galvanized steel,
with epoxy paint]- suitable for local e
Lifting eyes : 4 Nos from the bottom.
Housing enclosure : 2 mm corrosion resistant Zinc/Aluminium alloy
coated sheet steels
Degree of Protection : HV Compartment: IP-54
Transformer Compartment: IP-23
LV Compartment: IP-54
All hinges, supports Nuts, wash- : Stainless steel
ers etc.
Paint : Epoxy
Roof Design Load [min] : 250 Kg/m2
Roof Design : Slanting on the sides
Top of Roof : Removable
Ventilation : With louvers
(no exhaust fans shall be used)
Sound Level : 60 dB
Standard Applicable : IEC 62271-202
Number of earths : Two (at opposite ends)
Compartments : Three with independent doors

Construction
General
The enclosure shall be self-standing on a concrete base. Necessary civil requirements to be
satisfied for the concrete base shall be provided by the Agency. The levelling of ground and
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construction of the concrete base and associated civil works shall also be in the scope of
the Agency.
The compact substation is completely self-contained, mounted upon a 4 mm thick galva-
nised steel base frame, epoxy painted, factory assembled in a totally enclosed, aesthetically
acceptable metal cladding, vandal-proof and weatherproof housing ready for placing into
position upon a concrete base.
The lifting arrangement shall be with four lifting eyes from the bottom of the enclosure &
not from the top.
The structure of the substation shall be capable of supporting the gross weight of all the
equipment & the roof of the substation compartment shall be designed to support adequate
loads. In case of relocation of the Package Substation, the entire substation shall be capable
of getting lifted and placed as a Single Unit without dismantling of any of the major equip-
ment inside the enclosure. The complete housing assembly with four lifting eyes shall be
easy to lift and position the whole unit at the site by the use of crane. The substation can be
lifted without damage or distortion. The transformer is located in the middle of the substa-
tion while the HV and LV compartments are located at both ends of the substation adjacent
to the corresponding bushings of the transformer. The arrangement is subject to the ap-
proval of the Client or site Engineer-in-Charge.
There shall be adequate ventilation inside the enclosure so that hot air inside enclosure is
directed out by help of duct. Louvers apertures shall be provided so that there is circulation
of natural air inside the enclosure. The Package Substation shall be designed & Engineer-
in-Charge to have natural cooling & ventilation only. No forced cooling / ventilation is
acceptable.
The enclosure must be weather proof installation with proper measures against rusting.
The enclosure must also be vermin proof to prevent the entry of rodents, reptiles, & flying
insects, which are prevalent in the area.
The enclosure shall be pre-fabricated such that fire from one compartment MUST NOT
spread to other compartments.
It shall have easy access to all the equipment inside the enclosure, viz RMU, transformer,
LV switchboard, capacitor bank, connections, and terminations of HV & LV cables.
The metal base and all supporting channels shall be hot dip galvanized. These shall ensure
rigidity, ease in transportation to sites and installation.

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The outdoor panel envelope may be made of electro-galvanised mild steel with nominal
thickness of not less than 3 mm. The housing of the enclosure shall be made of 2 mm
corrosion resistant Zinc / Aluminium alloy coated steel sheets.
All hardware such as hinges, supports, screws, nuts, bolts, washers etc. shall be made of
stainless steel. All locking bolts shall be accessible from inside to prevent the unauthorised
dismantling.
All the enclosures shall be or of similar type & design.
The colour of the enclosure shall be decided by Engineer-in-Charge during detailed Engi-
neer-in-Charge, if different from the one given. The last finish coat shall be of epoxy paint.
The roof of the substation enclosure shall be designed to support loads up to 250 kg/m2.
The roof shall be sloped on the sides so that the rain water cannot stay on roof during rainy
days.
The pre-fabricated roof of the enclosure shall be removable whenever required. The locking
nuts, bolts to allow the removal of roof shall be only accessible from inside the enclosure.
 Covers & Doors:
Covers & doors are part of the enclosure. When they are closed, they shall provide the
degree of protection specified for the enclosure. All covers, doors or roof shall be provided
with locking facility or it shall not be possible to open or remove them before doors in
normal operation have been opened. The doors shall open outward at an angle of at least
90degrees & be equipped with a device able to maintain them in an open position. Proper
padlocking facility shall be provided for doors of each compartment. Transformer compart-
ment doors must be open from both the sides.
Door closing shall be by means of a three-point linkage arrangement (i.e. Centre, top and
bottom) and controlled by a centrally located stainless steel operating handle. Pad locking
facilities along with Master pad locks shall be provided. Master pad locks shall be operated
by a master key for all the substations.
The outer doors of the enclosure shall be wide and provided with heavy duty hinges to
prevent distortion and misalignment. A robust door restraint shall be provided to hold each
door in the 950 open positions. The restraint shall be of a captive design so that it cannot
be easily removed and shall be self-strong when the door is closed such that it cannot rattle.
With the door in this position, operation of LV and HV switchgear shall be possible without
endangering operator’s hands, etc.

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When doors are closed, they are firmly locked; as such entry of dust, vermin and rainwater
is completely prevented. Neoprene gaskets are to be used.
The HV doors are provided with a drawing pocket to keep drawing inside.
A weatherproof nameplate shall be provided on the door.
The edges of the doors are bended at both sides to assure they fit properly so that the door
jams and misalignment is prevented.
The transformer, low voltage and HV compartments are completely separated by steel
sheet. The barrier between the HV switchgear and the transformer is provided with pressure
relief flaps.
All compartments are individually accessible by their own doors from outside.
Labyrinthine louvers form the sidings of the transformer room to assure free entry and ex-
haust of air, as such the inside temperature is kept within limits. Openings located at the
lower and upper sides of the slanted roof shall allow air circulation as part of the ventilation
design.
No exhaust fans shall be used. Ventilation louvers shall be required to provide sufficient
ventilation.
All compartments are equipped with internal lighting consisting of 25 watts LED lamps
controlled by their respective door micro switches. MCB shall be provided to control the
supply.
Space heaters shall be provided to control condensing type humidity.
Labels for warning, manufacturer’s operating instructions etc. & those according to local
standards & regulations shall be pasted / provided inside and shall be durable & clearly
legible.
The substation forms a complete metallic structure bolted together and each compartment
is to be provided with tinned copper, grounding bus-bar. Bonding and interconnection of
the grounding buses shall be made of 70 mm2 bare stranded copper tinned conductors. The
ring main unit shall have 25x8 mm grounding bus while the low voltage switchgear shall
have 30 x 10 mm tinned copper grounding buses to which connection to the grounding
system at site can be made. At least two grounding points for bolting to ground conductor
shall be provided on opposite ends.
All metallic components shall be earthed to a common earthing point. It shall be terminated
by an adequate terminal intended for connection to the earth system of the installation, by

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way of flexible jumpers/strips & Lug arrangement. The continuity of the earth system shall
be ensured taking into account the thermal & mechanical stresses caused by the current it
may have to carry. The components to be connected to the earth system shall include :
The enclosure of Unitized / prefabricated substation.
The enclosure of High voltage switchgear & control gear from the terminal provided for
the purpose.
The metal screen & the low - high voltage cable earth conductor.
The transformer tank or metal frame of transformer.
The frame &/or enclosure of low voltage switchgear.
 Dimensions
The overall typical dimensions of the enclosure may be around 2.5 m x 2.0 m (or 5m2)
having height of about 2 m. To achieve necessary clearances, Agency may propose alternate
size of the enclosure depending upon the dimensions of the equipment supplied.
 Enclosure Requirements
The enclosure must be totally safe to the personnel in the populated areas as the packaged
substation shall be established in the residential townships.
The equipment in the enclosure must be accommodated with necessary clearances, easy
access to the RMU, and transformer, LT switchgear and capacitor bank for testing, mainte-
nance, removal and normal operation (including operation with normal switchgear han-
dles).
There shall be unhindered access to the transformer, operation of OFF load tap changer and
other normal operating requirements. Similarly, termination & removal of cables, with-
drawals of ACB from LV board shall be easy & comfortable.
It shall be the sole responsibility of the contrator to satisfy all the statutory clearances and
to provide safety measures against all possible hazards to the equipment in the enclosures,
such as internal arcing faults in the enclosure considering environmental conditions exist-
ing at site.
Failure within the unitized substation due either to a defect, or mal-operation may initiate
an internal arc. Such an event may lead to the risk of injury, if persons are present. It is
desirable that the unit shall be tested for Internal Arc fault test to the tune of at least 20KA
for 1 second as per latest IEC 62271-202 standard. The enclosure must be so designed that
internal arc faults are directed away from places where personnel or public may be present.

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Test certificates from a recognised national / international test house [acceptable to Engi-
neer-in-Charge] shall be supplied for internal arc.
Testing of incoming & outgoing cables and use of testing equipment for the same shall not
entail the dismantling the sides or the roof of the enclosure.
There shall be sufficient space for termination & removal of cables from Load Break
Switches & also from the LV board.
Sufficient clearance must be kept between the top of any equipment installed in the pre-
fabricated substation and the roof of the substation for ventilation and operational purposes.
 Interconnection
The equipment inside the enclosure shall be interconnected as follows:
The RMU shall be directly coupled by VCB feeder to distribution transformer through in-
sulated copper bars or cables as per manufacturer standard.
The LV side (three phases plus one neutral conductor) of distribution transformer shall be
connected to LV incomer Air Circuit Breaker via flexible insulated copper bars or through
a four-conductor sand-witched insulated bars or with bus duct enclosure.
The HV termination to Load Break Switches shall be from 33kv, Al. armoured XLPE ca-
bles, fitted with termination kits, for the ring system.
The earthing of pre-fabrication station shall be provided at two opposite ends for connection
to the outside earth rods. It shall be a bolted connection.
 Drawings
The following drawings shall be submitted with the tender.
 The detailed sketch of the enclosure indicating general view, position of louvers etc.
 The drawing showing the layout of HV, transformer & LV switchgear along with
interconnections.
 Size & position of doors in the enclosure.
 Fixing details of the enclosure including civil foundations (if any).
 Safety Measures
The enclosure shall have the following safety measures:
 Electric shock treatment chart duly framed shall be fixed in a conspicuous position
inside the enclosure.
 Danger notice in English/ Hindi/ Telugu language conforming to IS: 2551 shall be fixed
on all the four sides of the enclosure.

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 Electric insulated rubber mat (non-skid type) with flouted top and plain border end, 12
mm thick to withstand 12kV di-electric strength shall be provided in front of HV/LV
boards where people have to work.
 Two number portable fire extinguisher typically 2 litre, suitable for transformer / cable
and other electrical equipment fires shall be placed & fixed in a suitable location in the
enclosure, away from the place where fire is expected.
 Tests
 The following tests shall be carried out on the enclosure as per IEC standard at the
works of the manufacture:
 The complete prefabricated substation unit will be tested at full load for temperature
rise. The maximum temperature rise on any part of the equipment placed inside the
enclosure shall not exceed the value as specified in IEC 62271-202.
 Test to verify the sound level of the pre-fabricated substation, which shall be less than
60 db.
 Test to verify the degree of protection of enclosure for various compartments.
 For the internal arc fault test on the enclosure the following need to be observed and
tested as below:
 Internal Arc Fault tested to 20 kA 1 sec.
 Test to accessibility of Type “B” that is with unrestricted accessibility including that of
the general public (Annex. AA.2 IEC). Although test to accessibility of Type “A” is not
required, tenderers shall also provide adequate measures to have any hot gases directed
away from the operator during switching with the door open.
 Arc initiation is made inside the SF6 gas compartment of the RMU (Annex. AA.3 IEC).
 Assessment of the internal arc fault test is based on the fulfilment of all 6 criteria as
stated in Annex. AA.6 of IEC.
 Other Checks
 Inspection of conformity with the specification & approved drawings.
 Inspection of devices locking out and interlocks.
 Inspection and checking electrical continuity of metallic frame and earthing system.
 Dielectric tests of M.V. and L.V. bus bar.
 Provision of two earths as per Indian Electricity Rules.
 Tests as per IEC standard.

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TECHNICAL SPECIFICATION FOR 33kV & 6.6kV METAL ENCLOSED

SWITCHGEAR
Applicable standards
The switchgear and its components shall conform to the latest applicable standards speci-
fied below. In case of conflict between standards and this specification, this specification
shall govern.

Circuit Breakers IS: 13118 / BS : 5311 / IEC : 56,694

Metal Enclosed switchgear IS: 3427 / BSEN:60298 / IEC:298

Current Transformers IS: 2705 / BS: 7626

Voltage Transformers IS: 3156 / BS: 7625 / IEC: 186

Arrangement for Switchgear Busbars, Main Con-
IS: 5578, 11353
nections and Auxiliary wiring
Busbar Support insulators IS: 2544 / BS: 3297 / IEC: 273
IS: 13947 (Part 1) / IEC: 947-1 / BSEN:
Degree of Protection
60529
Electrical Relays for Power system protection IS: 3231, 3842 / BS: 142 / IEC: 255

Electrical Indicating Instruments IS: 1248 / BS: 89 / IEC: 51

High Voltage Fuses IS: 9385 / BS: 2692 / IEC: 282

AC Static Electricity Meters of accuracy Class
IEC: 687 / IEC : 620053-22
0.5S/0.2S
Specification for copper rods and bars for electri-
IS: 613
cal purposes
Code of practice for phosphating iron and Steel IS : 6005 / BS : 3189
Alternating current Switches for voltages above
IS : 9920 / IEC : 129, 265 & 298
1000 V
Low voltage fuses IS : 13703 / BS 1362 / IEC 269

Toggle switches IS : 3452 / BS : 3676

IS : 10118 and maintenance of switch-
Code of practice for selection, installation gear & control gear
Control switches IS:6875 / BSEN 60947 / IEC : 947

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Circuit Breaker
Circuit breakers shall be Vacuum/SF6 type. Circuit breaker along with its operating mech-
anism shall be mounted on a wheeled carriage moving on guides, designed to align cor-
rectly and allow easy movement. Plugs and sockets for power circuits shall be silver faced
and shall be insulated with suitable insulating material shrouds. All corresponding compo-
nents of circuit breaker cubicles of same rating shall be interchangeable with one another.
There shall be ‘Service’, ‘Test’ & ‘Fully withdrawn’ positions for the breakers. In the ‘Test’
position the circuit breaker shall be capable of being tested for operation without energizing
the power circuits, i.e. the control circuits shall remain undisturbed while the power con-
tacts shall remain disconnected.
Separate limit switches, each having a minimum of 2 ‘NO’ + 2 ‘NC’ contacts, shall be
provided for both ‘Service’ and ‘Test’ positions of the circuit breakers.
Electrical tripping shall be performed by shunt trip coils. “Local / Remote” selector switch
lockable in “Local” position shall be provided on the cubicle door. ‘Red’ and ‘Green’ indi-
cating lamps shall be provided on cubicle door to indicate breaker close and open positions.
Breaker “Service” and “Test” positions shall be indicated by separate indicating lamps on
the cubicle door, in case mechanical indication of “Service” and “Test” positions are not
available on the cubicle door.
Connection of the control / interlocking circuits between the fixed portion of the cubicle
and the breaker carriage shall be preferably by means of plug socket arrangement.
Operating mechanism control
Circuit breakers shall be operated by a motor spring charging type of mechanism. The
mechanism shall be complete with motor, opening spring, closing spring and all accessories
to make the mechanism a complete operating unit. Operating mechanism shall normally be
operated from the breaker cubicle itself.
The tripping spring shall be charged by the closing action, to enable quick tripping. Closing
of the circuit breaker shall automatically initiate recharging of the springs to enable the
mechanism to be ready for the next closing stroke. Charging time for the springs shall not
exceed 30 seconds. It shall be possible to manually charge the springs in an emergency.
Transfer from motor to manual charging shall automatically disconnect the charging motor.
All operating mechanisms shall be provided with "ON" - "OFF" mechanical indication. The

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charging mechanism shall be provided with mechanical indicators to show "charged" and
"discharged" conditions of the spring. Failure of any spring, vibration or mechanical shock
shall not cause tripping or closing of the circuit breaker.
Only one closing operation of the circuit breaker shall result from each closing impulse
(manual or electrical), even if the breaker trips while the control device (manual or electri-
cal) is being held in the "close" position.
The circuit breaker mechanism shall make one complete closing operation, once the push
button (PB) or control switch has been operated and the first device in the control scheme
has responded, even though the PB or control switch is released before the closing operation
is complete, subject to the condition that there is no counter- impulse for tripping.
Means shall be provided to manually open and close the breakers slowly, when the operat-
ing power is not available, for maintenance and adjustments. A local manual trip device
shall also be provided on the operating mechanism.
Circuit breaker control shall be 110V DC. Closing coils and other auxiliary devices shall
operate satisfactorily at all voltages between 80-110 % of the control voltage. Trip coils
shall operate satisfactorily between 50 -110 % the rated control voltage.
Safety interlocks and features
Withdrawal or engagement of a circuit breaker shall not be possible unless it is in the open
position.
Operation of a circuit breaker shall not be possible unless it is in service position, withdrawn
to test position or fully drawn out. It shall not be possible to close the circuit breaker elec-
trically in the service position, without completing the auxiliary circuit between the fixed
and moving portions.
Circuit breaker cubicles shall be provided with safety shutters operated automatically by
the movement of the circuit breaker / switch disconnector carriage to cover the stationary
isolated contacts when the breaker / switch disconnector is withdrawn. Padlocking facilities
shall be provided for locking the shutters positively in the closed position. It shall, however,
be possible to open the shutters intentionally against spring pressure for testing purposes.
The circuit breaker carriage shall be earthed before the circuit breaker reaches the test po-
sition from fully withdrawn position. In case of breakers with automatic disconnecting type
of auxiliary disconnects, the carriage shall be earthed before the auxiliary disconnects are
made and the carriage earthing shall break only after the auxiliary disconnects break.

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Caution nameplate, “Caution Live Terminals” shall be provided at all points where the ter-
minals are likely to remain live and isolation is possible only at remote end, i.e. incomer to
the switchboard. Suitable interlock shall be wired for the purpose.
Constructional Features of Switchboard
Switchboard design shall comprise metal enclosed, fully compartmental execution having
separate sections for each circuit. Compartments with doors for access to operating mech-
anism shall be so arranged as not to expose high voltage circuits. Switchboard cubicle shall
be provided with hinged door on the front with facility for locking door handle. Switch-
board shall be dust and vermin-proof and shall have a degree of protection of enclosure of
IP 4X. All removable covers shall be gasketted all around with neoprene or superior gas-
kets.
Instruments, relays and control devices shall be flush-mounted on hinged door of the me-
tering compartment located in the front portion of cubicle. The metering compartment shall
be properly shielded to prevent mal-operation of electronic equipment such as numerical /
static relays due to electro-magnetic fields. Separate signal earth shall be provided for such
devices, if necessary.
Each switchboard cubicle shall be fitted with a label on the front and rear of the cubicle.
Each switchboard shall also be fitted with label indicating the switchboard designation,
rating and duty. Each relay, instrument, switch, fuse and other devices shall be provided
with separate label.
Sheet steel used for fabrication of switchboards, control cabinets, marshalling boxes, etc
shall be cold rolled. All panels, cabinets, kiosks and boards shall comprise rigid welded
structural frames made of structural steel sections or of pressed and formed cold rolled
sheet steel of thickness not less than 2.5 mm. The frames shall be enclosed by sheet steel
of at least 2 mm thickness. Stiffeners shall be provided wherever necessary. All doors, re-
movable covers, gland plates, etc. shall be of at least 2 mm thickness and shall be gasketted
all-round the perimeter. All doors shall be supported by strong hinges of the disappearing
or internal type and braced in such a manner as to ensure freedom from sagging, bending
and general distortion of panel or hinged parts. All floor mounted panels / boards shall be
provided with a channel base frame. It shall be possible to extend the switchboard on both
sides.

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The fully draw-out modules shall have all the circuit components mounted on withdrawable
type steel chassis. All power and control connections shall be of the draw out type. It shall
be possible to withdraw the chassis mounted circuit components without disconnecting any
connections. All draw-out contacts shall be of silver plated copper.
In case of circuit breaker compartments, suitable barriers shall be provided between breaker
and all control, protective and indication circuit equipment including instrument transform-
ers such that no live parts are accessible. External cable connections shall be through sep-
arate cable compartments for power and control cables.
One metal sheet shall be provided between two adjacent vertical sections running to the
full height of the switchboard except for the horizontal busbar compartment. However, each
shipping section shall have metal sheets at both ends. After isolation of the power and con-
trol connections of a circuit, it shall be possible to carry out maintenance in a compartment
safely, with the bus bars and adjacent circuits alive.
Earthing
Aluminum earthing bus shall be provided and extended throughout the length of the switch-
board. It shall be bolted to the framework of each unit and brazed to each breaker earthing
contact bar. It shall be located at the bottom of the board. The earth bus shall have sufficient
cross section to carry the momentary short circuit and short time fault current for at least 1
second or higher without exceeding maximum allowable temperature rise. The earth bus
shall be properly supported to withstand stresses induced by the momentary short circuit
current.
Suitable clamp type terminals at each end of the earth bus shall be provided to suit the size
of the earthing conductors. Bolted joints, slices, tap, etc. to the earth bus shall be made with
at least two bolts. Positive earthing of circuit breaker frame shall be maintained when it is
in the connected position and in all other positions whilst the auxiliary circuits are not to-
tally disconnected.
Hinged doors shall be earthed through flexible earthing braid of adequate cross section. All
non-current carrying metal work of the switchboard shall be effectively bonded to the earth
bus.
Positive connection of the frames of all the equipment mounted in the switchboard to the
earth busbar shall be maintained through insulated conductors of size equal to the earth
busbar or the load current carrying conductor, whichever is smaller.

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All instrument and relay cases shall be connected to earth busbar by means of 1100V grade,
green colored, PVC insulated, stranded, tinned copper, 2.5 sq. mm conductor looped
through each of the earth terminals.
Circuit / Busbar Earthing Facility
It shall be possible to connect each circuit or set of 3 phase bus bars of the switchboard to
earth through earthing switches. Earthing switches / earthing devices shall be mechanically
interlocked with the associated breakers to prevent accidental earthing of live circuit or bus
bars. In case the earthing facility comprises earthing trucks to be inserted in place of circuit
breakers, separate earthing trucks shall be supplied for each type / size of breaker. The
earthing facilities proposed to be provided by the Bidder shall be clearly detailed in
the Bid and shall be subject to Authority's approval. Auxiliary contacts (min. 2 NO + 2 NC)
shall be provided on each earth switch / earthing device and shall be wired to the terminal
block for interlocking purpose.
Annunciators
Annunciators shall be of facia type with translucent plastic window for each alarm point.
Annunciator facia plates shall be engraved in block lettering with respective alarm inscrip-
tions. The inscriptions shall be clearly readable and visible when the respective facia light
is lighted. Each annunciation window shall be provided with two lamps to provide redun-
dancy against lamp failure. Lamps shall be replaceable from the front. Lamps shall be of
clustered LED type.
All facia annunciator points shall be suitable to accept external contacts of either ‘NO’ or
‘NC’ self or hand reset type for initiating the annunciation sequence. Annunciators shall be
suitable for accepting fleeting faults of duration as less as 15millisecond.
For static annunciator schemes, special precaution shall be taken by the Agency to ensure
that spurious alarm conditions do not appear due to influence of external magnetic
fields on the annunciator wiring and switching disturbances from the neighboring circuits
within the panels / desks.
A “Lamp Test” push button shall be provided for each individual panel’s group of annun-
ciators to limit the sudden drain on the battery. Provision of testing facilities for flasher and
audible alarm circuits of annunciators is desirable. The Agency shall give the details of the
offered scheme.
Annunciators shall have following features:

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Suitable for annunciating subsequent faults immediately after the sound cancel of the pre-
vious fault.
During lamp test, if a fault occurs, the corresponding lamp circuit shall be automatically
disconnected from the “lamp test” circuit and shall start flashing.
Designed to prevent mal-operation of the scheme or sequence when the push buttons are
pressed incorrectly or in the wrong order.
"Alarm Supply Failure” Alarm scheme similar to the normal annunciation sequence, but
shall operate on a different DC supply or on AC auxiliary supply.
Instruments
All electrical instruments and meters shall comply with IEC 60051, 61010 and IS 722,
1248. All indicating and recording instruments shall be flush mounted in dust proof cases
complying with IEC 60068 and dimensions to IEC 61554. All digital instruments shall have
interface facilities to communicate data to SCADA system.
Indicating Instruments
Electrical indicating instruments shall be 144mm x 144mm square with 2400 scale. Taut
band type of instruments is preferred. Taut band moving coil instruments for use on AC
systems shall incorporate built-in transducers.
Instrument dials shall be white with black numbers and lettering. A red line shall be drawn
on each scale to represent rated conditions.
Normal maximum meter reading shall be of the order of 60 % normal full scale deflection.
Ammeters for motor feeders shall have suppressed scale to show current from full load up
to six times the full load current.
Instruments shall have accuracy class of 0.2. The design of the scales shall be such that it
can read to a resolution corresponding to 50% of the accuracy class index.
Ammeters and current coils of Watt meters and Voltmeters shall continuously withstand
120% of rated current and 10 times the rated current for 0.5 sec., without loss of accuracy.
Voltmeters and potential coils of Watt meters and Varmeters shall withstand 120% of rated
voltage continuously and twice the rated voltage for 0.5 sec. without loss of accuracy.
Alternatively, instruments can be electronic / digital type with LCD display. These instru-
ments shall have high performance ratio and can be equipped with digital output (for
alarms) or with interfacing facilities for communication and remote reading of parameters.
Metering instruments

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Watt-hour meters shall be of the static type and shall be provided with reverse running
stops.
Watt-hour and Varhour meters shall be of the three phase two element type of accuracy
class 0.2, suitable for measurement of unbalanced loads in three phase three wire circuits.
Watt-hour and Varhour meters shall be suitable for operation from the secondary of CTs
and VTs. They shall be provided with a separate 3 phase 4 wire type test blocks for the
testing of the meters without disturbing the CT and VT secondary connections.
All the meters shall be electronic / digital type with LCD display. These instruments shall
have high performance ratio and can be equipped with digital output (for alarms).
Control and Selector Switches
Control and instrument switches shall be rotary type, provided with escutcheon plates
clearly marked to show operating position and suitable for semi-flush mounting with only
the switch front plate and operating handle projecting out. The connections shall be from
the back. The contact assembly at the back of the switch shall be enclosed in dust tight
removable covers.
The control switches shall be 3 position, spring return to neutral type. They shall be pro-
vided with contacts to close in ‘normal after close’ and ‘normal after trip’ position. Each
switch shall have external red and green indicating lamps, (except when discrepancy type
switches are called for). In addition, a semaphore indicator shall be provided for earthing
switch.
Contacts of the switches shall be spring assisted and contact faces shall be of silver / silver
alloy. Springs shall not be used as current carrying parts. Contact rating and configurations
of the switches shall be adequate for the functions desired.
Instrument selector switches shall be of the maintained (stay-put) type. Ammeter selector
switches shall have make-before-break type contacts so as to prevent open circuiting of CT
secondary when changing the position of the switch.
Lockable type switches, which can be locked in a particular position, shall be provided, if
required.
Emergency stop buttons, if any, shall incorporate ‘stay-put’ features with independent reset
facilities.
Indicating Lamps / Pilot Lights

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Indicating lamp shall be of the double contact, bayonet cap type rated for operation at either
230 V AC or at the specified DC system voltage as applicable. Lamps shall be provided
with translucent lamp covers.
Clustered LED type lamps shall be provided. Lenses shall be glass or plastic in standard
colors, red, green, blue, white and amber, in accordance with IEC 60073. Bulbs and lenses
shall be interchangeable and easily
replaceable from the front of the panel. Tools, if any, which are required for replacing the
bulbs and lenses, shall also be included in the scope of supply.
Miniature pilot lamps may be provided with plastic marking plate contained inside square
(or rectangular) front lens to provide indication of legend or symbols engraved on the mark-
ing plate.
The basis of colors shall be as follows:

Red : Flow of energy.

Green : No flow of energy.
White : Supervision of power available, relay coil healthy, etc.
Amber : Disagreement with original condition, ‘abnormal’ condition or
‘Sequence–on’ condition.
Push Buttons
Push buttons shall be of momentary contact type with rear terminal connections. The color
of the push button actuator shall be red for ‘OPEN / STOP’ and green for ‘CLOSE /
START’. The push button knob shall be suitably shrouded to prevent inadvertent operation.
The push buttons shall be provided with integral inscription plates engraved with their des-
ignation.
All push buttons shall have independent, potential free, 2NO + 2NC contacts. The contact
faces shall be of silver / silver alloy. The contacts shall be rated 10A and capable of breaking
inductive load of 5A at 110V DC.
Cubicle Lighting / Receptacle
Each cubicle shall be provided with interior lighting by means of 18 W fluorescent tube
lighting fixture. An MCB shall be provided for the lighting circuit. The lighting fixture shall
be suitable for operation from a 230 V, 1 ph, 50 Hz, AC supply. A 230 V, 1 phase, AC
receptacle (socket) plug point shall be provided in the interior of each panel with an MCB.
Power and Control Cable Terminations

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Terminals for power connections shall be complete with adequate phase segregating insu-
lating barriers, shrouds and suitable crimping type of lugs for terminating the cables.
Double compression type glands with armour and bonding clamps for the termination of
all solid dielectric multicore cables shall be provided. They shall be designed to secure the
armour wires to provide electrical continuity between the armour and the threaded fixing
component of the gland and to provide watertight seals between the cable outer sheath and
gland and between the inner sheath and threaded fixing component. The gland shall pref-
erably project above the gland plate to avoid entry of moisture.
Earthing connectors between cable armour and earth shall be routed outside the cable gland
in an approved manner. Gland insulation shall be capable of withstanding test for appropri-
ate high voltage for one minute.
Cable terminations for HV / MV cables shall be heat / cold shrinkable type. Adequately
sized shrouds / bolts shall be provided at connections to completely cover the terminations.
Where core-balance type current transformers are provided on the feeder cables for earth
fault protection, glands for cables shall be insulated from earth in an approved manner.
Wiring for Control and Protective Circuits
All low voltage wiring for control, protection and indication circuits shall be carried out
with 1100 V grade, PVC insulated cable with stranded, tinned copper conductor of mini-
mum 1.5 sq. mm size. The size of conductor for CT circuits shall be minimum 2.5 sq. mm.
All wiring shall be run on the sides of panels and shall be neatly bunched and cleated with-
out affecting access to equipment mounted in the panel. The wiring shall be bound and
supported by clamping, roughing or lacing. Spiral wrapping will not be accepted. Wireways
shall not be more than 50% full. Adequate slack wire shall be provided to allow for one
restripping and reconnection at the end of each wire. When screened cables or wires are
necessary, an insulating sheath shall be included. Wiring and supports shall be of fire re-
sistant material.
Wiring shall only be jointed or teed at terminals. Terminals of the clamp type shall not have
more than two wires connected.
Terminations and Ferrules
Engraved core identification ferrules, marked to correspond with the wiring diagram, shall
be fitted to each wire and each core of multicore cables terminated on the panels.

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Moisture and oil resisting insulating material shall be used. The ferrules shall be of the
interlocking type and shall grip the insulation firmly without falling off when the wire is
removed.
All wires forming part of a tripping circuit shall be distinctively marked. Spare auxiliary
contacts of electrical equipment shall be wired to terminal blocks.
Control Wiring Terminal Blocks
Terminal blocks shall be of 1000 V grade and stud type. Brass stud of at least 6 mm dia.
with fine threads shall be used and securely locked within the mounting base to prevent
turning. Each terminal shall comprise two threaded studs, with a link between them, wash-
ers, and matching nuts and locknuts for each stud. Connections to the terminals shall be at
the front.
Terminals shall be numbered for identification, grouped according to function. Engraved
‘black on-white’ labels shall be provided on the terminal blocks describing the function of
the circuit.
Terminals for circuits with voltage exceeding 110 V shall be shrouded. Terminal blocks at
different voltages shall be segregated into groups and distinctively labeled. Terminals used
for connecting current transformer secondary leads shall be ‘disconnecting and shorting’
type with a facility for earthing the secondary.
Terminal blocks shall be arranged with 100 mm clearance, between any two sets. Separate
terminal stems shall be provided for internal and external wiring respectively. All wiring
shall be terminated on terminal blocks, using crimping type lugs or claw type of termina-
tions.
Busbars
The phase and neutral busbars shall be of rating indicated in the corresponding one-line
diagram. Busbars shall be of Copper type and shall be provided with minimum clearances
as specified.
All busbars and bus taps shall be insulated with close fitting sleeve of hard, smooth, dust
and dirt free, heat shrunk PVC insulation of high dielectric strength, to provide a permanent
non-ageing and non-tracking protection, impervious to water, tropical conditions and fungi.
The insulation shall be non-inflammable and self-extinguishing type and in fast colours to
indicate phases. The dielectric strength and properties shall hold good for the temperature

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range of 0 to 95 degree centigrade. If the insulating sleeve is not coloured, bus bars shall
be colour coded with coloured PVC tape at suitable intervals.
Busbar joints shall be of the bolted type. Spring washers shall be provided to ensure good
contact at the joints. Busbars shall be thoroughly cleaned at the joints and suitable contact
grease shall be applied just before making a joint.
Direct access to, or accidental contact with busbars and primary connections shall not be
possible. All apertures and slots shall be protected by baffles to prevent accidental shorting
of busbars due to insertion of maintenance tools.
Sequence of red, yellow and blue phases and neutral for four-pole equipment shall be left
to right and top to bottom, for horizontal and vertical layouts respectively.
The HV switchboards are being procured under the present scope of works with following
protections systems:
Over current / Earth Fault Protection
This relay shall be of the multi-characteristics type which has a flexible mode selection
facility so that it is possible to select one mode for the over current elements and another
for the earth fault element.
Phase current range shall cover at least 50-300% of ‘In’ in steps of not more than 10% while
the earth current range shall cover at least 5-100% of ‘In’ in steps of not more than 5%.
The time setting range of the definite time mode shall not be less than 5 seconds in steps of
0.1 second each.
The time multiplier setting for the inverse time-current characteristic modes shall have a
range not less than 0.05- 1.6 in steps of 0.05.
Over current and earth fault relays shall have separate timers and operation indicators.
The high set element shall have a range of 2 - 15 times the nominal current in steps of ‘In’
and shall be of low transient overreach, with a tripping time of less than 25 ms and possible
to be selected on "blocked" position. Reset time shall be not more than 50 ms for both
elements.
The relays that are installed on the transformer neutral side shall be of single phase version,
but they shall have the same characteristics as the phase side relays.
Under voltage relays
Suitable voltage operated relays for sensing loss of voltage shall be provided. The relay
shall have a drop off to pick up ratio of the order 90%. The relays shall be fast operating

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type and shall be fitted with operation indication. The indication shall come on drop off or
loss of voltage.
Additional potential free contacts for all the relay outputs i.e. trip as well as alarm signals
shall be provided for connection
Following Minimum protections to be provided for incomer & outgoing which are listed
below
Incomer & Outgoing
IDMTL over current (51) for phase fault
Definite time O/C relay (50 N) for earth fault.
Auxiliary Relays and Timers
Following auxiliary relays shall be provided on each breaker cubicle:
Trip circuit supervision relay
Anti- pumping relay
Hand reset type lockout (tripping) relays and timers shall be provided as required in addi-
tion to the protection relays given in the single line diagram.
Auxiliary relays and timers shall be rated to operate satisfactorily between 70 % and 110
% of the rated voltage.
Voltage operated relays with sufficient contacts to initiate tripping, alarm, annunciation for
various trip functions like Buchholz relay operation, high oil temperature, high winding
temperature, pressure relief device (PRD) operation etc. shall be provided. Each relay shall
have four (4) pairs of self-reset contacts except for
Buchholz and "PRD" trip which shall have hand-reset contact. The relays shall have hand-
reset operation indicators.
Voltage operated relays with sufficient contacts to initiate alarm and data logging for vari-
ous alarm functions for transformers, etc. shall be provided. Each relay shall have four (4)
normally open self-reset contacts. The auxiliary relay for Buchholz alarm shall be slugged
to have delay on drop off at 100ms. The relays shall have hand reset operation indicator.
Component Identification
A component reference number shall be marked adjacent to each component. Where this is
impossible, components shall be identifiable from the layout drawings provided.
The following shall be marked in all instances:

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Fuses: The rating and the circuit identification of each fuse shall be marked adjacent to the
fuse base.
Control, Protection and Indication Devices: The function of each control, protection and
indication device shall be marked. The caption and its arrangement shall be subject to the
approval of the Authority’s Representative.
Preset Controls: The circuit reference and if possible, the function shall be marked adjacent
to each preset control in a position where it will be clearly visible while the adjustment is
being made.
Connectors: The diagram reference number shall be marked on or adjacent to each con-
nector.
Test points shall be individually marked with the diagram reference number.
The polarity of any polarized devices (e.g. diodes) shall be marked.
Test Terminal Blocks
Test terminal blocks, if any, shall be provided for secondary injection and testing of relays.
A suitable metering block shall be provided for the connection of a portable precision in-
strument to be operated when required for specific plant testing purposes.
Tests
The following routine tests shall be carried out on the assembled switchboard / panel during
inspection at the manufacturer’s works in addition to other tests as per applicable standards.
Primary injection tests to ensure correct ratios and polarity of current and voltage trans-
formers and of the current operated protection relays and direct acting coils, over their full
range of settings.
Balance earth fault stability test by primary current injection. Care must be taken to repro-
duce accurately the burdens of interconnecting cables. A further test to ensure correct po-
larity must be made after assembly.
Tests on auxiliary relays at normal operating voltages by operation of associated remote
relays.
Correct operation of sequencing and control circuits at normal operating voltages by oper-
ation of local control switches, and simulation of operation from remote control positions.
Carry out functionality tests, check interfacing status contacts and instrumentation.
Checking of Differential protection relay.
One-minute power-frequency voltage dry withstand tests on the main circuits

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One-minute power-frequency voltage dry withstand tests on auxiliary circuits

Insulation resistance tests
Following minimum type tests shall be performed on a typical section of the bus assembly,
unless otherwise mentioned.
Impulse Test & PF withstand test
Temperature rise Test
Short circuit Test
Internal Arc Test for 25kA 1 sec
Short circuit test duties
Mechanical Endurance test
The offered switchgear panel shall be one which is successfully type tested for Inclination
and Vibration and Seismic conditions.
All circuit breakers shall be subject to the following tests:
Routine tests including HV pressure test, milli-volt drop tests and mechanical tests.
To ensure the operation of the dc closing coil and satisfactory closing of the circuit breaker
with the voltage of the coil down to 80% of its rated voltage, and that mal-operation does
not occur with a voltage on the coil of 120% of its rated voltage.
Inter changeability of withdrawable identically equipped circuit breakers, and checking of
all mechanical and electrical interlocks.
Type test figures for heat test runs performed on identical panel types shall be made avail-
able.
Specific technical particulars of the 33kV Metal Enclosed Switchgear shall be as shown in
the technical data sheet below:

Description Unit Particulars

General
Metal enclosed, compartmentalized
Type
draw-out type
Rated voltage, no. of phases and rated
kV / - / Hz 36 kV, 3 Phase, 50Hz
frequency
System neutral earthing 33kV system earthed
Rated Insulation Levels
Rated short duration power frequency
kV (rms) 70
withstand voltage

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Rated lightning impulse withstand volt-

kV (peak) 170
age
Rated normal current of bus bars under
A Aluminium - suitable for 100% load
design ambient temperature of 450C
and material of busbar
Rated short-time withstand current and kA (rms) / 25 kA for 1 sec
time sec
Dynamic rating kA (peak) 62.5
Constructional Requirements
Minimum thickness of sheet steel in
Frame – 2.5
mm Cold rolled (Frame/Enclosure/Co- mm
Doors/Covers – 2.0
vers)
Degree of protection of enclosure IP-4X

Description Unit Particulars

Color finish shade
- Interior Glossy White
- Exterior Light Grey Semi Glossy
- Cable connection Bottom entry and exit
Circuit Breakers
Type Vacuum/SF6
Rated current inside the cubicle un-
der design ambient temperature at A (*)
45°C
Rated operating sequence O–3 Min–CO-3 Min-CO
Rated short time breaking current kA (rms) 25
Rated short time making current kA (peak) 62.5
Rated short-time withstand current kA (rms) /
25 kA for 1 sec
and time sec
Rated peak withstand current kA (peak) 62.5
6 NO + 6 NC after internal use by manu-
Min. no. of auxiliary contacts
facturer
Type of operating mechanism
- Normal Spring charging for closing and tripping
Manual and spring charged for closing
- Emergency
and tripping
Auxiliary control voltage
(i) For closing / tripping coil V 110 DC
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- Spring charging motor V 110 DC

- Space heater and lighting V 230 AC
Earthing switch Required
Current Transformers
Type Cast resin
Class of insulation Class E or better
Rated current ratio and burden
A & VA (*)
(i) Incomer
(ii) Outgoing feeders A & VA (*)
Accuracy class
0.2
(i) Metering
(ii) Protection 5P20
Short time 1 sec current rating kA (rms) 25
Dynamic rating kA (peak) 62.5
Voltage Transformers
Type Cast resin
Rated Voltage
(i) Primary V 33000/√3
(ii) (ii) Secondary – S1 V 110/√3
Method of connection
Star, earthed
(i) Primary – P
Star, earthed
(ii) Secondary – S1
Application – S1 Metering and Protection
Rated burden VA (*)
Metering 0.2
Accuracy class
Protection 3.0
Rated voltage factor
1.1
(i) Continuous
(ii) Short time 1.5
Insulation class Class E or better
Meters
Make As per Preferred Makes/ Manufacturers
Accuracy Class
(i) Indicating Meters Class 0.2
(ii) Energy Meter Class 0.2
Details of ratio, taps, burden, accu-
(*)
racy
Protective Relays

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Type Numerical Type

Auxiliary supply V 110 DC

Specific technical particulars of the 6.6kV Metal Enclosed Switchgear shall be as shown in
the technical data sheet below:

Description Unit Particulars

General
Metal enclosed, compartmental-
Type
ized, draw-out type
Rated voltage, no. of phases and rated
kV / - / Hz 7.2 kV, 3 Phase, 50Hz
frequency
System neutral earthing 7.2 kV Earthed
Rated Insulation Levels
- Rated short duration power fre-
kV (rms) 28
quency withstand voltage
- Rated lightning impulse withstand
kV (peak) 75
voltage
Rated normal current of bus bars un-
der design ambient temperature under Aluminium - suitable for 100%
A
design ambient temperature of 450C load
and material of busbar
Rated short-time withstand current kA (rms) /
25 kA for 1 sec
and time sec
Dynamic rating kA (peak) 62.5
Constructional Requirements
Minimum thickness of sheet steel in Frame – 2.5
Minimum thickness of sheet steel in
Mm Doors/Covers – 2.0
mm Cold (Frame/Enclosure/Covers)
Degree of protection of enclosure IP- 4X
Color finish shade
- Interior Glossy White
- Exterior Light Grey Semi Glossy
- Cable connection Bottom entry and exit
Circuit Breakers
Type Vacuum

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Rated current inside the cubicle un-

der design ambient temperature at A (*)
45°C
Rated operating sequence O–3 Min–CO-3 Min-CO
Rated short time breaking current kA (rms) 25
Rated short time making current kA (peak) 62.5
Rated short-time withstand current kA (rms) /
25 kA for 1 sec
and time sec
Rated peak withstand current kA (peak) 62.5
6 NO + 6 NC after internal use by
Min. no. of auxiliary contacts
manufacturer
Type of operating mechanism
Type of operating mechanism Spring charging for closing and
- Normal tripping
Manual and Spring charged for
- Emergency
closing and tripping
Auxiliary control voltage
(i) For closing / tripping coil V 110 DC
- Spring charging motor V 110 DC
- Space heater and lighting V 230 AC
Earthing switch Required
Current Transformers
Type Cast resin
Class of insulation Class E or better
Rated current ratio and burden
A & VA (*)
(i) Incomer
(ii) Outgoing feeders A & VA (*)
Accuracy class
0.2
(i)Metering
(ii) Protection 5P20
Short time 1 sec current rating kA (rms) 25

Description Unit Particulars

Dynamic rating kA (peak) 62.5

Voltage Transformers
Type Cast resin
Rated Voltage V 6600/√3
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(i) Primary
(ii) Secondary – S1 V 110/√3
Method of connection
Star, earthed
(i) Primary – P
(ii) Secondary – S1 Star, earthed
Application – S1 Metering and Protection
Rated burden VA (*)
Accuracy class Metering 0.2
Protection 3.0
Rated voltage factor
1.1
(i) Continuous
(ii) Short time 1.5
Insulation class Class E or better
Meters
As per preferred Makes/manu-
Make
facturers
Accuracy Class
(i) Indicating Meters Class 0.2
(ii) Energy Meter Class 0.2
Details of ratio, taps, burden,
(*)
accuracy

Description Unit Particulars

Protective Relays
Type Numerical Type
Auxiliary supply V 110 DC

TECHNICAL SPECIFICATION FOR 415V METAL ENCLOSED SWITCHGEAR PMCC

/MCC /SWITCHBOARDS /LIGHTING PANELS
Applicable Standard
The switchgear and components shall conform to the latest applicable standards specified
below:
Switchgear General Requirements IS:13947/BS:5486/IEC:60947
Factory Built Assemblies of SWGR and Control
gear for Voltages upto and including 1000V AC & IS:8623/BS:5486/IEC:60439
1200V DC

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IS:13947-P3/BSEN60947/
Air Break Switches
IEC:60947-3
IS 2516/IEC 60947-2/BS EN
Moulded Case Circuit Breaker
60947-2
Miniature Circuit Breakers IS:8828/BSEN:60898

Low voltage Fuses IS:13703/BS:1362/IEC:60269-1

IS:13947/BS EN60947-4
Contactors
/IEC:60947-1
IS:13947/BS EN60947-4/
Starters
IEC:60292-1TO 4
Control Switches / Push buttons IS:6875 / BSEN 60947

Current Transformers IS:2705/BS:7626

Voltage Transformers IS:3156/BS:7625/IEC:60044, 60186

Indicating instruments IS:1248/BS:89/IEC:60051

Marking and Identification of Conductors and Ap-
IS:11353/BS:159
paratus Terminals
IS:722,8530/BS:5685/ IEC
A.C. Electricity Meters
60145,60 211
Degree of Protection IS:13947/IEC:60947-P1
Selection installation and maintenance of
IS:10118
switchgear and Control gear
Code of practice for phosphating iron and
IS:6005/BS:3189
Steel
Specification for copper rods and bars for
IS:613
electrical purposes
Control transformers for switchgear and Control
IS:12021
gear voltage not exceeding 1000V AC

Features of Construction
(a) General Constructional Requirements
Lighting/UPS Distribution Boards/Panels
Lighting Distribution board shall be wall mounted, IP42 with Metallic Double door with
incomer & outgoing as per indicated in single line diagram.
Panels shall be Epoxy Powder coated with paint shed RAL 7032. Din rails shall be provided
for mounting of MCB/MCCB as applicable.

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Panels shall have copper Bus bars which shall be sized considering design ambient tem-
perature of 50 Deg C.
Panels shall have separate terminal strip for circuit neutrals and earth connection.
For termination of incomer and outgoing cables / wires adequate space shall be provided
including proper clamping and dressing arrangements for cores. The busbar Links shall be
fork type, tin plated copper and shall have end caps. For 50sq.mm and above size cable
terminations entry terminals shall be used.
In case of Aluminum cables being terminated on tinned copper Busbars, the tinning shall
withstand the temperature rise and aberration so as to avoid bi-metallic corrosion.
External Earthing stud shall be provided on both sides of panels.
Panels shall be wall mounted on metallic bracket, which shall be painted with anti-corro-
sive epoxy paint.
The MCBs shall be IP20 with current ratings and kA ratings as indicated. For lighting cir-
cuits MCBs with Characteristic ‘C” shall be used. For Power circuits MCBs with Charac-
teristics “D” shall be used.
MCB shall have Label Holder, Combined head screws, two positions Dolley.
All MCCBs shall have extended Rotary Handle & Extension Links/Spreaders.
Current density for busbars shall be 0.7A/mm2
All identical equipment and corresponding parts shall be fully interchangeable without any
modifications.
Busbar material shall be copper upto & including 100A and above 100A, it shall be Alu-
minium
The neutral bus of the main 3 phase, 4 wire distribution board shall be rated not less than
50% of the phase busbars. The neutral bus of the 1 phase ways lighting panel shall be rated
same as the phase busbars. The neutral bus shall have sufficient terminals and detachable
links for full number of single-phase outgoing lighting circuits.
Main LT PMCC Panel/MCC Panels
The following clauses shall be deemed to apply for this Panel.
Sheet steel used for fabrication of switchboards, control cabinets, marshalling boxes, etc
shall be cold rolled.
All panels, cabinets, kiosks and boards shall comprise rigid welded structural frames made
of structural steel sections or of pressed and formed cold rolled sheet steel of thickness not

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less than 2 mm. The frames shall be enclosed by sheet steel of at least 2 mm thickness.
Stiffeners shall be provided wherever necessary.
All doors, removable covers, gland plates, etc. shall be of at least 1.6 mm thickness and
shall be gasketed all-round the perimeter.
All doors shall be supported by strong hinges of the disappearing or internal type and
braced in such a manner as to ensure freedom from sagging, bending and general distortion
of panel or hinged parts.
All floor mounted panels/boards shall be provided with a channel base frame. Total height
of all floor mounted cubicles/panels shall not be greater than 2300 mm. Where steel ped-
estals for mounting of boards/panels are specified, the total height including that of the
pedestal shall exceed 2300 mm.
Switchboard/control cabinet/panel shall be dust and vermin proof. Degree of protection of
the enclosure shall be IP 54 for indoor installations and IP 55 for outdoor installations.
Separate, segregated metal clad compartments shall be provided for main and auxiliary bus
bars, each feeder and cable alleys. Metal clad cubicles/modules shall be provided with
hinged doors in the front, with facility for padlocking door handles. More than one module
may be arranged in the same vertical section. Circuits not controlled by air circuit breaker
(ACB) shall be of the fixed type. The switchboard enclosure shall conform to “Form – 4”
as per IS-8623. It shall be possible to extend the switchboard on both sides.
ACB, if any, shall be fully draw-out type. The breaker carriage shall be fitted with positive
guides to ensure proper alignment. All corresponding components of circuit breaker cubi-
cles of same rating shall be interchangeable with one another.
The fully draw-out modules shall have all the circuit components mounted on withdrawa-
ble type steel chassis. All power and control connections shall be of the draw out type. It
shall be possible to withdraw the chassis mounted circuit components without disconnect-
ing any connections. All draw-out contacts shall be of silver plated copper.
In case of circuit breaker compartments, suitable barriers shall be provided between breaker
and all control, protective and indication circuit equipment including instrument transform-
ers. External cable connections shall be through separate cable compartments for power
and control cables.

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The fixed type module shall have all the circuit components mounted in the compartment,
with bolted type power and control connections. It shall be possible to remove all circuit
components after removing the connections and the component fixing bolts.
Instruments, relays and control devices shall be mounted flush on hinged door of the cubi-
cles. Switchboard shall be complete with inter-panel wiring.
Each switchboard shall also be fitted with a label indicating its title. Each cubicle shall be
fitted with a label on the front and rear of the cubicle. Each relay, instrument, switch, fuse,
contactor and MCCB/MCB shall be provided with a separate label.
One metal sheet shall be provided between two adjacent vertical sections running to the
full height of the switchboard except for the horizontal busbar compartment. However,
each shipping sections shall have metal sheets at both ends.
After isolation of the power and control connections of a circuit, it shall be possible to carry
out maintenance in a compartment safely, with the busbars and adjacent circuits alive.
The current rating of outgoing feeders of any switchboard shall not be less than 10% of
that of the incoming feeder. Deviation from this requirement shall be subject to the ap-
proval.
Busbars
The phase and neutral busbars shall be of rating indicated in the corresponding one-line
diagram. Busbars shall be of aluminium and shall be provided with minimum clearances
as specified.
All busbars and bus taps shall be insulated with close fitting sleeve of hard, smooth, dust
and dirt free, heat shrunk PVC insulation of high dielectric strength, to provide a permanent
non-ageing and non-tracking protection, impervious to water, tropical conditions and fungi.
The insulation shall be non-inflammable and self-extinguishing type and in fast colours to
indicate phases. The dielectric strength and properties shall hold good for the temperature
range of 0 to 95 degree centigrade. If the insulating sleeve is not coloured, bus bars shall
be colour coded with coloured PVC tape at suitable intervals.
Busbar joints shall be of the bolted type. Spring washers shall be provided to ensure good
contact at the joints. Busbars shall be thoroughly cleaned at the joints and suitable contact
grease shall be applied just before making a joint.

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Direct access to, or accidental contact with busbars and primary connections shall not be
possible. All apertures and slots shall be protected by baffles to prevent accidental shorting
of busbars due to insertion of maintenance tools.
Sequence of red, yellow and blue phases and neutral for four-pole equipment.

Air Circuit Breaker (ACB)

Circuit breakers shall be operated by a motor spring charging type of mechanism. The mo-
tor operated spring charged mechanism shall be complete with motor, opening spring, clos-
ing spring and all accessories to make the mechanism a complete operating unit.
The tripping spring shall be charged by the closing action, to enable quick tripping. Closing
of the circuit breaker shall automatically initiate recharging of the springs to enable the
mechanism to be ready for the next closing stroke. Charging time for the springs shall not
exceed 30 seconds. It shall be possible to manually charge the springs in an emergency.
Transfer from motor to manual charging shall automatically disconnect the charging motor.
The charging mechanism shall be provided with mechanical indicators to show "charged"
and "discharged" conditions of the spring. Failure of any spring, vibration or mechanical
shock shall not cause tripping or closing of the circuit breaker.
Only one closing operation of the circuit breaker shall result from each closing impulse
(manual or electrical), even if the breaker trips while the control device (manual or electri-
cal) is being held in the "close" position.
The circuit breaker mechanism shall make one complete closing operation, once the push
button has been operated and the first device in the control scheme has responded, even
though the PB is released before the closing operation is complete, subject to the condition
that there is no counter- impulse for tripping.
Means shall be provided to manually open and close the breakers slowly, when the operat-
ing power is not available, for maintenance and adjustments. A local manual trip device
shall be provided on the operating mechanism.
All operating mechanisms shall be provided with "ON" - "OFF" mechanical indication.
Closing coils and other auxiliary devices shall operate satisfactorily at all voltages between
85-110 % of the control voltage. Trip coils shall operate satisfactorily between 70 -110 %
the rated control voltage.

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The Breaker shall be provided with Microprocessor based releases for Inverse-time delayed
overload releases for the phases, Short-time delayed short-circuit releases and earth-fault
releases
The breaker service Short Circuit breaking capacity (ICS) shall be equal to ultimate Short
Circuit capacity (ICU) and shall be equal to short time withstand current of Breaker (ICW)
Moulded Case Circuit Breaker (MCCB)
MCCBs shall be of the air break, quick make, quick break and trip free type and shall be
totally enclosed in a heat resistant, moulded, insulating material housing. MCCBs shall
have an ultimate short circuit capacity not less than the short circuit current Specified-
MCCBs shall have a service short circuit breaking capacity (ICS) equal to the ultimate
short-circuit capacity (ICU).
Each pole of MCCB shall be fitted with a bi-metallic thermal element for inverse time delay
protection and a magnetic element for short circuit protection. Alternatively, they shall be
fitted with a solid-state protection system. Such a protection system shall be fully self-
contained, needing no separate power supply to operate the circuit breaker tripping mech-
anism. Thermal element shall be adjustable. Adjustments shall be made simultaneously on
all poles from a common facility. Thermal elements shall be ambient temperature compen-
sated.
The MCCBs shall be provided with the following features:
Common trip bar for simultaneous tripping of all poles
Shrouded terminals
Time for clearing short circuit current of 20 msec.
2 NO + 2 NC auxiliary contacts
Miniature Circuit Breaker (MCB)
MCB shall be hand operated, air break, quick make, quick break type.
Operating mechanisms shall be mechanically trip-free from the operating knob to prevent
the contacts being held closed under overload or short-circuit conditions.
Each pole shall be fitted with a bi-metallic element for overload protection and a magnetic
element for short-circuit protection. Multiple pole MCBs shall be mechanically linked such
that tripping of one pole simultaneously trips all the other poles. The magnetic element
tripping current classification shall be of the type suitable for the connected load. Where

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this is not specified, it shall be Type C. The short circuit rating shall be not less than that of
the system to which they are connected.
Contactors
The power contactors used in the switchboard shall be of, air break, single throw, triple
pole, electromagnetic type. Contactors shall be suitable for uninterrupted duty and rated for
Class AC3 duty in accordance with the latest edition of IS 13947.
Operating coils of all contactors shall be suitable for operation on 240 V, single phase, 50
Hz supply. Contactors shall be provided with at least two pairs of NO and NC auxiliary
contacts. Contactors shall not drop out at voltages down to 70 % of coil rated voltage.
Contactors shall be provided with a three element, positive acting, ambient temperature
compensated, time lagged, hand reset type thermal overload relay with adjustable settings.
The hand reset button shall be flush with the front door of the control module, and shall be
suitable for resetting the overload relay with the module door closed. Relays shall be either
direct connected or CT operated. Overload relay and reset button shall be independent of
the "Start" and "Stop" push buttons. All contactor shall all be provided with single phasing
preventer (SPP).
Motor starters shall be complete with auxiliary relays, timers and necessary indications.
Current Transformers
Current Transformers shall be Cast Resin type.
Current transformers shall have polarity markings indelibly marked on each transformer
and at the lead terminations at the associated terminal block
Current transformers shall be able to withstand the thermal and mechanical stresses result-
ing from the maximum short circuit and momentary duties of the switchgear, as indicated
in the Technical Specification.
CT core laminations shall be of high grade silicon steel.
Identification labels shall be fitted giving type, ratio, rating, output and serial numbers.
Voltage Transformers
Voltage Transformers shall be Cast Resin type.
Secondary and tertiary windings of voltage transformers shall be rated for a three-phase
line to line voltage of 110 V.
It shall be possible to replace voltage transformer fuses easily without having to de-energise
the main bus-bars.

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Indicating Instruments & Meters

Electrical indicating instruments shall be 110 mm square with 240º scale. Taut band type
of instruments is preferred. Taut band moving coil instruments for use on AC systems shall
incorporate built-in transducers. Instrument dials shall be white with black numbers and
lettering. Normal maximum meter reading shall be of the order of 60 % normal full-scale
deflection. Ammeters for motor feeders shall have suppressed scale to show current from
full load up to six times the full load current. Watt hour meters shall be of the static type
and shall be provided with reverse running stops. Instruments shall have an accuracy of
Class 1.0.
Indicating Lamps
Indicating lamps shall be of the cluster LED type, with low watt consumption. Indicating
lamp shall be of the double contact, bayonet cap type rated for operation at either 240 V
AC or at the specified DC system voltage as applicable. Lamps shall be provided with
translucent lamp covers. Bulbs and lenses shall be interchangeable and easily replaceable
from the front.
Push Buttons
"Start" and "Stop" push buttons shall be coloured green and red respectively. Stop Push
Button shall be lockable stay-put type with Mushroom head.
Safety Arrangements
All terminals, connections and other components, which may be “live” when front access
door is open, shall be adequately screened. It shall not be possible to obtain access to an
adjacent cubicle or module when any door is opened. Components within the cubicles shall
be labeled to facilitate testing.
Earthing of Switchboards / Panels
Each switchboard, control panel, etc. shall be provided with an earth busbar running along
its entire length. The earth bus bar shall be located at the bottom of the board/panel.
Earth bus bars shall be of copper and shall be rated to carry the rated symmetrical short
circuit current of the associated board/panel for one second, unless otherwise specified.
Earth bus bars shall be properly supported to withstand stresses induced by the momentary
short circuit current of value equal to the momentary short circuit rating of the associated
switchboard/panel.

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Positive connection of the frames of all the equipment mounted in the switchboard to the
earth bus bar shall be maintained through insulated conductors of size equal to the earth
bus bar or the load current carrying conductor, whichever is smaller.
All instrument and relay cases shall be connected to earth bus bar by means of 1100 V
grade, green coloured, PVC insulated, stranded, tinned copper, 2.5 sq. mm conductor
looped through the case earth terminals.
Internal Wiring
The internal wiring shall be carried out with 650/1100V grade, PVC insulated, stranded
conductor wires. The minimum size of conductor for power circuits shall be 4 Sq.mm cop-
per or equivalent size aluminium conductor. Control circuits shall be wired with copper
conductor of at least 1.5 Sq.mm.
The specific technical particulars of Main LT PMCC Panel / MCC Panel / Chiller PCC /
UPS & Lighting Distribution Board shall be as given below:

Description Particulars
Rated voltage, Phases and Frequency 415 V, 3 Ph, 50 Hz
For Main LT PMCC/MCC/Chiller PCC
Panel - Single front, fixed type with IP54
Type of Construction Enclosure
For UPS/Lighting DB- Wall Mounted with
Degree of protection IP 42
Maximum system voltage 476 V
One-minute Power Frequency withstand voltage
Power circuit 3000 V (rms)
Control Circuit 2000 V (rms)
Auxiliary circuit connection to secondary of CTs 2000 V (rms)
Current rating of busbars over design ambient tempera-
As per ………….
ture of 50 Degree C
Short circuit withstand for main and auxiliary busbars
As per …………….
(1 sec.)
Maximum temperature of main and auxiliary busbars at
continuous rated current rating under site design ambient 85
temperature of 50 Degree C
Colour finish shade as per IS:5
Interior Glossy white
Exterior Light grey, semi-glossy, shade 631 of IS 5

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Earthing bus material and size Copper, 25 x 6 mm

Clearances in air of live parts 25.4 mm
Type of Mounting Floor / Wall Mounted
Cable Entry To be decided based on Layout
Type of Starter for MCC Panel VFD : For all pumping Motors

415V CAPACITOR BANKS WITH APFCR PANEL

Applicable Standards
The capacitor and control panel conform to the latest applicable standards specified below.
In case of conflict between standards and this specification, this specification shall govern
Shunt capacitors for power systems IS: 13340
Internal fuses and internal overpressure disconnectors: IS:12672 for shunt capacitors
Metal enclosed switchgear IS: 3427 / BSEN 60298/ IEC: 60298
Code of practice for phosphating iron and steel IS: 6005/BS: 3189
Specification for copper rods and bars for electrical purpose IS: 613
2.5.2 Design Features
The capacitor banks shall be complete with all parts that are necessary or essential for effi-
cient operation. Such parts shall be deemed to be within the scope of supply whether spe-
cifically mentioned or not.
The capacitor bank shall be complete with the required capacitors along with the supporting
post insulators, steel rack assembly, copper bus bars, copper connecting strips, foundation
channels, fuses, fuse clips, etc. The steel rack assembly shall be hot dip galvanised.
The capacitor bank may comprise of suitable number of single phase units in series parallel
combination. However, the number of parallel units in each of the series racks shall be such
that failure of one unit shall not create an overvoltage on the units in parallel with it, which
will result in the failure of the parallel units.
The complete capacitor banks with its accessories shall be metal enclosed (in sheet steel
cubicle), indoor floor mounting and free-standing type.
All sheet steel work shall be thoroughly cleaned of rust, scale, oil, grease, dirt and swarf by
pickling, emulsion cleaning etc. The sheet steel shall be phosphated and then painted with
two coats of zinc rich primer paint. After application of primer, two coats of finishing syn-
thetic enamel paint oven baked/stoved shall be applied.

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The assembly of the banks shall be such that it provides sufficient ventilation for each unit.
Necessary louvers may be provided in the cubicle to ensure proper ventilation.
Each capacitor unit/bank shall be fitted with directly connected continuously rated, low loss
discharge device to discharge the capacitors to reduce the voltage to 50 volts within one-
minute in accordance with the provisions of the latest edition of IS: 2834.
Capacitors shall be of Mixed Dielectric of polypropylene and paper with internal element
fuses. The impregnant shall be non-PCB (poly chlorinated biphenyl) oil.
Each unit shall satisfactorily operate at 135% of rated KVAR including factors of overvolt-
age, harmonic currents and manufacturing tolerance. The units shall be capable of contin-
uously withstanding satisfactorily any overvoltage upto a maximum of 10% above the rated
voltage, excluding transients.
Unit Protection
Each capacitor unit shall be individually protected by an HRC fuse suitably rated for load
current and interrupting capacity, so that a faulty capacitor unit shall be disconnected by
the fuse without causing the bank to be disconnected. Thus, the fuse shall disconnect only
the faulty unit and shall leave the rest of the units undisturbed. An operated fuse shall give
visual indication so that it may be detected during periodic inspection. The fuse braking
time shall co-ordinate with the pressure built up within the unit to avoid explosion. Mount-
ing of the individual fuse may be internal or external to the capacitor case.
Power Capacitor and Control Panel
Power capacitor and control panel shall be housed in metal enclosed cubicle. Power capac-
itor shall be housed in the lower compartment and capacitor control panel at top compart-
ment.
The control equipment including capacitors shall be mounted in a panel of cold rolled sheet
steel. The panel shall be of indoor type and shall consist of:
 Busbars shall be of copper conductor of hard drawn (HD) and high conductivity
 Isolating switch
 Contactor with overload element
 Relays responsive to current/voltage/KVAR/PF as specified for automatic switching
 Sequencing devices, timers and auxiliary relays for automatic sequential switching of
the capacitors in and out of the circuit.
 Auto-manual selector switches

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 Push button for opening and closing the power circuit.

 Red and green lamps for capacitors ON/OFF indication
 Protective relays to protect the healthy capacitor units when one unit fails in a series
connection
 Space heater and cubicle lighting as per the requirements.
The specific technical particulars for 415V Capacitor Banks with APFCR Panel shall be as
given below:

Description Unit Technical Particulars

General
As per Preferred Makes/Manufac-
Make
turers.
Rated Capacity KVAR (*)
Rated voltage V 415
Rated frequency and phases 50 Hz, 3 Phase
Ambient temperature oC v
Cable gland required Yes
Type of cable 1.1 kV, XLPE, Al. Conductor
Size of cable (*)
Cable entry Bottom
Constructional Requirement
Thickness of sheet steel
i) Frame, Frame enclosures, doors co- Mm Cold rolled 2.0
vers and partition
Degree of protection IP 54
Interior: Glossy white
Colour finish shade Exterior: Light Grey Semi Glossy
Shade 631 of IS 5
Material Copper
Earthing bus
Size mm x mm
Earthing Material GI Flat
conductor Size mm x mm (*)
Design Requirement
Insulation level kV (rms) 3.0
Capacitor bank connection Delta

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Short circuit withstands for busbars

kA (rms) 10
i) Short time (1 sec)
(ii)Dynamic kA (peak) 25
Automatic switching responsive to
Type of switching power factor through power factor
sensing relay
Switching steps Minimum 8 steps
Rating of contactor To suit KVAR unit
Incomer switch current rating To suit rated capacity of KVAR
Busbars Copper

7.0 TECHNICAL SPECIFICATION FOR BACKUP SYSTEM:

UNINTERRUPTED POWER SUPPLY (UPS):
The UPS system shall be true on-line static type and the components of UPS shall isolate
power line transients, frequency and voltage variations. The UPS shall provide no-break
power supply to the critical loads under normal conditions, during outages in the input
power and during failure / maloperation of the main components of the UPS by switching
the alternate supply.
Static UPS systems shall be of the type described below:
Non-Redundant UPS with static bypass to regulated supply
The non-redundant UPS shall comprise a solid-state rectifier/ battery charger, battery, a
solid-state inverter, static switches and stand-by regulated AC supply as mentioned in Data
sheet at the end of this section. The three phase AC mains input is fed to the controlled
rectifier via a matching 2 winding Delta-star connected Isolation transformer. The down-
stream inverter converts the DC into a regulated AC. In the event of power sag or failure,
the battery which is connected to the DC link circuit, is called up automatically, without
any interruption, to supply to critical loads. On mains recovery, the rectifier resumes its
function of supplying the inverter and charging the battery. When a fault develops in the
inverter or an overload occurs, the static switch automatically transfers the critical load to
the stand-by AC supply, until manually reset.
The List of Applicable standards is given below:

Basic climatic & mechanical durability tests for components for electronic
IS 9000
and electrical equipment
Environmental tests for electronic & electrical equipment IS 9000
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Transformer and inductors (Power, Audio, Pulse & switching) for electronic
IS 6297
equipment
Printed wiring boards IS 7405
Environmental requirements for semiconductor
IS 6553
devices and integrated circuits
Terminals for electronic equipment IS 4007
HRC Cartridge fuses IS 9224
Indicating Instruments IS 1248
Degree of protection IS 13947
Semiconductor rectifier equipment code IS 6619
Thyristor converters IS 5082
Emergency std by power systems IEEE -446

Surge withstand capability test in accordance with IEC 60255-5

Harmonic levels IEEE -519

Design Requirements
UPS shall be designed in such a way that it shall be compatible to take DC power from DC
distribution board to which battery banks were connected. The total load capacity of the
DC DB shall be designed in such a manner to withstand both loads of DC and UPS. Dedi-
cated feeder to be provided for UPS.
UPS components, i.e., inverter, static switch, by-pass switch, isolation transformer, associ-
ated controls shall be mounted in floor mounted, sheet steel panel. The panels shall be de-
signed for continuous operation for the ambient conditions defined in Technical data sheet.
The battery shall be separately installed in a battery room, alternatively if Sealed mainte-
nance free batteries has been specified and offered, then the same may be integrated with
the UPS panels suitably. In case fans are required for cooling, 100% stand-by shall be pro-
vided to ensure rated output of the UPS.

Rectifier
The rectifier shall essentially be a three phase 6 pulse design with input isolation trans-
former. The rectifier shall be provided with soft start feature. The rectifier shall have fea-
tures for temperature compensation charging of the batteries

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The rectifier shall be capable of supplying the inverter full load, in addition to charging the
fully discharged batteries in 8 hours or as recommended by battery manufacturer and then
maintain the battery on trickle charge mode. The rectifiers shall automatically share the
load during parallel operation in case of common battery, as specified in Technical Data
Sheet.
Inverters
The inverter shall be of PWM (Pulse Width Modulation) type. The inverter system shall be
complete with necessary filters to limit the harmonic distortions to the load. The system
shall have features to prevent deep discharge of battery.
Static Switch
The static switch shall comprise thyristors connected in anti-parallel configuration, ena-
bling loads on each branch circuit to be connected to the inverter of the other branch circuit
or to the stand-by regulated AC supply.
The current rating of the static switch shall be not less than the continuous full load rating
of the branch circuit and short time rating of 750% for 1.0 sec.

Automatic initiation of the transfer from a faulty branch circuit to either a healthy
branch circuit or the stand-by regulated source shall be accomplished during follow-
ing conditions:
 Inverter failure.
 Loss of inverter AC output.
 Load over current (in case of non-redundant UPS with static by pass to regulated sup-
ply).

Regulated Stand-by AC Supply

Regulated stand-by AC supply shall be derived from stand-by source through a 3 ph servo
controlled voltage stabiliser (SCVS) and a 3 ph Delta-Vie connected adequately rated iso-
lation transformer.
The voltage regulation and transient response shall be as specified in Technical Data Sheet.
Circuit Protection
The following devices shall be provided to protect the UPS system:
 AC input circuit breaker to Rectifier unit.

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 AC input circuit breaker to supply stand-by transformer / voltage stabiliser.

 DC circuit breaker for battery output.
 Fast acting semiconductor fuses.
Indications & Annunciation
The UPS system shall be provided with necessary meters, mimic diagram, local indication
/ alarm conditions.
Meters
Meters shall be suitable for semi flush mounting with flanges projecting in vertical panels.
Meters shall have circular 2400C scale, 110 mm square, moving coil (taut band) type, con-
forming to IS: 1248 with accuracy class 0.2 or better.
DC ammeters shall be provided with external shunts. The following meters shall be pro-
vided:
 Voltmeter with selector switch to measure input voltage / stand-by AC supply.
 Ammeter with selector switch to measure input current.
DC Volt meter for rectifier .
 DC Ammeter for rectifier
 Volt meter for inverter output.
 Ammeter for AC output and regulated stand-by AC.
Control & Monitoring
Discrete LED indicators integrated in mimic diagram or multi line alpha numeric text dis-
play unit shall be provided for continuous monitoring of the UPS operation. The UPS con-
trol system shall be fully compatible for remote operation via communication link Vendor
to indicate the type of communication protocol supported by the system along with the
details of links provided in the system. The control system shall operate on Windows or
equivalent Platform. The following operating conditions shall be annunciated.
Alarm Indication
 System fault
 Rectifier charger failure
 Inverter failure
 Battery under voltage
 Thyristor over temperature
 Fuse failure
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 Over load
 Static transfer to stand-by
 Transfer inhibited
 Over load shutdown
 Emergency shutdown
 Battery circuit breaker / switch open
 AC Main failure
 AC stand-by source mains failure
 Manual bypass ON
 Fan failure
 Asynchronous condition
 Control power failure
 DC ground fault.
 Status Indication on Mimic
 Mains on
 Rectifier on
 Battery on load
 Inverter on
 AC Stand-by source on
 Inverter on –load
 Manual by-pass on
 Load on static by pass.
 Invertor faulty
Harmonics
Necessary input and output filters shall be provided or the Rectifier and Inverter design
shall be such that the harmonics injected back to the source and to the load shall be within
limits specified in IEEE-519 at the point of coupling of the UPS to the system. The fault
level of the system at the point of common coupling shall be as specified in Technical Data
Sheet.
System Earthing

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The VENDOR shall clearly bring out the earthing philosophy to be adopted for the UPS
electronics, protective earthing (PE) and neutral earthing. The requirement of separate clean
earth independent of the plant electrical system earth shall be clearly brought out.
Tests On UPS
 Type and routine tests certificates for all components made use in the UPS system shall
be furnished. Tests for components shall be as per relevant standard specifications
indicated.
 Vendor shall furnish his quality assurance plan for the equipment offered. The quality
assurance plan shall include bought out components and assemblies used in the UPS
system.
 Routine tests on the complete UPS system shall be carried out as per relevant standards
for each major sub-system in the UPS, viz., Rectifier, Inverters, batteries, stand-by
supply etc.
 System tests shall be performed on the completely assembled UPS system. System tests
shall include frequency regulations. Voltage regulation, current limiting feature and
harmonic content tests in addition to the tests to prove the functional requirements such
synchronisation with range of adjustments, transfer of static switches for conditions of
loss of square wave, overload and under voltage conditions
 Type, routine and optional tests covered under clause 7.3 of IEC-60146-4 shall be
conducted on the UPS system in addition to the system tests.
 Endurance test on static switches shall be performed for not less than 10 transfer /
retransfer cycles at full load.
 The complete assembled UPS system shall be operated at rated load under relevant
ambient conditions for not less than 96 hours continuously prior to release for shipment.
Spares
Vendor shall include list of spares with quantities as recommended by him for three years
trouble free operation. The offer shall include list and quantity of Start-Up spares required
for commissioning of the equipment and Essential Spares for one year.
The items and quantities of the above shall include all but not limited to those indicated in
Technical Data Sheet below:
Sr.No. Description Unit Particulars
1.1 Application UPS

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Power rating at load PF 0.8

1.2 kVA (*)
lagging
1.3 Quantity Nos. As per Requirement
1.4 Method of energy storage Nickel Cadmium Battery – 30 Min.
Non-Redundant with static by pass
1.5 Type
to regulated supply
1.6 Installation Indoor, Natural ventilated
1.7 Ambient Temperature (0C) 45
1.8 Relative Humidity % Upto 95 Non-condensing
2.0 ENCLOSURE
2mm, CRCA for doors and 1.6mm
2.1 Sheet steel thickness
CRCA for side covers
Degree of protection as per
2.2 IP-31
IS-13947
2.3 Painting
- Exterior RAL 7032
- Interior Glossy white
2.4 Cable Entry Top
60 – 65 upto 40 kVA
2.5 Acoustic Noise level dBA 60 – 70 above 40 kVA
Measured at a distance of 1m
2.6 Space heater, 240V, 1 Ph Required
3.0 UPS SYSTEM
3.1 Input
Supply voltage V 415
3.1.1 No. of Phases Nos. 3
Frequency Hz 50
Allowable Variation
Voltage % + 10
3.1.2
Frequency % +5
Combined voltage + frequency % 10
3.2 Output
3.2.1 Output voltage V 240
No. of Phases Nos. 1

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AC voltage accuracy (steady + 2% for balanced load

state) + 3% for 20% unbalanced load
3.2.2
Over entire load, load PF & DC (RYB 100%, 80%, 0% or 100%,
voltage range. 100%, 80%
3.2.3 Transient voltage regulation % + 8 at 100% load step
Return to steady state condition
3.2.4 Transient recovery
within 50 ms after disturbance.
3.2.5 Voltage wave from Sinusoidal
Range of adjustment of AC
3.2.6 % + 5 at rated load
output voltage
AC Harmonic content (THD-
3.2.7 % 5 Total, 3 for any single harmonic
Voltage)
Phase displacement for three 1200 + 10 for balance load 1200 +
3.2.8
phase output 30 for 20% unbalanced load.
3.2.9 Nominal frequency Hz 50
Frequency regulation (Without
3.2.10 Hz + 0.1
Static by-pass source)
Frequency regulation (With static
3.2.11 Hz ±2
by-pass source)
3.3 AC standby supply
Servo controlled voltage stabi-
lizer
(SCVS) Rating Overload capac-
Required
ity
To match UPS continuous rating
Input voltage phase & fre-
10 times rated current for 100mS
3.3.1 quency %
415V + 10% 3 ph 3 wire 50 HZ
Percentage voltage regulation
+2
Spike
Required.
busters/surge suppressors and in-
put
filters
Isolation transformer Rating In-
To be decided by Vendor
put V
415V
3.3.2 voltage & frequency No. Of Nos
3
phase Hz
50
requency
3.4 Maintenance by pass switch Required.
4.0 RECTIFIER
4.1 Rectifier unit Three phases 6 pulse
4.2 Parallel Operation Required

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Recharge Time on battery boost As per Battery manufacturers recom-

4.3
charge mendation
5.0 INVERTER
% 125 for 10 Min.
5.1 Overload Capacity % 150 for 1Min
% 500 for 5 milli seconds
Synchronising
- Between inverters Required
5.2
- Between inverters
Not required
And standby supply
5.3 Parallel Operation Required
5.4 Synchronising Range 50 ± 2 Hz(adjustable)
6.0 STATIC SWITCH
6.1 Maximum transfer time ms 5 (1/4 cycle)
6.2 Short time current rating % 750 for 1.0 secs.
CIRCUIT BREAKER & LOAD
7.0
BREAK SWITCHES
7.1 Type MCCB / LOAD BREAK SWITCH

NICKEL – CADMIUM BATTERY

Design Features
 Battery offered shall be Nickel Cadmium (Ni-Cd) type. Nickel hydroxide and Cadmium
hydroxide shall be used for positive and negative electrode respectively. Aqueous
solution of Potassium hydroxide with small quantities of lithium hydroxide shall be
used as electrolyte. It shall be used only for ion transfer and shall not chemically change
during charging/ discharging.
 The containers shall be transparent and preferably be made of toughened glass or plastic
and provided with acid level indicator. The battery shall be rated on 5-hour basis and
for the specified ambient temperature. The battery shall have maximum recharge time
of 8 hours.
 Terminal posts shall be designed to accommodate external bolted connection
conveniently and positively. Each terminal post shall have two bolt holes of the same
diameter, preferably at right angles to each other. The bottom hole shall be used to
terminate the inter-cell connection. The top hole shall be left for external terminal
connections. Bolts, heads and nuts, except seal nuts, shall be hexagonal and shall be
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lead covered. The junction between terminal posts and cover and between cover and
container shall be so sealed as to prevent any seepage of electrolyte. Required quantity
of electrolyte for first filling with 10% extra shall be supplied in non-returnable
containers.
 Each battery shall be complete with following accessories, as applicable, that include,
but are not limited to:
 Battery racks
 Porcelain insulators, rubber pads, etc.
 Set of inter-cell, inter-tier and inter-bank connectors as required for the complete
installation.
 Electrolyte for first filling + 10% extra.
 1 set of accessories for testing and maintenance shall also be provided suitable for
all the three battery banks.

-3, 0, +3 volts DC voltmeter with built-in discharging resistor

i. One -
and suitable leads for measuring cell voltage.

Filler hole thermometer fitted with plug and cap and having
ii. One -
specific gravity correction scale.

iii. Three - Pocket thermometers

iv Two - Cell lifting straps

Terminals and cable boxes with glands for connecting cable as
required.
One set Spare connectors
v -
Each of Spare vent plugs
Spare nuts and bolts
Suitable set of spanners

Each battery shall be mounted in a manner that permits easy accessibility to any cell. The
racks shall be suitable for fixing on flat concrete floor. The complete racks shall be suitable
for bolting end to end.
It shall be the responsibility of the Agency to provide batteries of adequate capacities to
meet specified requirements pertaining to control, indication annunciation, etc. and emer-
gency lighting. For computing battery capacity, it shall be assumed that the battery is fully
charged at the beginning of loading cycle and is discharged to a voltage of 1.2 volts per cell
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at the end of the loading cycle. The battery shall have minimal difference (approx. 0.3 V
per cell) between float and boost charging voltages. The Battery Voltage shall be 240V DC.
The specific technical particulars of Nickel Cadmium Battery shall be as given below:
Description Unit Technical Particulars
As per Preferred Makes /
Make
Manufacturers
Type of battery Ni-Cd
Applicable Standards As per Specification
Number of battery banks required As per requirement (*)
Min. Temp. 25° C
Ambient conditions
Max. Temp 45° C
D.C. system voltage V 110
Ampere hour capacity of battery at 27
Deg. C at 5-hour rate to give final cell Ah As per the Requirement
voltage of 1.16 volts/cell
Momentary load/duration A As per the Requirement
Emergency load/duration A To be furnished by the Agency
Continuous load/duration A
Cell voltage - initial/final V 1.42/1.16 V
Number of cells required to give rated
Nos To be furnished by the Agency
voltage
Number of spare cells Nos To be furnished by the Agency
Overall dimensions
Each Cell (L x W x H) To be furnished by the Agency
Complete battery in the rack To be furnished by the Agency
Mounting arrangement Multi-tier
Charging method Float cum boost charging

BATTERY CHARGER AND D.C. DISTRIBUTION BOARD

Applicable Standards
The battery charger and D.C. distribution board shall conform to the latest applicable stand-
ards specified below. In case of conflict between the standards and this Specification, this
Specification shall govern

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Basic climatic and mechanical durability tests

for components for electronic and electrical : IS 9000
equipment

Environmental tests for electronic and electrical

IS:9000
equipment

Metal clad base material for printed circuits for

use in electronic and telecommunication IS:5921
equipment

Transformers and inductors (power, audio, pulse

IS:6297
and switching) for electronic equipment

Printed wiring boards IS:7405

Environmental requirements for semi-conductor

IS 6553
devices and integrated circuits
Terminals for electronic equipment IS:4007
Factory built assemblies of switchgear and
control gear for voltages upto and including IS:8623/BS: 5486 / IEC:439
1000 V AC and 1200 V DC
Air break switches IS : 13947 (Part –3)BSEN 60947-3
Miniature circuit breakers IS 8828/BSEN:60898
HRC cartridge fuses IS:9224/BS:88
Contactors IS:13947 (Part – 3) /BS:775/ IEC:158-1
Control switches/push buttons IS:6875
Indicating instruments IS:1248/BC:89/ EC:51
Degree of Protection IS:13947- (Part 1) /IEC:947-1
Climate-proofing of electrical equipment BSCP:1014

Code of practice for phosphating iron and steel IS:6005/BS:3189

Semi-conductor converters IEC:146
Semi-conductor rectifier equipment safety code IS:6619

Specification for copper rods and bars for

IS : 613
electrical purposes

Battery Charger

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Battery charger shall be combined float-cum-boost type. The charger shall be static type
composed of silicon controlled rectifiers (SCRs) and diodes connected in three phase full
wave half controlled bridge circuit. The rectifier transformers for float and boost chargers
shall be indoor dry type, double wound with delta-star connections. The Agency shall as-
certain if taps are required and provide adequate number of primary and secondary taps, if
necessary.
 The float charger shall be designed for supplying :
 The D.C. loads specified, i.e. continuous load and short-time overload.
 The trickle charging current of the battery.
 The boost charger shall be designed for supplying the boost charging current of the bat-
tery.
If the battery and charger are to be supplied by separate Agency, the charger Agency shall
coordinate with the battery. Agency regarding the float/trickle and boost charging current
and voltages required by the battery,
 Performance
 Float Charger
The D.C. output voltage during float charging shall be stabilised within ±1% of the set DC
bus voltage. There shall be provision for manual control if auto mode fails.
Boost Charger
For boost charging the discharged battery after a mains failure, the rectifier shall charge the
battery at high rate limited to the maximum boost charging voltage. After a specified num-
ber of hours (adjustable) when the rated cell voltage is reached, the charger shall be returned
to float charge status.
In case of combined float-cum-boost charger, the switching and control of high rate charge
and return to float charge shall be by automatic controller/regulator. There shall be provi-
sion for manual control if auto-mode fails.
During boost charging, following emergency measures shall be provided:
 If the AC mains supply fails, an arrangement shall be made to automatically connect the
battery directly across the load.
 If the separate or spare float charger supplying D.C. load fails, the load shall be fed from
the point of connection at the tapping of the battery via adequately rated blocking diodes.
The specific technical particulars of Battery charger shall be as given below:

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Description Unit Technical Particulars

General
As per Preferred Makes /
Make
Manufacturers
Applicable Standards As per Specification
Number required
(i) Battery charger Nos (*)
Rated Output voltage (DC) V 110
Rated Output kW (*)
DC System Earthing Unearthed
Voltage regulation from no load to
% ±1
rated load
Ambient Design Temperature Deg. C 45° C
Busbar material & size - Copper, size as per Requirement
Overall dimensions To be furnished by the Agency
Battery Details
Float/Trickle charging current of
A (*)
battery
Boost Charging Current of Battery
A (*)
(Maximum)
Boost Charging Voltage of Battery
V 142
(maximum)
Maximum Time for Boost charging
hr 5
of Battery
Ah (*)
Battery capacity & no. of cells
Nos. (*)
AC System Data
Supply
V 415
Voltage
Nos. 3
Phase
(i) Variation in supply Voltage % ± 10
(ii) Variation in supply frequency % ±5
Short Circuit level kA 40
Type of Earthing Solidly Earthed
Performance

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DC voltage setting adjustment for

±10% of nominal voltage
float charger
Voltage stabilisation for constant ±1% of set D.C. voltage, with AC
voltage input variation and DC load variation
regulator from 0 to 100%

Maximum permissible variation

± 1%
in DC voltage (no load to full load)
D.C. voltage setting adjustment for
70% to 100% of max. boost charging
boost
voltage
charging
D.C. current adjustment for boost 30% to 100% of max. boost charging
Charging current
Current stabilisation for constant
± 2%
current regulator for boost charger
Minimum permissible power factor
0.8
to rated continuous load

Permissible ripple content at rated

3% (maximum)
continuous load
Relay for auto changeover from
Float to boost mode to be provided
Yes
(in case of float-cum-boost
charger)
Constructional Features
Thickness of sheet steel Frame,
Frame
mm Cold rolled 2.0
enclosures, doors, covers and parti-
tion
Degree of protection IP 42
Interior : Glossy white
Colour finish shade Exterior : Light Grey Semi Glossy
Shade 631 of IS 5
Earthing bus
Copper
Material mm x mm
(*)
Size
Earthing conductor
GS
Material mm x mm
(*)
Size
Cable entry Bottom
Cable Sizes

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(i) Battery sq.mm As per the Requirement

(ii) DC output sq.mm As per the Requirement
(iii) AC input sq.mm As per the Requirement

Charger Panel and D.C. Distribution Board

 Battery charger panel and D.C. distribution board shall be sheet metal enclosure free
standing type with cable entry from bottom.
 Indications, controls and output voltage setting adjustments shall be on front panel. The
Agency shall submit a scheme for alarm and trip indication lamps on the cabinet and for
fault annunciation contacts paralleled for remote annunciation.
 The components shall be liberally rated and housed in a well ventilated sheet metal cu-
bicle complete with input and output terminals. Louvers shall be provided for ventilation
backed up by fine wire mesh so that the degree of protection shall be equal to or better
than IP- 42.
 Busbars shall be of copper conductor of hard drawn (HD) and high conductivity. Busbars
shall be fully insulated by encapsulation in epoxy resin with moulded caps protecting
all joints
 All printed circuit cards shall be plug-in type, interlocked to prevent insertion in a wrong
slot. Each card shall have LED indication on its front plate to indicate normal condition
and readily and marked test pins.
 All components shall be accessible to the maintenance technician for easy disassembly
and replacement. Access to parts of equipment shall be with minimum danger from all
hazards.
 All components and modules shall be clearly and unambiguously marked and all wiring
colour-coded and tagged.
 All power and control wiring within the cubicle shall be done with stranded copper
wires. The power wiring shall be adequately sized for the required rating. The minimum
sizes for control wiring will be 1.5 mm2 and for power wiring shall be 2.5 mm2.
 Ground terminals with isolating links shall be provided.
 Cable glands shall be provided to suit the incoming and outgoing cables.
Components/Accessories

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Amaravati Development Corporation Limited

 The main items are listed below. However, additional items required for completeness
or to meet the specified performance or operational requirements of the charger, shall be
deemed to be included in the Agency scope. Instead of incoming ON/OFF switches,
stricker fuses and contactors, the Agency may provide suitably rated 3 pole MCBs with
overload and short circuit protection and auxiliary contacts.
 One (1) set - Three phase full wave half controlled bridge rectifier circuit comprising
silicon controlled rectifiers and silicon diodes complete with resistor/capacitor network
for surge protection. The diodes/SCRs shall be individually protected by fuses with fuse
fail indication.
 One (1) Double wound, dry type, three phase suitably rated mains transformer.
 One (1) set of suitably rated control transformers for electronic controller.
 One (1) Electronic controller comprising of power supply card, soft start cum current
limit card, auto trickle mode card with facility for setting trickle charge current and
monitoring battery current, error amplifier cards and pulse generating cards for achiev-
ing the DC output voltage stabilisation of ±1% and also for achieving current limiting
feature. The electronic controller shall have protection features with indications for un-
der-voltage, over-voltage, set output voltage and phase failure or voltage unbalance.
 The electronic controller shall be provided with following features.
 Boost current stabilisation of ±2% with AC input variation of voltage and frequency
variation of ±10% and ±5% respectively.
 Boost charge current limiter with potentiometer to adjust the setting.
 Adequately sized necessary built-in accessories shall be provided such that on failure of
the controller in auto mode the voltage can be effectively controlled manually.
 One (1) Filter circuit comprising of smoothing choke and condensers complete with
HRC fuse with trip indication for filter condenser circuit.
 One (1) Auto/Manual selector switch for selecting the mode of operation of the control-
ler.
 One (1) front panel mounted potentiometer for set point adjustment of output voltage in
auto mode.
 One (1) front panel mounted potentiometer for manual adjustment of voltage in manual
mode.
 One (1) TP AC ON/OFF switch for float charger incoming.
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 One (1) set of HRC fuses complete with fuse fittings for AC input with suitable ratings
and with trip indication.
 One (1) set of the pilot lamps with series resistors to indicate float charger AC Mains
‘ON’ condition.
 One (1) AC contactor with suitably rated coil and three main and 2 NO + 2 NC auxiliary
contacts, suitably rated thermal overload relay and ON/OFF control switch.
 One (1) set of HRC fuses complete with fuse fittings for the DC output, and with trip
indication.
 One (1) moving coil DC ammeter, with shunt, of size 96 x 96 mm and suitable range to
read the float charger output current.
 One (1) Double pole DC ON/OFF rotary switch for float charger output.
 One (1) pilot lamp with series resistor to indicate float charger DC ‘ON’ condition.
Power Electronic Components
 Diode and thyristors shall be of monocrystalline type silicon, capable of continuous out-
put at specified voltages. It shall have high power efficiency.
 If many diode or thyristor assemblies are connected in parallel, care shall be taken to
ensure that each rectifier or thyristor operates within its rating and shares the load uni-
formly. This may be achieved with the help of chokes. Also, care shall be taken to select
matched pairs of rectifier heat sink units.
 Each diode or thyristor built in a multi-built assembly shall be provided with a short
circuit protection to avoid complete shut-down of the equipment because of a fault on
single unit. Suitable fuses shall be provided for such protection.
 Necessary spare capacity shall be built in the equipment to continuously supply full load
even with one unit out of circuit.
 The diodes or thyristor banks shall be natural air cooled.
 The diodes or thyristors shall be protected against overvotage due to chopping surges
with the aid of snubbers (i.e. resistor-capacitor combination and Metal oxide varister).
It shall be ensured that normal load currents and especially fault currents are shared
equally between parallel links, within the specified limits. To achieve this, great care
shall be taken to design the layout of the rectifier links to ensure equal lengths of busbars
and as near as possible identical contact resistance in each current path.

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The specific technical particulars of Charger Panel & DC Distribution Board shall be as
given below:
Description Unit Technical Particulars
General
As per Preferred Makes /
Make
Manufacturers
Applicable standards As per specification
DC System voltage V 110
DC Bus Load
Total continuous DC load A (*)
Short time loads (Additional to
continuous loads)
(i) DC lights/Facia lamps A (*)
(ii)Starting current and duration A (*)
of Largest Connected DC Motor Secs (*)

Bus bar material and rating Copper , size as per Requirement

Constructional Features
Thickness of sheet steel Frame,
Frame enclosures, doors, covers mm Cold rolled 2.0
and partition
Degree of protection IP 54
Interior : Glossy white
Colour finish shade Exterior : Light Grey Semi Glossy
Shade 631 of IS 5
Earthing bus
Copper
Material mm x mm
(*)
Size
Earthing conductor
GS
Material
Size mm x mm (*)
Cable entry Bottom
Cable Sizes
(i) Battery sq.mm (*)
(ii)DC output sq.mm (*)
(iii) AC input sq.mm (*)

TECHNICAL SPECIFICATIONS FOR HT & LT INDUCTION MOTORS

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Motors Rated 175kW & below shall be suitable for 415V, 3 Phase, 4 Wire, 50Hz, Solidly
Earthed System and remaining motors are to be designed for 6.6KV system.
The Motors Shall be of Reputed and Reliable make and the same shall be subject to ap-
proval of PURCHASER.
Performance and Characteristics
 HT & LT induction motors shall conform to IS: 325/IS:9283. The motor shall be three
phase squirrel cage induction type with non-overloading characteristics, energy efficient
motors.
 Motors shall be capable of giving rated output without reduction in the expected life
span when operated continuously under the following supply conditions:
 Variation of supply voltage ±50%
 Variation of supply frequency ±50%
 Combined voltage and frequency variation ±50%
 The starting current of motor shall not exceed 130% of rated full load current for VFD
starting under any circumstances.
 Motors shall be suitable to operate with Variable Frequency Drives.
 Motors shall be capable of starting and accelerating the load with the applicable method
of starting, without exceeding acceptable winding temperatures, when the supply volt-
age is in the range 85% of the rated motor voltage.
 Motors shall be designed to withstand 120% of rated speed for two minutes without any
mechanical damage, in either direction of rotation.
 The motor vibrations shall be within the limits specified in the relevant standard.
 Except as mentioned herein, the guaranteed performances of the motor shall be met with
tolerances specified in applicable standard, IS: 9283-1979.
 The enclosure for motor shall be IP-68.
 Minimum three number thermistors in series are to be provided to sense the stator wind-
ing temperature.
 Bimetallic thermal switch to trip the motor against increase in temperature shall be pro-
vided.
 The power rating of the motor shall be larger of the following:
 115% of the power input to the pump at duty point.
 105% of the power input to the pump at 75% head.
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Earthing
Earthing of the motor shall be done in accordance with the relevant provisions of IS:
3043:1966.
For the purpose of earthing these motors, earthing connection may be made to discharge
pipe.
Insulation
The stator winding shall be made from high conductivity annealed copper conductor; wind-
ing insulation shall be of class-F insulation, conforming to IS: 325. The stator winding shall
be of high conductivity annealed copper enameled insulated wires conforming to IS: 4800
(Part-VII): 1970 for induction type motors.
Constructional Features
 The motor shall be suitable for continuous duty as well as intermittent duty with or with-
out full submergence of the motor.
 Aluminium die cast rotor to be provided for better starting torque characteristics.
 The electric motor shall be suitable for 10 starts & stops per hour.
 Single phasing and overload protection system shall be provided.
 The motor degree of protection shall be IP68.
 Each motor shall be provided with minimum 25 m length of power & control cables and
15 m length of lifting chain.
 Junction box (i.e.) for terminating power & control cables for each motor.
Induction Motor Characteristics
All motors shall comply with IEC 60034, 60072 and IS-325, 4029, 4722 including stand-
ards referred to therein.
Description Unit Particulars
Type Squirrel cage Induction motor
Rating kW As per BOQ
Rated voltage kV 6.6KV & 0.415
Synchronous speed Rpm As per BOQ
Quantity Nos. As per BOQ

Horizontal/ Vertical (depending on application and

Type of mounting
process requirement)

Duty type Continuous (S1)

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Description Unit Particulars

Method of starting Variable Frequency Drives

Type of system earthing Effectively Earthed.

Class of insulation F
o
Design ambient temperature C 50

Location Indoor

Degree of Protection IP55

Cooling designation IC416
Terminal box LHS – looking from NDE end

External cable details As per BOQ. Aluminum, XLPE, armoured

 Motors shall be energy efficient (Category –2 or better) squirrel cage induction motors
(TEFC type) with degree of protection for enclosure of IP 55. They shall be capable of
starting and accelerating the load for the method of starting, as per SLD without exceed-
ing acceptable winding temperatures, when the supply voltage is 80% of the rated volt-
age. Main conductor and insulation shall be non-hygroscopic and in accordance with
Class F of IEC 60085.
 Motors shall be capable of giving rated output without reduction in the expected life
span when operated continuously under the following supply conditions:
 Variation in supply voltage ±50%
 Variation in supply frequency ±50%
 Combined voltage and frequency variation ±50%
 Motors shall be capable of starting and accelerating the load with the applicable method
of starting, without exceeding permissible winding temperatures, when the supply volt-
age is 80% of the rated voltage. Motors shall be capable of satisfactory operation at full
load at a supply voltage of 80% of the rated voltage for 5 minutes, commencing from
hot condition.
 The Power rating of the motor shall be the larger of the following:
 115% of the power input to the pump at duty point.
 105% of the power input to the pump between 110% to 75% head.

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 Motors shall withstand the voltage and torque stresses developed due to the vector dif-
ference between the motor residual voltage and the incoming supply voltage equal to
150% of the rated voltage, during fast changeover of buses. The duration of this condi-
tion is envisaged for a period of one second.
 The locked rotor withstand time under hot conditions at 110% rated voltage shall be
more than the starting time at minimum permissible voltage by atleast two seconds or
15% of the accelerating time, whichever is greater.
 The motors shall be provided with class F insulation with temperature limited to that of
class B insulation.
 Motors when started with the drive imposing its full starting torque under the specified
supply voltage variations shall be capable of withstanding at least two successive starts
from cold conditions and one start from hot condition without injurious heating of wind-
ings. The motors shall also be suitable for three equally spread starts per hour under the
above referred supply conditions.
Constructional Features
 Motors weighing more than 25 kg shall be provided with eyebolts, lugs or other means
to facilitate safe lifting.
 The motor construction shall be suitable for easy disassembly and re-assembly. The en-
closure shall be sturdy and shall permit easy removal of any part of the motor for in-
spection and repair.
 The rotor bars shall not be insulated in the slot portion between the inner core lamina-
tions for squirrel cage motors.
 All bearings shall be fitted with oil or grease lubricators. Motor bearings shall not be
subjected to any external thrust load. Unless otherwise specified, motor bearings shall
have an estimated life of at least 40,000 hrs. It shall be possible to lubricate the bearings
without dismantling any part of the motor. All terminals shall be of the stud type of
adequate size for the particular duty, marked in accordance with an approved standard
and enclosed in a weatherproof box.
 The equipment shall be thoroughly degreased, all rust, sharp edges and scale removed
and treated with one coat of primer and finished with two coats of grey enamel paint.
Terminal Box

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 Terminal boxes shall be of weather proof construction designed for outdoor service. To
eliminate entry to dust and water, gaskets of neoprene or approved equivalent shall be
provided at cover joints and between box and motor frame. It shall be suitable for bottom
entry of cables. It shall be capable of being turned through 360 degree in steps of 90
degree.
 The terminals shall be of the stud type with necessary plain washers, spring washers and
check-nuts. They shall be designed for the current carrying capacity and shall ensure
ample phase to phase and phase to ground clearances. Suitable cable glands and cable
lugs shall be supplied.
 Separate terminal boxes shall be provided for each of the following:
 Stator Leads
 Space Heaters
Accessories
Drain Plugs
Motors shall be provided with drain plugs, so located to drain water, resulting from con-
densation or due to other causes, from all pockets in the motor casing.
Heating during Idle Period
 For motors rated below 30 kW, during idle periods, the stator winding will be connected
to required single phase, 50 Hz, AC supply for heating and elimination of moisture. The
supply will be connected between any two terminals.
 Motors rated 30kW and above shall have space heaters suitable for 230V, single phase,
50 Hz, AC supply. Space heaters shall have adequate capacity to maintain motor internal
temperature above dew point to prevent moisture condensation during idle period. The
space heaters shall be placed in easily accessible positions in the lowest part of the motor
frame.
Earthing Pad
Two independent earthing pads of non-corrodible metal shall be welded or brazed at two
locations on opposite sides complete with suitable bolt and washers for earthing. These
earthing pads shall be in addition to earthing stud provided in the terminal box.
Rating Plate
 The following details, in addition to those specified in applicable standards shall be in-
cluded on the rating plate.

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 Rated voltage, kW rating, frequency, efficiency, power factor, temperature rise of wind-
ings in degree centigrade at rated load, and ambient conditions.
 Type of bearings, recommended lubricant, lubricating interval & re-lubricating quantity.
Tests
Motor shall be subjected to all the type test (one from similar rating of each lot) and routine
tests as per applicable standard, in the presence of the Engineer-in-Charge. Copies of test
certificates for all brought out items shall be furnished at the time of inspection for the
Authority’s approval. The Agency shall ensure to use calibrated test equipment / instru-
ments having valid calibration test certificates from standard laboratories traceable to Na-
tional / International standards.
Air Compressors (Rotary Screw Compressor)
The operation of all valves and instruments will be done electrically. However, if a Com-
pressor system is required for some reason, it shall comprise compressors, after-coolers and
air/dryers, duty/standby air receivers together with control equipment, oil eliminating fil-
ters, flow regulators and oil mist lubricators as required.
Electrically driven screw air compressor sets shall operate up to minimum10 bar working
pressure.
Compressor sets with at least 1 standby shall be provided complete with the following:
 Common base frame for Compressor & Motor
 Single stage air-cooled unit
 Isolating valves
 Air filter and silencer
 Pressure relief valve or excess pressure safety device
 pressure reducing valves
 Pressure gauges
 Pressure tank
 Off loading piston
 Automatic changeover (failure of duty unit)
 drain pipes
 Isolating valve
 Stoppers
 Air-receivers
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 Others necessary appurtenances

Compressors shall be arranged for automatic changeover on failure of the duty unit. Failure
of the duty unit shall initiate an alarm. Control equipment shall include automatic unloading
valves, pressure switches for duty standby and alarm, and lockable changeover switches.
1 Duty & 1 Standby after coolers shall be provided. Water- cooled or air blast types will be
considered. Air receivers shall be designed and fabricated in accordance with relevant ap-
proved standards. They shall be mounted vertically on steel feet so that sufficient space is
allowed for each access to the whole outside surface. Receivers shall be provided with drain
cocks piped to drain pressure gauges and relief and check valves.
Supply of all necessary electrical components, devices, equipment, control panels, etc. to-
gether with cabling, earthing provisions, etc. shall be the responsibility of the Agency.
Interconnecting pipe work shall be arranged to avoid low points, which may trap water.
Unavoidable low points shall be provided with drain cocks piped to waste.
Electric actuators
 The actuators shall be suitable for use on a nominal _volt _ phase Hz power supply and
are to incorporate motor, integral reversing starter, local control facilities and terminals
for remote control and indication connections housed within a self contained, sealed
enclosure.
 In order to maintain the integrity of the enclosure, setting of the torque levels, position
limits and configuration of the indication contacts etc shall be carried out without the
removal of any actuator covers over an Infra red interface. Sufficient commissioning
tools shall be provided with the actuators and must meet the enclosure protection and
certification levels of the actuators. Commissioning tools shall not form an integral part
of the actuator and must be removable for secure storage/authorised release. In addition,
provision shall be made for the protection of configured actuator settings by a means
independent of access to the commissioning tool.
 The actuator shall include a device to ensure that the motor runs with the correct rotation
for the required direction of valve travel irrespective of the connection sequence of the
power supply.
 Actuators shall be suitable for indoor and outdoor use. The actuator shall be capable of
functioning in an ambient temperature ranging from 15 to 45 degree C, up to 100%
relative humidity.

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 Actuators for hazardous area applications shall meet the area classification, gas group
and surface temperature requirements specified in data sheet.
Actuator sizing
The actuator shall be sized to guarantee valve closure at the specified differential pressure
and temperature. The safety margin of motor power available for seating and unseating the
valve shall be sufficient to ensure torque switch trip at maximum valve torque with the
supply voltage 10% below nominal. For linear operating valves, the operating speed shall
be such as to give valve closing and opening at approximately 10-12 inches per minute
unless otherwise stated. For 90 valve types the operating time shall be specified.
Enclosure
Actuators shall be 0-ring sealed, watertight to /IP68 7m for 72hrs, NEMA 4, 6. The motor
and all other internal electrical elements of the actuator shall be protected from ingress of
moisture and dust when the terminal cover is removed for site for cabling, the terminal
compartment having the same ingress protection rating as the actuator with the terminal
cover removed.
Enclosure must allow for temporary site storage without the need for electrical supply con-
nection.
All external fasteners shall be zinc plated stainless steel. The use of unplated stainless steel
or steel fasteners is not permitted.
Motor
The motor shall an integral part of the actuator, designed specifically for valve actuator
applications. It shall be a low inertia high torque design, class F insulated with a class B
temperature rise giving a time rating of 15 minutes at 40°C(104°F) at an average load of at
least 33% of maximum valve torque. Temperature shall be limited by thermostats embed-
ded in the motor end windings and integrated into its control. Electrical and mechanical
disconnection of the motor shall be possible without draining the lubricant from the actuator
gearcase.
Motor protection
Protection shall be provided for the motor as follows:
 Stall - the motor shall be de-energized within 8 seconds in the event of a stall when
attempting to unseat a jammed valve.
 Over temperature - thermostat will cause tripping of the motor. Auto-reset on cooling

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 Single phasing - lost phase protection.

 Direction – phase rotation correction.
Gearing
The actuator gearing shall be totally enclosed in a oil-filled gearcase suitable for operation
at any angle. Grease lubrication is not permissible. All drive gearing and components
must be of metal construction and incorporate a lost-motion hammerblow feature. For ris-
ing spindle valves the output shaft shall be hollow to accept a rising stem, and incorporate
thrust bearings of the ball or roller type at the base of the actuator. The design shall be such
as to permit the opening of the gearcase for inspection or disassembled without releasing
the stem thrust or taking the valve out of service. For 90 operating type of valves drive
gearing shall be self locking to prevent the valve backdriving the actuator.
Hand operation
A handwheel shall be provided for emergency operation, engaged when the motor is de-
clutched by a lever or similar means, the drive being restored to power automatically by
starting the motor. The handwheel or selection lever shall not move on restoration of motor
drive. Provision shall be made for the hand/auto selection lever to be locked in both hand
and auto positions. It shall be possible to select hand operation while the actuator is running
or start the actuator motor while the hand/auto selection lever is locked in hand without
damage to the drive train.
Clockwise operation of the handwheel shall give closing movement of the valve unless
otherwise stated in the data sheet. For linear valve types the actuator handwheel drive must
be mechanically independent of the motor drive and shall be such as to permit valve oper-
ation in a reasonable time with a manual force not exceeding 400N through stroke and
800N for seating/unseating of the valve.
Drive bushing
The actuator shall be furnished with a drive bushing easily detachable for machining to suit
the valve stem or gearbox. input shaft. Normally the drive bush shall be positioned in a
detachable base of the actuator. Thrust bearings, when housed in a separate thrust base shall
be of the sealed for life type.
Torque and turns limitation
Torque and turns limitation to be adjustable as follows:

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 Position setting range – multi-turn: 2.5 to 100,000 turns, with resolution to 15 deg. of
actuator output.
 Position setting range – direct drive part turn actuators: 90 +/-10, with resolution to
0.1 deg. of actuator output.
 Torque setting: 40% to 100% rated torque.
 Measurement of torque shall be from direct measurement of force at the output of the
actuator. Methods of determining torque-using data derived from the motor such as mo-
tor speed, current, flux etc are not acceptable A means for automatic “torque switch by-
pass” to inhibit torque off during valve unseating and “latching” to prevent torque switch
hammer under maintained or repeated control signals shall be provided.
The electrical circuit diagram of the actuator shall not vary with valve type remaining iden-
tical regardless of whether the valve is to open or close on torque or position limit.
Remote valve position/actuator status indication.
 Four contacts shall be provided which can be selected to indicate any position of the
valve, Provision shall be made for the selection of a normally closed or open contact
form. Contacts shall maintain and update position indication during handwheel opera-
tion when all external power to the actuator is isolated.
 The contacts shall be rated at 5A, 250V AC, 30V DC.
 As an alternative to providing valve position any of the four above contacts shall be
selectable to signal one of the following:
 Valve opening, closing or moving
 Thermostat tripped, lost phase
 Motor tripped on torque in mid travel, motor stalled
 Remote selected
 Actuator being operated by handwheel
 Provision shall be made in the design for an additional 4 contacts having the same func-
tionality. Provision shall be made in the design for the addition of a contactless trans-
mitter to give a 4-20mA analogue signal corresponding to valve travel for remote indi-
cation when required. The transmitter will auto range to the set limits
Local position indication
 The actuator display shall include a dedicated numeric/symbol digital position indicator
displaying valve position from fully open to fully closed in 1% increments. Valve closed
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and open positions shall be indicated by symbols showing valve position in relation to
the pipework to ensure that valve status is clearly interpreted. With main power on the
display shall be backlit to enhance contrast at low light levels and shall be legible from
a distance of at least 6 feet (2m).
 Red, green, and yellow lights corresponding to open, closed, and intermediate valve
positions shall be included on the actuator display when power is switched on. The dig-
ital display shall be maintained and updated during handwheel operation when all power
to the actuator is isolated.
 In addition, the actuator display shall include a separate text display element with a min-
imum of 32 characters to display operational, alarm and configuration status.. The text
display shall be selectable between English and one of the following languages: Hindi
or Marthi. Provision shall be made to upload a different language without removal of
any covers or using specialized tools not provided as standard with the actuator. Provi-
sion shall be made to orientate the actuator display through increments of 90degres.
Local torque Indication:
The digital display shall be capable of indicating real time torque and valve position sim-
ultaneously, both being displayed in 1% increments of valve position and actuator rated
torque. In addition, torque shall also be displayed in horizontal bar graph form.
Integral starter and transformer
The reversing starter, control transformer and local controls shall be integral with the valve
actuator suitably housed to prevent breathing and condensation. The starter shall be suitable
for 60 starts per hour and of rating appropriate to motor size. The controls supply trans-
former shall be fed from two of the incoming three phases and incorporate overload pro-
tection. It shall have the necessary tappings and be adequately rated to provide power for
the following functions:
 Energization of the contactor coils.
 24V DC output for remote controls.
 Supply for all the internal electrical circuits.
Local controls

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 The actuator shall incorporate local controls for Open, Close and Stop and a Lo-
cal/Stop/Remote mode selector switch lockable in any one of the following three posi-
tions: local control only, stop (no electrical operation), remote control plus local stop
only. It shall be possible to select maintained or non-maintained local control.
 The local controls shall be arranged so that the direction of valve travel can be reversed
without the necessity of stopping the actuator.
 Provision shall be made to orientate the local controls through increments of 90 degree.
Control facilities
 The necessary control, wiring and terminals shall be provided in the actuator for the
following functions:
 Open and close external interlocks to inhibit local and remote valve opening and/or clos-
ing control. It shall be possible to configure the interlocks to be active in remote control
only.
 Remote controls fed from an internal 24V DC supply and/or from an external supply
between 20V and 120V AC or 20V and 60 V DC, to be suitable for any one or more of
the following methods of control:
1) Open, Close and Stop control.
2) Open and Close maintained or “push to run” (inching) control.
3) Overriding Emergency Shut-down to Close (or Open) valve from a normally closed
or open contact.
4) Two-wire control, energise to close (or open), de-energise to open (or close).
 It shall be possible to reverse valve travel without the necessity of stopping the actuator.
The motor starter shall be protected from excessive current surges during rapid travel
reversal.
 The internal circuits associated with the remote control and monitoring functions are to
be designed to withstand simulated lightning impulses of up to 2kV.
 Provision shall be made for operation by distributed control system utilising the follow-
ing network systems.
1) Modbus
2) Profibus
3) Foundation Fieldbus
4) DeviceNet

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5) Pakscan
Monitoring facilities
Facilities shall be provided for monitoring actuator operation and availability as follows:
Monitor (availability) relay, having one change-over contact, the relay being energized
from the control transformer will de-energise under any one or more the following condi-
tions:
 Loss of main or customer 24V DC power supply
 Actuator control selected to local or stop
 Motor thermostat tripped
 Actuator internal fault
Where specified, provision shall be made for contacts to provide discreet indication of one
or more of the following:
 Remote selected
 Thermostat trip
 Actuator fault
Actuator text display indication of the following status/alarms:
 Closed Limit, open limit, moving open, moving closed, stopped
 Torque trip closing, torque trip opening, stalled
 ESD active, interlock active
 Thermostat trip, phase lost, 24V supply lost, Local control failure
 Configuration error, Position sensor failure, Torque sensor failure
 Battery low, power loss inhibit
Integral datalogger to record and store the following operational data:
 Opening last /average torque against position
 Closing last /average torque against position
 Opening motor starts against position
 Closing motor starts against position
 Total open/closed operations
 Maximum recorded opening and closing torque values
 Event recorder logging operational conditions (valve, control and actuator)
The datalogger shall record relevant time and date information for stored data.

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Datalogger data is to be accessed via non-intrusive IrDA communication. Sufficient stand-

ard intrinsically safe tools shall be provided for downloading datalogger and actuator con-
figuration files from the actuators and subsequent uploading to a PC. The actuator manu-
facturer shall supply PC software to enable datalogger files to be viewed and analysed.
Wiring and terminals
Internal wiring shall be tropical grade PVC insulated stranded cable of appropriate size for
the control and 3- phase power. Each wire shall be clearly identified at each end.
The terminals shall be embedded in a terminal block of high tracking resistance compound.
The terminal compartment shall be separated from the inner electrical components of the
actuator by means of a watertight seal and shall be provided with a minimum of 2 threaded
cable entries with provision for a maximum of 4.
All wiring supplied as part of the actuator to be contained within the main enclosure for
physical and environmental protection. External conduit connections between components
are not acceptable.
A durable terminal identification card showing plan of terminals shall be provided attached
to the inside of the terminal box cover indicating:
The code card shall be suitable for the Agency to inscribe cable core identification along-
side terminal numbers.

TECHNICAL SPECIFICATIONS FOR VARIABLE FREQUENCY DRIVES

The rating of motors in the pumping stations will be on higher side. To limit the starting
current of the motors and minimize mechanical jerk on motor and pump shaft, it is proposed
to install VFD for the motor starting purpose. VFDs are proposed in this installation con-
sidering the reliability and advantages in operation post consideration of losses in the VFD
drive. The smooth and trouble free starting is envisaged.
APPLICABLE STANDARDS:
The specified VFD shall be designed and materials shall be furnished in accordance with
the latest revisions of applicable sections of the following Codes and Standards.
International / European Standards for Design and Construction
IEC/EN 60071-1: Insulation coordination - Part 1: Definitions, principles and rules
IEC / EN 60146: Semiconductor Converters

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IEC / EN 60664-1 Insulation coordination for equipment within low-voltage

systems - Part 1: Principles, requirements and tests
IEC / EN 61800-4 Adjustable speed electrical power drive systems-Part 4: General
requirements – Rating specifications for a.c. power drive systems above
1 000 V a.c. and not exceeding 35 kV
IEC / EN 61800-5-1 Safety requirements electrical thermal and energy
IEC 62103 Electronic equipment for use in power installations (EN 50178)
IEC 62271-200 High-voltage switchgear and controlgear – Part 200: AC metal-enclosed
switchgear and controlgear for rated voltages above 1 kV and up to and
including 52 kV
International / European Standards for Transformers
IEC 60146-1-3 Semiconductor Converters – General requirements and line commutated
converters – Part 1-3: Transformers and reactors
IEC 61378-1 Converter transformers – Part 1: Transformers for industrial applications

EMC Standards
CISPR 22 Cl A Information technology equipment - Radio disturbance characteristics;
Limits and methods of measurement
IEC / EN 61000-2-4 Electromagnetic compatibility (EMC) – Part 2-4: Environment
– Compatibility levels in industrial plants for low-frequency conducted
disturbances
IEC / EN 61800-3 Adjustable speed electrical power drive systems - Part 3: EMC
requirements and specific test methods

Environmental Standards
IEC / EN 60721-3-1 Classification of environmental conditions – Part 3: Classification of
groups of environmental parameters and their severities – Section 1:
Storage
IEC / EN 60721-3-2 Classification of environmental conditions – Part 3: Classification of
groups of environmental parameters and their severities – Section 2:
Transport

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IEC / EN 60721-3-3 Classification of environmental conditions – Part 3: Classification of

groups of environmental parameters and their severities – Section 3:
Stationary use at weather protected locations

American Standards
IEEE 519 Guide for Harmonic Control and Reactive Compensation of Static
Power Converters
IEEE 958 Guide for Application of AC Adjustable Speed Drives on 2400-13800
V auxiliary systems in electric power generating stations
IEEE 1566 Standard for Performance of Adjustable Speed AC Drives Rated 375
kW and Larger
IEEE C57.12.00 General Requirements for Liquid-Immersed Distribution Power and
Regulating Transformers
IEEE C57.12.01 General Requirements for Dry-Type Distribution and Power
Transformers
IEEE C57.18.10 Practices and Requirements for Semiconductor Power Rectifier
Transformers
ICS7.1 NEMA Safety standard for construction and guide to selection,
installation and operation of Adjustable Frequency Drive Systems

Configuration

Frequency drives shall have one of the two configurations given below:

a) Current source inverter.

b) Voltage source inverter.

Smoothing Reactors for Current and Voltage Source Inverter

a) The smoothing reactor shall be sized to avoid conditions of discontinuous current
Operation of the frequency converter at its lowest frequency of operation, which shall not
be less than 5 Hz.
The smoothing reactor shall be uniformly insulated and shall be protected for voltage
surges occurring during sudden load throw-off.

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The smoothing reactor shall be made from electrolytic grade copper/aluminium and shall
be epoxy encapsulated with suitable class of resin decided from techno-economic consid-
erations and performance requirements in conformity with IEC-146.
Inverter
The inverter system suitable for three phase output shall consist of the following subsys-
tems:
 The basic inverter circuit consisting of the switching device say
Thyristors/Transistors/IGBT/MOSFET, connected so as to supply three phase power.
 The logic network to enable rapid transition of the main inverter switching devices
from on-state to off-state.
 Suitable feedback system to allow balance of reactive power flow during load power
factor fluctuation as well as regeneration.
 The filter system of the inverter output to suppress 5th, 7th, 11th, 13th harmonics at
the output of the inverter to less than 5% of the fundamental amplitude.
 The ripple control system to limit current ripple to 4% at the input terminals of the
inverter caused by distorted current output.
 The output frequency of inverter shall be controlled to within the limits.
Inverter for AC drive
CURRENT SOURCE INVERTER
a) Constant Torque Operation
The current output by the DC link shall be accurately monitored so that the ratio of the
terminal voltage of the motor and the corresponding frequency remains constant. Necessary
protective features for tripping the frequency converter, alarm/annunciation and fault diag-
nostics shall be provided.
b) Constant Horsepower Operation
In this type of operation, the motor’s internal voltage shall be maintained within + 1% while
the frequency of the inverter is varied to meet the duty cycle requirements. Necessary pro-
tective features for tripping the frequency converter, alarm/annunciation and fault diagnos-
tics shall be provided.
VOLTAGE SOURCE INVERTER
a) Constant Torque Operation

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The DC voltage input to the inverter shall be accurately monitored to maintain the ratio the
terminal voltage of the motor to frequency at the rated/design value. The DC voltage input
shall be maintained within + 1% of the required value. Shall this fall for any reason, neces-
sary action for tripping the frequency converter, and initiation of annunciation/alarm and
fault diagnostic shall be provided.
b) Constant Horsepower Operation
In this type of operation, the voltage at the terminals of the motor shall be maintained within
+1% of the rated value while the frequency of the inverter is varied to meet the duty cycle
requirements. Necessary protective features for tripping the frequency converter, initiation
of alarm/annunciation and fault diagnostic shall be provided.
Output Overcurrent Limit
Unless otherwise stated, the inverter shall be capable of being temporarily overloaded to
150% of its full load ampere capacity for sixty (60) seconds beyond which a current limit
action shall be initiated and an alarm contact initiated for annunciation.
Control Modules
 All elements of the control system shall be mounted on epoxy laminate boards and
each board shall be a plug in module mounted on a standard nineteen inch rack which
shall be accessible from the front. Each card shall have LED indication on its front plate
to indicate normal condition of the card. Readily accessible and clearly marked test
pins shall be provided at the important points on the cards to enable signal analysis.
 The epoxy laminates shall be free from manufacturing errors and shall be designed to
prevent incorrect insertion in the card rack. The copper side of the card shall be
suitably lacquered to prevent oxidation. The gap between two cards shall be sufficient
to permit adequate ventilation.
 Adjustments susceptible to change by accidental contact shall be lockable.
Control and performance Requirements
VFD operational range shall be 25Hz to 50Hz to control the motor speed.
Short time voltage dips upto 80% of nominal (e.g. in case of large motor start-up connected
to same bus) shall not cause the control system to stop functioning and shall not trip the
drive system.

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The drive motor shall be speed regulated corresponding to 4-20mA or 0-10V reference
input signal. Upon complete loss of users speed reference signal, the drive shall automati-
cally run at constant speed as determined by the last speed reference available prior to loss
of the signal.
The required provision for interfacing with PLC/DCS, including details of communication
module and data transfer facility, I/O details shall be furnished by the Bidder.
 The VFD shall run with a sensorless torque control algorithm with static speed error
of less than 0.2% and torque step rise time of less than 10 milliseconds.
 Unless specified, the VFD shall not require the use of a speed encoder.
 Drive shall have minimum 24 pulse configuration.
 To use auto-restart and / or Flying start instead of power loss ride-through function
is not allowed.
 The VFD shall be able to catch and take control of a spinning load if started while
rotating equipment is already spinning. Appropriate safeguards shall be included in
this operation to prevent damaging torque excitations, voltages or currents from
impacting any of the equipment. The user shall have the option of employing this
feature or disabling it.
 The VFD shall be able to control the motor current from 0 Hz to maximum motor
frequency and provide a “soft start” torque profile for the motor-load combination.
 The VFD shall provide current and torque limit adjustments to limit the maximum
VFD output current and the maximum torque produced by the motor.
 The VFD shall accept a start/stop command and speed reference from a local VFD
panel, or from a remote panel.
 Each VFD shall be equipped with a front mounted operator control panel consisting
of a back lighted alphanumeric display and a keypad with the functions:
 Run/Stop command
 Local/Remote command
 Speed Increase/Decrease command
 Menu navigation and parameter selection
 All parameter names, fault messages, warnings and other information shall be
displayed.

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 During normal operation, the speed reference, run/stop, forward/reverse and

local/remote status shall be displayed. At least 3 additional user selectable analog
values shall be available for display including the following values as a minimum:
 Motor speed, current and power
 Output frequency, voltage and torque
 DC bus voltage
 Values of analog input and output signals
 Status of discrete inputs and outputs.
 Password protection shall be available for prevention of unauthorized parameter
access.
 If specified, hardware inputs and outputs shall be provided to interface with external
operator and supervisory control and monitoring equipment. The following
galvanically isolated I/O points shall be included:
 Discrete (binary) inputs shall be designed for 24 VDC. Discrete input functions shall
include ‘Run/Stop’, ‘Disable Local’ (to prevent unauthorized operation from the local
panel) and ‘Remote Reset’ (minimum 4 channels).
 Analog outputs shall be 4 to 20 mA signals. Analog outputs shall be programmable to
provide signals proportional to at least output motor speed, current, torque or power
(minimum 3 channels).
 Relay contact outputs shall be rated to switch in minimum 3 A at 24 VDC or 230 VAC.
Function selections shall include ‘VFD ready’, ‘Running’, ‘Alarm’ and ‘Trip’
indications.
If specified in Buyer’s Datasheet, serial fieldbus communication interface modules shall be provided.
Microsoft Windows based software shall be provided for VFD commissioning, parameters setup, fault log
viewing, diagnostic analysis, monitoring and control. The software shall provide real time graphical displays
of VFD performance.
Protection
 Protection of Power Semiconductor
 Each power semiconductor shall be protected against short circuit. The fuse shall be
sized so that its I2t does not exceed the I2t characteristic of the power semiconductor
itself. The voltage and current rating of the fuse shall match the duty on the power
semiconductor. The arc voltage, due to melting of the fuse shall not exceed the
repetitive peak reverse voltage of the power semiconductor.

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 All fuses shall have a trip indicator to operate a suitable microswitch with at least 1
NO + 1 NC potential free contacts for annunciation and/or tripping.
 A fast tripping feeder circuit breaker shall be used in case fuses for short circuit
protection of thyristors are not used.

 Protective Systems for AC Inverter Drive

 Fuses for all power semiconductors and/or other devices like commutation chokes,
capacitors etc. which are not adequately protected against flow of abnormal currents.
 Under voltage and over voltage protection on the input side. Loss of input voltage to
inverter shall entail tripping of the inverter.
 Protection for all control cards, power supply stabilisers, filter circuits etc. Protection
shall be provided such that failure of a part does not cause damage elsewhere in the
system.
 Polarising relay to prevent reversal of polarity on the input side of the inverter.
 Protection of inverter thyristor, commutating circuits and other inverter elements
during regenerative operation of the inverter and also during sudden load throw-off.
 Current limit fuses at the output of the inverter.
 Commutation circuit undervoltage
 Inverter overfrequency
 Programmable overcurrent
 Phase sequence/loss of phase protection
 Earth fault protection
 DC link overvoltage protection
 Specific motor protection
 Incoming line surge protection
 Ventilation Loss
 Over temperature
Cooling of Power Converters
Power semiconductors shall be mounted on heatsink which can be individual or common to a number of de-
vices. Adequate provision for clamping and mounting the power semiconductors shall be available. Cooling
of power semiconductors can either be natural air cooled or forced air cooled. The Agency shall recommend
the type of cooling. However, for power converters which exceed capacities of 2kA continuous load, alterna-
tive cooling methods as oil or water cooling shall be considered. The power semiconductors shall preferably

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be double side cooled.

Switching Devices
Switching devices such as circuit breakers, isolators, contactors, switch-fuse units etc. shall be considered in
the scope of supply. The switching devices shall be enclosed in a separate enclosure forming the set of panels
for the power converters. They shall have adequate clearance both with adjacent devices and metalwork at
earth potential. Connection between devices shall be by adequate size of electrolytic grade of copper/alumin-
ium strips. These connections shall be adequately braced and insulated.
Constructional Features
The controller shall have modular construction to facilitate maintenance.
 Bus bars
 Power connections shall be of the bolted type and mating surfaces shall be tinned.
 The bus bars running to various converters shall be suitably designed to ensure equal
sharing between the parallel strings and prevent mechanical stress on the fuse.
 All bus bars shall be adequately insulated for full circuit voltage by insulating tapes
and similar insulating material.
 In case aluminium bus bars are specified, care shall be taken to ensure that bimetallic
connections are provided wherever necessary.
 All cubicles shall have copper earth buses of adequate size running the entire cubicle
height along the sides.
 Cubicle
 Cubicles housing the power semiconductors and drive level control system shall
conform to IP 42 degree of protection to enclosures.
 Panels shall be free standing, floor mounting type and shall comprise rigid welded
structural frames enclosed completely with cold rolled sheet steel of thickness no less
than 2.5 mm for front and rear portions and 2.0 mm for sides, top and bottom portions.
There shall be sufficient re-inforcement to provide level surfaces, resistance to
vibrations and rigidity during transportation and installation.
 All doors, removable covers and panels shall be gasketed all round with neoprene
gaskets. Ventilating louvers shall have screens and filters. The screens shall be made
of either brass or GI wire mesh.
 Design, material selection and workmanship shall be such as to result in a neat
appearance inside and outside with no welds, rivets or belt heads apparent from
outside, with all exterior surfaces true and smooth.

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 Painting
 All sheet steel work shall be phosphated in accordance with the following procedure
and in accordance with IS: 6005 “Code of Practice for Phosphating Iron and Steel”.
 Oil, grease, dirt and swarf shall be thoroughly removed by emulsion cleaning.
 Rust and scale shall be removed by pickling with dilute acid followed by washing with
running water, rinsing with slightly alkaline hot water and drying.
 After phosphating, thorough rinsing shall be carried out with clean water followed by
final rinsing with dilute dichromate solution and even drying.
 The phosphate coating shall be followed by the application of two coats of ready mixed
stoving type zinc chromate primer. The first coat may be “flash dried” while the
second coat shall be stoved.
 After application of the two coats of primer finishing synthetic enamel paint shall be
applied, each coat followed by stoving. The second finishing coat shall be applied after
completion of tests.
 The final finished thickness of paint film on steel shall not be less than 100 microns and
shall not be more than 150 microns.
 Finished painted surface of panels shall present an aesthetically pleasing appearance
free from dents and uneven surface.
 A small quantity of finishing paint shall be supplied for minor touching up required
at site after the installation of the panels.
 Bins and Printed Circuit Cards
 Individual bins shall be mounted on a swingable frame so that the connections at the
rear are also accessible.
 Self retaining thumb head screws shall be needed for holding the bins in position.
 Adequate number of card/bin extenders for testing of PCBs shall be provided, each
with flexible cables at least two metres long. These extenders shall be of a universal
type suitable for use with any card / bin as the case may be.
 All adjustments which are to be made while changing a card shall be outside in a
separate module preferably plugged into the regulator bin.
 Locking of individual cards in a bin shall preferably be through self retaining thumb-
head screws.

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 Control modules shall be in the form of plug in packages, plugged into a module bin.
Each plug in unit shall consist of a strong frame on which a printed circuit board would
be permanently screwed.
 The plug connections shall only be of the pin type.
 The printed circuit board (P.C.B.) shall be made of glass fibre filled with epoxy
laminates. The plug in unit shall be screwed to the basic socket in the module bin with
long through bolts and knurled heads.
 The front plates of the plug in unit shall have the switches, the potentiometers,
miniature monitoring meters, test points etc. Each plug in unit shall have its own
identification legend.
 All plug in units shall be polarised to prevent incorrect insertions into the module bin.
 The gap between two plug in units inside a bin shall be sufficient to permit adequate
ventilation.
 The copper side of the printed circuit board shall be lacquered to prevent oxidation.
 Each side of the printed circuit board shall have a shield cover to prevent inter circuit
and external interference.
 The P.C.B. shall be mounted on P.C.B. guides fixed on standard racks and the shield
properly grounded.
 Control circuit test points shall be easily accessible for monitoring and maintenance.
 Annunciation
 The annunciator shall work on DC power supply.
 Each annunciator window shall have two lamps connected in parallel which operate
at not more than 75% of their rated voltage.
 Window shall be arranged in a logical group.
 The annunciator shall have a module construction with glass epoxy plug in cards.
 Alarm bell/siren shall be continuously rated and shall have a series resistance.
 The annunciator shall have the following facilities.
a) First in sequence, memory reset.
b) Fleeting faults shall be memorised.
c) Test Feature.
 There shall be a three-tier system of protection and annunciation:
a) Alarm both audible and visual.

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b) Warning with delayed shut down –time delay through a timer of range 0-60 sec.
c) Disturbance associated with failures of systems elsewhere.
 Meters
 Individual meters shall be provided for speed reference, speed feedback, current
reference, current feedback, pulse output, and regulated power supply voltages.
 All meters shall be identical and fed through individual buffer I.C. amplifiers.
 All meters shall be the circular scale type having a full scale deflection of 2700.
 All meters shall conform to at accuracy class 0.2
 All meters with their individual buffer amplifier cards shall be housed in separate bin.
It is recommended that the buffer amplifiers all be housed on a single/two card/s and
this card/s be itself/themselves housed in the regulator bin.
 Sensitive signal leads in that case will not have to traverse from one bin to another,
only noise insensitive buffer amplifier output leads will need to go to the meter bin.
 Selector switches if used with any meters shall have pistol grip handles.

 Wiring
 Stranded, flexible copper cable of 2.5 sq.mm shall be used for C.T. circuits and 1.5
sq.mm for other control circuits. However, for PCB terminals 0.75 sq.mm may be
accepted.
 Ultra-flexible cables shall be used for all connections from a fixed part to a movable
member. In addition, a hanging loop of sufficient length shall be provided to avoid
any cable stressing.
 All terminal boards for outgoing connections shall be at a height of at least 250 mm
from the cubicle floor, and preferably tilted at an angle of 450 to the horizontal for ease
of connections. Similarly, connection of the incoming power cables to the bus bars shall
be done at a height of at least 250 mm from the cubicle floor.
 Item designation and location marking shall be in line with IEC recommendations.
 Device labeling shall be on its fixed mounting and not on the device itself such that
labeling remains even when the device is replaced. Metallic labels/paper labels or
sticker shall be accepted.
 The specific technical particulars of Variable Frequency Drive shall be as given
below:

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Description Unit Technical Particulars

Make As per Preferred Makes/Manufacturers
Type of Drive Inverter Controlled A.C Drives

Rated voltage, frequency and Phases 433, V 50 Hz, 3 Phase

Variation in voltage 415 V + 10
Variation in frequency 50 Hz + 5
100% continuous, 150 % overload for 2
minute once in period of 24 hours, 200
Type of Duty
% overload for 10 seconds once in
period of 24 hours
Design Ambient Temperature 45 C
Less than 5% as per limits given in IEC
Overall Harmonic Limitation
61800
Application As per Requirement
Interfaces Serial or Profit bus
TECHNICAL SPECIFICATIONS FOR HV & LV POWER CABLES AND CONTROL CA-
BLES
Applicable Standards
The cables shall conform to the latest applicable standards specified below.

PVC insulated cables

: IS:694
(for voltage upto 1100 V)

HRPVC & PVC insulated cables

: IS:1554
heavy duty

Cross linked polyethylene insulated

: IS: 7098
PVC sheathed cables

Low frequency cables and wires with : IEC: 60189-1 &

PVC insulation and sheath IEC-60189-2

PVC insulation and sheath of electric

: IS: 5831
cables

Polyethylene insulation and sheath for

: IS:6474
electric cables

Conductors for insulated electric cables : IS:8130

Methods of test for cables : IS:10810
Specification for drums of electric cables : IS:10418

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Specification for PVC insulated cables

: BS:6346
for electricity supply

Specification for PVC insulation and

: BS:6746
sheath of electric cables

Features of Construction
XLPE Insulated HV Power Cables:
The Cables shall be 33kV Earthed grade & 6.6kV Unearthed grade, heavy duty, stranded
aluminium Conductor, XLPE Insulated, Conductor Screening by extruded Semiconducting
Compound, insulation screening through Combination of semi conducting compound and
non-magnetic tape (Copper tape), inner sheath over laid up cores, galvanised steel wire
/strip armoured (Aluminium wire armouring for single core cables), outer sheath of ex-
truded black PVC Compound type ST-2. Core Identification shall be by printed numer-
als.XLPE Insulated LV Power & PVC Insulated Control Cables
LV Power Cables:
The Cable shall be 1.1 KV Grade, heavy duty, stranded aluminium/Copper Conductor,
XLPE insulated, Extruded PVC inner sheathed, galvanised steel wire/strip armoured, Ex-
truded black PVC Compound type ST2 outer sheathed.
LV Control Cables:
The Cables shall be 1.1 KV Grade, heavy duty, Stranded Copper Conductor, PVC Com-
pound type A insulated, PVC Tape inner sheathed, galvanised steel wire/strip armoured,
black PVC compound type ST1 outer sheathed.
Cable Rating
 The Agency shall ensure that cable and wires associated with the distribution and
control systems, plant wiring and all other installations throughout the Works are
adequately rated for their use.
 In assessing the rating of any cable or wire, the following factors shall be taken into
account
 Supply voltage and frequency
 Maximum voltage drop permissible
 Type and magnitude of load
 Fault level and duration related to circuit protection relays and fuses
 Circuit Overcurrent protection
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 Route length and disposition of cables

 Ambient temperature
 Method of installation
 All power cables shall be sized for continuous current carrying capacity at the ambient
temperature of 500C. The design current of any circuit shall exceed the full load current
of the supplied device by at least 10%. Power cables shall be sized to limit the
maximum voltage drop to no more than 3 %.
 Under motor starting conditions, the corresponding voltage drop shall not affect the
operation of the motor controls or the ability of the motor to start and run effectively
and in any event, shall not exceed 10%. The Agency when sizing cables for the remote
operation of shunt trip coils shall take due account of the voltage drop caused by the
momentary current surge taken at the instant of energisation. HV and LV cables shall
be sized for a fault clearance time of 0.5 seconds for the incoming feeders and 0.16
seconds for switchboard feeders controlled by circuit breaker.
Cable Colours
 All cable cores shall be colour coded throughout their length and shall be so connected
between switchboard, distribution board, plant and accessories, that the correct
sequence or phase colours are preserved throughout the system.
 The colour coding shall be as follows:
3 phase red, yellow and blue
single phase or dc red and black
earth green/yellow
control blue (dc), red (ac)
Cable Conductors
Copper conductors shall be used for cables of sizes upto 4 Sq.mm. Aluminium conductors
shall be used for cables of size 6 Sqmm and above. Cores of cross-sectional area greater
than 1.5 mm2 shall be stranded. Lighting final distribution circuits shall be of a minimum
cross-section of 1.5 mm2. Power cables shall be of a minimum cross-section of 2.5 mm2.
Internal wiring of control panels shall be of a minimum cross-section of 1.0 mm2 flexible
and stranded. Control cables shall be of a minimum cross-section 1.5 mm2 for external use
and 1.0 mm2 for internal use.
2.10.6 Cable Numbering

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All cables shall be allocated a unique number which shall be fixed to each end of the cable
using a corrosion resistant label. Cables of different categories shall be tagged with the
following subscripts and three digit number.
HV power HV-P_ _ _
LV power P_ _ _
Control C_ _ _
Instrumentation I_ _ _
Protection PR_ _ _
2.10.7 Cable Drums
 Cables shall be supplied in non-returnable wooden drums. The wood used for
construction of the drum shall be properly seasoned and free from defects and wood
preservative shall be applied to the entire drum. All ferrous parts shall be treated with
a suitable rust preventive coating to avoid rusting during transit or storage.
 The Bidder shall indicate in the offer, the maximum length for each size of cable, which
can be supplied on one drum. The actual length supplied on each drum shall be within
tolerance limit of ± 5% without any tolerance on total ordered quantity of each size of
cable. However before winding the cables on drums, Agency shall obtain Authority’s
approval for the drum lengths.
 Each drum or coil of cable shall be accompanied by a certificate stating the
manufacturer's name, cable size, number of cores, length, result and date of tests as
required in the Authority’s Requirements. Cables manufactured more than 12 months
before delivery will not be accepted. All cables shall be delivered with cable ends
effectively sealed by hygroscopic scaling caps. When a cable is cut from a drum both
ends shall be immediately sealed to prevent ingress of moisture. Cables shall not be
transported to site in loose coils but a number of short lengths of cable may be
transported on the same drum. The Agency shall be wholly responsible for the
purchase and/or hire costs of all cable drums and for the removal of these drums from
site after use.
Cable Installation
General

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 Cables shall be installed in such a way that the minimum bending radii are not reduced
when installed or during installation. Cables shall not be installed in ambient
temperatures below that recommended by the cable manufacturer.
 Cables grouped together shall have insulation capable of withstanding the highest
voltage present in the group.
 Cables of different categories shall be installed so as to maintain satisfactory clearances
for safety and in order to reduce the possibility of electrical interference. The following
Table details the distances in mm that shall be maintained between the different
categories of cable.
Table of Separation Distances in mm between different Categories of Cable

Cable Category HV Power LV Power C&I/Protection

HV Power N/A 300 500
LV Power 300 N/A 300
C&I/Protection 500 300 N/A

 These separations are minimum and special circumstances such as the presence of
high current flows, or harmonic content may necessitate larger separation distances.
 In order to make economic use of the cable support system, cables shall be arranged
in groups of 50 mm maximum overall diameter. These groups shall be securely tied to
the cable support system at intervals not exceeding 900 mm for horizontal runs and
300 mm intervals on vertical runs.
 Cables shall be laid in a manner such that any electrical interference between cables
shall not have a detrimental effect on the life and operation of Plant.
 Where practical a separate cable support system shall be provided for power and non-
power cables. Where this is not practical a separation of 150 mm shall be maintained
between power and non-power cables when run on the same support system.
 Heavy duty galvanised iron cable tray and ladder racking shall be used for cable
support systems. Plastic or GRP cable support systems shall be used in areas used for
the storage and handling of chlorine. These systems shall be used to route cables
around walls and within cable trenches. Cables shall be securely fixed to the support

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systems. Bundling of cables shall be permitted where allowance for this practice has
been made in sizing the cables.
Cables Laid Direct in Ground
 Buried cable up to 650/1 100 V shall have a minimum cover of 500 mm measured to
the top of the highest cable. On crossing roadways the cable shall be run through a
PVC-U duct of minimum diameter 100 mm with a minimum of 1000 mm cover and
encased on all sides by 150 mm of concrete.
 Cables of greater than 650/1100 V shall be buried with a minimum cover of 1m.The
bottom of the cable trench shall be freed of sharp stones and such like and 75 mm of
sieved sand laid below the cable. After cable laying 75mm of sieved sand shall be laid
above the cable.
 Interlocking cable protective covers, minimum 1m long x 300mm wide, marked
`Danger -Electric Cable' in English and the vernacular shall be laid on top of the sieved
sand. Covers shall extend the whole length of the cable trench and shall overlap cables
by a minimum of 50mm.
 Warning tape shall be laid a minimum of 200mm above the protective covers.
 Cables are to be installed without tees or through joints unless otherwise approved by
the Engineer-in-Charge. Single core cables shall be run in trefoil formation.
Cables Laid in Underground Ducts
 Underground ducts shall be constructed of impact resistant PVC-U and laid at a
minimum depth of 500 mm, ducts shall be surrounded by at least 75 mm of sieved
sand except at road crossings where it shall be 1m deep and encased on all sides by
150mm of concrete.
 The Agency shall ensure that sufficient draw-in points have been provided and that
adequate room has been allowed for installation of cables. Drawstrings shall be
provided in all ducts to enable additional cables to be installed when required.
 Where cables pass in or out of any duct entries into or within buildings such entries,
together with any spare ducts shall be sealed against the ingress of moisture by means
of duct stoppers and bituminous compounds or by any other method approved by the
Engineer-in-Charge. The stopper shall have a fire resistance of at least 30 minutes.
Single core cables in trefoil formation shall pass through the same duct and shall not
be separated.

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Cables installed in Conduit

General
 Conduits shall be galvanised heavy gauge solid drawn or welded screwed steel type
and be in accordance with IS 9537 Part 2 or BS 4568. Accessories shall either be
malleable cast iron screwed type or pressed steel and galvanised.
 A space factor of 40% shall not be exceeded, but in any case conduit of less than 20
diameter shall not be permitted. The tubing shall be perfectly smooth inside and out
and free from flaws and imperfections of any kind. Both ends of every length of tubing
shall be properly reamed with all sharp edges removed before erection.
 Where a number of conduits converge, malleable cast iron or heavy gauge sheet steel
adaptable boxes shall be employed in order to avoid crossings. Conduits shall be
connected by means of male brass bushes and couplings.
 Where conduits are greater than 25 mm, straight through joint boxes shall be of the
trough type. Where conduit and/or fittings are attached to equipment casings, the
material or case of the casing shall be tapped for a depth of not less than 10 mm or
male bushes and flanged couplings shall be used.
 Heavy hexagonal lock nuts shall be used at all positions where running joints are
required and great care shall be taken to ensure that they seat firmly and evenly on to
the mating faces of coupling or other adjacent accessories. All junction boxes, draw-in
boxes, and inspection fittings, shall be so placed that the cables can be inspected and,
if necessary, withdrawn and re-wired throughout the life of the installation.
 Generally not more than two bends or offsets or one coupling will be permitted
without a suitable inspection accessory. Fish wires shall not be left in conduits after
erection. The whole of the installation shall be arranged for a loop-in type of system
with joints being carried out at switches, isolators, etc. Intermediate joints in the cable
will only be allowed by arrangement with the Engineer-in-Charge. Where terminal
blocks are necessary, they shall be of the porcelain type with brass pinching screws.
 Ends of conduits which are liable to be left open for any length of time during building
operations shall be plugged to prevent the ingress of dirt, cement, etc. and covers,
either temporary or permanent, shall be fitted on all boxes.

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 Generally, conduits shall not cross expansion joints of buildings, but where they
cannot be installed in any other manner then a flexible conduit shall be used across the
expansion joint. A total 150mm movement shall be allowed.
Surface Installation
 Surface conduits shall be secured and fixed by means of distance spacing saddles or
approved purpose made clips which allow the conduits to be taken directly into
accessories without sets or bends. Conduits shall be run in a square and symmetrical
manner. An efficient means shall be adopted to provide for the drainage of
condensation and the runs shall be properly ventilated. All surface conduit runs shall
be marked out for approval by the Engineer-in-Charge before the installation is carried
out. Where large multiple parallel conduit runs would occur, use may be made of
galvanised cable trunking. Conduits installed on structural steelwork shall be secured
at spacings not exceeding those for surface conduit by girder clips, otherwise fixing
shall be as for surface conduits on walls, drilled and tapped to the metalwork. Power
driven fixings shall only be used with the express permission of the Engineer-in-
Charge. Any drilling or access which is required through any structural member of the
building shall be agreed with the Engineer-in-Charge before carrying out the work.
 Exposed threads and places where galvanising has been damaged shall then be
painted with two coats of an approved metallic zinc based paint. This treatment shall
be applied as the work proceeds.
Concealed Installation
 Concealed conduits shall be securely fixed to prevent movement before laying of
screeds, floating of plaster, casting of columns or other building operations necessary
after the conduit installation. Crampets or similar fixings shall be used for attaching
the conduit to blockwork, etc. Building nails will not be accepted.
 At least 15 mm cover shall be allowed for finishes over the conduit. Where this cover
cannot be maintained then expanded metal shall be fitted with the conduit. Conduit
cast into reinforced concrete floors shall be fixed to the steel reinforcing with binding
wire and the conduit boxes filled with expanded polystyrene or enclosed in a plastic
bag to prevent the ingress of concrete when poured. Where possible, the conduit boxes
shall be fixed to shuttering to give a flush finish.

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 Conduit installed in voids, false ceilings, and other concealed routes shall be installed
as specified for the surface conduits. Wiring shall be carried out after the false ceiling
or permanent ducts have been completed. Conduit installed in floors shall be sealed
against ingress of moisture.
 The conduit installation shall be inspected by the Engineer-in-Charge before the
building operation conceals the work.
Cable Installed in Flexible Conduit
 Flexible conduit shall be of the waterproof galvanised type or PVC wire-wound type
with cadmium plated mild steel couplings. Lengths of flexible conduits shall be
sufficient to permit withdrawal, adjustment or movement of the equipment to which
it is attached and shall have a minimum length of 300mm. Flexible conduit shall not
be used as a means of providing earth continuity. A single earth conductor of adequate
size shall be installed external to the conduit complete with earth terminations. Where
conversion from rigid conduit to flexible metallic conduit is to be made, the rigid
conduit shall terminate in a through type box and the flexible conduit shall extend
from this box to the equipment, the earth continuity cable shall be secured to the box
and to the piece of equipment by properly designed earthing screws. The use of lid
facing screws, etc., will not be permitted. Adapters shall incorporate a grub screw or a
gland to prevent the flexible conduit becoming loose.
Cable Installed in Cable Trunking – Metal
 Cable trunking shall be manufactured from mild steel of not less than 1.25 mm and
shall be hot dipped galvanised. The Agency shall ensure that the size of the trunking
is adequate for the number of cables to be installed together with 50% spare capacity
and shall in any case be 50mm x 50mm minimum size.
 Segregation of cables shall be carried out if required using continuous sheet steel
barriers with the bottom edge welded to the trunking.
 The trunking shall have two return flanges for rigidity. Where necessary, additional
strengthening straps shall be fitted internally. The cover shall overlap the trunking and
be made of the same gauge. Fixing screws for covers shall be recessed and be of the
self retaining `quick fix' type. All bends, tees and intersections shall be of the gusset
type and shall, wherever possible, be purpose made by the manufacturer and of a
matching design to the main trunking.

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 Cables shall be retained in the trunking when the cover is removed by means of straps.
Internal connecting sleeves shall be fitted across joints in the trunking and earth
continuity ensured by bonding each section of trunking to a continuous earth wire.
 Non-flammable fire barriers shall be inserted where the trunking passes through walls
or floors. Conduit connections to trunking shall be made by flanged couplings and
male bushes.
 Trunking shall be supported at intervals not greater than 2 m horizontally or 2.5 m
vertically.
 Crossings over expansion joints shall be made in flexible conduit.
 Shall it be necessary to cut or drill a section of trunking or a trunking fitting the bared
ends shall immediately be given a coat of zinc rich cold galvanising paint.
 Cable and conduit/trunking runs shall be determined by the Agency and agreed by
the Engineer-in-Charge before any work is started. The run shall be at least 150 mm
clear of plumbing and mechanical services.
 Conduit/trunking systems erected outside a building shall be weatherproof.
Cable Installed on Cable Tray
 Cable tray shall be of perforated sheet steel with formed flanges and of minimum
thickness not less than 1 mm for trays up to 100 mm width, not less than 1.25 mm for
trays from 100 mm to 150 mm width and not less than 1.5 mm for trays from 150 mm
to 300 mm width.
 Cable tray shall be hot dipped galvanised. Cable tray for use in areas where chlorine
gas may be present shall constructed from U-PVC or GRP. Cable tray supports shall
be of a compatible finish with the associated cable tray.
 All cable tray tees, intersection units, bends, turns and sets shall, whenever possible,
be purpose made by the manufacturer and shall be of a matching design to the main
section of cable tray.
 Tray shall only be joined by couplers supplied by the manufacturers. The joint shall be
secured in accordance with the manufacturer’s instructions.
 Cable tray supports supplied by a manufacturer or made up on Site shall be of ample
strength to maintain rigid support to the fully laden cable tray along its entire length
and shall ensure that the deflection of any one section does not exceed 15 mm at
midspan.

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 Wherever possible, cable trays shall be installed in full lengths without cutting. Shall
it be necessary to cut or drill a length of tray, then for galvanised trays, the bared ends
or damaged section of the tray shall immediately be given a coat of zinc rich cold
galvanised paint. All site manufactured accessories, supports and metal fittings
required to ensure correct installation of the cable trays shall be similarly treated.
 All cables shall be firmly secured to the tray using purpose made saddles, as approved
by the Engineer-in-Charge, together with proprietary nylon fasteners and/or cable
cleats. Following installation of cables, the tray shall remain rigidly supported and the
deflection of any section shall not exceed 15 mm at midspan. All brackets and tray
work shall be suitable for withstanding a temporary weight of 125 kg.
 Cable trays shall not be cut to allow the passage of cables through the surfaces of the
tray.
 The sizing of the cable tray shall provide a minimum of 25% spare capacity.
 The tray shall be run at least 150 mm clear of plumbing and mechanical services.
Cable Installed on Ladder Rack Systems
 Ladder racking either light or heavy weight shall be proprietary item and installed in
accordance with manufacturer's instructions. Bends in the installation shall take
account of the minimum bending radii of cables to be installed.
 Cables shall be clipped to the ladder rack using clips designed for the system in use
and appropriate to the type and size of cable installed.
 The sizing of the cable rack system shall provide a minimum of 25% spare capacity.
 The ladder racking shall be run at least 150 mm clear of plumbing and mechanical
services.
Cable Clipped Direct
 All cable hangers, clips, cleats and saddles shall be of an approved type and
appropriate to the type and size of cable installed.
 Their spacing shall be such as to ensure a neat appearance and prevent sagging of the
cables at all times during their installed life.
Cable Installed in Internal Floor Trench
In Shallow trenches (maximum depth 500 mm)

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 In shallow trenches used for electrical services only, cables may be laid in a neat and
orderly manner on the floor of the trench. One layer only shall be allowed. Additional
cables shall be installed on the walls of the trench in an approved manner.
 Where the trench is shared by other services, cables shall be installed on the walls of
the trench in an approved manner.
All other trenches including walk through service ducts
Cabling shall be installed to the walls of the trench in an approved manner. Where other
services are present the cables shall be segregated from them and wherever possible kept
above `cold' wet services. Cables shall not be run if at all possible above or in close prox-
imity to `hot' services. The cabling shall be installed in such a manner as to allow access to
the other services for normal maintenance without disturbance of the electrical installation.
Cable Terminations and Joints
Multi core or Control Cable Terminations
 A sufficient number of terminals shall be provided to terminate all cable cores. For
control and auxiliary wiring an additional 20% of this number shall be provided as
spares.
 Not more than one core of internal or external wiring shall be connected on any one
terminal. Where duplication of terminal blocks is necessary, purpose-made solid links
shall be incorporated in the design of the terminal blocks.
 Terminals which remain energised when the main equipment is isolated shall be
suitably screened and labelled.
 Terminal blocks for different voltages or circuit type shall be segregated into groups
and distinctively labelled.
Cable Fixings
 Ties and strapping shall be suitable for securing cable and cable groups to cable tray
or ladder. They shall be resistant to chemical and marine corrosion. Plastic coated
metal ties used in order to obtain corrosion resistance shall not be acceptable. Nylon
ties shall be resistant to the effects of ultra-violet light and shall be self-extinguishing.
 Large single cables shall be secured with cable clamps or cable cleats.
Cable Identification
 At each end of each cable, in a uniform and visible position a label shall be fixed on
the cable in accordance with the cable schedule. Labels shall be made of PVC and shall

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be indelibly marked to the approval of the Engineer-in-Charge. The label shall be

retained using proprietary nylon strips passing through two fixing holes at either end
of the label. If the cable gland is not normally visible, then the label shall be fixed inside
the panel by means of screws.
Cable Glands
 Glands shall generally be of the mechanical compression hexagon type. Earth
continuity of brass glands shall be assured. This may be achieved by the rigid clamping
of the armour within the gland and the intimate contact between the threaded
components of the gland and the equipment. Each gland shall be installed complete
with proprietary earth tag providing a ready means of connecting a flexible strand or
strip earth bond to the gland at any position around the gland in relation to the
associated apparatus. Adequate earth continuity shall be assured between the earth
tag, the gland and the armour wires of the cable where applicable.
 Glands for single core cables shall be constructed from non-magnetic materials.
 Each gland shall be installed complete with a proprietary non-ferrous lock-nut to
secure the gland body to the equipment where the entry hole is plain, i.e. not tapped.
 Where holes for cable entries are not provided it shall be the responsibility of the
Agency to mark out and drill such holes. Burrs and swarf shall be removed, care being
taken to ensure that swarf and filings, etc do not enter the equipment.
 For non-hazardous areas cable glands in situations where moisture may be present
shall be double seal weatherproof type, gland shrouds shall be used and entry shall be
sealed.
 For dry indoor situations, standard industrial glands with shrouds are acceptable. For
hazardous areas, glands used shall be used with double seal and shroud.
 Power cable glanding arrangements in hazardous areas shall incorporate an insulated
adapter and earth link. This shall provide the facility to disconnect the armouring from
the glanded device in order that a true earth loop value may be measured when
carrying out tests on the installation.
Marking Locations of Underground Cables
 The location of all underground cables shall be engraved on brass or other non-
corrodible plates to be fixed to the exterior surface of all walls of buildings 300mm
above ground level and directly above the point where cables pass through the wall.

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 In addition, concrete marker posts shall be installed at intervals of not more than 50m
at all junctions and changes of direction along the cable route. Such marker posts shall
be not less than 200mm high and of substantial construction. A drawing or sample of
a typical marker post shall be submitted for the approval of the Engineer-in-Charge.
 The markers shall be marked `electric cable' in English and the vernacular
The specific technical particulars of HV & LV Cables shall be as given below:
Description Unit Technical Particulars
33kV EARTHED GRADE
XLPE INSULATED POWER
CABLES
Make As per Preferred Makes/Manufacturers
Applicable Standards
Continuous current rating with
cable laid in air under specified A (*)
ambient temperature
Overall diameter of the cable mm To be furnished by the Agency
Recommended minimum bending
mm To be furnished by the Agency
radius
Safe pulling force when pulled
To be furnished by the Agency
by using pulling eye
Standard length of cable on
mtr As per requirement
each drum
6.6KV UNEARTHED GRADE
XLPE INSULATED POWER CA-
BLES
Make
Applicable Standards
Continuous current rating with
cable laid in air under specified A As per requirement
ambient temperature
Overall diameter of the cable mm To be furnished by the Agency
Recommended Minimum bending
mm To be furnished by the Agency
radius
Standard length of cable on
mtr To be furnished by the Agency
each drum
1.1kV EARTHED GRADE XLPE
INSULATED POWER CABLES
Make

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Applicable Standards
Continuous current rating with
cable laid in air under specified A As per requirement
ambient temperature
Overall diameter of the cable mm To be furnished by the Agency
Recommended minimum bending
mm To be furnished by the Agency
radius
Standard length of cable on
mtr To be furnished by the Agency
each drum
650/1100V Grade PVC Insulated
Control Cables
Make As per Preferred Makes/Manufacturers
Applicable Standards
Rated voltage V As per requirement
Overall diameter of the cable mm To be furnished by the bidder
Standard length of cable on
mts To be furnished by the bidder
each drum

CABLE CARRIER SYSTEM

General
Applicable Standards

Steel for general structural purposes : IS:2062

Dimensions for hot rolled steel beam,

: IS:808
column channel and angle sections
Code of practice for use of metal arc
welding for general construction in : IS:816
mild steel
Hot deep galvanising of iron & steel : IS:2629
Methods of testing uniformity of coating of
: IS:2633
zinc coated articles
Hot dip zinc coatings on structural
: IS:4759
steel and other allied products

Cable Racks and Trays

 Cable racks/trays shall be fabricated from standard structural steel members.
 All cable trays, vertical raceways, cable racks and cable tray supporting structures shall
be hot dip galvanised.

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Galvanising
Wherever galvanising has been specified, the hot dip process shall be used. The galvanised
coating shall be of uniform thickness. Weight of Zinc coatings for various applications shall
not be less than those indicated below:

(a) Fabricated Steel

Thickness less than 2 mm, but not less than 1.2 mm 340 gms/sq.m
Thickness less than 5 mm, but not less than 2 mm 460 gms/sq.m
Thickness 5 mm and over 610 gms/sq.m
(b) Fasteners

Upto nominal size M10 270 gms/sq.m

Over M10 300 gms/sq.m

Galvanising shall be carried out after all drilling, punching, cutting, bending and welding
operations have been carried out. Burrs shall be removed before galvanising. Any site mod-
ification of galvanised parts shall be covered well by zinc rich primer and aluminium paint.
TECHNICAL SPECIFICATION FOR LIGHTING SYSTEM
General Requirements
 The Lighting system includes the following items.
 Indoor & outdoor Lighting fixtures complete with Lamps and accessories
 Lighting system equipment
 Light control switches, receptacle units with control switch units, lighting wires, con-
duits and other similar items necessary to complete lighting system.
 Lighting fixture supports, street lighting poles and flood light towers
 Main Lighting distribution board, lighting panels.
 Multi core cables for street, boundary and flood lighting.
Applicable Standards
The design, manufacture and performance of equipment shall conform to the latest stand-
ards specified below.

(a) Lighting Fixtures & Accessories

Electrical lighting fittings general and
: IS: 1913/ BS: 4533
safety requirements
Code of practice for industrial lighting : IS: 6665
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Calculation of co-efficient of utilisation : IS: 3646 (Part - III)

Industrial lighting fittings with metal
: IS: 1777
Reflectors
Decorative lighting outfits : IS: 5077
Dust tight electric lighting fittings : IS: 4013
Flood lights : IS: 10322/BS: 4533
Luminaries for street lighting : IS: 10322 Part 5
IS: 3553/ BS: 4533,
Water tight electric lighting fittings :
5225(I)
IS:1258/BSEN
Bayonet lamp holder :
61184IEC:60061
Edison screw lamp holders : IS: 10276/BSEN 60238
Cast acrylic sheets for use in Luminaires : IS:7569
Screwless terminal and electrical connections for light-
: IS:10322
ing fittings
Emergency lighting units : IS:9583
Ignition proof enclosures, dust-tight for
: IS:11005
elect. equipment
Luminaires : IS:10322 (Part I to V)
Dust proof electric lighting fittings : IS: 4012

(b) Lighting System Equipment

Switches for domestic and similar purposes : IS:3854/BS:3676
Three pin plugs and socket outlets : IS:1293/BS:546
Boxes for enclosure of electrical accessories : IS:5133(1)
Rigid steel conduits for electrical wiring : IS:9537/BS:31
Accessories for rigid steel conduits for
: IS:3837/BS-31
electrical wiring
Flexible steel conduits for electrical wiring : IS:3480
Rigid non-metallic conduits for electrical
: IS:9537/BS:4607(2)
installations
Fittings for rigid non-metallic conduits : IS:3419/BS:4607(2)
PVC insulated cables for working voltages
: IS:694
upto and including 1100 V
Tubular steel poles : IS:2713
Specification for copper rods and bars
: IS:613
for electrical purposes
Code of practice for phosphating iron
: IS:6005/ BS:3189
and steel

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Fittings for rigid steel conduits for

: IS:2667
electrical wiring

Lighting Fixtures (Luminaires)

 Luminaires shall be designed for continuous trouble-free operation without reduction
in lamp life or without deterioration of materials and internal wiring. Outdoor fittings
shall be weather-proof and rain-proof type.
 The Luminaires shall be designed so as to facilitate easy maintenance, including clean-
ing, replacement of lamps/starters etc.
 Connections between different components shall be made in such a way that they will
not work loose by small vibration.
 For each type of Luminaires, the Agency shall furnish the utilisation factor tables to
indicate the proportion of the light emitted by the bare lamps which falls on the working
plane.
 All Luminaires shall be supplied complete with lamps suitable for operation on a supply
voltage with the variation in supply voltage, frequency and combined voltage and fre-
quency of ±10%, ±5% and ±10% respectively.
 The Luminaires and accessories shall be designed to have low temperature rise. The
temperature rise above the ambient temperature shall be as indicated in the relevant
Standards.
 Led type Luminaires shall be complete with accessories like lamps, drivers, etc. These
shall be mounted as far as possible in the luminaire housing only. If these cannot be
accommodated integral with the Luminaires then a separate metal enclosed control gear
box shall be included to accommodate the control accessories together with a terminal
block suitable for loop-in, loop-out connections. Outdoor type fixtures shall be provided
with outdoor type weather-proof box.
 Each luminaire shall have a terminal block suitable for loop-in, loop-out and T-off con-
nection by 250/400 V, 1 core, PVC insulated copper/aluminium conductor wires upto 4
sq.mm in size. In outdoor areas the termination at the luminaire shall be suitable for
1100 V, PVC insulated, copper/aluminium conductor, armoured cables of sizes upto 6
sq.mm conductor. Terminals shall be of stud or clamp type. The internal wiring shall be
completed by means of standard copper wire of minimum 1 sq.mm size and terminated

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on the terminal block. Terminal blocks shall be mounted with minimum two fixing
screws.
 Mounting facility and conduit knock-outs for the luminaries shall be provided.
 The fixtures provided shall be energy efficient and shall be consuming less power.
Earthing
Each luminaire shall be provided with an earthing terminal suitable for connection to the
earthing conductor of 12 SWG GI wire. Where separate control gear box is provided for
housing the accessories the same shall be provided with an earthing terminal suitable for
connecting earthing conductor of 12 SWG GI wire. All metal or metal enclosed parts of the
luminaire/control gear box shall be bonded and connected to the earthing terminal so as to
ensure satisfactory earthing continuity.
Painting/Finish
All surfaces of the Luminaire/Control gear box housing accessories shall be thoroughly
cleaned and degreased. It shall be free from scale, rust, sharp edges and burrs. When enamel
finish is specified, it shall have a minimum thickness of 2 mils for outside surface and 1.5
mils for inside surface. The finish shall be non-porous and free from blemishes, blisters and
fading. The luminaire housing shall be stove-enameled/epoxy stove-enamelled-vitreous
enamelled or anodised as indicated under various types of fittings. The surface shall be
scratch resistant and shall show no sign of cracking or flaking when bent through 90 deg.
over 1/2” dia. mandrel. The finish of the luminaire shall be such that no bright spots are
produced either by direct light source or by reflection. External control gear box provided
for housing accessories shall be painted or galvanised.
LED STREET LIGHT LUMINAIRE
 Supply of LED streetlight luminaries complete with pressure die cast/extruded alumin-
ium housing and adhering to the following specifications and lighting design require-
ments will be as per actual applications-
 Efficiency of driver electronics shall be more than 95%.
 The LED shall be driven at the suitable current and within the permissible limits spec-
ified by the LED manufacturer.
 Power factor of the electronic driver shall be at least >0.95 with THD <10%.

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 The LED luminaries shall produce constant lux level in the voltage range of 100V to
280V. Voltage variations/ fluctuations in the specified voltage range shall not impinge
upon the lux level it produces.
 The life span of the LED source including its Driver shall be greater than 50000 hours.
 The luminaries shall conform to IEC 60598 or equivalent standard. The driver shall
comply with IEC 61347-2-13, IEC 61547, CISPR-15; and 61000-3-2.
 The luminaire shall be suitable for 80W, LED and for mounting height up to 9mtrs from
ground level.
ELECTRONIC COMPONENTS
The electronic components used shall be as follows
 IC (integrated circuit) used shall be of industrial grade.
 The resistors shall be preferably made of metal film of adequate rating.
 The conformal coating used on PCBs shall be cleared and transparent and shall not
affect color code of electronic components.
 The heavy components shall be properly fixed. The solder connection shall be with
good finish.
CONSTRUCTION
 The casing of the lighting luminaries shall be made of pressure die cast aluminium
coated with epoxy polyester powder coat single, self-contained device not requiring any
on-site assembly for installation onto an existing lighting luminaries integral with
power supply unit. The driver unit must be accessible and if need be replaceable easily
and with minimum use of tools.
 The casing made of non-corrosive aluminium having high conductivity shall have ex-
ternal surface designed in a manner so as to act as an efficient heat sink to extract heat
generated at pn-junction of a LED. Efforts shall be made to keep the overall outer di-
mensions as minimum as possible without compromising on the performance of the
LEDs or luminary.
 The assembly and manufacturing process for the LED source assembly in modules/
arrays shall be designed to assure all internal components are adequately supported to
withstand sudden impacts and mechanical shock and vibration from high winds and
other sources.
 No part shall be constructed of polycarbonate unless it is UV stabilized
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 Material used for the lens of LED source shall be of toughened glass, heat resistant and
shall not undergo discoloration during lifetime of the LED source. It shall conform to
ASTM specifications for the materials. Any discoloration observed in the lens shall be
considered a failure under warranty clause.
 All luminaires shall be provided with acrylic / polycarbonate / glass diffusers and/or
aluminized reflectors and/or lenses to provide proper road lighting distribution.
 Toughened and/or tempered glass of sufficient strength may be provided under the LED
chamber to protect the LEDs and luminaires.
 The LED lens shall be UV stabilized and shall be capable of withstanding ultraviolet
(direct sunlight) exposure for a minimum period of 60 months without exhibiting evi-
dence of deterioration.
 The luminaries shall be capable of operating normally in ambient temperatures from -
20*C to 50*C maintaining junction temperature below 100*C and heat sink tempera-
ture below 60*C, ensuring efficient thermal management of the luminaire.
 The fixture shall be designed in such a manner that it is easy to handle and install, is
not too large and unwieldy, is of robust construction, light weight and conforms to min-
imum IP65 class of protection for outdoor use against dust and moisture intrusion.
 The luminary shall be provided with a built-in external heat sink as well as an aluminum
MCPCB printed circuit board, designed in such a way that the heat generated within
the LED source is efficiently dissipated to the surrounding atmosphere without abnor-
mal rise in temperature. Any debris build up shall not degrade heat dissipation perfor-
mance of the luminaries.
2.12.6 Flood Light Luminaire
General Purpose Flood Light Luminaire
 Flood light luminaires shall be of weather proof construction with cast aluminium hous-
ing, anodised aluminium mirror polished reflector, heat resistant, toughened glass cover
and necessary neoprene gaskets to prevent ingress of dust.
 The housing shall be supported on a cast iron base and capable of being swivelled in
both horizontal and vertical directions and locked in any desired position.
 For focussing purposes, knobs, shall be provided along with sector plate indicating the
angle in degrees between 0 and 90 deg. in vertical direction.
 The Luminaires shall be suitable for LED upto 250 watts.
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 The luminaire shall be provided with cable gland on the canopy in down ward direction
for cable connection.
 It shall be possible to adjust the lamp position to achieve wide beam, medium beam or
narrow beam.
 It shall be possible to replace the lamp from the canopy without opening the front glass.
2.12.10 Lighting System Equipment
Light Control Switches
Light control switches of ratings and types, i.e. decorative/industrial shall be supplied as
required. The switches shall be suitable for use on 240 V, 1 Ph, 50 Hz supply.
Switches shall be of flush type for mounting behind an insulated plate or incorporated with
a switch plate for mounting flush with the surface of wall or switch box/suitable enclosure.
The switch box/enclosure may be recessed into or mounted on a wall as per the requirement
of project layouts.
The size of enclosure boxes shall be chosen to accommodate the number of switches to be
installed at the particular location. The enclosures shall be 18 gauge sheet steel galvanised.
The enclosure box shall be covered with perspex/insulating cover. An enclosure intended
for surface mounting shall not have holes or gaps in its sides other than those expressly
provided for cable entry.
Receptacle Units
Receptacle units shall consist of socket outlet with associated switch and plug. The socket
outlet and switch or MCB shall be flush mounted within galvanised 18 gauge steel enclo-
sure with insulation cover. The box may be recessed into or mounted on a wall as per re-
quirements of project layouts.The receptacle units shall be suitable for 240 V, 1 ph - N, 50
Hz/415 V, 3 Ph - N, 50 Hz supply as required.Single phase receptacles shall be associated
with a switch/MCB of same current rating and the receptacle shall become live only when
the associated switch/MCB is in “ON” position. Three phase receptacles shall be associated
with a TPN switch housed in the same enclosure. The receptacle shall become live only
when the associated switch is in “ON” position. The plugs shall be provided with cord grips
to prevent strain and damage to conductors/wires at connection and entry points.
Lighting Wires
The wires for wiring in lighting system shall be 250/440V, 1/C, PVC insulated, unarmoured
with stranded copper conductors. The minimum area of conductors shall be 1.5sq.mm. for

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light fittings and 5A Receptacles and 2.5 sq.mm for receptacles rated 15A and above. The
wires shall be coded white for phase/positive of D.C. and black for neutral/negative of D.C.
Estimation for point wiring
Wiring of all lighting fixtures, fans and receptacles and earthing wiring shall be on point
wiring basis. Insulated green coloured earthing wire shall also be run in conduits. Indian
TNS type of distribution (as per IS 3043) shall be followed. Neutral of the circuits shall not
be looped.
Point wiring for lighting and fans
Primary point (GI) shall consist of supply, installation and testing commissioning of light-
ing system / fan system including supply of 19/25 mm (16G) GI conduits with all accesso-
ries (e.g. bends, reducers, couplers, switches for control, junction boxes, 16 SWG green
copper wire for earthing, etc.) with 1.5 sq. mm. copper PVC wires and their termination
etc.
The point wiring for lighting and fans shall be classified into the following lengths:
i. Short point from 0 to 5m
ii. Medium Point 5 to 10m
iii. Long Point 10 to 20m
iv. Extra long point more than 20m

Point wiring for receptacles (5/15A)

Primary point (GI) shall consist of supply, installation and testing commissioning of 5A
receptacle including supply of 19/ 25 mm (16G) GI conduits with all accessories (e.g.
bends, reducers, couplers, switches for control, junction boxes, 16 SWG green copper wire
for earthing, etc.) with 4 sq. mm. copper PVC wires and their termination etc.
The point wiring for 5A receptacles shall be classified into the following lengths:

i. Short point from 0 to 5m

ii. Medium Point 5 to 10m
iii. Long Point 10 to 20m
iv. Extra long point more than 20m

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Conduits
Rigid steel/non-metallic conduits and their associated fittings as required shall conform to
applicable standards. The minimum size of conduit shall be 20mm for surface installation
and 25mm for concealed installation. Steel conduits shall be seamed by welding and hot
dip galvanised. They shall be supplied in standard lengths of 5m. Supply of conduits shall
include all associated fittings like couplers, bends and tees as required for lighting system
installation work.
Junction Boxes
Junction boxes with terminals shall be supplied for branching and terminating lighting ca-
bles when required for outdoor areas, 3 phase receptacles etc.The junction boxes shall be
dust and vermin proof and shall be fabricated from 14 gauge sheet steel and shall be com-
plete with removable cover plate with gaskets, two earthing terminals each with nut, bolt
and washer. Boxes shall be additionally weather proof.The boxes shall have provision for
wall, column, pole or structure mounting and shall be provided with cable/conduit entry
knock outs, terminal blocks, HRC fuses as required.The terminal blocks, with specified
number of terminals, shall be mounted securely on brackets welded to the back sheet of the
box. The terminals shall be 600 V, grade, one piece construction complete with terminals,
insulation barriers, galvanised nuts, bolts and washers and provided with identification
strips of PVC. The terminals shall be made of copper alloy and shall be of box clamp type.
The boxes shall be painted with one shop coat of Red oxide zinc chromate primer followed
by a finishing coat of paint.
Lighting Poles and Flood Light Pole Mounting
Lighting poles for street lights and flood lights shall be of stepped tubular steel poles con-
struction as per applicable standard. These poles shall be coated with bituminous preserv-
ative paint on the inside as well as embedded outside surface. Exposed outside surface shall
be painted with one coat of red lead oxide primer. After completion of installation two coats
of aluminium paint shall be applied. Poles for mounting flood lights shall be supplied when-
ever required and as per typical attached drawing. Unless otherwise specified, poles, shall
be painted with red lead oxide primer and two coats of aluminium paint. A steel ladder shall
be provided. The length of each step of the ladder shall be at least 300 mm and spacing
between two adjacent steps not more than 300 mm. The supply of poles shall be complete

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with fixing bracket/necessary pipe reducer for fixing the fitting and also include the neces-
sary associated pole mounted junction boxes. The required sizes of poles and the junction
box shall be as indicated in the attached drawings.
The specific type of Luminaire to be used at various areas shall be as given below:

Area/Structure Type of Fixtures Type of Luminaire.

Industrial low bay for mounting
1 x 30 W LED
heights > 5 to 6 M Industrial
1 x 80/ 120 W LED
Pump House Medium bay for mounting
1 x 180 - 200 W LED
heights > 6 to 9 M Industrial
high bay for mounting heights > 9 M.
Industrial type with vitreous
Switchgear / PMCC / MCC Room 1 or 2 10-20 W LED
enamel reflector
Office / Control Room/ Labora- (Mirror optics)
2 x 10-20 W LED
tory (Decorative)
Periphery Street lighting cut off type 1 x 30 W LED
Internal Road lighting Street lighting cut off type 1 x 60-70 W LED
Chiller Room Industrial Corrosion proof IP65 2 x 20W LED
Corridors / passage Mirror optics, Surface type 1 x 20W LED

The specific technical particulars of Lighting Fixtures & Accessories shall be as given below:

Description Unit Technical Particulars

General
Make As per Preferred Makes/Manufacturers
IS:3036 Part-I & given in General Design
Illumination levels at various premises
criteria
Normal supply voltage, phase
AC 240 V, 1 ph, 2 wire, 50 Hz
and frequency
Variation in supply:
(i) Voltage (AC & DC) % + 10
(ii) Frequency % +5
(iii) Combined voltage & frequency % + 10
Design ambient air temperature 0C 45° C

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Luminaire terminal suitable for Indoor

area
(i) Conductor material Copper
(ii) Cable size Coresxmm2 (*)
Outdoor area
(i) Conductor material Aluminium
(ii) Cable size Cores x mm2 (*)
Luminaire earthing terminal suitable
for
(i) Conductor material G. I. wire
(ii) Conductor size SWG (*)

LOW VOLTAGE FEEDER PILLARS

This specification covers the design, Engineer-in-Charge, manufacture, testing at works,
packing, supply, delivery and storage at site of low voltage outdoor type feeder and lighting
pillars for lighting of streets, parking areas landscaped/developed area including all mount-
ing bolts and other accessories required to make the pillars operable for 3 phase, 4-wire,
415 volts, 50 Hz. Neutral grounded distribution system. The pillars shall be complete with
links, MCCBs, MCBs, Bus bars, Ammeter with CTs, Voltmeter / indicating lights & all
such other accessories as required, even though specifically not mentioned.
Standard and System Conditions
Standard
The equipment covered in this specification shall conform to the following updated I.E.C.
Publications / ISS:
S. No Standard Number Description
Marking and arrangement for switchgear bus-bars, main
1 IS : 375
Connectors and auxiliary wiring.
Basic climatic & Mechanical durability test for compo-
2 IS : 589
nents for electronic & electrical equipment.
3 IS : 1336 Push buttons
4 IS : 1554 PVC insulated (Heavy duty) electric cables
5 IS : 2147 Degree of protection provided by enclosure
6 IS : 3202 Climatic proofing of electric equipment

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Air break switches, air break dis-connectors, air break

7 IS : 4064 switch disconnectors and fuse combination units for volt-
ages not exceeding 1000V.
8 IS : 5039 - 1991 Distribution pillars for voltage not exceeding 1000 Volts.
9 IS : 8623 (Part I-3) Specification for switchgear & control assemblies.
10 IS : 8828 Specification for MCBs
11 IS :3947 (Part-II) Low voltage switchgear and control gear
Insulation co-ordination with in low voltage systems in-
12 IEC 664 A-1980
cluding clearance and creepage distance for equipment.
13 IS : 2551 Danger plate
14 IS : 0580 Service conditions for electrical equipment
Guide for insulation coordination within low voltage sys-
15 SP : 39-987
tems.

The equipment complying with other internationally accepted standards shall also be considered if
they ensure performance equivalent to or superior to Indian Standards.

Quality of Material
All material used shall be new and of best quality and of class, most suitable for working under the
conditions specified herein without distortion or deterioration.
Design and Standardization
General
 The equipment shall be designed to ensure satisfactory operation in which continuity
of service is the first consideration and shall also be designed to with stand sudden load
variations due to short circuits and fault conditions. The design shall incorporate every
reasonable precaution and shall have necessary provision for the safety of all those
concerned in the operation and maintenance of the pillars.
 The mechanism shall be made of such materials as to prevent sluggishness due to rust
or corrosion. All connections and contacts shall be of ample section and contact surface
for carrying continuously the specified current without undue heating and shall be
secured rigidly and locked in position. Standard sizes of stainless bolts, screws, pipes
and other fittings are to be used and number of sizes is to be kept to the minimum.
 Cast Iron shall not be used for any part of the equipment which may be subjected to
mechanical stresses.
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 All apparatus shall be so designed and constructed as to obviate the risks of short
circuits of the live parts by lizards etc. Metal cubical, housings and covers shall be 100%
weather / vermin proof & shall be able to provide the degree of protection IP 45 in
accordance with latest version of IS:2147.
 All parts shall be manufactured in accordance with relevant standard specifications of
IEC/IS, corresponding parts of similar equipment and apparatus shall be mutually
interchangeable.
 All apparatus, connection and cabling shall be designed and arranged to minimise the
risk of fire and any damage which might be caused in the event of fire.
 The distribution feeder / service pillars shall be suitable for working outdoor in the
conditions given herein. As the feeder / service pillar will be installed normally on
footpaths adjoining to the roads, these shall be made robust and capable of withstanding
the vibrations normally experienced due to vehicular traffic.

Clearance & Creepage Distances

The clearance & creepage distance shall be in accordance with IS: 13947 Part-I updated &
corrected for operation under environmental conditions of site.
Labels and Marking of Connections / Feeder Pillars
All apparatus, control gear and the apparatus mounted there on shall be clearly labelled
indicating, their purpose and the ‘ON’ ‘OFF’ and ‘EARTH’ positions, as applicable. The
labels shall be clearly lettered on enamelled surface or other approved materials. Brass shall
not be used for labels. Each phase of alternating current and connections shall be coloured
by heat shrinkable sleeves to distinguish phase, neutral and earth. The colouring shall be
red, yellow, blue for phases black for neutral and green for earth. Feeder pillar shall be
labelled as per designation shown in the single line diagram. The labelling shall be finalised
after the samples and arrangement for the same is approved by the Agency during detailed
desing/Engineer-in-Charge phase.
Drawings & Literature
 Four sets of tentative G.A., schematic drawings and detailed literature of equipment
shall be submitted within 120 days after contract award clearly giving the scope of
supply and bill of material to enable the Engineer-in-Charge to scrutinise all aspects of

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design including arrangement and support of cable accessibility for maintenance work
and future additions, cable connections, general appearance etc.
 Further sets of drawings & literature are to be furnished by successful tenderer / bidder
within 2 weeks after the award of contract by the Engineer-in-Charge, which shall
include the following:
 Complete assembly drawings of the pillars, showing plan, elevation, typical section,
location of terminal blocks for external wiring connections and mounting details of
various devices with dimension.
 Foundation plan showing embedment channel frame in the floor with associated holes
and suitable size of bolts for fixing to channel frame of feeder pillars.
 Wiring diagrams including terminal wiring design and cable schedule.
 Schematic control diagram for controls, relays, instruments, space heaters, cubicle
illumination and receptacle etc.
 Detailed bill of material of each feeder pillar.
 Layout plan of feeder pillar.
Bought Out Items
All bought out items such as switches, MCCBs, MCB’s meters, terminals, cables etc. shall
be of reputed make. Engineer-in-Charge reserves the right to accept only materials of
proven make at its sole discretion.
Specification of LT Feeder pillars
Constructional Details
 A totally enclosed cubicle shall be fabricated out of heavy gauge stainless steel sheets
of thickness not less than 3.15 mm on all sides and mounted on angle iron frame or of
coating of Aluminium / non rusting and non corrosive material on mild steel sheet. A
set of double hinged doors shall be provided on front, to enable installation,
maintenance and inspection of cable connection and other equipment inside the cubicle
from the front side. Three heavy duty stainless steel hinges (not visible from outside)
shall be provided per door in such a way so that interior gasketing of the doors shall be
continuous. Good quality neoprene gaskets, weather resistant shall be used. The design
shall permit the doors being completely removed when necessary. The doors shall be
so fitted as to provide the interior with maximum protection from atmospheric

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conditions. The doors shall get closed as in case of a steel almirah through a handle so
as to have a tight fitted door.
 The door handles shall be of rectangular shape made out of 12 mm round or equivalent
size of flats.
 A pad lock of suitable size, rust proof, operatable in outdoor humid conditions shall be
welded to one of the doors. All the locks on the feeder pillars shall be opened and closed
by a single master key.
 The ammeter, LT CTs, voltmeter, selector switches, MCCB shall be provided on the
incoming side of the MCCB on an openable and separate inside the pillar and not on
the main door leaves.
 The top of the pillar shall have a sloping canopy having necessary slope so that rain
water does not accumulate there. The canopy shall project over the sides of the pillar
shell which shall be lower than the top section.
 The pillar is to be mounted on brick and cement concrete plinth by the road side and
the dimensions shall be such that it does not obstruct the normal traffic on the footpath.
 The lower part i.e. apron shall be covered with 3.15 mm sheet on all sides. The sheet
covers shall be welded to the frame on three sides except on the front side where it shall
be bolted so that it can be removed for fixing cables. Ingress of water or any other
insects etc. does not take place from this portion as well.
 The stand shall be made of rust proof angle of 75x35x6mm and shall have adequate
height to provide a strong supporting structure to the shell.
 Suitable ventilation louvers with wire mesh inside shall be provided at the side sections
of the shell in a flat frame welded inside so that no object, lizard etc. can enter the pillar
through the ventilation louvers.
 The gland plate shall be of thickness 3.15 mm thick Aluminium & detachable type. All
the cable glands shall be chrome plated and double compression type and shall be
supplied with the pillar box for the cable sizes given.
 The bus bars shall be rectangular and of electrolytic aluminium.
 Phase as well as neutral size shall be suitable for continuous current rating. The bus
bars shall be insulated with heat shrinkable tapes with red, yellow and blue colours for
the 3 phases and black for neutral. All bus bar tapping and markings shall be in
accordance with relevant IEC/IS, 374-1963. The bus bar shall be mounted on insulators.
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The inter-connections between bus bars and MCBs units shall be solid electrolytic
Aluminium / strip/Aluminium conductor permanently riveted with the busbar. The
connections between outgoing side of MCBs and outgoing cable shall be through an
isolating link so as to ensure a physical isolation of outgoing circuit whenever needed.
These shall be suitably taped with colours as that of bus bars. Thimbles, nuts & bolts
etc., (which must be non-rusting) for the incoming and outgoing cables terminals shall
be included & provided with the pillar. Only external cables shall be brought from
outside for making connections to the pillars at site. The bus bar joints shall be given a
thin coat of conducting grease after fully cleaning both the surfaces. The terminals shall
be of substantial mechanical strength & shall provide adequate electrical contact for the
cable size used & shall be capable of receiving the size of cable. It will be ensured that
necessary contact pressure is maintained permanently.
 The above arrangement shall be got approved by Agency by designer / client / site
Engineer-in-Charge prior to fabrication.
Outgoing Feeders
Outgoing circuits fed by MCB’s of suitable ratings for controlling the outgoing cable cir-
cuits from feeder pillar shall be provided. A 4-pole disconnecting link of the rating corre-
sponding to the rating of MCB shall also be provided between the cable connection termi-
nals and MCB. This link shall provide visible disconnection in the case of any maintenance
work required to be carried out on the outgoing cable circuit.
Earthing
 The distribution feeder pillar shall be provided with two separate earthing terminals on
its casing for copper earthing.
 The earthing terminals shall be easily accessible and so placed that the earthing
connection of the distribution pillars is maintained when the cover or any other
moveable part is replaced.
 The earthing terminals shall be identified by means of proper indelible green sign marks
adjacent to the terminals.
 The feeder pillar shall also have an inside earth bus bar for connecting the cable gland
earthing and the armouring to it. The size of the earth bus bar shall be suitable to carry
50 kA for one second. The bus bar shall not be visible or removable from outside the
cubical. The earth bus bar shall have necessary holes, nuts & bolts including washers

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for making earth connection of cable glands / armouring of the incoming / outgoing
cables. Mild steel galvanised or otherwise is not acceptable due to harsh environment.
Feeder Pillar Lighting & Heating
A lamp holder with a 11 W CFL lamp and operated by an internal SP-MCB shall be fitted
in the canopy of the feeder pillar for internal illumination. In addition, a 3 pin 5A socket
shall also be provided with a separate SP-MCB onside of the pillar box. Space heater of
suitable rating, with thermostat and SP-MCB shall also be provided inside the pillar near
the bottom to avoid any moisture condensation inside the cubicle.
Danger Plate
An enamelled sheet steel danger plate of approved design as per IS: 2551 shall be fixed on
the left upper front door of the pillar.
Painting
 All sheet steel work shall be phosphatised in accordance with the relevant IEC/IS: 6005
Code of Practice of phosphatizing iron and steel with seven tank process.
 After application of the primer, two coats of finishing synthetic enamel epoxy paint of
reputed make shall be applied, each coat followed by stoving. The second finishing coat
shall be applied after completion of tests. The colour for the finishing paint shall be
light grey as per shade no. 631 of IS:5 or other equivalent standard shade. Each coat of
primer and finishing paint shall be with slightly different shade to enable inspection of
the painting.
 The finishing painted surface of pillars shall present aesthetically pleasing appearance
free form dents and uneven surface.
 A small quantity of finishing paint shall be supplied for minor touching up required at
site after the installation of the pillars.
Tests
 Type Tests
 The Engineer-in-Charge may ask the manufacture to conduct the following type tests
on one of the feeder pillars out of any of the consignment, considering site conditions.
 Verification of temperature rise limits test
 Verification of rain test to determine the degree of protection against rain.
 Verification of dielectric properties.
 Necessary type tests as per IS on all the bought out items such as MCB’s, MCCB’s etc.
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 The Engineer-in-Charge, at his option, may waive the above type tests provided type
test reports of the above type tests carried out on essentially identical unit in their
factory / testing laboratory of repute in India are furnished by the manufacturer.
 Routine Tests
 The pillars shall be subjected to high voltage tests described in the relevant ISS. The
test voltage to be applied shall be for a period of one minute.
 Meggar tests with meggar of 500 volts before and after the high voltage test shall be
carried out on the feeder pillars and the recorded readings shall be furnished to the
Engineer-in-Charge prior to the despatch of feeder pillar.
 Routine tests, as per IS shall be carried out on the bought out items viz. MCCB’s and
MCBs etc.
 Site Tests
 Engineer-in-Charge at its sole discretion reserves to carryout the necessary tests at site
to ensure that the equipment is not disturbed / damaged during transportation.
 Cable Terminations
 Incoming and outgoing cables to be terminated in the feeder pillar shall be Aluminium
or copper XLPE insulated PVC sheathed armoured / unarmoured.
 Horizontal angle iron bars shall be provided with bolted holes so that the cables could
be clamped by ‘U’ bolts of 12 mm diameter, so that no pull is exerted on the terminals
due to the weight of the cable. U bolts of necessary size to clamp the cables shall be
supplied fitted with nuts & washers, fitted on the bars.
 Specification for LT Street lighting pillars
The L.T. street lighting service pillars shall be manufactured suitable for outdoor installa-
tion and shall have all constructional details, earthing arrangement, danger plate, painting,
other features and tests as specified under various paras above for L.T. feeder / service
pillars. The final paint on the street lighting service pillars shall be red. The L.T., street
lighting pillars shall have circuits as detailed below:
 Incoming
One No. 3 phase, 4 wire incoming circuit placed on the left hand side having 4-pole MCCB
of suitable rating complying with IS: 13947-2 as updated with 50-100% adjustable thermal
release and & breaking capacity of 50 kA suitable for incoming XLPE aluminium conduc-
tor cable..

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 Outgoing circuits
3 Number Single phase 2 wire outgoing circuits with voltage rating of 240 volts & current
rating of 25A having 2 pole, MCB of 16 A rating, suitable for outgoing aluminium cable of
size provided.
 SCADA Controlled Dimmer and Astronomical Switch
The above shall be provided to automatically switch OFF and switch ON the supplies in
line with sunrise and sunset with astronomical clock. Further there shall be automatic dim-
ming arrangement with reference to time at night.
 LT Moulded Case Circuit Breakers (MCCB’S)
 The incoming underground cable to the feeder pillar from the LT AC Board in the
substation shall be controlled by DRAW OUT, CURRENT LIMITING type moulded
case circuit breaker.
 The moulded case circuit breakers shall be of a robust construction and shall comprise
of a switching mechanism, contact system, arc extinguishing device and a tripping unit
contained in a compact moulded case and cover. The insulating case and cover shall be
made of high strength, heat-resistant and flame-retardant thermo-setting insulating
material.
 The switching mechanism shall be quick-make / quick break type, and shall be trip-
free.
 The arc extinguishing device shall comprise of a series of grid plates mounted in parallel
between supports of insulating material. The arc shall be drawn from the moving
contact into the divide chamber and extinguished.
 The moulded case circuit breakers shall have a thermo-magnetic type tripping
mechanism, where the heating effect and the electromagnetic effect of current are made
use of to provide protection against overload and short-circuit conditions respectively.
The heated-bimetal strip in each phase of the MCCB shall actuate the tripping system
following on inverse-time-current characteristics depending upon the severity of the
overload. During short-circuits, the system shall trip instantaneously. The tripping
element provided on each pole of the MCCB shall operate on a common trip bar,
thereby preventing single phasing in the event of fault on any of the phases. The tripping
device shall be ambient temperature compensated type.

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 The MCCB shall have a minimum rupturing capacity of 25.8 MVA. Positive indication
about the position of the MCCB i.e. whether ‘ON’, ‘OFF’ or ‘TRIPPED’ shall be
provided.
 The short circuit breaking capacity and operating of the MCCB shall be supported by
test certificates.
 The detailed specifications of the MCCBs shall be as under:
3-phase, 4 wire, neutral earthed
system no. of pole : 4 Pole
Service voltage : 415 volts
Normal current : Rating shown in SLD
Frequency : 50 Hz.
Short circuit current rating [ Ics ] : 36 KA
 Crimp type cable lugs shall be used on the outgoing side of the MCCBs and the 4-pole
links for each of the outgoing feeder.
 All the MCCBs, used in LT feeder / service / street lighting pillars for controlling the
LT feeders shall have a current setting of 50 to 100% of its rated current.
 Miniature Circuit Breaker (MCB)
 The outgoing underground feeders / service lines from the LT feeder pillars shall be
controlled by MCBs. It shall provide protection against over loads and short circuit.
 The MCBs shall be of robust construction with insulating case made of self
extinguishing, thermoplastic material. The switching mechanism shall be quick make /
quick break.
 The details specification of the MCBs shall be as under:
No. of poles 4 and 2 poles as required
Service voltage 415 / 240 volts
Normal current Rating shown in SLD
Frequency 50 Hz
Breaking capacity 20 kA (as per clause no. 5.3.4.2 of IS: 8828-1996)
 Specific Technical Parameters
Low Tension A.C. Feeder Pillar
Feeder Pillar
Rated Voltage : 3 Phase, 4 wire 415 volts 10%

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Rated current at 50oC (A) : as per design

Frequency (Hz) : 50
Symmetrical short circuit withstand : 36 current for 1 sec at rated voltage (kA rms)
Degree of protection as per IS: 2147 for
Outdoor IP : 45
 Material of Cubical
Cubical sheet metal for panel : CRCA, Electrically Aluminium Coated
or
other non- rusting material except galvanised]
Thickness, structural frames and : 3.15
load bearing members for panel (mm)
Thickness, front & rear (mm) : 3.15
Thickness sides & top (mm) : 3.15
Size of non rusting Angle Support frame : 75 mm x 35 mm x 6 mm Painting shade as
per
IS: 5
External surfaces : 631
Internal surfaces : White
Minimum clearance air (bus-bars)
Between phase : As per relevant Indian
Standard
Between phase & earth : -do-
Bus-bar Details L.T. feeder pillar : Electrolytic Aluminium used for bus bar
 construction shall be preferably equivalent to E91 E of BS-2398 with mechanical
strength properties approximating closely to that of copper.
 Protection against accidental Contact: Heat shrinkable sleeving with requisite dielectric
properties leaving no voids or pin holes. Sleeving to be permanent & non removable by
hand. Busbars joints and tee off, where possible to be provided with removable shrouds
for complete isolation.
 Temperature rise over design ambient As per relevant BIS / IEC Temperature of
50oC for continuous current rating deg.
Indicating lamps 240 V

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Space Heater rated voltage 240 V

 Components

 MCCB
No. of Pole 4 Pole
Rating (A) As per design
Rupturing capacity (kA)-Ics 36
Thermal Tripping range 50 to 100%
Short circuit release To be fixed for 36 kA
 MCB
No. of Pole 4 Pole
Rating (A) As per design
Rupturing capacity (kA) 20 kA
Tripping Thermal overload

EXTERNAL ILLUMINATION
 The specification covers the design, Engineer-in-Charge, material, fabrication testing,
inspection, packing, forwarding supply, delivery and installation of Poles composite
street light, LED lights fittings complete in all respects for the street lighting system by
underground cables under the project. Exterior lighting shall be provided for streets,
parking areas, open areas developed areas, as per following items of work.
 The components of street lighting shall be supplied and installed, complete in all
respects. All the equipment and materials used for installation shall be brand new and
of high quality in design and performance. Unless otherwise specified, all the items
shall be tested and installed as per the latest Indian Standards Specification.
POWER SUPPLY
The voltage available for the street lighting and security lighting will be 415 volts three
phase and neutral 50Hz AC from the main external lighting board located in outdoor area.
WIRING OF FIXTURES
The street light fixtures shall be wired from terminal block by means of flexible (3 * 2.5 sq
mm) copper conductor, PVC insulated cable through a rewire-able MCB and neutral or
suitable sized MCB.

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CABLE
All cables shall be aluminum conductor (unless copper wire is specifically asked for), PVC
insulated, PVC sheathed, armoured of 1100 V grade. The wire of different colours shall be
used for quick identification of phase wire and neutral. The cable shall be of approved
make as specified in the list of makes
GENERAL
 All light luminaires shall conform to the relevant Indian Standard Specification. The
assembly of light luminaires shall be such that it is easy to handle, install, operate and
maintain them. The equipment shall be reliable in operation.
 All the hardware used in the assembly of the luminaires, shall be either galvansied or
painted with corrosive paint.
 The internal wiring of the luminaires, from the junction box shall be done with wires of
adequate size. All the accessories of the fittings shall be clamped/supported suitably at
the entry to the luminaires.
 All light luminaires and the associated control gear shall be rated for operation at 230
V, 50 Hz. A.C. supply unless otherwise specified in this specification.
 The supplier shall supply all the technical features, light distribution diagrams; zonal
luminous flux diagram and isocandala diagram of the luminaries. A dimensional
drawing giving the overall dimension of the luminaires shall also be supplied.
 The lighting circuits are generally of three phase and neutral 500 V distribution with
Aluminum conductor PVC insulated armoured cables.
 Installation price of cables buried underground shall include excavation and back
filling, supplying of sand, brick, protective cover, identification tags. Termination of
lighting cables at both ends and all accessories are grouped together The installation
price of lighting poles shall include all necessary foundation work including
concreting, mounting of loop-in and loop-out box. Lighting luminaires fixing along
with a PVC insulated copper conductor cable from the loopin and loop-out box to
fittings is taken together in one item.
 The installation price of earthing electrode shall include burying of the electrode and
the termination of the earthing conductor.
 For all the installation work necessary materials, accessories, hardware etc. as required
to make the installation complete in all respects shall be included in the offer.
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 While loading, transporting, unloading and erecting the poles, care shall be taken so
that the poles do not get bent out of shape and where necessary, such defects shall be
rectified before the poles are erected in position. The poles shall be erected in plumb
line and correct level as indicated in drawing and to the satisfaction of the Engineer-
in-Charge. They shall be kept in this position with the help of manila ropes until the
foundations are constructed, (for a minimum period of 7 days) and the backfilling is
complete.
 At road crossing, the cables shall be taken through RCC Hume pipe to be buried at a
depth of 1 meter below the finished round level and shall cover and run below the
drainages on both sides of the road. The trenches excavated for embedding the RCC
Hume pipe shall be back filled with the excavated earth and compacted to same degree
as that of the surrounding area.
 The protection of cement mortar for brick work to be used shall be CM: 1:4 for covering
the hume pipe at the road crossing.
ROUTE MARKER
Cable route marker marked "CABLE" shall be provided along route of the cable and loca-
tion of loops. The route markers shall be of tapered concrete slab of 60 * 60cm at bottom
and 50 * 50cm at top having a thickness of 10cm having 1:2:4 mix. Cable marker shall be
mounted parallel to and 50 cm away from the edge of the trench. The concrete marker
shall be laid over the trench projecting over the surrounding surface.
STEEL TUBULAR POLES
The steel tubular poles shall be Galvanised octagonal types.
Galvanized Octagonal Poles
Design
The Octagonal poles shall be designed to withstand the maximum wind speed of 169 KM
/ Hr. as per IS 875. The top loading i.e. area and the weight of fixtures are to be considered
to calculate maximum deflection of the pole and the same shall meet the requirement of BS
: 5649 Part VI 1982.
Pole Shaft
The pole shaft shall have octagonal cross section and shall be continuously tapered with
single longitudinal welding. There shall not be any circumferential welding. The welding
of pole shaft shall be done by submerged Arc Welding (SAW) process. All octagonal pole

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shafts shall be provided with the rigid flange plate of suitable thickness with provision for
fixing 4 foundation bolts. This base plate shall be fillet welded to the pole shaft at two
locations i.e. from inside and outside. The welding shall be done as per qualified MMAW
process approved by Third Party Inspection agency.
Door opening
The octagonal poles shall have door of approximate 500 mm length at the elevation of 500
mm from the Base plate. The door shall be vandal resistance and shall be weather proof to
ensure safety of inside connections. The door shall be flush with the exterior surface and
shall have suitable locking arrangement. There shall also be suitable arrangement for the
purpose of earthing.
The pole shall be adequately strengthened at the location of the door to compensate for the
loss in section.
Material
Octagonal Poles - HT Steel Conforming to grade S355JO
Base Plate - Fe 410 conforming to IS 226 / IS 2062
Foundation Bolts - EN.8 grade
Welding
The welding shall be carried out confirming to approved procedures duly qualified by third
party inspection agency. The welders shall also be qualified for welding the octagonal
shafts.
Pole sections
The Octagonal Poles shall be in single section (upto 11 mtr). There shall not be any cir-
cumferential weld joint.
Galvanization
The poles shall be hot dip galvanized as per IS 2629 / IS 2633 / IS 4759 standards with
average coating thickness of 70 micron. The galvanizing shall be done in single dipping.
Xing type
The Octagonal Poles shall be bolted on a pre-cast foundation with a set of four foundation
bolts for greater rigidity.
Top Mountings
The galvanized mounting bracket shall be supplied along with the Octagonal Poles for In-
stallation of the luminaries.

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Manufacturing
The pole manufacturing & galvanizing unit shall be ISO 9001 : 2000 & ISO 14001 certified
to ensure consistent quality & environmental protection.
Service window
A service window of the size 150 mm x 100 mm shall be provided in the base of the pole
to allow access to electrical connections and terminations. It shall be covered with MS
plate and proper rubber gaskets shall be provided to prevent any ingress of water etc..
Electrical connections
Four way connectors shall be provided along with Slide lock and 1 no. 6 amps Sp MCB
including 2.5 sqmm PVC insulated copper conductor wires from the terminal block to the
fixture and 2 nos. 32 mm dia GI sleeves of suitable length shall be provided upto the service
window. An earth boss is provided on the control plate along with connectors and interrupt-
ers.
Galvanized Octagonal Poles Dimensions
FOUNDATION BOLT
Top Bottom Sheet Base Plate Bolt Pitch
Projected
Height Dia Dia Thick Dimensions Size Circle Bolt
Bolt
(A/F) (A/F) -ness (LXBXT) (No. X Dia Length
Length
Dia) (PCD)
(mtr) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
3 70 130 3 200 x 200 x 12 4 x 16 200 450 80
4 70 130 3 200 x 200 x 12 4 x 16 200 450 80
5 70 130 3 200 x 200 x 12 4 x 16 200 600 80
6 70 130 3 220 x 220 x 12 4 x 20 205 600 100
7 70 130 3 220 x 220 x 12 4 x 20 205 700 100
8 70 135 3 225 x 225 x 16 4 x 20 210 750 100
9 70 155 3 260 x 260 x 16 4 x 24 250 750 125
10 70 175 3 275 x 275 x 16 4 x 24 270 750 125
11 90 210 3 300 x 300 x 20 4 x 24 300 750 125
12 90 240 3 320 x 320 x 20 4 x 24 325 850 125

TESTS
The supplier, before handing over the installation to the Engineer-in-Charge, shall carry out
tests on all fittings and cables as per IS Specifications. The test shall include:
Megger test
Continuity test.

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Phase seq
CONSTRUCTION
 The casing of the lighting luminaries shall be made of pressure die cast aluminium
coated with epoxy polyester powder coat single, self-contained device not requiring any
on-site assembly for installation onto an existing lighting luminaries integral with
power supply unit. The driver unit must be accessible and if need be replaceable easily
and with minimum use of tools.
 The casing made of non-corrosive aluminium having high conductivity shall have
external surface designed in a manner so as to act as an efficient heat sink to extract
heat generated at pn-junction of a LED. Efforts shall be made to keep the overall outer
dimensions as minimum as possible without compromising on the performance of the
LEDs or luminary.
 The assembly and manufacturing process for the LED source assembly in modules/
arrays shall be designed to assure all internal components are adequately supported to
withstand sudden impacts and mechanical shock and vibration from high winds and
other sources.
 No part shall be constructed of polycarbonate unless it is UV stabilized
 Material used for the lens of LED source shall be of toughened glass, heat resistant and
shall not undergo discoloration during lifetime of the LED source. It shall conform to
ASTM specifications for the materials. Any discoloration observed in the lens shall be
considered a failure under warranty clause.
 All luminaires shall be provided with acrylic / polycarbonate / glass diffusers and/or
aluminized reflectors and/or lenses to provide proper road lighting distribution.
 Toughened and/or tempered glass of sufficient strength may be provided under the LED
chamber to protect the LEDs and luminaires.
 The LED lens shall be UV stabilized and shall be capable of withstanding ultraviolet
(direct sunlight) exposure for a minimum period of 60 months without exhibiting
evidence of deterioration.
 The luminaries shall be capable of operating normally in ambient temperatures from -
20*C to 50*C maintaining junction temperature below 100*C and heat sink
temperature below 60*C, ensuring efficient thermal management of the luminaire.

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 The fixture shall be designed in such a manner that it is easy to handle and install, is
not too large and unwieldy, is of robust construction, light weight and conforms to
minimum IP65 class of protection for outdoor use against dust and moisture intrusion.
The luminary shall be provided with a built-in external heat sink as well as an aluminum
MCPCB printed circuit board, designed in such a way that the heat generated within
the LED source is efficiently dissipated to the surrounding atmosphere without abnor-
mal rise in temperature. Any debris build up shall not degrade heat dissipation perfor-
mance of the luminaries.

TECHNICAL SPECIFICATION FOR EARTHING AND LIGHTNING PROTEC-

TION SYSTEM
 This specification covers the technical and associated requirements for the entire
earthing system substations, required to protect persons and equipment and to allow
safe service and maintenance of the installations. The earthing system includes the
underground grid, ground rods and connections. The earthing system shall be designed
to minimise the dangers from step, touch and transferred potentials which can occur
under maximum fault conditions. The Agency shall design, furnish and install the
substation earthing system in accordance with the provision on latest IEEE Std. 80,
Guide for Safety in Substation Earthing, IS: 3043, Code of Practice For Earthing and
the provision of this specification. The Agency shall submit calculations in support of
his design.
 In addition to the above codes and standards, the Agency shall comply with applicable
national and local laws, codes, regulations, statutes and ordinances.
 The Agency shall bear full responsibility that the earthing system materials have been
designed and fabricated in accordance with all codes and standards and that they
perform under the conditions and to the standards specified herein.
 The Agency shall carry out earth resistivity measurement for the substation site. Based
on the result of this measurement and the system parameter, the appropriate design and
the calculation will be determined whether impermissible touch and step voltages occur
at any place of the station (including outside area) which may be endangered. These
calculations will decide on the provisions for earthing to be made with the relevant part
of the civil works related to foundations. It shall be agreed between Engineer-in-Charge

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and Agency, about special arrangements, if calculations prove that touch and step
voltages are higher than permitted and the Agency proves that he modified the earthing
grid to its optimum. Only calculations built up on computer generated design
programmes shall be accepted. A special software for providing detailed analysis of the
actual step and touch voltages likely to be generated has to be used.
 The HV and LV systems are solidly earthed at the neutral point of the power
transformer. The size of earthing conductors to be connected with the earthing system
shall be designed for an earth fault level of 40 kA (1 sec). The material for earthing in
particular for jointing shall be selected to prevent corrosion at the connection points as
well as at the earthing material itself, both underground and exposed to air. If necessary,
cathodic protection of an approved design shall be applied. In order to minimise the
effect of seasonal variations of earth resistance, the earthing system shall be designed
for the worst conditions.
Description of Services
The Agency shall provide a complete earthing system consisting of:
 The main outdoor subsoil earthing system, with individual loops around each building,
foundation, structure, etc., of the site.
 Sub-earthing systems for buildings, foundations, structures, tanks, etc., being connected
to the subsoil earthing system as required
 All electrical equipment such as motors, transformers, substations, foundations,
switchboards, control boards, relay and auxiliary relay boards, all other subsidiary
electrical equipment as well as all metal parts of civil construction or the mechanical
equipment such as transformer rails, pumps, pipes, steel structure, tanks, cable trays,
etc. shall be connected to the earthing system.
 All materials and parts which are not specifically mentioned herein but are necessary
for the safety of operating personnel and safe operation of the substation shall be
furnished and determined by the Agency at no increase in cost to the Owner.
Design Requirements
General
 The ground grid shall be composed of a system of galvanized conductors buried
approximately 500 mm below finished ground level, excluding crushed rock surfacing.
The grid system shall cover the entire fenced substation area and shall be extended to

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the outer of the substation fence. A perimeter conductor shall run around the substation
in a distance of 0.5m to the fence and shall be connected to the inner earthing grid and
to the fence in regular intervals. Where necessary to reduce the overall earth resistance,
earth electrodes shall be provided and connected to the perimeter of the main earth grid.
A minimum of four (4) of the specified ground rods must be installed (one at each
corner of the ground grid). The Agency shall determine the spacing of ground grid
conductors and the total number and location of ground rods and their lengths.
 Earthing conductors buried in the soil shall be of galvanized steel rounds, coated if and
as necessary. Earthing conductors embedded in concrete shall be of galvanized steel.
Adequate corrosion protection shall be provided when conductors leave the concrete,
respectively the soil.
 The design of the earthing system and the materials to be used shall comply with the
requirements for the specified cathodic corrosion protection.
 Earthing conductors laid on cable trays or similar shall be galvanized steel.
 All interconnections of the earthing grid to equipment and the connections be-tween
the earthing grid and the earthing rods shall be made by the termite welding process.
Only those connections located in earthing pits and occasion-ally intended to be opened
for testing purposes shall be of the bolted type.
 When a substation is located adjacent to the existing earthing system, the ground
systems of the existing or new facilities shall be connected together by at least three
galvanized steel strips appropriately sized for mechanical strength and the specified
fault current with minimum conductor size to be 125 mm2.
 Drawings and calculations shall be submitted for approval giving sufficient in-
formation on the earthing, lightning protection, the earthing of structure mounted
equipment, as well as on methods of measuring the earth resistance, respectively the
earth voltage, the touch and the step voltage.
 If the actually measured resistance of the Agency-designed and installed ground grid is
higher than one ohm or as specified, the Agency shall install, at no extra cost to the
Owner, additional earthing rods, mats, earthing electrodes, etc., until the field-measured
resistance is equal to or less than the specified value.
 Joints which are indicated as test points shall be bolted or clamped. Joints in tape, other
than at test points, shall be made by the welding process. All welding joints shall be

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with bitumen coating with non-rusting paints. Overlap of conductors shall be not less
than 100mm.
 Joints and connections shall be protected by a coating which will form a seal and
exclude moisture in all weather conditions. At connections to earth electrodes the
coating shall cover all exposed conductors. Protective coatings shall be of a water proof,
inert, tenacious material.
 Bolts, screws, nuts, washers and rivets shall be stainless steel of superior quality.
Equipment and Materials Requirements
The equipment and materials shall be suitable for outdoor installation and use at specified
service condition without corrosion, deterioration or degradation of performance characteris-
tics.
Main Earthing Grid 50 X 10 Mm Flat
Interconnection To Cps 25 X 3 Mm Flat
Local Push Buttons 14 SWG Wire
Lighting Distribution Board 4 SWG Wire
Lighting And Receptacle System 12 SWG Wire
Outdoor Street Lighting 8 SWG Wire
Ladder Rack And Cable Tray At Suitable Points 25 X 3 Mm Flat
Hand Rails And Metallic Structures 25 X 3 Mm Flat
Building Reinforcement 25 X 3 Mm Flat
Incoming And Outgoing Process Services 25 X 3 Mm Flat
Steel Structures Comprising Storage Tanks,
Mezzanine Platform, Crane Rails, Air Handling Duct- 25 X 3 Mm Flat
work Systems Etc.,
Earthing Conductors
 Earthing conductor shall be copper conductor of soft drawn concentric stranding bare
copper conductor.
 Ground leads running down from the lightning rod or air terminal rods shall be hard
drawn galvanised steel and shall be provided with the required clamp supports mounted
on the steel structure at approximately 1.5 m intervals.
 The cross sections of the various earth conductors shall be determined in accordance
with IEEE standard / IS: 3043, however, the minimum conductor cross sections shall
be as follows:

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50 x 6 mm HV and LV switchgear

25 x 6 mm Motor

25 x 6 mm Metal raceways and cable trays

Intermediate terminal boxes, cabinets,

25 x 6 mm
panels

25 x 6 mm Other metal parts as may be required

Ground Rods
 The ground rod shall be copper-covered steel of circular cross section, with a nominal
diameter of 19 mm and not less than 3 meters long in section of 1.5 meters. If more
than one earthing rod are necessary they shall not be less than 3 m apart.
 Each ground rod shall have a conical swaged point at one end and shall have a
continuous smooth copper covering of at least 0.254 mm thickness molten-welded or
copper bonded (electro-deposit) to a steel core. The copper clad or pressed type will not
be accepted.
 Where earth plates are indicated, they shall be 600mm x 600mm minimum, of solid or
lattice copper not less than 3mm thick.
 Electrodes shall be installed in undisturbed ground. The distance between any two
electrodes shall be not less than the sum of the lengths of the two electrodes.
 Backfill immediately surrounding plate electrodes shall have a low specific resistivity
and good water retention properties, and shall be well compacted.
Inspection Pits
 Unless otherwise indicated or required, connection between an earth conductor and its
associated earth electrode system shall be in an enclosure.
 The enclosure shall have a removable top cover, which shall be flush with finished
ground level. The enclosure shall be a purpose made inspection pit made of concrete.
The earth electrode connection shall be just below the lid of the inspection pit with
adequate access for testing purposes. The enclosure shall be clearly labelled to indicate
the electrodes function and, where appropriate, its identification number.
Earthing Hardware
Steel Structure Earthing
 Every steel structure that carries insulators or apparatuses shall be connected to the
earthing grid. To ensure contact even if a connection fails or a conductor is cut off,
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every structure must be connected via two different risers to two different parts of the
earthing grid.
 Steel structures with more than one leg shall have two legs connected to the grid, with
one connection to each leg. The legs with the greatest spacing between shall be chosen
for the earth connection.
 Circuit breaker framework is not considered as proper connections between steel
structures. If there are no connections between the legs which are able to carry the
current, all legs must be connected to the grid with their own risers.
 Operating mechanisms and motor drives placed on separate stands shall be connected
as above.
Transformer Earthing
 The transformer tank shall be connected to earth following the same principles as for
steel structures.
 The neutral point of transformers shall be connected to the earthing grid via an isolated
link or conductor. The connection to the two earthing rods, which are also connected to
earthing grid, shall be made by two independent copper strips from the neutral.
Earthing of Switchgear
 Earthing switches are to be connected via a direct earthing connection and not via the
steel structure. Connections between any type of earthing device, e.g. earthing switch,
and risers from the earthing grid shall be made through a copper wire connected
between the earth contact of the earthing device and a riser. The neutral of the primary
winding of Voltage Transformer, shall be grounded via a separate earthing connection
to earthing rod and not via the steel structure.
 Each lighting arrester shall be grounded separately with a full rated earthing connection
and not via the steel structure. In addition, an earthing rod shall be driven into the
ground at each earthing point of a lighting arrester as close as possible to the lighting
arrester and connected to it.
Earthing inside Buildings
 For potential equalising of the building an earthing grid of 8 mm reinforcement bars
shall be cast into the surface concrete of all floors of all switchgear room or basements
with power cables installed. The connection points shall be welded. The mesh size shall
not be greater than 3 x 3 m. Suitable connection points shall be brought out of the

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concrete to allow connection to the main earthing and to all parts of equipment and
building to be earthed. The part of these connecting points which protrudes from the
concrete shall be tinned. The earthing grids of the different levels shall be connected at
8 to 10 m. on the periphery distributed locations.
 The size of the main earthing shall be defined by earthing calculations. The design value
for the main earthing grid shall be 40 kA (1 s) rating and with consideration of
CADWELDED joints.
 To ensure that reinforcement grid is made electrical continuous, a sufficient number of
connection points shall be brought out of the concrete. Together with the detailed civil
Engineer-in-Charge drawings, the earthing design is to be checked before releasing for
construction.
 The connections to these parts shall be of tinned copper of adequate cross section of at
least 70 mm². Further similar connection points shall be installed at a number of places
for the connection of portable earthing equipment when working in the station. All iron
parts of the building and the reinforcement shall be connected to this common earthing
installation.
 Generally, each electrical device must be equipped with an earthing screw of sufficient
diameter for connection to the earthing system. The same applies to all metallic parts
such as panels, doors, rails, fences, transformers, etc. are effectively connected by earth
conductors.
 High voltage equipment and each GIS or metal enclosed switchgear bay shall be
equipped with at least two terminal bolt M 16 in diameter or suitable earthing pads of
adequate size to accommodate at least two bolts for proper connection to the earthing
system.
 For connection to all kind of control, protection, LV, panels etc. an earthing grid shall
be laid in all cable trenches of at least 50 x 5 mm tinned copper bar.
 Control panels and desks, switchboards, etc. consisting of several individual sections
or compartments shall each be connected to this tinned copper earth bar unless all panels
are solidly welded together, or other approved means are applied ensuring solid earthing
connections. In such a case, provisions for earthing must be made at one end at least.
Earthing outside Buildings

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 As a minimum, one grading ring of galvanized steel strip shall be laid around each
building at a distance of 1 m (each) and at a depth of 0.6 m.
 The connections to the building earthing installation shall be made within the building.
An earthing grid of sufficient size, defined by earthing calculations and consisting of
galvanised steel conductor with a maximum mesh size of 3 x 3 m shall also be installed
in the transformer bays.
 All individual earthing grids shall be interconnected at spacing by not more than 5
meters. Buried in ground or supported on building structures, cable trenches, walls, etc.
by means of brass clamps with spacing of not more than 1.25 m.
 Steel fences within and around the substation area shall be connected to the earthing
system at least at two different points and at maximum 10 meters intervals. All metal
parts have to be connected through by welding or suitable earthing conductors.
Other Earthing Arrangements
 Connection boxes for low voltage or control cables shall be connected via one 50 mm2
wire (35 mm2 copper if the terminal of the box does not allow more), irrespective of
whether the box is mounted on an otherwise earthed steel structure or not.
 Poles for lighting and other types of metal structures within the substation area, not
mentioned hitherto, shall be connected to the earthing grid one connection for each
item.
Earthing Equipment
 To meet the safety regulations before any maintenance or repair works are started on
the HV/ LV power equipment, the disconnected "live" parts of the equipment shall be
grounded by means of mobile earthing sets. The portable or mobile earthing sets
(Substation Earthing Sets) shall be supplied by the Agency. One earthing set shall be
supplied per substation and voltage level.
Tests
General
The Agency shall carry out at his own expense all tests necessary to ensure the satisfactory
design and manufacture of all earthing equipment and materials in accordance with Indian
/ IEC Standard.
Design Tests

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Conductors, hardware’s and materials shall be subjected to the design (or type) tests in
accordance with applicable Indian or equivalent IEC standards. Even though the Engineer-
in-Charge witnesses the required tests and the earthing, hardware’s and materials meet the
acceptance criteria, the Agency shall not be relieved of the responsibility of providing con-
ductors, hard-ware’s and materials conforming to all the requirements of the specification.
Quality Conformance and Routine Test
Earthing Conductors
The tests shall be performed in accordance with IEC 60621-2 and shall include, but not
limited to the following:
 Tensile strength tests
 Elongation tests
 Conductor resistivity tests
 Dimension measurement
 Surface finish inspection
 Weight of conductor
Miscellaneous Hardware
The test shall be performed in accordance with IEC 60621-2 and the manufacturer standard.
The routine tests shall be performed by selecting the samples from each lot of equipment.
The number of samples required for the tests shall be: all for 1-3 sets; 3 for 4-30 sets; and
10% for over 30 sets.
 General inspection
 Measurement of dimensions
 Tensile tests No. of samples required: 1 for 20-50 sets;
 2 for 51-100 sets; and
 4 for over 100 sets
 Galvanising tests
Earthing Materials
Quality conformance tests are required to verify the quality of materials and workmanship.
They are to be made on fittings taken on random from the various lots offered for ac-
ceptance.
Routine Tests

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These tests are intended to eliminate defective materials and fittings. They are to be made
on all materials and fittings of the type to which they are applicable, per applicable stand-
ards and / or per Agency quality assurance methods if accepted by the Authoritys Engineer-
in-Charge.
Field Tests
 Field tests and acceptance tests, if any shall be performed by the Agency as per IS: 3043
/ IEC /IEEE-80 standard. The Agency shall provide instructions and acceptance criteria
including the calculated value of the resistance of the installed earthing grid for field
testing and measurement prior to energising the substation / equipment.
 Measurement of the earth voltage by the voltmeter/ ammeter method, test current 100 -
300 A or an equivalent approved method.
 Measurement of the step and touch voltage.
 The lightning protection shall be provided by the Agency as per code of practice for
lightning protection – IS : 2309.

Main Equipotential Bonding Conductor

Main Equipotential bonding conductors shall be provided to connect the earth electrode
system to conductive parts forming the Works.
Equipotential bonding conductors shall have the following minimum sizes.
The Agency shall carry out insulation resistance tests by a megger of following rating
Control circuits up to 220 V - 500 V megger
Power circuits up to 1.1 kV - 1000 V megger
In general, the following checks shall be carried out on all the equipment/systems, as ap-
plicable.
 Name plate details according to approved drawings/ specifications
 Any physical damage or defect and cleanliness
 Tightness of all bolts, clamps and connections
 Oil leakages and oil level
 Condition of accessories and their completeness
 Clearances
 Earthing connections
 Correctness of installation with respect to approved drawings/specifications
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Amaravati Development Corporation Limited

 Lubrication of moving parts

 Alignment
 Correctness and condition of connections

Commissioning Tests
The following commissioning tests are to be carried out on all the equipment/systems, as
applicable.
 Insulation resistance measurement of equipment, accessories, cabling/wiring etc.
 Dielectric tests on equipment, accessories, cabling/ wires etc.
 Phase sequence and polarity
 Voltage and current ratios
 Vector group
 Resistance measurement of winding, contacts etc.
 Continuity tests
 Calibration of indicators, meters, relays, etc.
 Control and interlock checks
 Settings of equipment and accessories
 Checking of accuracy/error
 Checking of operating characteristics, pick-up voltages and currents, etc.
 Operational and functional tests on equipment, accessories, control schemes,
alarm/trip/indication circuits, etc.
 Measurement of guaranteed/approved design values including lighting levels, earth
resistance measurement, etc.
 Complete commissioning checks of the system
SAFETY PROCEDURE AND PRACTICE
Following safety procedure and practice shall be provided by Electrical Agency in switch-
board room/substation as per latest edition of I.S. 5216.
Rubber matting in front of LT PMCC Panel and other panels in substation room, Pump
house MCC room etc
 One shock treatment chart in substation room,
 Caution/Danger Board on all panels, MCC, Switchgear,

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 Sand buckets at substation room, PCC/MCC Panel Room, Chiller Pumps location
 Fire extinguisher at substation room
 One set of hand gloves at substation room
 Fire Safety
The requirement of hand appliance in switchboard room, electrical equipment room
shall be as per the latest edition of Fire Protection Manual by Regional Tariff Commit-
tee.

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LIST OF APPROVED MAKES

Sr. Item/equipment List of Makes of various equipment

No.
01 Squirrel cage Induction Motor Kirloskar (KEC) /Jyoti / Siemens/ Crompton/
(100 HP &above) BHEL/ NGEF/ Bharat Bijlee/ GE
02 Squirrel cage Induction Motor Kirloskar(KEC)/Jyoti/ Siemens/Crompton/
(Below 100 HP) BHEL/NGEF/GE/Bharat Bijlee/ GE/ Kirloskar
(KBL)
03 VT/ Centrifugal water Pump sets Kirloskar/ Jyoti/ M&P (Wilo) / FBM(Pentair)/
(500 HP & above) Grundfoss
04 VT/ Centrifugal water Pump sets Kirloskar/ Jyoti/ M&P (Wilo) / FBM(Pentair)/
(100 HP to 499 HP) Aqua/ WPIL/ Grundfoss/ Flowserve
05 VT/ Centrifugal Water Pump sets Kirloskar/ Jyoti/ WPIL/ M&P (Wilo) / FBM(Pen-
(Below 100 HP) tair)/ Aqua/ Grundfoss/ Flowmore / Flowserve/ Bea-
con/ KSB/CNP/ Laxmi/Shakti
06 Effluent/ Sewage/ Sludge pumps Kirloskar / Jyoti / WPIL/ M&P (Wilo)/ Voltas / KSB
/ FLowmore / Meghraj Machine / Aqua / Kishor/
Beacon
07 Submersible pump set Kirloskar / Crompton Greaves/ Siemens/ NGEF/
KSB/ Voltas / Su-pump/ Aqua/ Kishor
08 Sluice Valve / Reflux Valve/ Fouress/ IVC/ Kirloskar/ IVI/Calsens/ VAG/ Pat-
Butterfly valve son/ Avishkar/Durga /Mayur/Dynamic/KPM/AVK
09 Air valve Fouress/ IVC/ Kirloskar/ IVI/ ARI/Amflow/ VAG/
Avishkar/KPM/ Durga/Patson/ Mayur/ Dynamic/
AVK
10 Electrical actuators Auma/ Marsh/ Rotark/ Siemens/Emtork
11 DG set (Alternator) Crompton Greaves / Kirloskar Green/ Stampford /
KEC/ Leroy somer
12 DG set (Engine) Cummins/ Kirloskar Green/ Caterpillar/ Penta
Volvo /Ashok Leyland /Mahindra & Mahindra/
Perkins
13 LT PVC / XLPE insulated cable CCI (Tropodour) / Asian cables/ Gloster/ Nicco/
(3.5 Core x 35 sqmm and above) Torrent / Polycab/Universal/ Havells/Finolex

14 LT PVC / XLPE insulated cable CCI (Tropodour) / Asian cables / Gloster/ Nicco /
(Up to 4 Core x 25 sqmm) Torrent/ Polycab/ Universal/ Havells/Finolex/ KEI
Incab / /Vishal/ Gulmarg/ /Indoasian
15 HT PVC / XLPE insulated cable CCI (Tropodour) / Asian cables/ Gloster/ Nicco /
Polycab/ Universal /Havells/Torrent
16 Cable Lugs & Glands Dowells / Braco/ Jainson/ Siemens/ Comet

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 Amaravati Development Corporation Limited

Sr. Item/equipment List of Makes of various equipment

No.
17 Measuring Instruments, Ammeter, Simco/ IMP/ Automatic/ GEC / MECO /AE/ Con-
Voltmeter, etc. serve/ Motwani / L&T/ Siemens /Industrial meters
18 Selector Switches, Rotary Switches Simco/ IMP/ Automatic/ GEC/ MECO/ AE/ Con-
serve / Motwani/ L&T/Siemens /Industrial meters
19 Contactor / starters Siemens/ Crompton/ C&S/ L&T/ ABB / GE /
Schneider/Indo Asian
20 Timers- electronic solid state ABB, BHEL, GE, Jyoti, L&T, BCH, Siemens,
Minilec, Legrand, GIC, C&S
21 ACB/MCCB /MCB / ELCB/ L&T/MDS/ABB/Crompton Greaves/GE/C&S/
RCCB/ SFU/ TPN/ Change Siemens/ Havells/ IndoAsian / Legrand/ Schnei-
over switch/ HRC fuses/ MCB Dis- der/GEC/ Merlin Gerin/ Indokapp
tribution Board
23 LED street light/ flood light fittingsPhilips/Crompton/ Bajaj/ Wipro/Surya/GE/
Havells /Asian/ Mahindra/Agile/Pharox
24 Bulk head fitting Philips /Crompton/ Lumex / Bajaj / Wipro/ Havells/
Surya
25 LED lamps Philips/ Osram/ Cree/ Edison / Nichiya/Syska
30 PVC Insulated copper/ Aluminum Polycab/ Finolex/ KEI/ Fort/ Gloster/ CCI/ Asian/
wire/flat Cable Gulmarg/ Anchor/ Nicco/ RR cable/ Havells/
L&T/ Jonson/Vishal
31 Casing capping/ Conduit Prestoplast/ Precision / Modi / Volex / Press Fit
/ BEC/ AKG/Finolex /Diamond
32 Holder/ ceiling rose/ switches/ Anchor/ Leader /Cona / Harison/ Indo Asian/
modular switches/ Plug/ sockets Legrand/ MK / Crabtree/ ABB/ Precision /Wipro/
Vinay
33 Bell Buzzer CONA/ MAX/ Anchor/ Leader/ SSK
34 Exhaust Fan/ Ceiling fan/ Air Crompton Greaves/ Usha/ Orient/ GEC/
circulator/ Pedestal fan/ Bracket fan Almonard/ Khaitan/ Havells/ Bajaj/ Philips / Polar/
Anchor
35 AC Units / Central ACs Hitachi / LG/ Samsung/ Voltas/ Blue star/ Carrier /
Godrej/ Videocon/ Mitsubhisi /LLoyed
36 Capacitor Bank ABB/CGL/Siemens/L&T/Asian/Powercap
37 Circuit Breaker (110kV / 132kV) ABB/Alstom/Siemens/BHEL/Crompton
39 Air circulators Crompton Greaves / Usha / GEC/ Alfa/ Unique/
Almonard/ Khetan/ Bajaj/ Havells
40 Fan regulator Anchor / Roma/ Rider/ Jainex / Cona/ Legrand/
Leader/ Crabtree/ MK / Anchor
41 Electronic Energy meter L&T/ Seimens/ Jaipur/ Mecco/ Enercon/ Udaipur/
Havells/ HPL/ IMP/ Secure/ Emco

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Sr. Item/equipment List of Makes of various equipment

No.
42 Electronic Ballast Philips/ Crompton/ Bajaj/ Wipro / GE/ Surya/
Havells/ Anchor
43 MS tubular pole Unique/ Singh profile/National/ India pole/Bombay
tube pole/Laxmi/ Ajay
44 GI Octagonal Pole & High Mast Philips/Crompton/ Bajaj/ Surya/ Wipro /Valmont/
Transrail
45 FRP Box Sintex/ United/ Indo Asian/National /Siemens
46 Transformer Bharat Bijlee/ Kirloskar/ Crompton/ EMCO/
(1000 KVA and above) Areva/ ABB/ BHEL/ IMP / Alstom / Siemens/
GEC/ Voltas
47 Transformer Bharat Bijlee/ Kirloskar / Crompton/ EMCO/
(Upto 750 KVA) Areva/ ABB/ BHEL/ IMP/ Alstom/ Aditya/ Vijay/
Siemens/ GEC/ Voltas/ NGEF/ Mahati/ Telwane/
Rakesh / Transfab/ Shrihans/ Urja / Nanda Trans-
former / Damsa Vidyut/ Volt–amp/ Saurabh/
Ramkrishna / Transdelta
50 Lighting arresters ELPRO / ABB / BHEL/ OBLUM
51 Cable Termination & Straight Raychem/ M-seal (3 M) / Xicon (CCI)/Densons /
Jointing kit Mahaindra & mahindra
52 RSJ pole TATA/SAIL/Jindal/ Zenith / Khandelwal

53 ACSR / AAAC Conductor Apar/ Sterllte/ Kanti cable/ Pratik conductors/

Bombay wire products/ Vekateshwar wires /
Prem cables/ Lunkad
55 HV indoor/ outdoor Circuit Crompton / ABB/ Siemens/ Scheinder/Alstom
Breakers (Areva)/ Jyoti / BHEL/Andrew Yule
56 LT Current Transformers Pragati/ Kappa/ AE/ Jyoti / C&S/ L&T / MECO/
Gyro/Crompton/Schneider
57 HT Current Transformers AE/ Jyoti / Crompton/ ABB/ Siemens /Scheinder/
Alstom Transdelta/Jain Electrical
58 LT & HT Capacitors Prabodhan / Universal/ Crompton/ ABB/ BHEL/
L&T/ EPCOS/ Shreem/ Khatau Junker/Voltas/ Sie-
mens/Schneider
59 Metering Kiosk ABB/ Huphen/ Transvolt/ Transdelta/ Jain Electrical
60 Indication LED Lamp/ Push L&T/ Siemens/ C&S/ Teknik / Rishab/ Asiatic/
Buttons Controls & Switchgear/ United Electric / Powergear
/ Pustron/ABB
61 Relay Alstom (Areva)/ Siemens/ ABB/Jyoti/ BHEL/L&T/
Easun Reyroll/ GE/ Enercon (Conserve)
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Sr. Item/equipment List of Makes of various equipment

No.
62 DC Battery Exide/ Amco/ Okaya/ SF Sonic/ Amaron/ AmarRaja
63 Battery charger Usha Rectifier/ Hind Rectifier/ National Engineer-
in-Charge Corporation / Suresh Electricals/Arti/
AE/ Suresh Electrical/Delta Electricals/Trinity
Electricals/Panva
64 On line UPS, Servo Stabilizer, AEI/ BHEL/ Hind Rectifier/ L&T/ NGEF/Siemens/
Inverter Hi-rel/ Autometer/ Enertech/ Pyramid/ APC/Dubas/
Luminous/ Microtech/TATA Libert
65 Bearing SKF/FAG
67 Electromagnetic Flow meter ABB/ Siemens/ Endress & Houser/Krohne Marshal/
Electronet/ Nivocontrol/ Mikamachi
68 HDPE pipes Jain Irrigation, Kimplas, Timeplast, Duraline
69 DI pipes Jindal, KOBOTA, Electrosteel, Lanco
70 CRANE & HOIST Hercules, Electromech, Eddy Cranes, Consolidated
Hoist, W H Brady
71 Air Compressor Kirloskar Pneumatics,ELGI, Atlas Copco, Ingersoll-
Rand
72 Reinforcement Steel SAIL, VIZAG STEEL, TATA
73 Cement ACC, Ambuja, Lafarge, Ultatech
74 Air Circuit Breakers ABB/ Alstom/ BHEL/ CGL/ Larsen & Toubro/
Legrand/ Schneider/ Siemens AG
75. Alternators AVK / SEGC/ Leyroy Sommers/ Stamford
76. Annuciator (Facia Type) Digicont/ Larsen & Toubro/ Procon
Anti Vibration Spring Mounts /
77 E&B Rubber Metal (EGAMA)/ Resistoflex
Pads
Automatic Voltage Regulating Re-
78 ABB/ Alstom
lay (AVR)
79 Balancing Valves Advance/Zoloto
82 Bimetalic Overload Relay ABB/ Larsen & Toubro/ Siemens AG
83 Buchholz Relay Prayog / Equivalent
Ducati/ Larsen & Toubro/ Globe Electricals/ Schnei-
84 Bus Ducts / Bus trunking
der/ Audco/Zoloto
86 Cables (Control & Instrumentation) Delton/ Polycab/ Thermo Cables/ Universal/ RPG
87 Capacitor Bank (6.6KV) ABB/ CGL/Asian/ Larsen & Toubro/ Powercap
88 Capacitor Bank (415V) ABB/ CGL/Asian/ Larsen & Toubro/ Powercap
89 Change Over Switches Control & Switchgear/ HPL/ Kirloskar
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 Amaravati Development Corporation Limited

Sr. Item/equipment List of Makes of various equipment

No.
90 Circuit Breaker (110kV / 132kV) ABB/ Alstom/BHEL/Crompton/ Siemens AG
Connector Upto 32 Amps Screw
91 LEGRAND/ Phoenix/Wago
less
92 Contactors / Auxiliary Contactors ABB/ Larsen & Toubro/ Schneider/ Siemens AG
Control & Relay Panel (110kV / ABB/ Alstom / Areva/ Bharat Bijlee/ Siemens AG/
93
132kV) CGL
94 CT & PT (6.6/ 3.3 kV) ABB/ Alstom/ CGL/Kappa
Distribution Boards (Lighting & Adlec/ Asiatic Switchgears/ Advance Panel & Swgr/
96
Power) Hensel
Distribution Boards (PCCs / ABB/ Larsen & Toubro/ Legrand/ Schneider/ Sie-
97
MCCs) mens AG
Engineer-in-Charge Plastics / GRP
98 Hensel/ Sumip/ Siemens AG/GE power
DB's & Panel Enclosures
Feeder Pillar (Non-Magnetic Stain-
99 ABB/ Amptech Electric
less Steel)
ABB/ Alstom/ GE Power/ Larsen & Toubro/ Sie-
100 Fusible Switches
mens AG
Glands (Brass - Single & Double
101 Comet / Dowell/ HMI/ Electromac/lotus/Leader
Compression )
103 Isolator ABB/ GR Power/ Siemens AG/ Elpro
104 Lightning Arrestors ABB/ Alstom/ CGL/ Lamco/ CAPE ELECTRIC
Liquid Resistance Starters (LRS),
105 BCH/ Enterprising/ Poineer/ Resitech
Grid Rotor Resistance (GRR)
ABB/ Alstom/ Siemens AG/ Larsen & Toubro/
106 Load Break Switch
H.H.E (Elecon)
107 Lugs (Copper) Comet/ HMI/ Dowell/ Lotus
Moulded Case Circuit Breaker ABB/ Alstom/ Larsen & Toubro/ Legrand/ Schnei-
109
(MCCB) der/ Siemens AG
Cutler Hammer/ National/ Pioneer Electricals/
110 Neutral Grounding Resistance
Ohmark/ Resitech/ RSI
111 Poles (FRP / GRP) Bajaj/ Sumip
112. Protection Relays (P.F. Correction) ABB/ Alstom/ DUCATI/ Larsen & Toubro/SIGMA
ABB/ Alstom/ Larsen &Toubro/ Switron/ Siemens
115 Rotary / Toggle Switches
AG/ Kaycee
116 Soft Starters ABB/ CGL/ Schneider/ Siemens AG
Vaccum Circuit Breaker (Indoor &
117. ABB/ Alstom / Areva/ Siemens AG
Outdoor)
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Sr. Item/equipment List of Makes of various equipment

No.
118. Vacuum Contactors ABB/ Alstom / Areva/ BHEL/CGL/ Siemens AG
119. Variable Frequency (Speed) Drives ABB/ Larsen & Toubro/ Siemens AG
II CONTROL & INSTRUMENTATION
120 Air Filter Regulator Placka/ Schrader-Schovill/ Shavo-Norgren
121 Auxiliary Relays OEN/ Siemens AG
Comet/ Dowell's Elektro Werke/ Gland Mech Indus-
122 Cable Glands
tries
Densons/ Ercon/ General composites/ Indiana/
123 Cable Trays - FRP / GRP
Premier/ Sumip
CMI/ Delton/ Finolex/ Havells/ KEI Industries/
124 Cables (Control & Instrumentation)
Lapp/ Nicco/ Polycab/ RPG/ Universal
125 Chlorine Measurement ABB/E&H/ Chemtrac/ ProMinent GmbH/YIL/Hach
Control Desk, I/O Panels& PLC Chemin/ Instrumentation Limited/ Siemens AG/ Lo-
126
Panels / Consoles tus/Forbes Marshal/
127 DC Power Supply Unit Aplab/ Siemens AG/ Schneider/ Phoenix
128 DCS Display Unit LG/ Philips/Sony/ Samsung
ABB/ Chemtrols (Fuji)/ Emerson (Rosemount)/
129 DP type Flow / Level Transmitters
Honeywell/ Yokogawa/ Siemens AG
130 Fiber Optic Cables Amp/ Krone/ Molex
131 Flow Switch Krohne-Marshall / Siemens AG/ Switzer/ Levcon
132 Instrument Panels Instrumentation Ltd/ Pyrotech/ Rittal
Apex Tubes Pvt Ltd./ Choksy Tube Co Ltd./ Maha-
133 Instrument Tubing rashtra Seamless Ltd./ Ratnamani Metal & Tubes
Ltd./ Swagelock
ABB / Chemtrols (Fuji)/ Endress & Hauser/ Emer-
Level (Ultrasonic Type) Transmit-
134 son (Rosemount)/ Krohne Marshall/ Siemens AG/
ter
Honeywell/ Yokogawa
Chemtrols (Vega)/ Endress & Hauser/ Switzer In-
135 Level Switch
struments/ Krohne Marshall/ABB
Bhartia Cutler Hammer/ Electromag/ Electronic &
Power Control Company/ Honeywell Automation
136 Limit switches
(I) Ltd/ L & T/ Siemens AG/ Speed O Controls Pvt
Ltd
ORP / pH / Conductivity Measure- ABB/ Forbes Marshall / Siemens AG/ Yokogawa/
137
ment Honeywell/ ProMinent GmbH/ Ametek/ Emerson

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 Amaravati Development Corporation Limited

Sr. Item/equipment List of Makes of various equipment

No.
Plant Control System / Process ABB/ Emerson (Rosemount)/ Honeywell/L&T/
138 Controller Distributed Control Sys- Rockwell Automation/ Schneider/ Forbes Marshall/
tem (DCS) Siemens AG/ Yokogawa
Pressure / Differential Pressure AN Instruments/ General Instruments/ KSB AG/
139
Gauge Waaree instruments/ Siemens AG/ Manometer India
Pressure / Differential Pressure ABB/ Chemtrols (Fuji)/ Emerson (Rosemount)/
140
Transmitter Honeywell/ KSB AG/ Siemens AG/ Yokogawa
Tyco Sanmar/ KSB AG/ Keystone valves Ltd./
141 Pressure Relief Valve
Sebim valves
Self-Regulating Pressure Control
142 Forbes Marshall/ Instrumentation Ltd./Keystone
Valve
Asco/ Avcon/ Herion, Rotex/ Jucomatic/ Schrader-
143 Solenoid Valve
Schovill
ABB/ E&H/ GE Instrumentation/YIL/Forbes Mar-
144 Turbidity Measurement
shal

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SECTION – V
Technical Specification for Mechanical Works
1. VERTICAL TURBINE (VT) PUMPS:
1.1. General
Pumps shall be vertical and shaft-driven by vertical-shaft motors. Impellers shall be of
the mixed or axial-flow multi-stage type, driven at a maximum speed of 960 rpm unless
otherwise specified.
Operation of pumps shall be automatic with working and standby pumps operated in
rotation such that no pump shall be operated continuously for longer duration.
The minimum clearance between adjacent pumps and between pump and wall shall be
as per Hydraulic Institute Standards.
For all the pumps the selected model shall be such that the operating point shall lie
nearest to best maximum efficiency point but towards the left of the maximum effi-
ciency point.
The impeller diameter selected shall be such that there shall be a minimum of one di-
ameter higher and one diameter lower size impeller is available for all the pumps.
The pump installation shall include SS 316 suction strainer, suction bell mouth, suitable
length column pipe, discharge head, motor stool, lower stool, all the accessories, etc.
complete.
The total suspension length shall be from suction point at bell mouth up to delivery
point at common header as per design. The vertical column shall be suitably supported
and anchored to prevent vibrations / movement.
The pumps shall confirm to IS: 1710 and IS: 5120. The pumps shall be capable of
handling raw water from a reservoir with expected turbidity up to 1000 PPM.

Vertical-shaft driving motors shall be mounted on the discharge head above the dis-
charge bend. Unless otherwise specified or approved, they shall be of the hollow shaft
type, fitted with an axially-adjustable thrust bearing designed to carry the combined
weight of pump and motor rotating parts, the drive shaft with couplings, and hydraulic
loadings.

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Support bearings shall be provided between each impeller stage. The impeller shaft
shall be corrosion-resistive low-alloy steel, designed for low stress and long life.
The drive-shaft couplings shall be designed to preserve true shaft alignment in all op-
erating conditions, and shall be close to bearings. Coupling design shall provide for
accurate assembly and re-assembly within the limits of the permissible end-float of the
shaft.
The drive shaft and couplings shall be designed to withstand the maximum accelerating
torque of the motor, with a factor of safety of at least two. When required, the Agency
shall provide his design calculations to demonstrate that the shaft size chosen meets the
requirement for safety factor.
Unless otherwise specified or approved, the drive arrangement shall incorporate an ap-
proved ratchet arrangement to ensure that Pump not rotating reverse direction, if the
pumps are driven in reverse for any reason, the motor is uncoupled from the pump.
Unless otherwise specified, the discharge pipe work shall include an automatic air in-
let/release valve, designed to vent the pipe work on pump start and to allow air ingress
when the pump stops. The valve shall be sized to ensure that accumulated air shall not
be passed to the delivery pipe work on starting. If draining the column pipe on pump
stopping could result in reverse rotation of the pump, means shall be incorporated to
ensure that the pump cannot be restarted before reverse rotation stops.

1.2. Codes and Standards

The design, manufacture and performance of the pumps shall comply with all currently
applicable statutes, regulations and safety codes in the locality where the equipment
will be installed. The equipment shall also conform to the latest applicable Indian or
equivalent international standard. Some of the relevant standards are:
IS 1710 : Vertical Turbine Pump for clear cold fresh water
IS 5120 : Technical requirement for rotodynamic special purpose pumps

1.3. Features of Construction

The hydraulic design of the pump shall meet the requirements of high efficiency atleast
85%, low submergence, high reliability, optimum system design.

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The shut off head shall be at least 110% of the total head and maximum of 130 % of
total head.
The first critical speed for the pump rotor shall be at least 30% above the operating
speed.
Pumps shall run smooth without undue noise and vibrations. The velocity of vibrations
and the noise level shall be as per latest IS code. To detect excessive vibrations exceed-
ing design limits as per standards, three axis vibration monitors shall be installed on the
motor at top. The motor shall stop automatically when the vibration exceeds the limits.
The power rating of the pump motor shall be higher of the following:
115% of the power input to the pump at duty point at a speed corresponding to given
frequency.
Maximum power input while operating single pump corresponding to the speed of 50
Hz.
Pump impeller shall be both statically and dynamically balanced.
The pumps of a particular category shall be identical. Components of identical pumps
shall be interchangeable.
Pump shall be provided with non-reversible ratchet to prevent reverse rotation.
All pumps shall be provided with suitable protections including protection against over-
load, bearing failure, increase in bearing temperature etc.
All accessories required for proper and safe operation shall be furnished with the
pumps.
Pump and motor shall be selected for VFD operation in variable frequency.

1.4. Reverse Rotation

Non-reverse ratchet arrangement shall be provided to prevent reverse rotation. How-
ever, the unit shall be designed to operate safely at the maximum speed attainable in the
reverse direction of rotation due to water returning through the pump at times when the
power supply to the motor is interrupted and the valve fails to disallow reverse flow
and non-reverse ratchet arrangement fails.

1.5. Noise and Vibration Level

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Pumps shall run smooth without undue noise and vibration and noise level shall be
limited to
a) Sound : 85db at a distance of 1.5 m.
b) Vibration : 4.5mm/s velocity. (Measured vertical, Horizontal and axial)

1.6. Column pipe

Column pipe shall be steel Manufactured from tubes confirming to either IS 1978:1982
or Gr A of IS 2062: 1984 for depths greater than 80m, the column pipe shall be manu-
factured from tubes confirming to IS 4270:1983.
The Standard lengths of column pipes shall be 1.5, 2.5 or 3m.
The column pipe may be threaded, flanged or provided with other methods of connec-
tion.

1.7. Gasket, Seal and Packing’s

Gaskets, seals and packings used for clear, cold water pumps shall confirm with those
specified in IS: 5120:1977.

1.8. Impeller:
The impeller shall be ASTM A 743 CF8M may be of the enclosed or semi-open type
impeller shall be fastened securely to the impeller shaft with keys, taper bushings, lock
nuts or split thrust rings.
They shall be adjustable vertically by means of a nut in the driver or an adjustable
coupling between the pump and the driver.
Impeller shall be properly balanced dynamic balancing is recommended. Closed impel-
lers may have a renewable sealing/wear ring fitted on to the front shroud or in the bowl
or both.

1.9. Bowl
The Bowl shall be Cast Iron conforming IS 210:1978 and casings of bowl shall be free
of blow holes, sand holes and other detrimental defects, the bowls shall be capable of
withstanding a hydrostatic pressure equal one and a half times maximum discharge
pressure (this included shut off head).

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Amaravati Development Corporation Limited

The bowls may be equipped with replaceable seal rings on suction side of enclosed
impellers. Water passages shall be smooth and the bowls may contain bushes to serve
as bearings for the impeller shaft.

1.10. Impeller Seal Ring:

The Wearing shall be ASTM A 743 CF8M wearing ring providing seal to enclosed im-
peller. It may be either on the impeller or in the bowl or on both.

1.11. Transmission Bearing Ring:

The Bowl-bearing/top bowl bearing shall be rubber; bronze conforming IS 318:1981
and bearing used for impeller shafts in each bowl.

1.12. Impeller/Line/head Shaft:

Impeller Shaft shall be stainless steel conforming IS 1570 (Part 5):1895 and it holds the
rotating impellers and coupled to the line shaft.

1.13. Material of Construction

The material of construction for various components shall be as under:
Casing & Suction bell : Cast Iron IS: 210, Grade FG 260
Bowl : Cast Iron IS: 210, Grade FG 260
Impeller : ASTM A 743 CF8M
Impeller Shaft : AISI 410
Head Shaft : AISI 410
Line Shaft : AISI 410
Discharge Head : MS IS 2062 Fe 410WA
Column pipe : MS Fabricated
Transmission Bearing : Rubber backed Bronze
Wearing Ring : ASTM A 743 CF8M
Suction strainer : SS 316
All fasteners including anchors bolts, foundation bolts, washers, nuts etc. in both in wet
and dry areas Stainless Steel SS 316

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Amaravati Development Corporation Limited

1.14. Discharge head and mounting plate

The discharge head shall be a composite fabrication or casting. The supporting-plate
assembly shall consist of a steel base plate, strong enough to carry the weight of the
complete pumping unit without significant deflection. The assembly shall provide the
motor mounting arrangement and support the pump. If required, the supporting plate
shall be supplied with a flanged sleeve to facilitate mounting, with a puddle flange for
building in.
The following shall be included:
• supporting plate with holding down bolts or studs;
• Bedplate ring with leveling screws and plates;
• Lifting lugs
• Fixings for motor and coupling;
• Provision for insertion of cables and level-recording equipment if required;
• Provision for access to service the shaft seal.
The discharge-head shaft seal shall be selected for long life with minimum mainte-
nance, and may be of the mechanical. The pressure limit of mechanical seals shall be at
least 50% greater than the pump closed-valve delivery pressure. Provision shall be
made to return to the pump well any water leaking past the head seal.

1.15. Water-lubricated line-shaft bearings

Bearings shall be spaced at the intervals needed to ensure vibration less running at all
possible pump operating speeds, with a maximum distance of 2.5 m apart. Guide bear-
ings shall be of resilient synthetic rubber, mounted in spider bearing-retaining assem-
blies.
The arrangements for supplying filtered water shall ensure:
a) That filters used are duplex type so that one filter can be cleaned while the second
remains in service;
b) That if required by the bearing design, a filtered water supply is provided to each
bearing before the shaft begins to rotate.
c) That if the installed arrangement makes any reverse rotation possible on pump stop-
ping, if required by the bearing design a filtered water supply is provided to each bear-
ing until reverse rotation stops.

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Amaravati Development Corporation Limited

1.16. Rejection
If the shop testing at factory premises, the guaranteed efficiency considering the zero
percent negative tolerance, is not met, the pump shall stand rejected.

1.17. Technical Data Sheet

The bidder shall submit detailed technical data sheet pump with their technical proposal
during bidding covering all the details of pumps.

1.18. Name Plate

All Pumps shall have a stainless-steel nameplate on the body. Project name shall be
printed by original manufacture

2. HORIZONTAL CENTRIFUGAL PUMPS:

2.1 General
The pumps proposed shall be suitable for installation at site whose altitude is as per site
level and shall work under maximum ambient temperature. The pump and motor shall
be capable of providing the required output when working under above conditions.

2.2 Specific Requirements

Design The design, manufacturing, performance of the horizontal execution pumps as
specified hereinafter, shall comply with the requirements of applicable codes, the latest
applicable IS standards, in particular and in that order of application, the following-

IS 5120 Technical requirements for rotodynamic special purpose pumps (Such

as centrifugal pump axial flow, mixed flow, turbo pumps) for liquids
other clear, cold, fresh water.
IS 6595 (Part 1 & 2):2002 Horizontal centrifugal pumps for clear, cold water
specification.
IS 9137 Code for acceptance test for centrifugal, mixed flow and axial pumps-
Class C.

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The materials of the various components shall be as per data sheet or equivalent mate-
rial conforming to applicable IS standards in that order of application.

2.3 DESIGN & CONSTRUCTION

2.3.1 Casing:
The casing shall be of robust construction and shall be tested to withstand 1.5 times
maximum discharge pressure for 2min.

2.3.2 Impeller:
Impeller shall be balanced as per grade ASTM A 743 CF8M

2.3.3 Codes and Standards

The design, manufacture and performance of the pumps shall comply with all currently
applicable statutes, regulations and safety codes in the area where the pumps will be
installed and shall confirm to IS:6595 (Part 1& 2). The performance of pumps shall be
guaranteed as per IS: 5120 and IS: 9137 with zero negative tolerance. The pump set
shall be coupled to 3 Phase, TEFC horizontal mounted induction motor.

2.3.4 Features of Construction

 Operation of pumps shall be automatic with working and standby pumps operated
in rotation such that no pump shall be operated continuously for longer duration.
 The minimum clearance between adjacent pumps and between pump and wall shall
be as per Hydraulic Institute Standards.
 For all the pumps the selected model shall be such that the operating point shall lie
nearest to maximum efficiency point but towards the left of the maximum efficiency
point.
 The impeller diameter selected shall be such that there shall be a minimum of one
diameter higher and one diameter lower size impeller is available for all the pumps.
 The Impeller shall be enclosed type, securely keyed to the shaft. Means shall be
provided to prevent losing operation including rotation in reverse direction.
 The pump shall be provided with renewable type casing ring
 The first critical speed for the pump rotor shall be at least 30% above the operating

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speed.
 Replaceable shaft sleeves shall be provided to protect the shaft where it passes
through stuffing boxes.
 Stuffing boxes shall be of such design that they can be repacked by removing the
mechanical seal and lantern ring.
 Pump shall be furnished complete with flexible coupling. Coupling guard made of
expanded metal bolted to the base plate shall be furnished.
 The base plate for pump and motor shall be common. Suitable holes shall be
provided in the foundations for fixing of bolts and grouting. Foundation bolts shall
be complete with nuts and washers.
 The gland and cooling water shall be collected and led by suitable pipeline up to the
sump pit.
 Suction and discharge connections shall be flanged.
 Pump impeller shall be dynamically and statically balanced.
 The pumps of a particular category shall be identical. Components of identical
pumps shall be interchangeable.
 The pump shall be capable of developing the required total head at rated capacity
for continuous operation. The pumps shall operate satisfactorily at any point on the
H-Q characteristic curve over a range of 50% to 130% capacity.
 The shut off head shall be at least 110% of total head and maximum of 130%.
 Pumps shall run smooth without undue noise and vibrations. The velocity of
vibrations and the noise level shall be as per latest IS code. To detect excessive
vibrations exceeding design limits as per standards, three axis vibration monitors
shall be installed. The motor shall stop automatically when the vibration exceeds
the limits.
a) Sound : 85db at a distance of 1.5 m.
b) vibration : 4.5mm/s velocity.
 The pumps shall be with zero negative tolerance (and not 5% as indicated in IS–
5120).
 The total head capacity curve shall be continuously rising towards the shut-off point
with the highest head at shut-off.
 The pump that works at the best efficient point for specified duty conditions would
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only be selected. However, the pump shall have a very good efficiency when it
works at lower heads due to higher level in the sump.
 Tappings at suction and discharge nozzles shall be provided for pressure gauge
connection. Casing drain connection with stainless steel collared plug shall be
provided.
The pump shall be provided with the following accessories;
 Pressure Gauge of suitable range with stainless steel connecting pipes, gooseneck,
cocks etc. complete.
 Priming Cock.
 Suitable piping for collection and leading off gland leaks etc. up to discharge point.
The power rating of the pump motor shall be higher of the following:
115% of the power input to the pump at duty point at a speed corresponding to given
frequency.
Maximum power input while operating single pump corresponding to the speed of 50
Hz.
 All accessories required for proper and safe operation shall be furnished with the
pumps.
 Pump and motor shall be selected for VFD operation in variable frequency.
 Pump rated efficiency of minimum of 85%

2.4 Material of Construction

The material of construction for different components of pump shall be as below.
S. No. Component Material
1 Casing Casting Grade FG 260 of IS 210
2 Sealing Mechanical seal.
3 Impeller ASTM A 743 CF8M
4 Wearing rings, Inter Stage Ring ASTM A 743 CF8M
5 Shaft AISI 410
6 Shaft Sleeve AISI 410
Fasteners, Anchors bolts, Foundation
7 Stainless Steel: 316
Bolts etc. both in wet and dry areas
8 Base Plate MS with epoxy coated

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2.5 Performance Data

Pump performance curves flow rate Vs head, BKW, efficiency, NPSHR from zero
flow to maximum flow and torque-speed curve with operating points clearly indicated
shall be submitted and verified at the time of testing and commissioning of the instal-
lation.

2.6 Testing
Pumps shall be tested for performance at manufacturer’s work and at site.
All pumps shall be tested at factory as per relevant BIS codes.
Hydro-test pressure on casing shall be 1.5 times maximum discharge head or twice
Differential head whichever is higher. (Maximum discharge head = shut-off head +
Maximum suction head). Unless otherwise stated in data sheet A, the hydrostatic tests
On the casing shall be conducted for a minimum duration of 30 minutes.
The pumps shall be tested as per IS 5120, at rated speed at MANUFACTURER's
Works to measure capacity, total head, efficiency and power. The negative tolerance
on Efficiency shall be limited to 2.5% and not 5% as indicated in IS 5120. These tests
Shall form the basis for acceptance of pumps except for vibration and noise. The
Pumps shall be tested over the range covering from shut-off head to the maximum
flow. The duration of the test shall be minimum one (1) hour. Minimum five (5) read-
ings approximately equi-distant shall be taken for plotting the performance curves.
After installation, the pumps shall be subjected to testing at site also. If
the site performance is found not to meet the requirements regarding vi-
bration and noise as specified, the equipment shall be rectified or replaced
by the VENDOR, at no extra cost.

2.7 Quality Assurance Plan (QAP)

Detailed dimensioned general arrangement drawing of pump and driver. This drawing
Shall indicate all the design data and information furnished. Foundation drawing of
Pump and driver with static and dynamic loads, details of fixing, grouting and all
Relevant data required for design of foundation.

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Cross-section drawing of the pump with complete part list, materials of construction
And relevant standards for each part.
Scheme for pump sealing, lubrication and cooling.
Driver dimensional drawing.
Surface preparation and painting procedures.
Catalogues, data sheets and drawings for instruments.
Installation, operation and maintenance manual along with lubrication
schedule

2.8 Name Plate:

All Pumps shall have a stainless-steel nameplate on the body. Project name shall be
printed by original manufacture.

2.9 Submittals
Submittals include the following and shall be specific to this project. General Submit-
tals not to be accepted.
 Sequence of operation
 Shop drawing indicating dimensions, required clearances and location and size of
each
 Field connection.
 Power and control wiring diagrams.
 Pump data sheets.
 Compliance statement of all technical requirements shall be attached with
submittals.
 2 sets of submittal copies shall be submitted for Engineer-in-Charge Incharge
Approvals for all mechanical equipment.

2.10 Quality Assurance

The pumping package shall be assembled by the pump manufacturer. An assembler of
pumping systems not actively engaged in the design and construction of centrifugal
pumps not to be considered a pump manufacturer. The manufacturer assumes “Unit
Responsibility” for the complete pumping package. Unit responsibility shall be defined

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as responsibility for interface and successful operation of all system components sup-
plied by the pumping system manufacturer.
The manufacturer have a minimum of 15 (Fifteen) years of experience in the design
and construction of variable speed pumping systems.
The local supplier of water supply Variable Speed Pumping System have relevant ex-
pertise in all aspects of design, application Engineer-in-Charge, installation, program-
ming, interfacing, commissioning and after sales service. Supplier must have commis-
sioned minimum 25 sets of water supply Variable Speed Pumping System
All functions of the variable speed pump control system be tested at the factory prior to
shipment. This test shall be conducted with motors and it shall test all inputs, outputs
and program execution specific to this application.
The manufacturer shall be fully certified by the International Standards Organization
per ISO 9001. Proof of this certification shall be furnished at time of submittal.
Manufacturer shall be listed by Underwriters Laboratories as manufacturer of packaged
pumping systems.
Tenderer comply with all sections of this specification relating to packaged pumping
systems. Any deviations from this specification shall be clearly defined in writing at
time of bid. If no exceptions are taken at time of bid, the supplier be bound by these
specifications.

2.11 Manufactured Units

Furnish and install as shown on the plans a Variable Speed Pumping System as per
approved manufacturers.
The control system include as, a minimum, the programmable logic pump controller,
adjustable frequency drive(s) and remote sensor / transmitters as indicated in the draw-
ings on the plans. Additional items shall be included as specified or as required to
properly execute the sequence of operation.
The variable speed pump logic controller, adjustable frequency drives, AFD bypass
and remote sensor / transmitters shall be shipped as individual components to the job
site.
Pump logic controller, adjustable frequency drives, sensor / transmitters and related
equipment shall be installed by the mechanical Agency as shown on the plans.

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Power wiring shall be installed by the mechanical Agency as shown on the field con-
nection drawings and wiring diagrams supplied with the pumping package.
Low voltage wiring shall be installed by the mechanical controls Agency
as shown on the field connection drawings and wiring diagrams supplied
with the pumping package.

3. Flanges
Valves shall be flanged and the flange face at right angles to the valve
Centerline. Backside of valve flanges shall be machined or spot faced for proper Seating
of the head and nut.
Flanges shall be machined on faces and edges to IS 6392 or BS 4504 or ANSI B16.5 for
flanges. For PN 16 nominal pressure rating unless otherwise required. Flange drilling
shall conform to IS 1538.
Flanges of entire intake well, rising main, WTP, clear water pumping main shall selected
from unique standard to maintain the minimum inventory spare. Accordingly, the valves
flanges also shall be selected.

4. Dismantling Jointing
4.1 Design Requirements
a. Dismantling joint shall be designed such that adequate space can be created by
collapsing the dismantling joint, for removal and for reinstallation of adjacent
valves.
b. (b) All parts of dismantling joints shall be amply proportioned to take care of all
stresses that may occur during installation and in operation.
c. Dismantling joints shall have end, thrust and follower flanges and rubber sealing
ring.
d. Tie rods shall be provided for rigid fixing after installation to enable transmission
of thrust. Tie rods shall be provided for minimum 30% of the holes.
e. With the use of dismantling joints, it shall be possible to have an approximate
clearance of 25 mm with the adjoining fittings.
f. All dismantling joints on the suction side shall be designed for a pressure of 2.5 bar
and on delivery side shall be designed for a pressure of 10 bar.

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4.2 Features of Construction

a. Outside of inner sleeve and inside of outer sleeve shall be machined to close
tolerances.
b. Inner sleeve end shall be chamfered for easy introduction of rubber ring.
c. Sleeves shall be of uniform bore and straight in axis. The flanges shall be square to
the axis of sleeve. The faces of flanges shall be parallel. The bolt holes circle and
outside periphery shall be concentric with the bore and bolt holes equally spaced.
Bolt holes in one flange shall be located in line with those in other.
d. Bolt holes on flanges shall be drilled with the help of drilling jig.
e. Flanges shall be machined flat faced and shall be full or spot faced on the back side.
Flange thickness shall be uniform throughout. Flange periphery also shall be
finished smooth. Flanges shall be as per relevant applicable standard corresponding
to design pressure. The flanges of dismantling joints mating with valves shall have
drilling stranded matching with that of the valve.
Materials of Construction
a. Body : CI IS: 210 Gr FG 260
b. Flanges : CI IS: 210 Gr FG 260
c. Seal ring : EPDM Rubber
d. Tie Rods, Bolts, and Nuts and: SS 304 Washers

4.3 Design parameters

a. Rating (bar) : 10
Data to Be Furnished by Agency after the Award of Contract.
Dimensional and cross section drawing of valves and dismantling joint.

5. Pressure Indicators:
Direct reading, pipe mounted Pressure gauges with siphon & cock valve of Stainless
Steel with 6-inch phenolic dial (white dial with black numerals), 316 SS Bourdon tube,
nylon movements and micrometer type adjustable aluminium pointer with accuracy of
+/-1% of span including accessories like siphons, snubbers for pump discharge appli-
cations and chemical diaphragm for corrosive and oil services and name plate, etc.

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Material of accessories shall be SS. IP65 degree of protection for enclosure. Over
range protection shall be 50% above maximum pressure. Armoured capillary of 15 M
shall be provided as required.
All pump suctions shall install compound gauge as per following detail
a. range : -1 to 1.5 kg/cm^2
b. least count : 0.05 kg/cm^2
All delivery line shall install pressure gauge as per following detail
a. range : 0 to 10 kg/cm^2
b. least count : 0.2 kg/cm^2

6 AIR VALVE

Air valves are used to protect the pipe line by filling air during draining, venting air
during filling and Continues venting of entrapped air during operation. Air valves shall
match with the following specifications

6.1 Material of Construction for DN 50mm to 150mm (PN 16 Bar)

Body : Ductile Iron ASTM A 536
Air & Vacuum Float : Polypropylene
Air & Vacuum Seal : EPDM
Automatic Float : Polypropylene
Rolling Seal : EPDM
Discharge Outlet : Polypropylene
O-Ring : EPDM
Discharge Outlet Seal : EPDM
Bolt : Stainless Steel SAE 304
Flange Standard : DIN 16

6.2 Material of Construction for DN 200mm (PN 16 Bar)

Body : Ductile Iron ASTM A 536 / EN 1563
Cover : Ductile Iron ASTM A 536 / EN 1563
Float : Polycarbonate
Orifice Seat : Bronze
Orifice Seal : EPDM

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Automatic Valve -
Body : Reinforced Nylon
Rolling Seal : Rubber E.P.D.M.
Clamping Stem : Reinforced Nylon
Float : Foamed Polypropylene
Base : Reinforced Nylon
O-Ring : BUNA-N

7 WAFER TYPE BUTTERFLY VALVES

Wafer type butterfly valves are used to isolate Air Valve as and when required for
Isolation or Maintenance Purpose.
7.1 Specifications:

 Body and Disc shall be Ductile Iron GGG40 having fully vulcanized liner seat
 Shaft shall be made with Stainless Steel
 Body shall Coated with Epoxy
 Valves shall be supplied with Hand lever up to 150 mm diameter and for the sizes
above 150mm with Gear Arrangement
 Face to face dimensions shall be confirming to ISO 5752

7.2 Material of Construction

Body : Ductile Iron GGG 40 + EPDM

Disc : Ductile Iron GGG 40
Shaft : SS 420/SS416
Bushing : Bronze/ Nylontrol
O-Rings : NBR/EPDM
Cover joint : Steel
Washer : Stainless Steel
Bolts : Stainless Steel

8 PUMP CONTROL VALVE (UPTO 400MM)

8.1 SPECIFICATION

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The Pump Control Valve shall open fully or shut off in response to electric signals. It
shall isolate the pump from the system during pump starting and stopping, to prevent
pipeline surges during Pump ON/OFF.
Valve Shall be with Rapid-action piston for Fast Opening/Closing action to facilitate
stable and accurate control.
Valve shall have High Kv factor e.g. 4” valve shall have KV value of 475 m3/hr,
Valve shall have Low head loss at high flow rates,
Valve shall be strong, lightweight and corrosion proof surfaces, which resist cavitation
Damage, thus increasing service life and reducing operation & maintenance cost.
Valve shall have Linear flow, Low turbulence to minimize cavitation, and allow high
flow velocities with low noise and vibration.
Valve shall have “Soft closure” feature to prevent water hammer.
Multi-Valve modular configuration Full redundancy enabled. Individual valves can be
possible to separately remove for maintenance or replacement which reduces downtime
and maintenance costs & allows maintenance work to be done without halting water
flow.
8.2 MATERIAL OF CONSTRUCTION:
Valve Body : Reinforced fiberglass nylon or Polypropylene
Pistons, Bushing, Front and Rear Cups: Reinforced fiberglass nylon or Polypropylene
Main seal : NBR, VITON or EPDM rubber,
O-rings : NBR or EPDM rubber
Inlets, outlets : Stainless steel/ Reinforced fiberglass nylon
Clamps, bolts : Stainless steel
Multi-Valve manifolds : Spheroid iron with polyester or epoxy coating
Pressure Rating : PN 16

9 PUMP DISCHARGE VALVES (500mm and above)

a. Change Level to Lever.

b. Radial Plunger / External Gear Pump. 2 Pumps: One operating & one stand-by with
automatic switch-over facility in case of the operating pump failure to be provided.

c. Local Electrical Control Panel attached to the HPU. The LCP should have facility to hook-
up with System Scada/ DDCMIS for Remote control also.
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Pump Discharge Pressure: Can be up-to 175 Bar because 230 bar Rated Gear pumps are easily
available in market. This will make the system more compact & cost competitive.
In case of Pump failure: Bladder type Accumulator should be provided which can open the valve
2 times without pump flow being available.
PD Valve Opening from 0% to 100%: Hydraulic System can achieve this. However, it is not
advisable to operate any conventional Butterfly Valve below 10% opening continuously due to
cavitation & erosion considerations.
Add: The Hydraulic Cylinder actuator should have cushioning at the full close end. To the extent
of 5 to 10% of stroke: adjustable.
Closing Time:
Normal: Planned Shut-down: 90% in 40 to 50 sec. & balance in 10-20 Sec.
Emergency (Main pump motor trip): 80-90% in 10-20 sec. & balance in 10 Sec.
Opening Time:
Upto 1200 mm Dia BFV: Upto 60 Sec. Larger than 1200mm BFV: upto 90 Sec.
5 Limit Switches: FO, FC, Crack Open, Intermediate Open & Creep to be provided.
Mechanical lock with Electrical interlock at full open & Full Closed positions required.
Position Transmitter for hooking up position of the valve with remote Control required.
Local control Panel to be mounted integrally on the Hydraulic Power Unit. This unit is to be
located at Valve floor level & can be hooked up with the SCADA/ DCIS. LCP to be provided
with pushbuttons & indicator lamps & selector switches.
Foundation with Sole Plate, Anchor Bolts & fasteners required.
Hydraulic Actuator should be body mounted.
9.1 CONSTRUCTION
Flanged /Wafer offset /Wafer Liner : Double Flanged
Rating : PN 1.6
Governing Standard : For upto size 2000 mm dia AWWA C 504
For above size 2000 mm dia : AWWA C 516
Flange Drilling Standard : AWWA C 207
9.2 Material of Construction
Body & Disc (Fabricated) : Mild Steel IS 2062 Gr. B
Shaft, Shear Pin : Stainless Steel AISI 431
Disc Seal Ring : Nitrile Rubber
Body Seat Ring : Stainless Steel AISI 304
Bearing Bush : Steel Backed PTFE Self Lubricated

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Clamping Ring : Stainless Steel AISI 304

MODE OF OPERATION
Hydraulic Actuator Hydro-Electrically operated complete with counter weight arrange-
ment and accessories.
ACCESSORIES With bypass sluice (01 MANUAL)
TESTING
Seat Test Pressure (Hydro Test) 16 Kg/cm2
Body Test Pressure (Hydro Test) 24 Kg/cm2

10 SLUICE VALVES (Resilient seated Gate valve/Sluice Valve from DN 50mm to

DN 1200mm)
10.1 Constructional Features
DI D/F non-rising spindle soft seated glandless Gate Valves with body and bonnet of ductile
cast iron of grade EN-JS 1050, wedge with fully encapsulated EPDM rubber (approved for
drinking water). The valves should be with replaceable stem nut. Valve stems shall be of single
piece thread rolled. Valve shall have 3 “O” rings of NBR for stem sealing. Gate valve shall be
compatible for buried applications without valve chamber. Face-to-face dimensions as per BS
5163-89/IS 14846-PD/EN 558F4 & F5 and flange connections as per EN 1092-2 / IS 1538,
Electrostatic epoxy powder/liquid coating (EP-P) inside and outside color blue with minimum
coating thickness of 250 microns.
Material of Construction:
Body, Bonnet : Ductile Iron EN-JS- 1050
Wedge : Ductile Iron EN-JS-1050) encapsulated with EPDM rubber.
Spindle/Stem : SS: AISI 420
Stem Nut : Copper Alloy
Bonnet Gasket : EPDM Rubber Grade W-270
Internal Fasteners: Steel 8.8 with geomet coated
Stem Sealing : Toroidal NBR sealing rings (Min 03 ‘O’ Rings)
Coating : Inside & Outside epoxy powder coated; DFT minimum 250 microns, shade
RAL 5015 (BLUE)
Mode of Operation: Hand wheel/ Actuator

11 BUTTERFLY VALVES
(All Size of Butterfly valves selection shall be same size of pipe Diameter)
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11.1 Constructional Features

DI D/F Resilient Seated Vacuum tight Butterfly Valve suitable for bidirectional flow
with Body and disc made of EN-JS 1030. Valve shall conform to double eccentric
design with specially designed wave form disc. The disc shall contain pressure
supported sealing system made of EPDM. The Body seat shall be PTA (Plasma
Transferred Arc) weld deposited with nickel chromium and micro finished. Closed Disk
Eye with dry shaft design made of Stainless steel with 13% chromium of grade 1.4021
connected with Medium free Bearing Bronze with double O-ring sealing of EPDM. The
shaft ends shall be of Polygon Plug Connection to ensure absolute clearance free
connection to the disc. The Valve shall be compatible for Buried application without
chamber. The Coating and the rubber parts shall comply with DVGW / KTW / W270
standards. The gearbox shall be of Slider Crank Mechanism type with stable adjustable
end stop, with IP-68 protection class and mechanical position indicator. The Valve shall
be according to EN593/IS 5163, the face-to-face length shall be EN 588-1, basic series
14/BS 5155(Long Body)/ IS13095 (Long Body) and drilling according to EN 1092-
2/IS 6418. Epoxy or liquid Epoxy coating with minimum thickness of 250 microns
according to GSK both applied inside and outside of both body and disc. (EP-P  it is
a resi-coat powder approved for drinking water application, applied through fusion
bonding technology process by dipping the shot-blasted casted components heated up
to 200 deg C).

11.2 Material of Construction:

Body : Ductile iron to EN-JS 1030
Disc : Ductile iron to EN-JS 1030
Retaining Ring : Stainless Steel encapsulated with EPDM up to DN600. Steel
from DN700.
Shaft : Stainless Steel 420 with 13% chromium (1.4021)
Shaft Bearing Bushes : Bearing Bronze
Seat : Integral Ni-Cr weld overlay, (Ni > 67% Cr = 19.5 %) micro
finished
Disc Sealing & ‘O’ rings: EPDM Rubber [W 270 Clause]
Surface Protection : Epoxy powder coating or epoxy liquid lacquer min. 250
microns thickness, colour Blue
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12 Electric Actuator
For Sluice/Butterfly valves installed on the Trunk network
Actuators shall be suitable for the medium, climatic, environmental and pressure con-
ditions of the system in which they are to be fitted.
Actuators shall be provided with:
a. AC Electric Motor.
b. Reduction gear unit.
c. Torque switches mechanism.
d. Limit switch mechanism complete with set of limit switches and additional two
spare sets for suitable position.
e. Hand wheel, for manual operation.
f. Valve position indicator.
g. Hand-auto lever with suitable locking arrangement.
h. 10 W single phase space heater in the switch compartment.
i. Blinking light throughout the valve operation.
j. Junction box for terminating power and control cables.
k. With additional accessories for integrating with PLC system.
The actuator shall be suitable for operation on 415V, 3 phase, 50 Hz power supply. The
motor winding insulation shall conform to class B as per relevant BS and motor shall
be protected by suitable thermal overload relays. The actuator shall be capable of pro-
ducing not less than 1 1/2 times the required operator torque at the required time cycle
of valve operation. The transmission shaft connecting the actuator to the valve shall be
provided with 2 bearings one at actuator end and one at valve end with universal cou-
plings at suitable places. The required number of switch/contacts meets for require-
ments for PLC system. The electrical actuator for butterfly valves acting as flow con-
trollers shall comprise of the additional necessary electronic card/ accessories required
for generating a 4-20 ma signal and for integrating it with the PLC system.
The electric motors shall be of the squirrel cage type as per IS 325 with insulation to IS
1271 Class B. The windings shall be impregnated to render them non-hygroscopic and
oil resistant. All internal metal parts shall be painted. The motor shall be rated for 15
minutes. They shall also be suitable for operating on the specified electric supply and

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shall satisfactorily open and close the valve under variations of electric supply speci-
fied.
Motor shall be protected by suitable overload protection device.
The reversing contactor starter and local controls shall be integral with the valve actu-
ator. The starter shall comprise mechanically and electrically interlocked reversing con-
tactors of appropriate rating fed from a 110 Volt control transformer. The common con-
nection of the contactor coils at the transformer shall be grounded. HRC cartridge type
primary and secondary fuses shall be provided.
Local control shall comprise pushbuttons for open, close and stop operations and a
Lockable Local/Remote/off selector switch. The control schematics shall be subject to
approval.
Internal wiring shall be of 650/1100-volt grade PVC insulated stranded copper conduc-
tor of minimum 1.5 sq. mm for control circuits and of minimum 4 sq.mm copper for
the power circuit. Each wire shall be number identified at each end. The terminals shall
be of stud type. Cable entries shall be suitable for PVC insulated/ sheathed, armored
cables. A separate terminal box shall be provided for the heater. A separate terminal box
shall be provided for cabling to control circuits.
The actuator enclosure shall be fully weatherproof and hose proof to IP 67 and shall be
fitted with an anti-condensation heater, which shall be switched off when the motor is
running.
The torque switch mechanism shall function as follows to stop the motor on closing or
opening of the valve, or upon actuation by the torque when the valve disc is restricted
in its attempt to open or close.
The torque switch in the closing direction shall interrupt the control circuit if mechan-
ical overload occurs during the closing cycle or when the valve is fully closed.
The torque switch in the opening direction shall interrupt the control circuit if mechan-
ical overload occurs during the opening cycle or when the valve is fully open.
The mechanism shall facilitate adjustment of the torque at which the switches are re-
quired to operate.
Non-adjustable limit switches shall stop the motor and give indication when the disc
has attained the fully open or closed position.

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The adjustable limit switches shall have control rated 2A, 48 V DC for specified system
interlock, at the desired value position in both the opening and closing directions.
Motor operators shall be provided with clearly visible local valve position indicators
mounted on the operator assembly to give an indication whether the valve is fully open,
fully closed or in an intermediate position.
Settings and emergency operation shall be possible with the use of a hand wheel. The
Hand wheel shall be of stainless steel and the drive mechanically independent of the
motor drive and any gearing shall limit the operating torque at the hand wheel to less
than 15 kg and be such as to permit emergency manual operation in a reasonable time.
During electric operation, the hand wheel shall not rotate.
Actuators shall be adjusted at the manufacturer’s works to ensure that they provide the
correct, fully, open position and fully closed position. Mechanical adjustable stops shall
be provided to prevent over-travel of the valve in the open and closed positions.

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SECTION - VI
Technical Specification for Instrumentation, Control Systems &
SCADA
1. INTRODUCTION
The potable water needs of Amravati capital city are such that the total ultimate capacity
of the scheme can be fully utilized at all times. Therefore, the throughput of the system
will be driven primarily by the capacity of the water treatment plant rather than the
demand. The Agency shall appoint experienced specialized SCADA agency as per the
approved list.
1.1 Purpose of Control System and Design requirement:
The purpose of the raw water and clear water pump control system are as follows:
 To ensure continuity of raw water and clear water flow through the system.
 To ensure satisfactory operation during transient conditions such as during start up
and shut down of the system.
 To ensure the capacity of water treatment plant is not exceeded.
 To monitor at a central point, the operation of the complete pumping installations.
 To allow change of system control set points from a central location.
 To provide facilities for alarm announcement and management, and in the event of
system faults, to take appropriate action to protect the faulted item and to effect
where possible remedial actions (i.e., in the event of a drive fault to raise an alarm
and initiate operation of a standby drive, if available).
In addition, the control system would permit:
 Trending of operational variables.
 Preparation of operational data archives.
 Preparation of on-demand periodical operational management reports.
1.2 Objectives for Introducing Control System:
The objectives of providing Instrumentation, Automation and Local SCADA for each
pumping station and the entire system network in general are as follows. Hydraulic
parameters monitoring and control.
 Electrical Energy monitoring.
 Supervisory Control & Monitoring of equipment i.e. pump, motors etc.
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 Shutdown sequence and emergency tripping conditions of all the individual and
complete system have to be defined.
 Two levels of Supervisory control shall be adopted for HMI and Control room
levels.
 Emergency response for stopping pumping station.
 Data acquisition of pump parameters and Pumping system efficiency monitoring.
 Optimization of pumping system.
 Monitoring, measurements and Control of Reservoir, Tapping points, Air valves,
District Outlets, Distribution Centers& Water Meter.
 Minimization of human errors.
 Aid to man power.
 Logging, reporting, preventive maintenance, safety etc.

1.3 Minimum Requirements of Control System in Pumping Station:

The monitoring and Control for Pumping Stations will comprise of PLC based system
equipped with Combination of optical fibre network and Ethernet network by using
media converts. This system will aid the operator to monitor and control the pumping
station Equipment both locally and remotely from Central SCADA.PLC at Pumping
Station will communicate to Central SCADA over both Wireless Communication and
Optical Fibre Network. Network including Raw Water, WTP, Clear Water Pumping Sta-
tion and Water Distribution Centre are interconnected using Optical Fibre as primary
communication media and wireless as secondary. Control System will be designed ac-
cordingly maintaining Interdependency between Pumping station and WDC’s. Follow-
ing sites will be provided with PLC based control System
 Raw Water Pumping Station
 Clear Water Pumping Station
 GLSR based Pumping Stations

1.4 Salient Features of Programmable Logic Controller (PLC):

i. Programmable Logic Controller (PLC) provided shall be of Hot Standby
Architecture for smooth, reliable, safe, efficient & trouble-free operation with

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optimum monitoring and control of process plant and equipment. In adverse

condition, i.e. In case of Failure of Primary PLC, Standby PLC will come into
action and maintain control process for smooth working of plant.
ii. All Controllers proposed for SCADA system shall be provided with facility to
download the modified logics online i.e. even during the operation of the plant.
In any case loading of the controller with modified logics & parameters shall not
stop any equipment used in Intake well and WTP.
iii. Indefinite High Resolution (IHR) controllers with inbuilt CPU having less scan
time shall be used for data acquisition & Control of Electrical signals i.e. for
Substation and all LV and HV switchgear controlling.
iv. Normal PLC with inbuilt Analog, Digital I/O cards can be used for data
acquisition and control of all remaining auxiliary signals.
v. The PLC will be of reputed make, proven technology, and microprocessor based,
with its control and monitoring functions distributed geographically &
functionally and designed for fault avoidance by proper selection of components.
vi. It will have high availability, high reliability & high maintainability.
vii. The system will be modular in nature and will have facilities for easy
expandability of modules to enhance its functionality or performance if required
in future.
viii. The system will be versatile, rugged and suitable for continuous duty in normal
industrial environment.
The offered system shall have following software based functions:
1. “Financial Modeling and sensitivity Analyses” to create a Business Financial Model
with implementation plan that shall analyze investment returns based on a full range
of varied cost inputs.
2. “Total System Optimisation” feature that uses the result of financial modeling to
optimise the design and operation of plant distribution piping and energy transfer
stations. This will include preparation of control system sequences that will
implement the optimisation strategies.
The PLC will be suitable to meet the specific process requirement of Pumping Station
including monitoring, control, interlocking & sequential operation of the process and

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will also be designed accordingly. Application software of the PLC will be developed
based on the functional requirements of the process.
Each system is connected to Programmable Logic Controller and the functional
distribution of hardware in a multi-level hierarchy to meet specific plant requirements
for monitoring, control, process visualisation & optimisation of pumping system. One
number Human Machine Interface (HMI) is provided in the PLC panel for monitoring
& controlling of the pumping station.
All Field Instruments and Electrical drives related inputs and outputs are connected to
PLC. Electrical system parameters are connected to PLC system to detect abnormalities
in electrical system. Each PLC System shall have 20% spare IOs for future requirement.
The Raw Water Pumping Station, WTP & Clear Water Pumping Station shall be
communicating over Fibre Optic Communication Network.
1.5 Sequence of operation:
Total operation of the plants shall be through proper defined starting and shut down
sequences and for emergency plant tripping sequence shall be designed with specific
time and approval from EIC shall be taken during design phase.

2. SPECIFICATIONS FOR RAW WATER INTAKE P.S.

2.1 General
It is proposed to have fully automatic and fail-safe operation of the pumping station to
meet the varied demand of clear water in most efficient manner. An Optical fibre
network shall be created so as to meet the requirement at Intake Pumping Station
depending upon current state of Clear water pumping station. The scope of work would
cover conceptualization, design, pre-dispatch inspections, supply, installation, and pre-
commissioning test, commissioning tests, commissioning, trial run and maintenance of
the entire Automation, Instrumentation and Control (PLC) system. Design of the
complete system along with the detailed specifications of the equipment proposed to be
installed shall be submitted for necessary approval of the Department. The design of
the system shall adhere to the principles detailed in the respective Chapter of
“Specifications for Automation Instrumentation and Control.
Irrespective of the detailed specifications of the respective items detailed in the chapters
of pumping stations and filter plant, it shall be required to provide all equipment,

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accessories, cabling, earthing, providing necessary transducers/sensors, system

hardware/software, programming logic etc. to achieve the objectives listed below.
The entire PLC system is required to receive, store and control the information From
Electrical, Mechanical & Instrumentation Equipment.

2.2 Electrical System:

 Input voltage and amperage of 33 KV/6.6 KV and input voltage and amperes of
0.415 kV to individual motors.
 Power consumption (kWH) and power factor on 33KV/6.6 KV system,
transformers and all individual HT&LT motors
 Status of all circuit breakers
 Status of all relays used in electrical installations controlling LT motors
 Status of all LT motors (on/off)/ & all parameters of Frequency Drives, etc.

2.3 Mechanical Equipment

 Status of all HT&LT pumps
 Status (on/off/percentage open) of all Butterfly/Pump Control Valves, on individual
pumps delivery
 Temperature monitoring of HT&LT pump and motors for bearing and winding, etc.

2.4 Instrumentation Equipment

 Flow data (instantaneous flow rates and total flow) from the pump house (through
flow meter & transducers installed on delivery manifold.
 Level of water in the intake.
 Pressures at delivery of each pump & manifold, etc.

2.5 Process the above information to Control

 Shut down of pumps in case of any non-transient abnormal conditions such as
low/high voltage, high current drawl, and thermal over load, etc.
 Shut down of pumps in case of low levels of water in sumps.
 Operation of all butterfly/Pump Control Valves to desired state.
 Generation of reports, etc.
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2.6 Alarm Situations

The alarm schedule is indicative of what is required. It shall provide for the annunciation of all
alarms necessary in order to achieve control and monitoring requirements
 33KV/6.6 KV power failure
 Tripping of outdoor VCB in 33KV/6.6 KV switchyard
 Tripping of any indoor ACB on transformer out-comers.
 Power Frequency in 33KV/6.6 KV abnormal Low/High
 Abnormal pressures in manifold
 Motor tripped on over-load.
 Pumps failed to start/stop.
 Valves unable to open/close
 Emergency stop operated
 UPS failure, etc.

2.7 Hardware & Software Requirements in PLC system

Each PLC system shall be supplied with:
 Redundant Central Processing Unit (CPU).
 Memory Unit
 Input/output Modules
 Programming Unit consisting of one desktop computer with requisite software
 The human machine interface (HMI) consisting of 15” Screen installed on the Panel
 GPRS Modem for communicating with Central Control Web SCADA
 Fibre Optic Modem and LIU boxes for communication with WTP SCADA System,
etc.
2.8 Requirement of Instrumentation
To achieve the objectives listed above in scope of work, It shall provide the required
numbers of equipment/sensors. Main equipment required is as listed below. The list is
not comprehensive and the scope of contract shall not be limited by the list but shall
include all probes level sensors, input-output modules, interfaces, other sensing ele-
ments, cabling, ducting, earthing, providing lightening protection, providing facilities
of local display of readings from instruments, etc.
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The main equipment required are as listed below but not limited to:
Full bore electromagnetic flow meter shall consist of flow sensor (i.e. flow tube), flow
transmitter and flow indicator and integrator and any other item required to complete
the system. To avoid the effects of disturbances in the velocity profile, a straight and
uninterrupted run, upstream as well as downstream from the location of the flow meter
shall be provided, as required by the flow meter manufacturer and in line with the ap-
plicable standards. Agency shall finalize the exact location of flow meter in consultation
with Representative of Authority.
Flow measurement shall not be affected by physical properties of water viz.,
temperature, pressure turbidity etc., within given limits. Agency shall provide
compensating Electronic circuits, if required. A lockable enclosure shall be provided
for the flow transmitter cum computing unit, if required.
Flow meters shall be suitable for the water turbidity at site during various seasons.
Flow tube shall be rugged in construction and shall be suitable for continuous
operation. Flow tube shall have waterproof construction and shall be suitable for
installation on underground /above ground pipe lines.
The flow computer and transmitter shall be a single unit suitable for panel mounting.
It shall accept inputs from flow tube, process the signals and shall provide an output
proportional to the flow rate. The distance between transmitter and flow tube shall be
maximum 250 mtrs. Taper pieces required for installation of flow meter shall not
exceed an angle of 8° in order to avoid disturbance in flow profile.

 Level sensors, transmitter and digital level indicators -1 Nos. at each

Sump/Reservoir
 Providing pressure gauges and other instruments at each suction and delivery
manifold of each pumping section based on design requirement.
 Pressure switches or transmitters and indicators at each manifold and delivery pipes
of each pump.
2.9 Instrumentation, Automation, Communication Control Panel (IACC)
It shall provide Design, Catalogue of manufacturing, installation & commissioning of
Instrumentation, Automation & communication control panel for Pump House
The IACC Panel at each head works shall include following
 Digital display meter for flow, water level.
 Automation components such as PLC, Digital IP, OP
 Communication components such as FO network, GPRS Modem, Converters,
Network switches and LIUs etc.

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 The control panel shall display all the sensors & recordable parameters on the HMI
of control panel. The following parameters shall be monitored:
 Water Level in Reservoir
 Motors: Start/Stop/Trip feedback and start /stop control from remote
 Motorized Valves/PCV: Open/Close feedback and open close from remote
 Flow Meters: Process Values and Set point settings for remote operation
 Pressure reading: Process Values and Set point setting for remote operation
 Each Motor has kWh meter with Modbus port available in MCC panel. This
parameter needs to be communicated to the SCADA system
 Pump House Incomer will have a multifunction meter with Modbus port. All
Electrical parameters from this meter may be used for logging in the SCADA
The work shall include panel, all indicators, PLC, internal wiring, cabling, conduits,
input and output facilities complete in all respect. The work will include providing cable
from field sensor up to the IACC and connecting them with field sensors and all
conduits, fixing arrangement. The work shall also include providing, fixing etc of
instrumentation & control cabling from & to all sensor/control elements

2.10 Control Room Furniture (System Console)

In addition to the HMI system equipment, it shall provide furniture system consoles if
required to complement or match both the color and styling of the equipment. Control
room furniture shall comply with relevant IEC standards for ergonomic design. Details
and design of system consoles shall be submitted to the Engineer-in-Charge for ap-
proval.
Typically, it shall provide two fabric-covered adjustable armchairs with casters, a rigid
and lockable steel cupboard for the storage of operating and maintenance manuals,
drawings, logger paper, charts, disks etc.

3. SPECIFICATIONS FOR WTP (Water Treatment Plant).

Water shall be pumped from Raw Water pumping station to WTP for further treatment.
There will be a parshall flume constructed for the measurement of water entering into
the plant. An open channel ultrasonic type flow meter shall be installed for this meas-
urement. Further water from parshall flume will be carried to flash mixer using a raw
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water channel. A Raw water quality-monitoring sensor consisting of Online Turbidity,

Online pH, Online Conductivity, Online DO etc. will be monitored at control room.
Necessary sampling accessories will be installed accordingly.
Provisions shall be made available at outlet of Flash mixers to connect the clarifloccu-
lators. The operation of flash mixers and clariflocculators will be done from the pro-
posed SCADA system. Sludge valves for each clarifloculator will be operated based on
measured sludge level by the sludge blanket level instrument. The clarified water then
flows into the plate settlers.
Further for the Filtration System a fully automated backwash system will be envisaged.
All the motorized gates/ valves in the filtration plant will be operated from PLC-
SCADA system. Turbidity analyzers are proposed to install at backwash line of each
filters. Loss of head instruments are proposed for the difference in the headwater levels
in each filter. Air flow and pressure from air blowers shall be measured by respective
instruments.

3.1 The Instrumentation and Control System Requirement.

The entire PLC system is required to receive, store & control the information From
Electrical, Mechanical & Instrumentation Equipment.
 Electrical System:
 Input voltage and amperage of 33 KV/6.6 KV and input voltage and amperes of
0.415 kV to individual motors.
 Power consumption (kWH) and power factor on 33KV/6.6 KV system,
transformers and all HT & LT motors
 Status of all circuit breakers
 Status of all relays used in electrical installations controlling HT&LT motors
 Status of all HT & LT motors (on/off)/ & all parameters of Frequency Drives
(if provided), etc.
 Mechanical Equipment
 Status of all HT & LT pumps
 Status (on/off/percentage open) of all Butterfly/Sluice Valves/Pump Control
Valves, on individual pumps delivery
 Temperature monitoring of LT pump and motors for bearing and winding, etc.

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 Instrumentation Equipment
 Flow data (instantaneous flow rates and total flow) from the pump house
(through flow meter & transducers installed on delivery manifold.
 Level of water in the clear water reservoirs and elevated service reservoirs
 Pressures at delivery of each pump & manifold, etc.
 Processing of above information will facilitate control below mentioned.
 Shut down of pumps in case of any non-transient abnormal conditions such as
low/high voltage, high current drawl, thermal over load.
 Shut down of pumps in case of low levels of water in sumps.
 Operation of all butterfly/sluice valves/Pump Control Valve to achieve desired
state.
 Generation of reports, etc.
 Alarm Situations
The alarm schedule is indicative of what is required. It shall provide for the
annunciation of all alarms necessary in order to achieve control and monitoring
requirements.
 33KV/6.6 KV power failure
 Tripping of outdoor VCB in 33KV/6.6 KV switchyard
 Tripping of any indoor ACB on transformer out-comers.
 Power Frequency in 33KV/6.6 KV abnormal Low/High
 Abnormal pressures in manifold
 Motor tripped on over-load.
 Pumps failed to start/stop.
 Valves unable to open/close
 Emergency stop operated
 UPS failure, etc.
 Hardware & Software Requirements in PLC system
Each PLC system shall be supplied with:
 Redundant Central Processing Unit (CPU).
 Memory Unit
 Input/output Modules
 Programming Unit consisting of one desktop computer with requisite software

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 Instrument Control Panel (I.C.P.) / Control Desk

The man machine interface (MMI) consisting of:
 Personal Computers with minimum 19” color monitor with other accessories
 12 PPM, A4 sized Laser Printers
 Panel Power Supply via an uninterruptible power supply (UPS) of one-hour
capacity, etc.

3.2 Requirement of Instrumentation

To achieve the objectives listed above in scope of work, It shall provide the required
numbers of equipment/sensors. Main equipment required is as listed below. The list is
not comprehensive and the scope of contract shall not be limited by the list but shall
include all probes level sensors, input-output modules, interfaces, other sensing
elements, cabling, ducting, earthing, providing lightening protection, providing
facilities of local display of readings from instruments, etc.
The main equipment required are as listed below but not limited to:
 Full bore electromagnetic flow meter shall consist of flow sensor (i.e. flow tube),
flow transmitter and flow indicator and integrator and any other item required to
complete the system. To avoid the effects of disturbances in the velocity profile, a
straight and uninterrupted run, upstream as well as downstream from the location
of the flow meter shall be provided, as required by the flow meter manufacturer and
in line with the applicable standards. Agency shall finalize the exact location of flow
meter in consultation with Representative of Authority.
 Flow measurement shall not be affected by physical properties of water viz.,
temperature, pressure turbidity etc., within given limits. Agency shall provide
compensating Electronic circuits, if required. A lockable enclosure shall be
provided for the flow transmitter cum computing unit, if required.
 Flow meters shall be suitable for the water turbidity at site during various seasons.
Flow tube shall be rugged in construction and shall be suitable for continuous
operation. Flow tube shall have waterproof construction and shall be suitable for
installation on underground /above ground pipe lines.
 The flow computer and transmitter shall be a single unit suitable for panel
mounting. It shall accept inputs from flow tube, process the signals and shall

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provide an output proportional to the flow rate. The distance between transmitter
and flow tube shall be maximum 250 mtrs. Taper pieces required for installation of
flow meter shall not exceed an angle of 8° in order to avoid disturbance in flow
profile.
 Level sensors, transmitter and digital level indicators – 1 Nos. at each
Sump/Reservoir
 Providing pressure gauges and other instruments at each suction and delivery
manifold of each pumping section based on design requirement.
 Pressure switches or transmitters and indicators at each manifold and delivery pipes
of each pump.

3.3 Operation of WTP

It is proposed to have MCC (Mater Control Centre) at the WTP premises. Water
Treatment Plant is required to be automated using latest PLC System as specified in
this section & other sections of this tender. The automation includes all the machinery
and processes of WTP as explained.
Entire backwash operation of filter beds right from sensing of bed choking to initial
backwash operation and complete cycle as per process design shall be completed
automatically through PLC to be provided at main control room. Further the plant
pumps / process equipment, shall operate in auto mode through PLC at ICP /main
control room and necessary instrumentation for the same shall be included in the scope
as per the scope / operation philosophy specified in the tender.
Auto backwash operation through PLC HMI/SCADA at main control room and the
status indication shall be provided at PLC HMI / SCADA All valves of a bed & air
blowers shall be possible to operate automatically as per logic for all pneumatically
operated Valves & Gates shall be monitored for full open and full close position and all
electrical drives for various equipment of WTP shall be monitored for on, off and trip
status at PLC HMI / SCADA. Green indication for Valve close / motor off status and
Red indication for Valve open / motor on status shall be provided. Indication for Trip
shall be Amber.

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Backwash tank water level sufficient for backwash operation shall also be indicated at
PLC HMI / SCADA. All valves shall be able to operate in the following modes: -
LOH/ROF level indication of associated bed shall be displayed at PLC HMI / SCADA.
 In Auto Mode: - Entire filter back wash shall be in auto mode with all valves / back
wash blowers shall operate in fully automatic mode through PLC.
 Semi-Auto Mode: - Where the operation of the valves/blowers is controlled from
the HMI / SCADA console through soft push button/selector switches by operator.
 In Off Mode: - Valve/Blower/compressor shall be operated manually from Filter
bed or locally in case of failure of PLC/Scada system.
Following shall be provided as a minimum in Automation System at main control room
to achieve the above objective:
 Selector Switch for Auto – Off – Semi-auto mode selection
 Open / Close Selector Switch or Open & Close Push Buttons for operation of each
filter bed valve (Soft).
 On / Off Selector Switch or On & Off Push Buttons for each of the back wash air
blowers for blower operation (Soft)
 On, off and Trip Indication Lamps (hard wired) & indication at HMI/SCADA
console for monitoring status of each air blower.
 Air Pressure Adequate Indication Lamp (Green, hard wired), which if ON shall
indicate sufficiency of air pressure for operation of pneumatic valves and OFF state
shall indicate vice versa as well as soft indication at HMI/SCADA.
 Backwash Water Adequate indication lamp through necessary level switch to be
provided in back wash tank when backwash water level is above the middle level
of tank liquid depth as well as soft indication at HMI/SCADA.
 Backwash Water Inadequate – Start filling indication lamp through necessary level
switch to be provided in back wash tank when backwash water level is at or below
middle level of tank liquid depth as well as soft indication at HMI/SCADA. This
signifies that water may or may not be sufficient for complete wash of one bed.
 Backwash Not Possible indication lamp to be provided in back wash tank when
backwash water level is at low level tank liquid depth as well as soft indication at
HMI/SCADA.

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 Filter Bed Clogged Indication Lamp on reaching the condition when LOH exceeds
design / set level and ROF is below the set level indicating the choking of bed
requiring backwash as well as soft indication at HMI/SCADA.
 Filter Bed In-Line or Standby selector switch. When in standby, the filter inlet valve
shall remain closed isolating the filter bed (filter outlet valve shall remain open).
When taken in-line, the filter inlet valve shall open and the bed shall operate as per
process logic depending in the selection of operation mode.
 LOH and ROF indication at HMI/SCADA. The scope of PLC in general is to
control working of entire water treatment plant including Rapid Gravity Filter Units
by way of allowing operation of all pneumatically operated filter bed valves in auto
mode for auto backwash or in semi-auto mode through selector switches at
ICP/HMI/SCADA/JB depending on the mode of operation selected and similarly
operating the clarifier de-sludging valves as well. Monitor, display & data logging
and control, as applicable, various process parameters of the plant like that of inlet
& outlet parshall flume flow and other flow meters as applicable, water quality
analyzer (pH, turbidity, residual chlorine, DO, etc.), display/control/alarm, as
applicable, the status of operation of all pneumatically actuated valves of the plant,
status of level in tanks/sumps for which level instruments are provided, status of
operation of electrical drives (on, off and trip) etc. Annunciation shall be provided
for various alarm conditions like quality parameter, flow, loss of head/rate of flow
of each filter unit, limits for backwash, drive trip status, valve failure status, process
equipment status, low and high level of various sumps, low level of particular
alum/poly solution tank in use at that time etc. It shall be possible to carry out
backwash operation of each filter bed in fully automatic mode by sensing the
required inputs from LOH/ROF indicators, fully automatic operation of all pumps
/ blowers / air compressors / process equipment with necessary interlocks (with on,
off and trip indication), as applicable, by providing necessary instrumentation for
auto operation, and also operation of valves and electric drives through various
LCPs by selecting suitable mode of operation through PLC based panel.
 The purpose is to minimize human intervention and increase reliability and ease in
operation of entire treatment plant. The PLC shall have necessary communication
port for communication with necessary field instruments specified like LOH/ROF

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instruments, analyzers, etc. as applicable. Instrument Panel / PLC Panel shall be

free standing, floor mounting cabinets of Rittal / BCH / Enklotek / equi. Make. It
shall refer panel specifications provided in this tender. PLC Supplier shall provide
a copy of all working programs/ application program / programming codes on
Compact Disk or suitable permanent media including necessary licenses where
applicable (for software’s specified for supply in this specifications), as well as a
printed program listing. PLC supplier shall also hand over all the access passwords
and the PLC Key (as applicable) for PLC/SCADA programming to client on
acceptance of the system. It is clearly to be noted that all the software/ programs/
programming codes / pass word codes/PLC Key, etc. shall be the property of
Amravati Development Corporation All the application programs handed over to
Client shall not be password protected or requisite password shall be furnished
 LOH and ROF indication at HMI/SCADA. The scope of PLC in general is to
control working of entire water treatment plant including Rapid Gravity Filter Units
by way of allowing operation of all pneumatically operated filter bed valves in auto
mode for auto backwash or in semi-auto mode through selector switches at
ICP/HMI/SCADA/JB depending on the mode of operation selected and similarly
operating the clarifier de-sludging valves as well. Monitor, display & data logging
and control, as applicable, various process parameters of the plant like that of inlet
& outlet parshall flume flow and other flow meters as applicable, water quality
analyzer (pH, turbidity, residual chlorine, DO, etc.), display/control/alarm, as
applicable, the status of operation of all pneumatically actuated valves of the plant,
status of level in tanks/sumps for which level instruments are provided, status of
operation of electrical drives (on, off and trip) etc. Annunciation shall be provided
for various alarm conditions like quality parameter, flow, loss of head/rate of flow
of each filter unit, limits for backwash, drive trip status, valve failure status, process
equipment status, low and high level of various sumps, low level of particular
alum/poly solution tank in use at that time etc. It shall be possible to carry out
backwash operation of each filter bed in fully automatic mode by sensing the
required inputs from LOH/ROF indicators, fully automatic operation of all pumps
/ blowers / air compressors / process equipment with necessary interlocks (with on,
off and trip indication), as applicable, by providing necessary instrumentation for

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auto operation, and also operation of valves and electric drives through various
LCPs by selecting suitable mode of operation through PLC based panel.
 The purpose is to minimize human intervention and increase reliability and ease in
operation of entire treatment plant. The PLC shall have necessary communication
port for communication with necessary field instruments specified like LOH/ROF
instruments, analyzers, etc. as applicable. Instrument Panel / PLC Panel shall be
free standing, floor mounting cabinets of Rittal / BCH / Enklotek / equi. Make. It
shall refer panel specifications provided in this tender. PLC Supplier shall provide
a copy of all working programs/ application program / programming codes on
Compact Disk or suitable permanent media including necessary licenses where
applicable (for software’s specified for supply in this specifications), as well as a
printed program listing. PLC supplier shall also hand over all the access passwords
and the PLC Key (as applicable) for PLC/SCADA programming to client on
acceptance of the system. It is clearly to be noted that all the software/ programs/
programming codes / pass word codes/PLC Key, etc. shall be the property of
Amravati Development Corporation All the application programs handed over to
Client shall not be password protected or requisite password shall be furnished.

4. PROGRAMMABLE LOGIC CONTROLLERS (PLC) SYSTEM SPECIFICATIONS

Codes and Standards
PLC shall comply with International standards such as NEMA, IEC, ANSI, ISA, IEEE,
DIN and VDE.

5. DESIGN AND CONSTRUCTION REQUIREMENTS

PLC H/W & S/W shall be from the same family and shall be sourced from renown
Vendors/System Integrators.
Programmable logic controller (PLC) shall be microprocessor based with 32/64 bit Re-
dundant processor and be fully programmable and capable of performing control relay
logic, including timing, counting, sequencing, and interlocking to provide the required
functionality.

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The PLC shall be high performance processors suitable for real time process applica-
tion. High inherent reliability, self-checking, error-recovery and trouble-shooting fea-
tures shall be some of the features of PLC. The PLC shall have a modular / modular
chassis design which allows for ease of future expansion. The processor module shall
be easily removed from the I/O chassis for service or repair. The I/O chassis shall have
slots for installing I/O cards, communications, or other special function modules. All
I/O cards and modules shall be capable of being installed in any open slot in the chassis
or shall be DIN rail mounted. Module and channel level diagnostics shall be standard
feature.
The PLC shall have a suitable power supply and can be easily serviced or replaceable.
The system shall be capable of being powered on 120VAC / 230VAC / 24V DC as per
mfr. Std. The PLC shall be rated to operate from 0 to 60 Degrees C, with a humidity
rating of 5 to 95% (non-condensing). All module circuit boards shall be encased and
protected such that, when properly installed, they are not exposed to accidental contact
by personnel or other
The PLC shall be of high quality and reliability with replacement processors, power
supplies, chassis, I/O and specialty modules that are readily available on an urgent or
emergency basis. All PLC products shall be fully supported and spares shall be availa-
ble for purchase for up to ten (10) years from the date of the original system purchase.
After completion of the automation and actual plant operation starts working on
PLC/SCADA System the concerned staff likely to run plant is required to be fully
trained by the executer for the operating features and preventive maintenance aspects
and preliminary trouble shooting methods of the offered system. This training at site
shall be of one day duration which shall be attended by 4-6 persons of client to be
deputed from various levels. Additionally, it shall also consider to provide class room
training of required duration (up to 7 days) for up to 2 persons of SMSS at PLC sup-
plier’s /Clients training centre within the country covering the selection & programming
aspects of PLC / SCADA system.

5.1 Basic Processor Functions

The system shall be provided with two identical central processors configured such that
they operate in Hot-Standby mode.

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Redundant system with hot back up redundancy feature shall be built in the CPU. Soft-
ware Engineer-in-Chargeed hot backup systems are not acceptable. CPU shall have the
memory expansion capability up to 7 MB. Both the CPU’s shall have separate back-
plane and associated hardware for redundancy. CPU system shall be able to communi-
cate with GPRS Modem to communicate with Web SCADA. SCADA connectivity with
the CPU will be on Ethernet network (10/100 Mbps with open Modbus TCP/IP proto-
col). On the event of hardware failure in primary system the standby system will pro-
vide dual connectivity with the SCADA. PLC Components like CPU and I/O modules,
Remote IO Modules shall be of the same logic family. It shall take note on the im-
portance of this obligation. The system shall be designed and implemented such that
when the Main processor fails, the Standby one shall automatically take over. The
changeover shall be seamless, smooth and without any time delay and shall not cause
any disruption to the overall distributed control system and to the ongoing processes.
The PLC system shall be expandable and shall be modular in construction, so as to
capable of future expansion without hardware modifications. The system hardware, ap-
plication software and database shall be sized to accommodate a total of 50% increase
in signal capacity and up to 100% increase in an individual zone. Sufficient plug in
modules shall be provided and wired to terminals ready to accept future signals of up
to 10 % for each IO card. Each IO card shall be able to accept at least two more I/O
cards without requiring replacement of, or additions to, the original equipment. The
system shall be modular and capable of integrating into a network with Central SCADA
Monitoring Centre (CSMC).

5.2 Features:
 Real-time control of output points for turning on and off digital devices such as
motor starters and solenoids.
 Read the status of real world digital inputs from limit switches, float switches, and
other field devices.
 Real-time control of analog process control variables.
 Read the status of real world analog set points and feedback values.
 Perform timing, counting, sequencing, and interlocking functions for
pump/equipment control.

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 Process local alarm handling functions

 Math and Advanced Functions
 Four function math in floating point or signed integer format
 Convert to/from BCD
 Data comparison and manipulation
 Scaling from integer data into Engineer-in-Charge units such as flow, level and
pressure
 Full PID Instructions for control of process control variables such as flow, level and
pressure.
 Compute Instruction which executes a mathematical expression and can be used for
totalizing functions
 Trigonometric and Exponential math functions
 Real-Time Calendar Clock for time stamping alarms and events.
 Automatic restart of the system on resumption of power shall be provided.

5.3 Memory Unit

Memory unit shall comprise of highly reliable memory chips which are industry stand-
ard, proven design with fast random access and suitable for operation in process envi-
ronments. Main memory shall be modular and facility shall be provided for the upgrad-
ing and expansion of memory to meet future demands.
Not less than 50 % spare program memory and data memory space shall be provided.
System initialization and application software shall be stored in Memory Card or
EPROM. Operating data shall be stored in a RAM fitted with an internal battery backup.
The battery backup provided shall support the memory on loss of power. The battery
life shall be at least 2 years.

5.4 I/O Modules

Standard rack mounted plug in I/O modules shall be provided. I/O Modules shall be of
the same family as that of PLC CPU. It shall take note on the importance of this obli-
gation. Field wiring shall be terminated in screwed terminal blocks and interconnected
to the processor I/O system with prefabricated cables and plug in card type connectors.
20% extra modules of installed capacity for each type of module shall be provided as
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spare. Provision shall be made for future expansion of additional 20% extra I/O mod-
ules of the installed capacity.

5.5 I/O modules shall be as follows:

 Inputs shall be optically isolated.
 filters shall be provided for noise rejection for Analogue
 output status shall be indicated by an LED
 all outputs shall be fuse protected and have fuse failure indication the fuses may be
mounted externally from the output module
 all the modules shall be of addressable type.
 Ethernet, I/O modules (If considered) shall be connected to the PLC by on board
Ethernet 10/100 Base-T connection port. Ethernet, I/O modules shall support
multiple communications including TCP/IP and Modbus ASCII and RTU allowing
connection to any device supporting these protocols over standard Ethernet
backplane
PLC’s provided under this specification shall be capable of performing the necessary
logic to control the system as previously defined. These capabilities shall include, but
not be limited to the following:
1. Discrete input/output 10 Latch/unlatch relays
2. Analog input 11. Counters
3. Analog output 12. Comparators
4. Timers 13. Ladder logic
5. Pump Controller 14. Flow Totalization/Integration
6. Pump Alternation 15. Intrusion Detection
7. Mathematical Function Blocks 16. Time of Day Control w/Lockout
8. Stage Blocks 17. Ramp Blocks
9. Trending 18. Data Logging

5.6 PLC Programming

PLC programming shall be carried using Ladder/FBD. The logic shall be prepared us-
ing proprietary programming software and shall be comprehensively annotated with
subroutine and rung comments to assist further development and maintenance. The sys-
tem shall support a simple programming of the application software comply with IEC
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61131-3. The system shall support a structured, modular programming. At following

standard operations are expected:
 Logic functions
 Timer functions
 Counter functions
 Skip functions
 Comparison functions
 Limit value functions
 Arithmetic functions
 Physical unit functions
It shall submit the logic diagrams for review. It shall include the as-built logic in the
final submission.

5.7 Programming Unit

The programming unit shall be of the portable type, industrial model designed to be
used during commissioning on site. A functional keyboard which supports different
type of programming methods shall be included, as well as a CRT or TFT display.
At least the following functions is expected
 On-line programming
 Off-line programming
 Flexible corrections during input
 Full screen editing functions
 Absolute and symbolic programming
 Input of comments and title blocks for complete documentation
 Complete application software documentation functions. Printouts of application
software logic functions shall preferably be in Ladder logic diagrams.
 Load and transfer functions
The computer shall be provided complete with proprietary PLC programming and
SCADA software complete with plant mimics and documentation software. Communi-
cation cables required to interact with the PLC, (E.g. Modbus Cable) would be supplied.
The software shall provide facilities for:
 insertion of comprehensive program subroutine and rung comments;
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 search and find and search and replace ‘contacts’ and ‘coils’;
 simulation functions and testing of the program by changing the status of contacts
and monitoring the outputs;
 preparation of coil and contact list and their locations and memory maps;
 upload and down load programs to the PLC on line;
 Carry out on line maintenance and fault finding on the PLC.

5.8 Supervisory Control and Data Acquisition System (SCADA/HMI)

The SCADA shall be a fully integrated microprocessor based control and data acquisi-
tion system which will monitor, control, display, record and trend all assigned plant
inputs and outputs. The SCADA shall be a fully dual redundant microprocessor based
computer system such that reliable and automatic plant control can be achieved. The
main process monitoring and control shall be by means of VDU based process operator
workstations that shall be located in the central control room
SCADA/HMI system would be Dual Redundant server system. The system shall be
designed and implemented such that the failure of a central processor does not inhibit
continuous automatic control of the plant. In the event of such a failure, historical data
shall be recoverable to a condition where a worst-case maximum of 15 minutes of his-
torical data is lost.
Failure of a single outstation or communications to that outstation shall not effect con-
trol or operation of any other outstation, unless the failed outstation provides essential
data to another outstation, in which case the non-failed outstations shall revert to a fail-
safe mode.

5.9 Hardware
The system shall support hardware and software interconnectivity to other networks
generally in accordance with the ISO Open System Interconnect 7-layer reference
model.

5.10 Computer
The computer hardware shall be of current technology at the time of installation. Stand-
ard server stations, Standard PC technology with modern hardware, Windows operating

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system and data transmission over Industrial Ethernet must be used for the Engineer-
in-Charge workstations.
The Engineer-in-Charge system must be an open system that, for example, permits the
importing of project data from Microsoft Excel, SQL etc. It must be possible to im-
port/export messages to/from Excel and Access for simple processing. Removable
memory media must also be provided for each workstation. It must be possible to back
up all database and configuration data both on removable media and on non-removable
storage media without the system being offline. The specs for computer hardware
shown are indicative only.
It is to select the appropriate hardware to suit the process requirements and data archiv-
ing. The computer shall, as a minimum comprise of a personal computer (PC) type
architecture, with IBM compatible Pentium IV based system or better, capable of run-
ning a multi-tasking real-time operating system suitable for process control applica-
tions:
 All workstations, servers, communications equipment and peripherals shall be from
reputed manufacturers, suitable for continuous operation and shall be the most
currently available models at the time of construction, subject to approval. Adequate
spare capacity shall be included to meet the specified requirements and future
expansions.
 The system shall support hardware and software interconnectivity to external
Programmable Logic Controllers (PLC‟s) over an RS-232/RS-485/Ethernet using
Profibus / Modbus, Ethernet or similar protocol, subject to the approval of the
Engineer-in-Charge.
 A historical data storage system with removable media for archive and backup will
be provided. The data storage system shall store alarms and events, with the time of
occurrence for one month and selected analogue signals connected to the system.
All alarms and events shall be archived in a first in first out buffer, for a period of
40 days.

5.11 Visual Display Unit (VDU):

Visual Display Units (VDU's) shall be color monitor screens, capable of displaying
information in alphanumeric, bar histogram, graphical and mimic diagram formats.

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Monitors shall simultaneously display a minimum of 256 colors, non-interlaced, low

radiation, and flat screen with no discernible flicker. Display of characters shall be leg-
ible and stable on a shadow mask tube, having a resolution of not less than 1024 by 768
pixels and a refresh rate of not less than 70 Hz. The units shall include all the necessary
picture controls to adjust the sharpness, contrast and position of the image. LCD VDUs
shall be flat screen. Minimum requirements: brightness 250 cd/m2, 500:1 contrast ratio,
1600 x 1200 pixels, 55 inch.

5.12 Printers:
 Color Laser Jet Specifications and features:

Print, copy, scan, fax, standalone scan-to

All-in-one functions
email, photo card slots
Multitasking capability Yes.

Print speed, black (normal quality mode) Up to 21 ppm

Print speed, color (normal quality mode) Up to 21 ppm

Exact speed varies depending on the system configu-

Print speed footnote
ration, software program, and document complexity.

First page out (color) As fast as 17.9 sec

Monthly duty cycle Up to 40,000 pages
Duty cycle is defined as the maximum number of pages
per month of imaged output. This value provides a com-
parison of product robustness in relation to other La-
Footnote for duty cycle
serJet or Color LaserJet devices, and enables appropriate
deployment of printers and MFPs to satisfy the demands
of connected individuals or groups.

Paper Heading:

50 sheet multi-purpose tray 1, 250-sheet input trays 2 and

Paper handling standard, input
3, 50-sheet ADF
Paper handling standard, output 150-sheet face-down output bin
Envelope capacity Up to 30 envelopes
Envelope feeder No
Duplex printing (printing on both sides of
Automatic (standard)
paper)

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Document finishing Sheet fed

Media sizes, standard Letter, legal, executive, envelopes (No. 10, Monarch)
Tray 1: 3 x 5 to 8.5 x 14 in; Tray 2, Tray 3: 3.94 x 5.83 to
Media sizes, custom
8.5 x 14 in

Paper (bond, brochure, colored, glossy, letterhead, photo,

Media types plain, preprinted, prepunched, recycled, rough), transpar-
encies, labels, envelopes

Tray 1: 16 to 47 lb (up to 58 lb with Color Laser glossy

photo papers); tray 2, tray 3: 16 to 43 lb (up to 47 lb with
Media weight
postcards, up to 58 lb with Color Laser glossy photo pa-
pers)
Weight 71.2 lb
Processor speed 450 MHz
Memory, standard 160 MB
Memory, maximum 416 MB

Scanner Specification:

Scanner type Flatbed, ADF

Scan resolution, optical Up to 1200 dpi
Bit depth 42-bit
Scan size, maximum (flatbed) 8.5 x 11.7 in
Scan size, maximum (ADF) 8.5 x 14 in
Scan speed (default) Up to 15 ppm
Automatic paper sensor No

Copier Specification:

Copy speed (black, best quality,

Up to 20 cpm
A4)
Copy speed black (best, letter) Up to 20 cpm
Copy speed color (best, letter) Up to 20 cpm
Copy resolution, black Up to 600 x 600 dpi
Copy resolution, color Up to 600 x 600 dpi
Copy reduce/enlarge settings 25 to 400%
Maximum number of copies Up to 99 copies

Fax Specification:

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Faxing Yes
Fax transmission speed (seconds
3 sec per page
per page)
Fax memory Up to 250 pages
Based on standard ITU-T test image #1 at standard res-
Fax note olution. More complicated pages or higher resolution
will take longer and use more memory.
Fax resolution, black (dots
Up to 203 x 196 dpi
per inch)
Speed dials, maximum number Up to 120 numbers
Auto redial Yes
Fax delayed sending Yes
Fax broadcast 119
Junk fax barrier Yes
Polling Yes (receive only)
Remote retrieval No
Fax forwarding Yes

6. Central SCADA/HMI Application:

The central SCADA/HMI shall comply to the below mentioned specifications:

6.1 INDUSTRY STANDARDS:

The system is expected to comply the industry standards, but not limited to:
 ODBC
 OLE
 ActiveX
 COM/DCOM
 DDE and Advance DDE
 Microsoft Windows 7/windows10
 TCP/IP
 OPC DE
 OPC Alarm and Events (A&E)
 XML
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 .NET
6.2 Graphical User Interface for WTP SCADA:
 The editing package shall include a Wizard / Symbol / Object Library to permit the
inclusion of pre-developed or third party graphic objects.
 The editor shall include a utility or tool for determining which points are referenced
in a screen, which objects reference them, and which points are not currently
defined or known to the software. This tool shall also include provision to search
and replace point names - for both single objects and groups of objects.
 Graphic objects on these screens can be linked by name to actual device and virtual
data through the distributed point database, direct OPC-DA, and Historical
expressions in either a real time or historical sense.
 The software shall support the following dynamic attributes:
 Annunciation, movement, blink, rotation, and fill (uni-directional and bi-
directional)
 Gradient fill
 Object border animation
 Object visibility
 Blink fill and blink rate
 Transfer tags for screen transfer or popup windows
 Procedure tags to invoke user defined scripts/programs
 Object and or application help screens
 Alarm information
 Trends charts
 Set point tags for point value changes
 Animated frames that can include other graphic objects
 Zoom to Best Fit, Resize Window to Zoom
 Manual and automated rubber band zooms
 Automatic font scaling when changing window sizes
 Graphic objects shall include:
 Embedded OLE, including ActiveX objects, sound, video, clip art, spreadsheets,
etc.
 SPC charts

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 Trend charts
 Historical Data displays
 Alarm displays
 Arcs
 Lines
 Circles
 Ellipses
 Lines
 Polylines
 Polygons
 Rectangles
 Text strings
 Buttons
 3-Dimensional Piping creator
 Graphics screens shall support compliant scripting language. The graphical editor
and viewer shall be capable of being an ActiveX container and shall support
ActiveX "methods". The methods may be used by the compliant scripting language.
 The graphical interface shall have historical playback and review capabilities. The
user shall be able to select a period of time and then replay the graphical screens
and watch the process parameters change on the screen in replay mode.
 The graphical runtime shall be able to optimize the display using anti-aliasing.
 The handling of graphic images shall be such that they can be scaled without
distortion.
The software shall provide the following defined user access levels as a minimum and
additional levels as instructed by the Engineer-in-Charge:
 Default level:
The default level shall permit users to view all displays except those specifically as-
signed to a higher level of access.
 Operator level:
The operator level shall permit authorized users to access default level activities in ad-
dition to the following:
 Perform control actions;

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 Acknowledge alarms;
 Enter or modify manually entered data for inclusion into reports.

 System manager level:

The system manager level shall permit authorized users to access default level and op-
erator level activities in addition to the following:
 Modify alarm and control set points, dead bands and time delays;
 Enter or modify historical data;
 Add, delete or modify individual I/O points or point attributes;
 Add, delete or modify field device configurations;
 Create, delete or modify control algorithms;
 Create, delete or modify graphic displays;
 Create, delete or modify system reports;
 Configure trend displays;
 Access the operating system;
 Assign access levels and user passwords;
 Perform any other system maintenance function
6.3 Web Technology
 The Central Control room shall also consist of Web Clients capable of displaying
entire data right from Intake well to water supplied to end user.
 The web-clients shall be available without a need to load any additional client
software on the user's PCs.
 Users must be able to view the information as well as with sufficient password
protection, enter or modify information of Pumping station and Distribution
Network.
 In addition, the software shall provide the ability to view point and alarm reports in
excel, pdf format in standard web browsers.
 The web server software shall allow for point data to be transferred between servers
across the Internet with proper security.
The Web SCADA at Central Control Room shall provide following features:
 Displaying the entire pumping station data such as Pump health, ON/OFF status,
flow rate and Pressure, total time of operation, Electrical parameters.

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 Displaying the entire data from Tapping Points, Water Distribution Centers, District
Outlets, Air-Valves, Surge Protection System, and Water Meters etc.
 Control of all the Pumps, Valves, Tapping Points, Water Distribution Centers &
District Outlets etc.
 Display the communication healthiness of field units and PLC System
 User will be able to change valve operation timings from the graphical screens.
 Control center shall be capable of Downloading data to FCU Units and Uploading
data from the FCU Units.
 Control Center will have a program to design and display an event report for each
Pumping Station and Distribution water network.
 Printer interface facility for printing report.
 The user shall be able to define all field Units and their associated configurations,
 The user shall be able to define all software application functionality and download
(send) the data to the field units, in order for them to perform the on-site function.
 The user will be able to upload the existing data from the field units in order to
monitor the entire system.
 The Control Centre shall provide the ability for the user to "zoom in" to the level of
single element characteristics (i.e. Input/Sensor, Output/Valve etc.) at each site.
 The user can able to monitor site conditions like inside, Battery Voltages,
GSM/Radio signal strength.
 The user can able to monitor the Panel door status at central.

6.4 Redundancy for WTP SCADA

 The system must support software based redundancy solution as well as hardware
dependent, high availability architectures as well.
 Redundancy applies to both hardware and software, and implies minimal loss of
continuity during the transfer of control between primary (active) and redundant
(backup) components.
 The system shall support Server Redundancy.
 Server redundancy involves a primary factory monitoring server and a redundant
"Hot Standby" server. The redundant server is essentially a mirror image of the
primary server, running alternate monitoring/control processes and applications.
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 Data collection is performed via independent or shared network paths to the same
devices, depending on the protocol.
 Upon detection of failure of the primary server, the secondary server can assume
control of data collection, alarm functions, applications, and allow user access with
minimal loss of continuity. When the primary server comes back on line, control
can be transferred back, and the secondary server will resume its backup role.

7. SCADA ROOM POWER & UPS:

The SCADA room processor(s), Monitors, logging printer and communications equip-
ment shall be powered through an uninterruptible power supply (UPS) via a dedicated
distribution system. The UPS shall provide for full functioning of this equipment for a
minimum of four hours in the event of a power failure. UPS capacity shall be over-
sized in terms of rating and power duration by 100% to provide for future additional
equipment. UPS batteries shall be sealed lead acid maintenance less type.
The UPS distribution cable sheaths shall be of a color which distinguishes them from
other service cabling. Each master station device shall be provided with a local isolating
device such as a fused spur or switched socket outlet.
 Master Control Room Furniture:
 Control Command Centre (C3) at WTP: Main control command centre located
at WTP, shall collect the data of from Intake well to all WDCs shall monitor on
Video wall and control. Provision need to be made connecting to C4 (City control
command centre). It shall comprise of Engineer-in-Charge station, historian station
along with real time data acquisition server.
 control command centre (C3) located at WTP, shall collect the data from Intake
well, Raw water raising main, WTP, Clear water pumping station, Clear water
pumping main, WDCs shall monitor on 2 Nos 90” Video wall & control, CC footage
of WTP. Provision need to be made connecting to C4 (City control command
centre). It shall comprise of Engineer-in-Charge station, historian station along with
real time data acquisition server
 Control command centre (C3) room shall consist of Reception furniture, visitors
lobby, visitor seating furniture, 3 operator work station, 3 nos Engineer-in-Charge

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work station, announcement facility, two nos 90” inch video wall (16:9 ratio), false
ceiling interior, glass patrician between visitor lobby and video wall station.
 Video wall: Advance technology with various content, IP camera, and multi-PC
playback with scheduling, display upto 250, linear and asymmetric, Scheduled play,
Multiple aspect ratios, Full HD on every screen, Display multiple sources, Display
images across single or multiple screens, HDCP support, Image rotation, Remote
monitor management, Live camera and PC feeds,
 Connectivity Technology: Set Back Box (SBB) for each display, Magic Info Player
I & Network switch/LAN/Gb Ethernet
 In addition to the SCADA/HMI system equipment, it shall provide furniture
(system console) to complement or match both the color and styling of the
equipment. Control room furniture shall comply with relevant IEC standards for
ergonomic design. Details of the control room furniture shall be submitted to the
Engineer-in-Charge for approval.
It shall provide 6 fabric-covered upholstered swivel-type adjustable arm chairs with
casters for Engineer-in-Charge and operators, 6 nos laptop for work station, 9 seats sofa
and glass top table, carpet flooring in visitor lobby, receptionist table with swivel-type
adjustable arm chairs, a rigid and lockable steel cupboard for the storage of operating
and maintenance manuals, drawings, logger paper, charts, disks and the like.
The visual display unit consoles or VDU desk shall incorporate at least one drawer unit
with drawers for operators use and for standard files.
Laptops Configuration for Portable Programming Unit & Administrators,
Engineer-in-Charges Usage:
Latest operating system software that shall be compatible with all Engineer-in-Charge
Software's including Automation Software's
Intel Core i7 (3.4 GHz/2.4 GHz)
Turbo Boost Technology
4 GB GDDR5, 4 GB RAM & 1

8. FIBER OPTIC CABLE

8.1 Scope:

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This specification defines the minimum requirements on manufacturing, installation,

splicing and testing and delivery of the fiber optic cable to be used for the “AMARA-
VATI CAPITAL CITY Project". The cable shall serve as the transmission medium for
a fiber optic data transmission system between Raw water, WTP, Clear Water Pumping
Stations, WDC’s and the Master control room building. For the laying of the fiber optic
cable, the HDPE conduit and the data transmission system reference following section”
Fiber Optic Cable Conduit and FOC Installation”
8.2 Codes and Standards:
The manufacturing, construction, labeling and testing of the fiber optic cable system
shall meet the requirements established in the following codes, standards and recom-
mendations and in the enclosed data sheet.
8.3 Standards for Cable:
 Optical fibers
 ITU-T G.652 characteristics of a Multi-mode optical fiber cable, and/or IEC 60793-
1-1 optical fibers - generic specification IEC 60793-2 optical fibers - product
specifications
 Fiber optical Cable
 ITU-T L.10 Optical fiber cables for duct and tunnel application, and/or IEC 60794
-1
Optical fiber cables - generic specification IEC 60794 -2 Optical fiber cables - indoor
cables IEC 60794 -3 Optical fiber cables - outdoor cables.
8.4 Standards for Measuring Methods:
IEC 60793-1-2 Optical fibres – generic specification – measuring methods for dimen-
sion IEC 60793-1-3 Optical fibres – generic specification – measuring methods for
mechanical characteristic
IEC 60793-1-4 Optical fibres - generic specification - measuring methods for trans-
mission and optical characteristic
IEC 60811 Common test methods for insulating and sheathing materials of electric and
optical cables.
8.5 Other Standards:

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ITU-T K.25 Protection of optical fibre cables IEC 60304 Standard colours for insula-
tion for low-frequency cables and wires wherever codes, standards and recommenda-
tions are mentioned, the latest published revision or issue shall be applicable.
8.6 Transport, Unloading and Storage:
All of this material shall be brought on site, unloaded and stored (if necessary) in such
a way that damages are avoided. Storage supports and stacking heights must be se-
lected in such a way that steady deformations of the cable conduits are avoided. Drums
shall be secured against roll off.
8.7 Fiber Optic Cable:
The fiber optic cable will be laid in a buried cable conduit. A fully dielectric fiber optic
cable, suitable for ducted or direct buried applications, filled with compound to prevent
axial and longitudinal ingress of water and / or soluble chemicals throughout the cable
shall be provided. The cable shall have loose tubes as secondary coating of fibers. The
cable length to be supplied shall be either 1,000 m or 2,000 m per drum, depending on
the actual required total length.
Traction elements shall be made out of Kevlar or equivalent. The allowable tensile
loading of the cable shall be 2.500 – 3.000 N, suitable for direct blowing or pulling the
cable into cable ducts.
The outer cladding of the cable shall consist out of black PE. Other color coding and
labeling of the particular cable components shall be according to IEC 60304. The
color-coding system shall be discernible throughout the design life of the cable. Cable
markings shall be printed on the outer fiber cable jacket. The markings shall be perma-
nent, insoluble in water and be legible for the duration of cable life. The markings shall
be printed at intervals of not more than 2 meters.
Optical Fiber racks:
Optical Fiber racks shall be installed in all the network and PLC panels, which shall
contain pigtails and output connector. Optical fiber cores shall be spliced to join with
pigtails so that the corresponding output connector can be utilized for the correspond-
ing local panel.

8.8 Tests:
Factory Acceptance Test

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Each particular cable length shall be factory acceptance tested and shall be delivered
together with the respective test reports.
a. Attenuation tests of each fiber at 1.300 +30/-15 nm and at 1.550 +30/-70 nm with
OTDR according to IEC 60793-1-4 double-sided shall be performed.
b. Dispersion tests of each fiber at 1.300 and 1.500 nm according to IEC 60793-1-4
shall be performed.
These measurements shall be performed on each fiber prior to cable manufacturing
and on the fabricated cable. Tension and temperature test of the fiber optic cable, as
homologation test and determination of resulting attenuation and variation in attenua-
tion according to IEC 60793-1-4 shall be performed. Prior to the factory acceptance
test the Agency shall provide a test procedure which is subject of approval by the
owner’s Engineer-in-Charge.
Receipt of Cable Test:
Each particular cable length shall be tested upon receipt on site. Attenuation tests of
each fibre at 1.300 +30/-15 nm and at 1.550 +30/-70 nm with OTDR according to
IEC:60793-1-4 double-sided shall be performed. Determination of optical length shall
be performed.
8.9 Test protocols:
Test protocols shall be provided for all activities conducted in course of tests.
Proposal Documents:
The following documents shall be provided with the bid:
a. Delivery time schedule
b. Filled in cable data sheet
c. Additional technical data of offered cable
Delivery Documents:
The documents to be provided per cable drum shall comprise:
a. Drum number b. Manufacturer c. Cable type
d. Cable length
e. Data sheet
f. Results of FAT
Documents before FOC Installation:

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Before commencement of the FOC laying works the tests to be performed after cable
receipt must be available and must prove that the cable is faultless. For tests after laying
and splicing reference is made to the Specification of section “Fibre Optic Cable Con-
duit and FOC Installation”.

9. FIBER OPTIC CABLE CONDUIT AND FOC INSTALLATION

9.1 Scope
This specification defines the general requirements for the fiber optic cable conduit to
be used for the “AMARAVATI CAPITAL CITY Project". In addition the several ac-
cessories and the FOC installation, including splicing and testing is defined herein.
The cable conduit shall be used for blowing in the fiber optic cable, which is defined
in the Specification of section “Fiber Optic Cables”.
9.2 General
The fiber optic cable shall be laid in buried cable conduit. The conduit shall be supplied
by the station Agency, and laid between the electrical buildings of the wastewater
pumping station and the control building. The FOC will be installed after backfilling
and removing of all heavy machinery by the cable blowing method.
9.3 Codes and Standards
The manufacturing, delivery, installation and testing of the cable Conduit shall meet
the requirements established in the following codes and standards:
ISO 161-1 Thermoplastics Pipes – Nominal Diameters; Nominal Pressures
ISO/DIS 1167 Thermoplastics Pipes – Resistance to Internal Pressure – Test Method
ISO/DIS 2505-1 Thermoplastics Pipes-Longitudinal Reversion-Determination Meth-
ods ISO/DIS 2505-2 Thermoplastics Pipes-Longitudinal Reversion-Determination Pa-
rameters ISO/TR 10358 Plastics Pipes and Fittings-Combined Chemical Resistance
Classification Table
DIN 8074 Polyethylene (PE) - Pipes PE 63, PE 80, PE 100, PE-HD Dimensions
DIN 8075 Polyethylene (PE) Pipes General Quality Requirements
Wherever codes, standards and recommendations are mentioned, the latest published
revision or issue shall be applicable.
9.4 Transport, Unloading and Storage

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All of this material shall be brought on site, unloaded and stored (if necessary) in such
a way that damages are avoided. Storage supports and stacking heights must be selected
in such a way that steady deformations of the cable conduits are avoided.
9.5 Cable Conduit
The cable conduits shall especially be suitable for blowing in fiber optic cables and
shall reduce the friction and abrasion of the fiber optic cable during the installation
process to a minimum. The inner surface of the cable conduit shall therefore provide
optimum sliding characteristics achieved by longitudinal rills.
9.6 Enclosures
Direct buried splice closures shall be used for straight through splicing and branch
splicing of single mode fiber cables. The splice closures (loose buffer tube with central
strength member) shall be suitable for a single mode fiber optic cable according to the
Specification of section “Fiber Optic Cable
In general, the enclosures will be used to splice one (1) fiber cable but shall have the
capability of splicing additional branch cables whenever the need arises. The following
minimum functional requirements shall be provided:
a. Mechanical protection of the splice
b. Accommodation for redundant fibres
c. Termination of the Fibre Optic Cable
The dimension of the concrete shafts shall be designed in this way that the cable loop
and the enclosures at a splicing point can be laid without to under-run the minimum
allowable bending radius of the fibre optic cable.

9.7 Optical Distribution Frame

The termination of each fiber in transmit and receive direction shall be provided on an
optical distribution frame (ODF) for access to the transmission equipment. The ODF
for receive and transmit direction shall be dimensioned in accordance to the specified
number of fibers referring to the Specification of “Fiber Optic Cable” plus additionally
20% of spare capacity. The ODF are to be installed in termination cabinets, which may
be combined with the communication system.
9.8 Marker
Buried passive markers (Ball EMS) shall be used.

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9.9 Warning Tape

A detectable reinforced underground marking and warning tape shall be laid in the
ground approx. 30 cm above the protection conduit.
9.10 Patch Cords, Pigtails, Optical Plug Connection
The patch cord consists of a single phase fibre optic cable with plug connections on
both ends. Pigtails are fibre cables pre-assembled with a connector at one end. The
optical plug connection consists of a plug and an adapter for the connection with a
further plug. All connectors must be from the same type as the connectors of the tele-
communication system. The fibres of the patch cords and pigtails shall be according
the specified fibres in the Specification of section “Fibre Optic Cable”. All Component
shall have a service life of more than 15 years with a minimum of contact durability of
1000.
9.11 General
The cable shall be laid with a minimum of splicing joints, if possible without any joint.
The cable laying shall be started after the cable conduit has been installed and tested
(calibration and pressure test) successfully between two points of cable termination.
After the cable conduit has successfully been tested and the trench surfaces have been
reinstated, the fibre optic cable will be blown in, respectively pulled in at difficult sec-
tions.
9.12 Laying Procedure
The cable shall be laid in buried conduits. The laying process has to be in compliance
with cable manufacturer’s recommendation (tensile load rating, pulling force, crushing
force, minimum allowed bending ratings, minimum outdoor laying temperature, etc.).
The use of additional lubricants during the cable installation shall be avoided. At dif-
ficult sections (e.g. road crossings) is will be allowed to pull the cable, if the require-
ments mentioned above are considered. At cable joint points a surplus cable of approx.
10 m shall be provided for splicing. After splicing the surplus cable shall be coiled up.
The surplus cable and the enclosure shall be installed in a prefabricated concrete shaft.
Markers shall be used to locate the position of the concrete shafts.
9.13 Cable Laying Inside Buildings

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Inside buildings the fiber optic cable shall be laid on cable trays or ducts. The fiber
optic cable shall be tied-in, laid, terminated and relieved from strain applying all ap-
plicable regulations. Grommets through walls and floors required in course of the
cable laying shall be opened and closed under consideration of fire safety regulations.
9.14 Cable Splicing
The splices shall be produced by use of fully automatic splicing devices applying
fusion splicing technology.
The splicing shall be conducted with the procedure outlined by the manufacturer of
the equipment with a particular emphasis on cleanliness.
For fiber optic cable connection only electric-arc fusion splicing is acceptable. Only
for test purposes (e.g. receipt of cable testing) mechanical splicing is allowed. Each
single splice shall not introduce to the fiber an attenuation exceeding 0.1 dB. The
splices shall be accommodated in splicing enclosures. At cable joint points all fibers
of the fiber optic cable shall be connected through by splices. All fibers of the cable
tied-in to a station shall be spliced in a fiber optic terminal box with splicing modules.
All fibers shall be spliced to pigtails which shall be terminated on an optical distribu-
tion frame with optical connectors providing access for a data transmission system to
the optical fibers. The fiber optic terminal box and the optical distribution frame shall
be housed in the cabinet for the data transmission system. All spare and standby fibers
terminated at the optical distribution frame shall be connected through by patch cords.

9.15 Connectors
The connecter loss shall not exceed 0.5 dB per connecter.

9.16 Tests
 Installation Test
The SubAgency has to perform immediately after a cable is installed a rough optical
time domain reflectrometer (OTDR) test just to verify if a cable damage has occurred
during the installation.
 Splice Test
A unidirectional OTDR-testing shall be performed after a splice is done.
 Acceptance Test

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After laying, installation, splicing and termination of each cable section the following
tests shall be performed on each fibre:
a. Attenuation tests of each fibre at 1.300 +30/-15 nm and at 1.550 +30/-70 nm
with(OTDR) IEC 60793 double-sided.
b. Attenuation tests of each fibre at 1.300 nm and at 1.550 nm with optical power
meters single-sided.
Having identified which splices have a loss exceeding the criteria, the next step is to
re- burn these splices to reduce the loss. Only if the measurements confirm that all
splices, terminations and attenuations of the several cable sections are according to
the cable/termination specification of manufacture and to this specification a cable
section can be completed.
 Test Protocols
Test protocols shall be provided for all activities conducted in course of tests.

9.17 Proposal Documents

The following documents shall be provided with the bid:
a. Technical data of offered conduit
b. Requirement for the laying of offered conduit
c. Examples/data sheets for enclosures, concrete shafts, ODFs and markers

9.18 Design Documents

Following approved design documents are necessary for the installation of the cable
conduit and the fiber optic cable:
 General documents
 Cable laying method statement
 Cable installation procedure
 Cable splicing method statement
 Drawing and document schedule (or part of an overall schedule)
 Time schedule (or part of an overall schedule)
 Power budget calculation
 Data sheets and sketches
 Enclosures data sheet
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 Concrete shaft data and sketch

 ODF data sheet
 Marker data sheet and sketch
 Pigtails and patch cord data sheets
 Optical plug connection data sheet
 Drawings
 Interconnection diagram, terminal block diagram, distribution board schedule
(ODF)
 Splicing location sheet

9.19 Documents for FOC Installation

Following documents are necessary for the Laying of the FOC:
a. Results of the test after receipt of FOC
b. Results of the calibration test

9.20 As-built Documents

The as-built documents to be provided Comprise:
a. Latest revision of all design Documents
b. Laying records
c. Splicing table and drawings with the coordinates of the splices
d. Test reports

Overall system architecture shown below of Amravati Capital city depicts complete system
flow right from Intake pumping station to consumer level. It displays complete data of all
pumping station and Distribution network in the center. Network including Raw Water, WTP,
Clear Water Pumping Station and Water Distribution Centre are interconnected using Optical
Fibre as primary communication media while wireless communication shall be secondary. This
provides quick action over interdependency between Pumping station, WTP and WDC’s. Data
from all the Stations and Distribution outlets shall be available at Central Control Room.

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Figure 3: System Architecture: (Drawing to be separate for P& ID, System Architecture)

9.21 Detailed Specifications for Instruments:

Pressure Indicators:
Direct reading, pipe mounted Pressure gauges of Stainless Steel with 6-inch phenolic
dial (white dial with black numerals), 316 SS Bourdon tube, nylon movements and
micrometer type adjustable aluminium pointer with accuracy of +/-1% of span in-
cluding accessories like siphons for steam services, snubbers for pump discharge ap-
plications and chemical diaphragm for corrosive and oil services and name plate, etc.
Material of accessories shall be SS. IP65 degree of protection for enclosure. Over
range protection shall be 50% above maximum pressure. Armoured capillary of 15
M shall be provided as required.
Pressure Switches/ DP Switches
Non-indicating type, field mounted Pressure Switches of aluminium casing (epoxy
coated), and 316 SS element and accuracy of +/-1% of span, including accessories

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like snubbers for pump discharge applications and chemical diaphragm for corrosive
and oil services, name plate & mounting brackets. Material of accessories shall be
Auto reset micro switch with internal adjustment for set values with 2 SPDT contacts
rated for 0.2 A at 220 V DC. IP 65 degree of protection for enclosure. Over range
protection 50% above maximum pressure. Scale for setting shall be provided.
Temperature Indicators (Thermometers)
Thermometers shall be Industrial type, Bi-metallic for low temperature applications
(<80O C), inert gas actuated vapour pressure type for above 80O C of SS bulb and
capillary. Body material-Die-cast aluminium. Dial size-150 mm with white dial and
black numerals and process connection-1/2’’NPT (M). Accuracy-+/- 1% of span.
IP65 protection class. Accessories include nameplate, mounting brackets and SS
Thermowell. Thermowell process connection- M33X2 and 1/2’’NPT (F) on ther-
mowell for thermometer.
Thermowells
Pipe/ equipment mounted temperature test wells of 316 SS with a process connection
of M33x2 thread and instrument connection of ½” NPT (F) in general or 150 RF
flanged. Accessories like name plate, plug with chain, etc. shall be provided. Material
of accessories shall be SS. Thermowell shall be hex head of barstock assembly. In
case flanged wells are required for any specific application, the same shall be sup-
plied as required. The thermowell construction shall meet the ANSI 19.3 (latest) re-
quirements. Thermowell shall be designed such that the resonant frequency is above
the exciting frequencies generated by vortex shedding in the process fluid. All Test
thermowell shall have the plug of SS316. IBR certification as applicable shall be
provided.
Temperature Elements (RTD)
Duplex type, PT – 100, with accuracy of +/-0.5% of span, response time 1-2 seconds;
Spring loaded mineral insulated three (3) wire RTD assembly with 316 SS Thermow-
ell housed in aluminium casing (epoxy coated) having a process connection of M33
x 2 thread and instrument connection of ½” NPT (F) in general or 150 RF flanged.
IP 65 or equivalent degree of protection for enclosure. Material of accessories (name
plate, etc.) shall be SS. Thermowell with hex head with screwed cover & SS chain,
barstock assembly. Element lead size shall be 18 AWG. The insulation resistance at

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540 Deg C shall not be less than 5M ohms. Repeatability over full range shall be
better than 0.02%. RTDs shall be ungrounded. RTD shall be supplied as an assembly
complete with thermowells meeting ANSI 19.3 (latest) requirements.
Level Gauges
Tubular/ float type level gauges with brass guard rods & brass holders shall be pro-
vided. Material of float & float chord shall be 316 SS & cage materials shall be fab-
ricated steel and the material of accessories (name plate, etc.) shall be SS. IP65 de-
gree of protection for enclosure. Connection shall be screwed or flanged (ANSI class
150 RF).
Level Switches
Top mounted float type level switches for water tanks/ sumps shall be supplied with
still tubes to suit the requirement. Micro switch with 2 SPDT contacts rated for 0.2
A, 220 V DC. Material of float & float chord shall be 316 SS & cage materials shall
be fabricated steel and the material of accessories shall be SS. IP65 degree of protec-
tion for enclosure.
Accessories like name plate, drain valve for external case type level switches, mating
flange, gaskets (asbestos), fasteners, bolts & nuts, etc. shall be supplied.
System/ Marshalling Cabinets
These cabinets shall house signal-conditioning cards, input/ output cards, processor
cards & associated power supply units. Indoor located, free standing vertical type
system cabinets with IP-42 enclosure and with 3 mm thick sheet metal of cold rolled
steel; double doors with neoprene gaskets; anti-vibration pads of 15 mm thick;
blower louvers in each cabinet with brass mesh; fire proof compound (50 mm thick-
ness) for sealing cable entry (bottom); fire detector for each cabinet. Beacon lamp
shall be provided in each cabinet to indicate the cabinet having fault condition. The
colour of the cabinets shall be indicated at detailed Engineer-in-Charge stage. Doors
shall have concealed type of hinges and swing of 100O. The doors shall be provided
both at the front and rear. Power supply distribution shall be provided on per cabinet
basis with all associated MCBs, protections, etc. The system cabinets, racks in sys-
tem cabinets, slots in the racks & the terminals shall have identification numbers. A
stainless-steel metal tag (plate) shall be fixed to the inside of the door & the layout
of the racks, slots details of the card type/ service shall be inscribed on this metal tag.

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Each cabinet shall be provided with one each 3 pin receptacles for 220 V AC, 1¢, 50
HZ and for +24V DC. Cabinet shall be delivered totally wired. All electronics shall
be mounted & wiring connections at these hardwares shall be terminated by Bidder.
Quantity shall be as required. All cabinets shall have common key for the locks. In
each cabinet, a 24 V DC Voltmeter shall be provided to check the Field Interrogation
voltage.
9.22 Flow Meter:
Electromagnetic Flow Meter of appropriate size shall be installed at the end of the
manifold to measure the quantity of water discharged in to the Distribution Chamber.
Full bore electromagnetic flow meter shall consist of flow sensor (i.e. flow tube),
flow transmitter and flow indicator and integrator and any other item required to
complete the system. To avoid the effects of disturbances in the velocity profile, a
straight and uninterrupted run, upstream as well as downstream from the location of
the flow meter shall be provided, as required by the flow meter manufacturer and in
line with the applicable standards. Agency shall finalize the exact location of flow
meter in consultation with Representative of Authority.
Flow measurement shall not be affected by physical properties of water viz., temper-
ature, pressure turbidity etc., within given limits. Agency shall provide compensating
Electronic circuits, if required.
A lockable enclosure shall be provided for the flow transmitter cum computing unit,
if required.
Flow meters shall be suitable for the water turbidity at site during various seasons.
Flow tube shall be rugged in construction and shall be suitable for continuous oper-
ation. Flow tube shall have waterproof construction and shall be suitable for instal-
lation on underground /above ground pipe lines.
The flow computer and transmitter shall be a single unit suitable for panel mounting.
It shall accept inputs from flow tube, process the signals and shall provide an output
proportional to the flow rate. The distance between transmitter and flow tube shall
be maximum 250 mtrs. Taper pieces required for installation of flow meter shall not
exceed an angle of 8° in order to avoid disturbance in flow profile.
a. General:
i. Accuracy of flow measurement during FAT ±0.5% of measured value

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ii. (ii) Overall accuracy of flow measurement loop ±1.0 % of measured flow
b. Flow tube
i. Application : The water pumping mains
ii. Type : In line full bore electromagnetic
iii. Size of flow tube : As approved by the Authority.
iv. Process connection : Flanges as per BS 4504
v. Weather Protection Class: IP 68 as per IS 13947
vi. Surge protection devices
(SPD) between flow tube
and flow transmitter : Required for protection from lightning surges
vii. Material of Construction:
Electrodes : SS 316, self-cleaning pipe
Coil Housing : carbon steel coil housing
Flanges : Carbon steel
Grounding ring : SS 316
viii. Flow tube Lining: EPDM/Neoprene/PTFE.
c. Flow Transmitter Unit
i. Type : Microprocessor based with facility to configure the
ranges.
ii. Type of display : 4-digit backlit LCD/ LCD, for flow rate in m3/hr.
8 digit
Backlit LCD/ LCD for totalized flow in ML
iii. Units of display : Flow rate -m3 / hr Totalized flow – ML
iv. Input : From flow tube
v. Output : 4-20 mA DC (isolated) proportional to flow rate
vi. Power Supply : 230 VAC
vii. Zero and Span Adjustment: Required
viii. Weather Protection Class: IP 68 as per IS 13947
ix. Battery backup for totalized
Flow Type : Online
Capacity : 2.5 mVA
Backup Time : 8 hours.

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x. Facility for on line diagnosis : Required

9.23 Calibration:
The Electromagnetic flow meter shall be wet calibrated for the full flow range
specified as per BS EN 29104/International Standard (Methods of evaluation of
electromagnetic flow meters).
The calibration method shall be either gravimetric method as per ISO 4185/Interna-
tional Standard (Measurement of fluid flow in closed conduits – weighing method) or
volumetric method as per ISO 8316 (Calibration by Volumetric Method). The ‘test bed’
shall be accredited by appropriate National / International certifying authority. The
Agency shall produce accreditation certificates for the test facility and calibration cer-
tificate for the flow meter for the review by representative of the Authority. The Agency
shall also demonstrate complete wet calibration on the test bed in the flow meter labor-
atory. The flow meter shall be acceptable if the accuracy and repeatability is equal to or
better than those specified.

Flow Indicator and Integrator

Flow indicator and integrators shall be modular in design. It shall consist of two sepa-
rate dedicated displays for flow rate indication and total flow indication. It shall accept
4-20 mA DC isolated input. The flow integration shall be carried out in the Program-
mable Logic Controller (PLC). The flow indicator cum flow integrator shall provide 4-
20 mA retransmission output proportional to flow rate.
Sl.
Details Description
No.
1 Type Microprocessor based

2 Mounting Front facia of Control Panel

Digital, seven segment back lit LCD / LED dis-
3 Display
play
4 Digit Height 14 mm or Higher
No. of Digits for
5 Flow indicator 4 Digits
Flow integrator 6 Digits
4-20 mA DC (Isolated) from flow transmitter
6 Input through
analogue signal multiplier (Refer Note 2)
Zero and span
7 Required
adjustment

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Manual Reset Facility Required (shall be password protected)

8
for flow integrator
Engineer-in-Charge units:
9 - Flow rate indicator Cum/hr
- Flow integrator ML
Required
10 Battery backup for integrator
11 Retransmitted output 4-20 mA proportional to flow rate
12 Alarm outputs 1 NO + 1 NC for high and low alarms (adjustable)
RS-485 (With Mod bus protocol) for interfacing
13 Communication port
with PLC
14 Weather Protection Class IP-52 of IS 13947 Part I
15 Accuracy ± 0.25% of span or better.

Note:
Digital flow indicator and flow integrator shall be a combined unit.
Facility shall be available in the analog signal multipliers and in the flow indicator and
integrator for providing excitation voltage for the flow transmitter in case of 2-wire
flow transmitters.

9.24 Installation
The installation of the Electromagnetic Flow meters shall be done at the locations de-
cided by the Engineer-in-Charge. The job covers supply of the Electromagnetic Flow
meters at work site with cost of all the required material and all types of taxes and
duties, cost of packing, loading, transportation, unloading, stacking and installation at
the specified location with cost of all jointing materials such as nuts and bolts, EPDM
rubber gaskets etc. The job also covers field hydraulic testing of the Electromagnetic
Flow meters after installation for the specified test pressure for the respective pipeline
section.

10. PRESSURE TRANSMITTERS.

Transmitters shall be manufactured from material suitable for use with the process me-
dium and for the site ambient conditions.
The transmitter shall be of suitable IP or as per data sheet, yoke mounting, provided
with mounting arrangements suitable for minimum 2” pipe mounting. The materials of

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construction shall be suitable for the local climatic conditions and where necessary suit-
able, weather proof enclosure with viewing windows shall be provided. Pressure sen-
sors shall be fully temperature compensated Transmitters shall be powered by 10-30V
DC with 4 to 20 mA output and SS-316L wetted parts.

11. LEVEL TRANSMITTERS/ Switches.

Suitable Level Transmitters/ Level Switches shall be supplied to measure liquid level
of tanks/sump like treated water / backwash service water sump, backwash water over
head tank (ESR), dirty water sump, and all alum/PAC solution preparation& dosing
tanks. The purpose is to monitor tanks/sump levels locally and at ICP at main control
room as well as provide low level trip for safety of pumps against dry running, start/stop
of pumps in auto mode through suitable logic to be decided during detailed Engineer-
in-Charge, low/high level alarm annunciation at HMI/SCADA at control room, etc. Ul-
trasonic level measurement shall be provided wherever necessary and based on site
feasibility. The measurement shall be accomplished by using non-contact, echo time
measuring equipment operating at ultra-sonic frequency.
Level transmitter shall consist of a sensor incorporating both transmitter and receiver
along with integral controller or a separate control unit. Control unit shall be program-
mable and shall have as per data sheet.
The sensor shall be suitable for mounting in the open, or within an enclosed tank, and
shall be with environmental protection as per data sheet.
The transmitter shall provide 4 to 20 mA with relevant IP 65 Class protection.

Ultrasonic Transmitter for Open Channel/Rectangular Flow Measurement:

Ultrasonic transmitter shall be provided to measure each open channel/weir flow as
provided for the treatment plant in Outlet of the Plant. The brief specifications in addi-
tion to above specifications shall be as under:
Type : Ultrasonic, fully user Programmable, microproc. based
Mode of Operation : Flow
Accuracy : ± 0.25% of range OR 6 mm, whichever is greater
Resolution : 0.1 % of range OR 2 mm, whichever is greater
Outputs : 4-20 mA analog output proportional to flow

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Programming Device In-Built in controller or Hand-held

Local Digital Display Flow in Engg. Units
Power : 230 V ac ± 15%, 50Hz OR 24 V DC
Control Unit Protection: IP-65 as a minimum
Operating Temp : 0 to 50 deg C
Proc. Temp. Compensation: Required, Built-in temp. sensor in transducer
Sensor MOC : PVDF or equi. suitable
Transducer Protection : IP-68
Transducer Cable Length: 10 m minimum
Communication Port : As given by manufacturer
Erection As per site requirement and directed by Engineer-in-Charge
Flume Flow (Instantaneous and Totalised) readings shall be continuously displayed lo-
cally and at PLC HMI at main control room and also at ICP (Control Panel) in main
control room on panel mounted indicators/totalizers. The instrument shall be competent
to perform open channel measurements for all kind of flumes & weirs.

12. ON-LINE RESIDUAL (FREE) CHLORINE MEASUREMENT SYSTEM:

Free Chlorine readings shall be continuously displayed locally and remotely at ICP at
main control room.
On-line type Free Residual Chlorine analyzer shall be provided to measure free residual
chlorine values in Clarified Water Outlet (Common channel to filter inlet) and for
treated water at Backwash Sump / Treated Outlet Chamber after required chlorination.
The specifications shall be as under:
Type : Microprocessor based, programmable
Measurement type : DPD Colorometric type
Range : 0-10 mg/l or suitable
All wetted parts MOC : Non-corrosive material
AnalogOutput : 4-20 mA proportional to residual chlorine
Contact Output : Min. 2 potential free changeover contacts
Local Display : Free Chlorine value
Accuracy : + 5% of reading or better
Mtg / Sensor Holder Type: Flow Through assembly or suitable as required (Suitable

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sampling system shall also be provided, if required)

Sensor Cable : included, min. 5m length or higher as suitably required

13. Power:
230 V AC, 50 Hz
Transmitter Housing: Weather proof to IP-65 / NEMA-4X as a minimum
Electrical Connection: ½” NPT
Sensor Failure Alarm: Required
Instrument Canopy: Required
FRC reading shall be continuously displayed locally and remotely at PLC HMI /
SCADA and ICP (Control Panel) in main control room on panel mounted. Low / High
FRC level alarm shall be annunciated at PLC / SCADA and at alarm annunciator in
main control room. Real time and historical trend shall be available as per requirement.
Chlorine dosing shall be shutoff on the high level of leakage of Chlorine Gas. The same
shall be incorporate in HMI/SCADA through chlorine gas detector transmitter. It shall
provide necessary arrangement to control chlorine dosing (pre-chlorination) in the treat-
ment to achieve accurate chlorine dosing level in ppm at the final outlet of treatment.
To achieve this, chlorinator shall be provided with auto control the chlorine dose with
required control valves based for closed loop control through feedback of either (clari-
fier outlet FRC or Filter outlet FRC) of the FRC analyzer feedback as selected by op-
erator at PLC/SCADA to maintain the FRC at selected location at programmed set
point.

14. CABLES:
All power & control cables for use on medium / low voltage shall be heavy duty type,
aluminium/ copper conductor. PVC (XLPE may also be accepted) insulated, inner
sheathed, armored and overall PVC sheathed as described below.
Cables shall be sized based on the maximum continuous load current and the voltage
drop. The derating due to ambient air temperature, ground temperature, grouping and
proximity of cables with each other etc. shall be taken into account. Below grade cables
in paved areas shall be in concrete lined trenches with concrete covers having proper
slope and suitable drainage arrangement to avoid water collection. In unpaved areas

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cables shall be in lined trenches or directly buries in ground. In hazardous areas trenches
shall be completely filled up with sand. Concrete lined cable trenches shall be sealed
against ingress of liquids or gases wherever the trenches leave a hazardous area or enter
control room or substation.
The cable trenches shall be sized depending upon the number and voltage grade of ca-
bles. Where underground cables cross roadways, pipe sleepers at grade, etc., they shall
be protected by being drawn through PVC sleeves/ducts or suitable RCC Pipes to pro-
vide a permanent crossing. Pipes laid for mechanical protection shall be sealed at both
ends. High voltage, medium/low voltage, control and signal cables shall be separated
from each other by adequate spacing or running through independent pipes, trenches or
cable trays as applicable. Cable trays, racks and trenches shall be sized to allow for 20%
future cables.
Cable installation shall provide minimum cable bending radii as recommended by cable
manufacturer. Cable route markers shall be installed at every 30m interval all along the
routes of directly buried cable trench and also at locations where the direction of cable
trench changes. All power and control cables shall be of continuous lengths without
intermediate joints. Where joints are unavoidable, these shall be provided with the per-
mission of Engineer-in-Charge. All cables shall carry tag numbers for easy identifica-
tion.
In case of control cables all cores shall be identified at both sides by their terminal
numbers using PVC ferrules as per interconnection diagrams.
Sequential marking of the length of the cable in meters shall be provided on the outer
sheath at every one meter. The embossing/engraving shall be legible and indelible. Control
cables having 6 cores and above shall be identified with prominent and indelible Arabic
numerals on the outer surface of the insulation. Colour of the numbers shall contrast with
the colour of insulation with a spacing of maximum 50mm between two consecutive num-
bers. Colour coding for cables up to 5 cores shall be as per IS.

14.1 Laying of Cables:

Cables shall be laid on trays, in trenches, conduits, ducts as necessary. Instrument cables
shall not be buried in ground as far as possible. Cable joints in instruments signal and
power supply cables shall not be permitted. In case if some of the instrument cables are

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to be buried in the ground, it shall be as per standard/good Engineer-in-Charge practice

and shall be subject to client’s/consultant’s approval.
It shall also supply necessary materials such as junction boxes, glands, lugs etc. required
for termination of cables. Each cable shall be terminated to individual panel/terminals
box. Cable glands shall be of Nickel plated Brass and of Double Compression Weather
proof type. Flame proof gland wherever required shall be with Ex (d) certification. A
distance of minimum 300 mm shall be maintained between the cables carrying low
voltage AC & DC signals and a distance of minimum 600 mm shall be maintained be-
tween cables carrying HT & LT cables.
Identification of each cable shall be by proper ferrules at each junction as per cable
schedule to be prepared. All cables shall be identified close to their termination point
by cable numbers as per cable interconnection schedule. Identification tags shall be
securely fastened to the cables at both ends.
Identification of each cable shall be by proper ferrules at each junction as per cable
schedule to be prepared. All cables shall be identified close to their termination point
by cable numbers as per cable interconnection schedule. Identification tags shall be
securely fastened to the cables at both ends.

14.2 Communication Cable

Suitable for supporting communication over Profibus, Serial (Modbus Protocol), Ether-
net etc. as per the communication option selected for various proposed analysers, in-
struments, VFDs, power analysers, relays and instrument, as applicable (existing in-
strument / equipment where applicable shall normally be without communication port
or if available shall be with Modbus, Profibus or Ethernet communication). Communi-
cation cables shall be shielded and shall be laid in PVC ducts of minimum 1” size (for
buried cables) / on ducts / trays (for in air / overhead cables). It shall offer the price for
various communication cable options as specified in the price bid and in case it is opting
for any other communication option not mentioned there in, he shall quote the price in
“Other Communication” option providing all necessary details in the technical bid.
However, it shall note that selection of communication option other than those specified
in the price bid are subject to review of client / consultant and client reserves to reject

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the proposal without assigning 258 any reason there of in which case it shall offer in-
strument / equipment with communication options mentioned in the bid (Profibus,
Modbus, Ethernet,). Necessary repeaters, couplers, termination kits, converters, con-
nectors / plugs, etc. as applicable for connecting with necessary instrument / equipment
shall be included appropriately based on the quantity (BOM) furnished for all instru-
ment / equipment for proposed as well as existing instrument / equipment for necessary
connection to communication network and communicate with PLC/SCADA system In
general, cables for Ethernet shall be twisted pair with RJ45 connector (Specify the re-
peater requirement for more than 90 Mtr. Length or as per manufacturer guideline), for
Modbus it shall be twisted pair, shielded cable with terminators, for Profibus-DP it shall
be shielded twisted-pair line or a fiber optic cable (with transmission standard EIA
RS485).
Network Cable – CAT6 UTP Cable: -
The copper cable shall either be 4-pair 100 ohms Balanced Twisted Pair cable (UTP)
with rip cord and dielectric central isolation member:
The 4-pair UTP cable shall meet and exceed the following specifications:
 Shall comply to the following standards:
 ANSI/TIA/EIA-568B.2-1
 ISO/IEC 11801:2002 2nd Edition (Category 6)-IEC 61156-5 1st Edition
 LSOH: IEC 332: Part 1, IEC 754 and IEC 1034
 UL CM
 Minimum bend radius 1.00”
 100 % of final production reels are tested to 550 MHz
 be 0.57mm (0.23 in) (24AWG) solid bare copper
 The maximum jacket diameter (for 4-pair UTP cable) shall not exceed 6.35 mm (0.25 in).
 sequential meter markings on jacket
 be appropriate for the environment in which it is installed.

14.3 Instrument Earthing:

All the non-current carrying metal parts of the electrical installation and mechanical equipment
shall be earthed properly. The cables armour and sheath, electric panel boards, lighting fixtures,
ceiling and exhaust fan and all other parts made of metal shall be bonded together and connected
by means of specific earthing system. An earth continuity conductor shall be installed with all
the feeders and circuit shall be connected from the earth bar of the panel boards to the conduit
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system, earth stud of the switch box, lighting fixtures, earth pin of the socket outlets and to any
metallic wall plates used. All the enclousers of the motors shall be also connected to the earthing
system.

14.4 SCOPE OF WORK

The scope of work shall cover supply, laying, installation, connecting, testing and commission-
ing of:
 Earthing station.
 Earthing G.I/Copper strips from earthing station to equipotential bar.
 Earthing G.I/Copper strips/ wires from equipotential bar to lay feeder mains and circuit to
 connect power panels, DBs, switchboards etc.
 Bonding of Non-current carrying parts and metallic parts of the electrical installation

14.5 STANDARDS
The following standards and the rules shall be applicable.
1) IS; 3043 – 1966 Code of practice for earthing.
2) Indian Electricity Act and Rules
All codes and standards mean the latest. Where not specified otherwise the installation
shall generally, follow the Indian Standard Code of Practice or the British Standard
Code of Practice in absence of Indian standards.

14.6 CABLE TRAYS:

All branch cables/tubes, cables on various civil units/structures shall run on cable trays
only. Cable trays shall be made out of galvanized mild steel sheets of 2.5 mm thickness.
The width shall be so selected that 40-50% space is available for future use. Suitable
cable clamps shall be supplied for binding cables / tubes at every 500mm.

14.7 JUNCTION BOX:

Junction Box material shall be Cast Aluminium (LM-6) only and shall be weather proof
to IP- 65. Flame proof junction boxes shall be supplied with ex (d) certification in ad-
dition. The boxes shall have terminals suitable for a minimum of 4 mm2 cable termi-
nation mounted on rails. 20% spare terminals shall be supplied in junction boxes. Each

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junction box shall have 10% or minimum 2nos. whichever is is a higher, spare entry of
each size. Spare entries shall be provided with plugs.

14.8 Air-conditioners
All control room, SCADA Panel room, Control command Centre, VFD panel room
shall provide air conditioning as per the approved heat load calculation and approved
lay out.

14.9 SPARES:
Start-up spares shall be as required
Essential spares shall be supplied as detailed below:
For field instruments, air filter regulators, E/P converter and junction box and drive
modules a minimum of one (1) No., or 10% of the quantity of each type and range,
whichever is higher, shall be provided.
PLC System
All modules like Signal distribution modules, signal conditioning modules, I/O mod-
ules, Processor modules, Power supply modules, Network cards etc., – 10% of each
type, or minimum one (1) No. whichever is higher.
Each type of fuse – 5 Nos., or 30% of each, whichever is higher.
Local Panels, System Cabinets 10% of each type, or minimum one (1) No. whichever
is higher shall be supplied for the following
Fuses of each type and rating.
MCB of each type.
Terminals of each type
Male & female parts of pre-fabricates Cables – 6 Nos., of each type.
Solenoid valves (for each valve):
Coil – 2 Nos., of each rating and insulation.
Plunger – 1 No. of each type and size.
Seat – 1 No. of each type and size
Gaskets – 2 sets of each type and size.
O-rings – 5 sets of each type and size.
Diaphragm – 2 Nos., of each type and size.

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Wiring, Termination & Accessories.

10% of each type, or minimum one (1) No. whichever is higher shall be supplied for
the following
Fuses of each type & rating.
Miniature circuit breaker of each type & rating
Terminals of each type.
Space heater with thermostatic controls.
Fire detectors.
Blower.
Blank CD’s for software back-up: 30 Nos.
Cable clamps each type.
Male & female pre-fabricated cables – 6 Nos., each type.
Spare terminal in each terminal block in all cabinets.
Spare space for counting additional terminal blocks in all cabinets.
Wiring raceways to accommodate additional 30% space of total quantity.

15. APPLICATION STANDARDS

All equipment shall comply with all applicable national and local laws regulations and stand-
ards, in addition to those listed below:
A. ISO 9000 and 09004: Quality Systems
B. IEEE 587 : Power Supply Surge Protection
C. IEC 61131-3 : Programming Languages for Programmable Controllers.
D. IEC 61158-2 : Communication Protocols
E. ISO 9075 (BS 6964): Structured Query Language (SQL)
F. BS 5515 : Documentation of Computer Based Systems
G. BS 7165 : Recommendation for Achievement of Quality in
Software
H. BS EN 50081 : Electromagnetic Compatibility
I. ISO 3511 : Process measurement control functions
instrumentation symbolic representation.
J. ISO-OSI : 7 Layer Communication Model
K. IEEE 472-1974 : Surge protection.
L. IEC 61850 : PLC sub-station automation protocol.

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M. IEC 8705101 : Modbus protocol conversion

N. ISO 9000 and 09004: Quality Systems

15.1 Submittals
Functional Design Specification (FDS):
The Functional Design Specification (FDS) shall be submitted to the Engineer-in-Charge
within 3 months on the award of the contract and approved before manufacture and purchasing
commences. FDS document for STP shall be submitted within the time period indicated above.
The system vendor and/or it shall include the following material as a minimum:
a. Project Overview, design concept, criteria and system architecture
b. Description of the design and design criteria.
c. Details of associated equipment.
d. Datasheets of the proposed equipment.
e. Electrical Design Specifications
f. Quality Plan.
g. Outline of acceptance test procedures (FAT & SAT).
h. Implementation program for manufacture, installation and commissioning.
i. Manufacturer’s literature for each item of equipment supplied/proposed.
j. Detailed Plant screens (SCADA screens)
k. Software architecture, etc.
Note: It shall be noted that no part approval of FDS will be accorded. FDS shall be submitted
in full with all details as detailed above.

15.2 Drawings and Documentation:

 Clear indication of all instruments addressed P&ID shall submit for Engineer-in-
Charge approval.
 System write up architecture indicate all process shall submit for Engineer-in-
Charge approval.
 Control philosophy explaining entire process from intake well to WDC shall
submit for Engineer-in-Charge approval.
 PLC system configuration With Technical Literature & PLC Requirements (Refer
TABLE-3)
 PLC I/O List
 G.A. Drawing for PLC cabinets
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 List of Feeders with Feeder Loads for 110 V AC (UPS) power supply
 Time stamping protocol required for PLC system from GPS master clock supplied
by Purchaser.
 Data sheet along with catalogues of manufacturers for all field instruments and
equipment supplied by vendor.
 Junction Box Grouping Details
 Cable Schedule
 Interconnection Schedule
 Data sheet along with catalogues of manufacturers for all field instruments and
equipment supplied by vendor
 QA Plan For I&C Equipment Final List of Essential Spares
 Earthing requirement for PLC system cabinets.
 All drawings of telemetry and instrumentation control and Automation (ICA)
equipment shall be on A3 size sheets, with title blocks approved by the Engineer-
in-Charge. Signature of the authorized representative to indicate the drawings have
been checked prior to submission.
 The text of all drawings and documentation provided shall be in the English
Language.
 All modifications or revisions to drawings shall be clearly indicated and the
revision reference changed.

15.3 Training Plan and Manuals:

As part of the Works and before beginning training, it shall submit to the Engineer-in-
Charge, 6 copies of complete operating and maintenance instructions for the system,
referring specifically to the Plant. The documents will also be presented on computer
disk in Microsoft Office 2003/2007 Word or latest version available for Windows soft-
ware format. Each copy of the instructions shall be contained in a substantial binder.
These manuals shall include but not be limited to the following information:
a. Detailed descriptions of the Plant operation and control scheme.
b. Manufacturer’s original operation and maintenance procedures.
c. Complete parts list for all items of the Plant.
d. Recommended spare parts list.
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e. Detailed maintenance instructions for all items as necessary to maintain the items
in good working order, including all step-by-step procedures for troubleshooting
and fault correction.
f. Detailed descriptions of the Plant operation and control scheme.
g. Manufacturer’s original operation and maintenance procedures.
h. Complete parts list for all items of the Plant.
i. Recommended spare parts list.
j. Detailed maintenance instructions for all items as necessary to maintain the items
in good working order, including all step-by-step procedures for troubleshooting
and fault correction.
k. Configuration of data base, reports, logs and screen displays.
l. Data communication interface standards and protocols.
m. FBD/Ladder and control loop flow diagrams.
n. Programme user instruction for all software
o. The system shall provide on line, complete user documentation, including examples
of how to operate the various modules within the system.

15.4 Commissioning
The Executor, the Engineer-in-Charge and any appropriate personnel of the Authority
shall be present when the equipment or installation is tested & commissioned. Com-
missioning shall include operating the equipment in a variety of modes and sequences
to prove its satisfactory operation, prior to commencing the formal site inspection and
testing.

15.5 Instrumentation, Control & Automation Training requirements

The Executor/ system supplier shall conduct training courses for personnel selected by
department. Training shall be conducted by personnel employed by the Executor/ sys-
tem supplier familiar with the system supplied and who have experience and training
in developing and implementing instructional courses.The executor shall arrange train-
ing for the department personnel for 5 days before the conduction of FAT. This training
shall be separate from the training for department (2 sessions of 5 days each) which
shall be conducted during SAT.

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The entire cost of the complete training program, including reasonable per diem ex-
penses to cover meals, lodging, transport and similar expenses for all personnel and the
consultants attending the training program, shall be the responsibility of the Executor/
system supplier and shall be included in the contract price. The Executor/ system sup-
plier shall submit information on the training program for approval, prior to shipment
of the equipment. This submittal shall include a course outline; time required, course
schedule, sample workbook and instructor qualification information for each level. The
Executor/ system supplier shall make a workbook on each course available to every
person taking the courses listed herein. The workbook shall be of sufficient detail so
that, at a later date, a trainee could review in detail the major topics of the course. The
training times shall be scheduled by the department in advance with the Executor/sys-
tem supplier so as not to disrupt the department’s ability to operate the plant.

15.6 Operations and Maintenance Training

Training shall be provided for ten (10) of the department personnel at the Executor/
system supplier facility on operations and maintenance of all system components. The
training program shall be divided into two segments and shall consist of at least 5 (five)
working days, each of 8 (eight) hours duration.The maintenance training program shall
be developed for personnel that have electronics maintenance and repair experience and
a general knowledge of computer systems, but shall not assume any familiarity with the
specific hardware furnished.
As a minimum, the following subjects shall be covered:
 System Architecture and Layout
 Hardware Components
 Module Switch Settings (Configuration Switches)
 I/O Modules
 Power Supplies
 Data Highway:
 Programmer connection
 IOP programming and diagnostic techniques
 Battery replacement and recharging
 PC and workstation familiarization and maintenance:
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 Troubleshooting
 Disassembly
 Cleaning
 Component Replacement
 Re-assembly

The operation training program shall include the following topics:

 Power-up, bootstrapping and shutdown of all hardware devices
 Interpretation of all standard displays
 Appropriate actions for software and hardware error occurrences
 Use of operator interface displays and keyboards
 Use of printer including replenishment of supplies
 Manual data entries
 Creation and editing of graphic operator display screens.
 Loading of any required software into the system
 Data base creation and editing.

16. CONTROL SYTEMS

16.1 RESERVOIR MANAGEMENT SYSTEM
Design, Supply, Erection and Commissioning of Reservoir Management System(RMS)
to enable to avoid the overflow of Reservoirs/Sumps, Uniform Distribution of Water to
the Reservoirs /Sumps irrespective of its location and distance from the source of sup-
ply. Also, the RMS shall have the outlet management valve / system. The system shall
be enabled to record, monitoring and control of the cumulative flow Delivered to the
Reservoirs/Sumps without any external Electric Energy and no high recovery cost for
Energy/Communication Cost such as GSM/GPRS/RADIO etc.

SPECIFICATION OF RESERVOIR MANANGEMENT SYSTEM (RMS)

 The System shall be able to operate without any External Electric Energy.
The System shall be capable to achieve the Uniform Distribution of Water to all the

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reservoirs/Sumps in the Network irrespective its Elevation and Distance from the
Source of Supply.
 The System shall be capable to avoid the overflow of Reservoirs/Sumps in the Net-
works.
 The System shall be able to Operate/Isolate remotely without any Electrical Energy.
 The System shall be able to record and generate the report of the Cumulative Flow
Delivered to Every Reservoirs/Sumps in the Network.
 The System shall be able to allow the flow to Reservoirs/ Sumps as per the Demand.
 The System shall be able to Operate, Monitor, Control and Manage the Water to
Reservoirs/ Sumps in Complete Distribution Network without any External Electric
Energy.
 The System shall not have any high recurring cost for Energy/Communication Cost
such as GSM/GPRS/RADIO etc.
 The System shall be kept in Protective Cover Box capable of giving Vandalism Alert
messages such as door open and site GPS co-ordinates.
 The System shall update battery status and atmospheric temp to control centre. Low
battery & High temp Alert messages shall be generated to avoid the faults.
 The System shall be capable of water quality monitoring and close in the event of
water security issues.
 RMS shall consist of PFCMD, Air valve, inlet and outlet isolation valves, solar
power panel of suitable capacity with 12 V battery having 04 days back up capacity
for communication, protective enclosure.

16.2 COMPONENTS OF RESERVOIR MANAGEMENT SYSTEM WITH OUTLET

MANGEMENT SYTEM (RMS)

Pressure Flow Control Monitoring Device (PFCMD)

 The Pressure & Flow Control and Monitoring Device (PFCMD) shall automatically
performs one, two or more independent functions as per the requirements, such as
Anti Draining of System, reducing higher upstream pressure to a constant maximal
downstream pressure or sustaining maximum set Flow. All functions are performed
irrespective of change in upstream pressure and/or demand. Functions can easily be

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added or removed in a modular way. The valve shall be compatible with Automation
System.
 Valve Shall be with Rapid-action piston for Fast Opening/Closing action to facili-
tate stable and accurate control of pressure, flow and level.
 Valve shall have Low head loss at high flow rates,
 Valve Shall have Precision molded composite construction (Nylon12 + 50% glass
fiber reinforced)
 Valve shall be strong, lightweight and corrosion proof surfaces, which resist cavita-
tion
 damage, thus increasing service life and reducing operation & maintenance cost.
 Valve shall have Linear flow, Low turbulence to minimize cavitation, and allow
high flow velocities with low noise and vibration.
 Valve shall have Double-chambered piston actuation for Drip-tight closure, even
when command pressure is lower than line pressure.
 Valve shall have “Soft closure” feature to prevent water hammer.
 Multi-Valve modular configuration Full redundancy enabled. Individual valves can
be possible to separately removed for maintenance or replacement which reduces
downtime and maintenance costs & allows maintenance work to be done without
halting water flow.
MATERIAL OF CONSTRUCTION:
Valve Body : Reinforced fiberglass nylon or Polypropylene
Pistons, Bushing, Front and Rear Cups: Reinforced fiberglass nylon or
Polypropylene
Main seal : NBR, VITON or EPDM rubber, Shore index: 80
O-rings : NBR or EPDM rubber, Shore index: 70
Inlets, outlets : Stainless steel/ Reinforced fiberglass nylon
Clamps, bolts : Stainless steel
Multi-Valve manifolds: Spheroid iron with polyester or epoxy coating/
Coated Steel
Pressure Rating : PN 16

16.3 SPECIAL COMBINATION AIR VALVES (FOR RMS)

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 Working pressure range : 0.1 to 10 bar

 Testing pressure : 16 bar
 Working temperature : 60 0C maximum
 Shall be suitable to prevent premature closing.
 Shall be suitable for low pressure sealing.
 Kinetic components : Valve shall discharge air at high velocity during
filling of system and admit air during draining of
water.

 Automatic components : Vacuum orifice making it less prone to

obstruction by debris.

 Body material : Reinforced Nylon.

 Installation : It shall be installed before the PFCMD in the
RMS System and has the features of an Air-re-
lease valve and Air / vacuum valve.

16.4 AUTOMATION SYSTEM FOR REMOTE CONTROL AND MONITORING

The proposed Automation System for RMS shall be able to control and monitor the
required parameters from Control Centre with the help of licence free radio frequency
and GPRS system.

A: Remote Control Centre

The Remote-Control Centre shall provide a management tool for controlling the all
Reservoir Inlets in the water network. Remote control station will be web based
application so that user can monitor and control each Reservoir from any place with the
help of internet connection.

System configuration:
 The Remote-Control Centre shall be able to configure system's parameters for op-
timal operation.
 The user shall be able to define all field Units and their associated configurations,
 The user shall be able to define all software application functionality and download
(send) the data to the field units, in order for them to perform the on-site function.

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 The user will be able to upload the existing data from the field units in order to
monitor the entire system.
 The Control Centre shall provide the ability for the user to "zoom in" to the level of
single element characteristics (i.e. Input/Sensor, Output/Pump etc.) at each site.
 The user can able to monitor site conditions like inside panel temperature, Battery
Voltages, GSM/Radio signal strength.
 The user can able to monitor the Panel door status at central

Management tools:
 Accumulation reporting, historical trends views and Events/Alarms logging.
 Interface to third party database and communication systems such as SMS, paging
alarms and weather stations.
 Time based and/or Volume based Weekly Auto schedule will be stored into the con-
trollers.
 Onsite Critical alarms and events are sent by email /SMS to user given email ID or
mobile nos.
Edit Mode:
The same Remote-Control Centre SW package shall provide both functionality of what
is known as Runtime Mode and Edit Mode (when changes to the runtime screens are
needed).

Part of the Remote-Control Centre a Zonal Field Control Unit (ZFCU).

 The ZFCU shall provide communication capabilities and interface between the Re-
mote-Control Centre and Field Control unit which is on the site.
 The ZFCU shall have the ability to perform "regular" Field Control Unit's func-
tionalities, such as monitoring sensors or activating pumps, in addition to its ZFCU
functionalities.
 As part of the Control Centre a front end (FEP) is requested (HW and/or SW) ena-
bling the communication between the Control Centre and the Field Control Units.
 The Control Centre shall be able to interface with various software applications
(third party), such as weather stations, and other management SW packages.
The Remote-Control Centre shall be able to execute and support the following features:

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 Displaying the entire data of Field Control Unit such as, flow rate/accumulated flow,
and total time of operation, balance time in the form of tables and graphical screens
 Displaying Field Control Unit's events and alarms and ability to report them utiliz-
ing SMS technology.
 Display the communication healthiness of field units.
 The user shall be able to change valve operation timings, from the graphical screens
 The user shall be able to operate valve from the graphical screens
 Shall be able to call the Downloading and Uploading data from the Field Control
Units
 Shall allow the quantity of water as per the Demand set by the operator.
 Shall have a program to design and display an event report for each Reservoir in the
water network.
 Shall have a program to calculate the predicted flow load, over the hydraulic system.
 Shall have a program for displaying sensors data historical trends and alarms.
 Shall have an Off-Line program for the Field Units in addition to the current run-
time unit's program.
B: Field Control Units
 Shall have Logic board incorporating microcontroller/microprocessor and data stor-
age components.
 Shall run on solar power or long-life lithium battery.
 Shall be with I/O port required for on-site sensor connection. I/O boards may be
expanded/ replaced on-site. These may be inputs such as water meters, reservoir
level, pressure meters, or general digital inputs, or outputs such as valves, pump
starts, general relays, etc.
 Communication Ports - enabling the Field Unit to communicate with the Remote-
Control Centre, and/or each other, and on-site programming/diagnostic tool (such
as laptop).
 Shall be able to operate not only the local I/Os (on board I/O connections), but re-
mote I/Os as well.
 Shall be able to update the Remote-Control Centre database upon request (by the
remote-Control Centre) or by exception. The Field Unit shall be able to report to
the Remote-Control Centre every defined alarm which occurs in the field.
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 Shall be capable of functioning in a stand-alone mode (no Remote-Control Centre),

as well as a part of a system with a Remote-Control Centre.
 Shall be able to perform Store & Forward functionality - receive information from
other sites, store it in memory, and then transmit (forward) the data to another site.
 Shall be able to support both local I/O's and Remote I/O's modules. The remote I/O
modules shall be equipped with radio technology, allowing the Field Unit full access
and control, as if they are locally connected.
 Shall be able to report by exception (known as burst) to the Control Centre upon
any Change-of-State (COS)
 Shall be equipped with a multi-tasking Operating System, specially designed for a
real-time environment.
C: Radio/GPRS communication Network
The Radio/GPRS communication network shall be able to make the communication
link between the Remote-Control Centre and Reservoir with conventional (865-
867MHz licenses free) frequency or using GPRS network.

The communication protocol shall be able to support multiple logical channels per
physical port, enabling simultaneous Central-to-Field Control Unit and Field Control
Unit -to-Field Control Unit sessions.

The communication protocol shall be able to support the following messaging methods:

Burst (also known as Contention) - this is transmission upon change of state.

Polling (also known as Interrogation) - automatically or manually request for data

updating.

Report by Exception - the unit shall only report data that have changed since the last
poll.

16.5 ISOLATION WAFER TYPE BUTTERFLY VALVE

Wafer Type BFV shall be provided to Inlet and outlet of PFCMD
Material of Construction
Body : Ductile Iron GGG 40
Disc : Ductile Iron GGG 40/50

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Shaft : Stainless Steel 410

O-Ring : NBR
Plug : Stainless Steel 410
Bushing : Bronze
Washer : Stainless Steel 410
Bolts : Galvanized Steel
TEST PRESSURE:
a) SEAT TEST : 16 Kg/cm2
b) BODY TEST: 24 Kg/cm2

16.6 ENCLOSURE
Enclosure to be made up of Reinforced Polyester with Door having vandalism alert.

16.7 BYPASS MANAGEMENT SYSTEM

Scope:
Supply, Erection and Commissioning of BMS System which shall be able to control the
flow as per demand to facilitate Uniform Distribution of Water to the Bypass s irrespec-
tive of its location, elevation and distance from the water source.
The system shall be able to record, monitor and control the cumulative quantity deliv-
ered to the Bypass s without any external Electric Energy and with no high recurring
cost for Communication with GSM/GPRS/RADIO etc.
General specifications:

 The System shall be able to Operate, Monitor, Control and Manage the Water to
Bypass in Complete Distribution Network without any External Electric Energy.
 The System shall be capable to achieve the Uniform Distribution of Water to all the
Bypass in the Network irrespective of its Elevation and Distance from the Source
of Supply.
 The System shall be able to record and generate the report of the Cumulative Quan-
tity delivered to every Bypass in the Network.
 The System shall be able to allow the quantity to Bypass as per the Demand / Quota.
 The System shall have minimum recurring cost for Communication by using
GSM/GPRS/RADIO etc.
 The System shall be kept in Protective Enclosure capable of giving Vandalism Alert.
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 The System shall be capable of water quality monitoring and close in the event of
water security issues
 BMS shall consist of PFCMD, Air valve, inlet and outlet isolation valves, solar
power panel of suitable capacity with 12 V battery having 04 days back up capacity
for communication, protective enclosure.

16.8 COMPONENTS OF BYPASS CONTROL MANAGEMENT SYSTEM (BMS)

Pressure Flow Control Monitoring Device (PFCMD)
 The Pressure & Flow Control and Monitoring Device (PFCMD) shall automatically
performs one, two or more independent functions as per the requirements, such as
Anti Draining of System, reducing higher upstream pressure to a constant maximal
downstream pressure or sustaining maximum set Flow. All functions are performed
irrespective of change in upstream pressure and/or demand. Functions can easily be
added or removed in a modular way. The valve shall be compatible with Automation
System.
 Valve Shall be with Rapid-action piston for Fast Opening/Closing action to facili-
tate stable and accurate control of pressure, flow and level.
 Valve shall have Low head loss at high flow rates,
 Valve Shall have Precision molded composite construction (Nylon12 + 50% glass
fiber reinforced)
 Valve shall be strong, lightweight and corrosion proof surfaces, which resist cavita-
tion damage, thus increasing service life and reducing operation & maintenance
cost.
 Valve shall have Linear flow, Low turbulence to minimize cavitation, and allow
high flow velocities with low noise and vibration.
 Valve shall have Double-chambered piston actuation for Drip-tight closure, even
when command pressure is lower than line pressure.
 Valve shall have “Soft closure” feature to prevent water hammer.
 Multi-Valve modular configuration Full redundancy enabled. Individual valves can
be possible to separately removed for maintenance or replacement which reduces
downtime and maintenance costs & allows maintenance work to be done without
halting water flow.
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MATERIAL OF CONSTRUCTION:
Valve Body : Reinforced fiberglass nylon or Polypropylene
Pistons, Bushing, Front
and Rear Cups : Reinforced fiberglass nylon or Polypropylene
Main seal : NBR, VITON or EPDM rubber, Shore index: 80
O-rings : NBR or EPDM rubber, Shore index: 70
Inlets, outlets : Stainless steel/ Reinforced fiberglass nylon
Clamps, bolts : Stainless steel
Multi-Valve manifolds: Spheroid iron with polyester or epoxy coating/
coated Steel
Pressure Rating : PN 16
16.9 SPECIAL COMBINATION AIR VALVES (FOR BMS)
 Working pressure range: 0.1 to 10 bar
 Testing pressure: 16 bar
 Working temperature: 60 0C maximum
 Shall be suitable to prevent premature closing.
 Shall be suitable for low pressure sealing.
 Kinetic components: Valve shall discharge air at high velocity during filling of
system and admit air during draining of water.
 Automatic components: Vacuum orifice making it less prone to obstruction by
debris.
 Body material: Reinforced Nylon.
 Installation: It shall be installed before the PFCMD in the BMS System and has
the features of an Air-release valve and Air / vacuum valve.
16.10 TECHNICAL SPECIFICATIONS OF AUTOMATION SYSTEM FOR REMOTE
CONTROL AND MONITORING
The proposed Automation System for BMS shall be able to control and monitor the
required parameters from Control Centre with the help of license free radio frequency
and GPRS system.

A: Remote Control Centre

The Remote-Control Centre shall provide a management tool for controlling the all
Bypass s in the water network. Remote control station will be web based application so
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that user can monitor and control each Bypass from any place with the help of internet
connection.

System configuration:
 The Remote-Control Centre shall be able to configure system's parameters for op-
timal operation.
 The user shall be able to define all field Units and their associated configurations,
 The user shall be able to define all software application functionality and download
(send) the data to the field units, in order for them to perform the on-site function.
 The user will be able to upload the existing data from the field units in order to
monitor the entire system.
 The Control Centre shall provide the ability for the user to "zoom in" to the level of
single element characteristics (i.e. Input/Sensor, Output/Pump etc.) at each site.
 The user can able to monitor site conditions like inside panel temperature, Battery
Voltages, GSM/Radio signal strength.
 The user can able to monitor the Panel door status at central
Management tools:
 Accumulation reporting, historical trends views and Events/Alarms logging.
 Interface to third party database and communication systems such as SMS, paging
alarms and weather stations
 Time based and/or Volume based Weekly Auto schedule will be stored into the con-
trollers
 Onsite Critical alarms and events are sent by email /SMS to user given email ID or
mobile nos.
Edit Mode:
The same Remote-Control Centre SW package shall provide both functionality of what
is known as Runtime Mode and Edit Mode (when changes to the runtime screens are
needed).

Part of the Remote-Control Centre a Zonal Field Control Unit (ZFCU).

 The ZFCU shall provide communication capabilities and interface between the Re-
mote-Control Centre and Field Control unit which is on the site.

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 The ZFCU shall have the ability to perform "regular" Field Control Unit's func-
tionalities, such as monitoring sensors or activating pumps, in addition to its ZFCU
functionalities.
 As part of the Control Centre a front end (FEP) is requested (HW and/or SW) ena-
bling the communication between the Control Centre and the Field Control Units.
 The Control Centre shall be able to interface with various software applications
(third party), such as weather stations, and other management SW packages.
The Remote-Control Centre shall be able to execute and support the following features:
 Displaying the entire data of Field Control Unit such as, flow rate/accumulated flow,
and total time of operation, balance time in the form of tables and graphical screens
 Displaying Field Control Unit's events and alarms and ability to report them utiliz-
ing SMS technology.
 Display the communication healthiness of field units.
 The user shall be able to change valve operation timings, from the graphical screens
 The user shall be able to operate valve from the graphical screens
 Shall be able to call the Downloading and Uploading data from the Field Control
Units
 Shall allow the quantity of water as per the Demand set by the operator.
 Shall have a program to design and display an event report for each Bypass in the
water network.
 Shall have a program to calculate the predicted flow load, over the hydraulic system.
 Shall have a program for displaying sensors data historical trends and alarms.
 Shall have an Off-Line program for the Field Units in addition to the current run-
time unit's program.
B: Field Control Units
 Shall have Logic board incorporating microcontroller/microprocessor and data stor-
age components.
 Shall run on solar power or long-life lithium battery.
 Shall be with I/O port required for on-site sensor connection. I/O boards may be
expanded/ replaced on-site. These may be inputs such as water meters, reservoir
level, pressure meters, or general digital inputs, or outputs such as valves, pump
starts, general relays, etc.
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 Communication Ports - enabling the Field Unit to communicate with the Remote-
Control Centre, and/or each other, and on-site programming/diagnostic tool (such
as laptop).
 Shall be able to operate not only the local I/O (on board I/O connections), but re-
mote I/O as well.
 Shall be able to update the Remote-Control Centre database upon request (by the
Remote-Control Centre) or by exception. The Field Unit shall be able to report to
the Remote-Control Centre every defined alarm which occurs in the field.
 Shall be capable of functioning in a stand-alone mode (no Remote-Control Centre),
as well as a part of a system with a Remote-Control Centre.
 Shall be able to perform Store & Forward functionality - receive information from
other sites, store it in memory, and then transmit (forward) the data to another site.
 Shall be able to support both local I/O's and Remote I/O's modules. The remote I/O
modules shall be equipped with radio technology, allowing the Field Unit full access
and control, as if they are locally connected.
 Shall be able to report by exception (known as burst) to the Control Centre upon
any Change-Of-State (COS)
 Shall be equipped with a multi-tasking Operating System, specially designed for a
real-time environment.
C: Radio/GPRS communication Network
The Radio/GPRS communication network shall be able to make the communication
link between the Remote-Control Centre and Bypass with conventional (865-867MHz
licenses free) frequency or using GPRS network.

The communication protocol shall be able to support multiple logical channels per
physical port, enabling simultaneous Central-to-Field Control Unit and Field Control
Unit -to-Field Control Unit sessions.

The communication protocol shall be able to support the following messaging methods:

Burst (also known as Contention) - this is transmission upon change of state.

Polling (also known as Interrogation)- automatically or manually request for data
updating.

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Report by Exception- the unit shall only report data that have changed since the last
poll.

16.11 ISOLATION WAFER TYPE BUTTERFLY VALVE

Wafer Type BFV shall be provided to Inlet and outlet of PFCMD
Material of Construction
Body : Ductile Iron GGG 40
Disc : Ductile Iron GGG 40/50
Shaft : Stainless Steel 410
O-Ring : NBR
Plug : Stainless Steel 410
Bushing : Bronze
Washer : Stainless Steel 410
Bolts : Galvanized Steel
EST PRESSURE:
a) SEAT TEST : 16 Kg/cm2
b) BODY TEST : 24 Kg/cm2

16.12 ENCLOSURE
Enclosure to be made up of Reinforced Polyester with Door having vandalism alert.
Note: Please refer the Schematic Flow Drawing and WDC installation drawings.

17.0 Closed Circuit Television System (CCTV)

The Contractor shall provide a CCTV System that shall include, but not be limited to,
the provision of CCTV Day/Night cameras, CCTV infra-red floodlights and control
panel, video signals data servers and panel enclosure complete with router/hub, digital
video recorders, surge and lightning protection devices, made necessary configuration,
user licenses of any software for the System and associated equipment fittings and ca-
bling necessary for the completion of the works. The CCTV shall be configured on
Operator Workstation essential software’s shall consider on the same.
Following areas shall be considered under CCTV surveillance.
 Raw Water Pumping station
 Raw Water Control Room
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 WTP area
 Clear Water Pumping Station
 Clear Water Control Room
 Water Distribution Centers
 Central Control Room
 Panel rooms.
 Substations and Transformer yards
 Entrance gates
 Security cabins
 Major equipment areas
The CCTV camera shall be inside and outside the buildings mentioned above.
Exact Locations and final quantities shall be decided during detail engineering.

17.1 Voice Communication

Communication system shall be between control room, machine hall floor, Powerhouse
security room & switchyard through EPABX system with spare outlet. The main con-
troller should be compatible with P&T system with a capacity for 2 P&T lines. The
following should be provided along with:
 EPABX system
 Telephone instrument sets
 UPS for above system

17.2 Site Acceptance Tests (SAT)

 After installation and commissioning, the contractor shall demonstrate, by tests in
the field, compliance of the values, functionalities, quality and reliability of the
complete system and its components, both hardware and software, as specified and
as per guarantees.
 Contractor shall fully participate in interfacing to the equipment of others. It shall
be Contractor’s responsibility to ensure satisfactory functioning of the system in
conjunction with related equipment like exchanges, data equipment and other
communication equipment of the Owner. Problems relating to such
interconnections shall be mutually resolved.
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 After tests as above, the complete system shall be on continuous uninterrupted

service with all functionalities and interconnections to Owner’s equipment for 4
weeks without any failures or manual interventions for correction, modification.

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SECTION – VII
Technical Specification for Erection, Testing & Commissioning

1. UNLOADING, HANDLING & STORAGE

1.1. The Agency shall be responsible for the delivery at site/sites of all equipment, material
and supplies required for the fulfillment of the contract up to handing over of the pro-
posed water supply to the Authority.
1.2 The Agency shall at his own expense and responsibility transport or shift to plant site,
all materials, equipment and supplies furnished for this contract. All movement of ma-
terials and equipment to and from storage shall be at the expense of the Agency. Space
for storage facilities shall be provided by the Authority at the site of the work as availa-
ble. If the Agency does not promptly shift and place for use in the premises, where the
work is to be done, any material, equipment or supplies delivered, the Authority may do
so, and charge all the costs thereof to the Agency and in any event the Authority shall
not be responsible for any damages, arising out of, or in any way connected with such
shifting or placing of the same. The Agency shall further after shifting, unpack the ma-
terials, verify contents against invoices and notify shortages or breakages to the Engi-
neer-in-Charge within one week of the receipt of materials and equipment at site, failing
which the Agency shall be held responsible for any consequences.
1.3 If requested by the Engineer-in-Charge, the planned method of transport of equipment
shall be submitted to the Engineer-in-Charge for approval. This approval shall not relieve
the Agency of any responsibility for the safety of the equipment and personnel.

2. AGENCY REMAINING INFORMED AS TO CONDITIONS

2.1 The Agency shall inspect, examine, obtain all information and satisfy himself regarding
all matters relating to the execution and maintenance of the works to be carried out under
the contract or any hindrances or interferences to or with the construction or mainte-
nances of the works from any cause whatsoever including any other operations of works
which may or shall be carried out on or adjacent to the site of the works before or during
the construction or maintenance of the works under the contract and shall make allow-
ance for all such contingencies in the contract price and shall not raise any claims or
objections against the Authority in respect of any of the matters mentioned above.

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2.2 The Agency shall take field measurements when or where necessary before detailing,
ordering or fabricating any material.
2.3 The acceptance of the order or making of a contract shall be construed as evidence that
such an examination was made and later claims for labour, equipment or materials re-
quired or for difficulties encountered, which could have been foreseen, shall not be al-
lowed.

3. PROSECUTION OF THE WORK

3.1 The Agency shall furnish adequate, courteous and competent labour, supervisors and
Engineer-in-Charges of all classes for the duration of the work to maintain progress of
erection in accordance with the requirement of the scheduled completion date, and shall
begin the work included in the contract at such time as well ensure its completion as
specified and shall complete the same, free of all liens and charges, at or before the time
specified for completion. The Agency shall make available qualified Engineer-in-
Charges for placing the equipment in operation, carrying out the necessary tests and trials
and the training of Authority's operating staff, as directed by the Engineer-in-Charge.
3.2 The Agency shall be completely responsible for the satisfactory construction, erection,
testing and commissioning of the works notwithstanding that he may have been assisted
by the Engineer-in-Charge in doing so.

4. WORK PERFORMED AT AGENCY RISK

4.1 The Agency shall take all precautions necessary and shall be responsible for the safety
of the work to be performed by him, and shall maintain all lights, guards, signs, tempo-
rary passages, or other protections necessary for the purpose. The Agency shall be re-
sponsible for any loss or damages to his personnel, materials, tools or other articles used
or held for use in such work. Such work shall be carried on to completion without dam-
age to any work or property of the Authority or of others and without interference with
the operation of existing machinery or equipment.

5. CONSTRUCTIONS TOOLS, EQUIPMENT AND SITE FACILITIES

5.1 The Agency shall, at his own expense, furnish all necessary false work, erection tools,
hoist, cranes, air compressors, rigging, skids, cribbing, blocking, scaffolding, sheet piles,

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equipment, appliances, materials and supplies required for erection and/or testing for
performances and start up (hereinafter in this section called 'construction tools and
equipment') that may be required to accomplish the work under contract unless otherwise
provided for. Adequacy of such shall be to the entire satisfaction of the Engineer-in-
Charge.
5.2 All piping for service, and drinking water to work area shall be furnished, installed and
maintained by the Agency at his own cost. He shall also furnish, install and maintain at
his own cost the power lines, junction boxes or any other electrical receptacles, apparatus
or equipment from starting points, to his area.
5.3 The Authority shall not be responsible or held liable for any damage to person or prop-
erty consequent upon the use, misuses or failure of any construction tools and equipment
used by the Agency or any of his sub-contracts, even though such construction tools and
equipment may have been furnished, rented or loaned to the Agency or any of his agents
by the Authority. The acceptance and/or use of any such construction tools and equip-
ment by the Agency or his agents shall be construed to mean that the Agency accepts all
responsibility for and agrees to indemnify and save harmless the Authority from said
use, misuse or failure of such construction tools and equipment for which the Authority
may be liable.
5.4 The Agency shall bear and pay all charges including freight, clearing, insurance, duty on
all construction tools and equipment furnished by him.

6. TRAVELLING AND LIVING EXPENSES

6.1 The contract price shall include all salaries and wages, all travelling time and expenses
and boarding and lodging allowances for all personnel furnished by the Agency and all
payments which the Agency may have to make in relation to the work of the labourers
and other personnel employed for complete installation.

7. SIMULTANEOUS WORK BY OTHERS

7.1 The Authority reserves the right to perform or have performed in and about the works
during the time when the Agency is performing his work hereunder such other work as
the Authority desires and the Agency shall make all reasonable effort to perform his work

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hereunder in such manner as shall enable such other work to be performed without hin-
drance from the Agency and shall make no claim for damages against the Authority aris-
ing out of such other work or interference therefrom. The Agency shall work in harmony
with such other Agencies regardless of race, religion, colour or national origin and any
dispute between Agencies shall be arbitrated by the Authority, if necessary.
8. START-UP AND GUARANTEES
8.1 Until such time as the equipment or material installed and erected under the contract is
finally accepted by the Authority in keeping with the terms and conditions of this con-
tract and associated specifications the responsibility for proper testing, maintenance and
efficient operation of the same shall be that of the Agency. Prior to start-up, the Agency
shall be required to service the equipment and during start-up render such assistance as
may be necessary or requested for by the Authority.
8.2 Where the equipment has not been manufactured by the Agency, the manufacturer's rec-
ommendations for installation of the same shall be strictly adhered to and any defects
developing due to faulty installation and/or erection during start-up or during a trial run
and period of one year from the date of commissioning shall be rectified, remedied or
made good by the Agency through the manufacturer if considered necessary by the Au-
thority at his own expense. When the equipment has been manufactured by the Agency
himself, rectification within similar period is compulsory.

9. AUTHORITY USE OF EQUIPMENT

The Authority shall have the right to use the materials and the equipment as he requires,
even prior to final acceptance.

10. Removal of Debris

10.1 The Agency shall always keep the site free of rubbish, debris and surplus materials so as
to render the place of work clean and safe for all personnel working in that area and upon
completion of the work shall remove all rubbish and waste materials resulting from his
work and leave the works and work site on a clean and finished condition. If the Agency
fails to comply, such work shall be performed by the Authority at Agency expense.

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10.2 Whenever demolition or other work of any kind creates harmful dust or fumes, equip-
ment for the complete protection of all personnel and property against dust fumes shall
be installed, maintained and effectively operated by the Agency as required by statute.
All such equipment shall be of a type approved by the State govt. / Central Govt. / or
municipal or any other regulatory body and the expression harmful dust or fumes shall
have the meaning assigned to it be such appropriate regulatory body.

11. Agency Obligations

11.1 Over and above the responsibilities of the Agency stipulated in this document, the fol-
lowing obligations shall be fulfilled by the Agency.
11.1.1 The Agency shall satisfy the Engineer-in-Charge that adequate provision has been made.
a) to carry out his instructions fully and with promptitude;
b) to ensure that parts required to be inspected before use are not used before inspection;
and
c) to ensure that adequate supervision is provided at all stages of the work and each
portion of the work is checked for accuracy before erection.
11.1.2 The Agency shall make necessary arrangements including provision of suitable spaces
and facilities for testing, for inspection at any stage of manufacture of plant and equip-
ment by the Engineer-in-Charge or his agents, as and when deemed necessary by the
Engineer-in-Charge; the time schedule for any inspection shall, however, follow the in-
spection schedule suggested by the Agency and agreed upon by the Engineer-in-Charge
during scrutiny of delivery plan. Irrespective of any inspection and tests made by the
Engineer-in-Charge, the Agency shall be entirely responsible for the proper execution of
the Contract notwithstanding any approval which may have been given by the Engineer-
in-Charge or the work or of tests carried out either by the Engineer-in-Charge or the
Agency. At least 15 days’ notice shall be required for inspection to be carried outside the
State.

11.1.3 The Agency shall at his own cost,

a. establish and maintain the area placed at his disposal for office/storage purposes.
b. provide the necessary power and water connection from the supply mains and install
and maintain the temporary distribution lines within the working area;
c. erect and maintain necessary offices and storage space;

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d. provide temporary lighting at erection site required for erection;

e. arrange for personnel accident insurance for his own personnel at site;
f. arrange adequate security lighting and watch system to safeguard the equipment
from any type of mishandling, theft, fire hazards etc. during the construction period,
period of Trial Run and period of maintenance;
g. Gardening and landscaping and beautification of the site before commissioning;
h. Curved Glow Signboard on each gate covering entire width of gate including
supporting frame structures and all electrical accessories. The details of the
signboard and its writings shall be as per instruction of the Engineer-in-Charge.
i. Identification metallic signboard for each units of the plant including supporting
frame structures and all electrical spotlight arrangements. The details of the
signboard and its writings shall be as per instruction of the Engineer-in-Charge.
11.1.4 The Agency shall design, manufacture, erect and dismantle any false work, staging tem-
porary support, etc. required for safe and accurate plant and equipment erection and
structural steelwork and shall be fully responsible for the adequacy of the same. The cost
of such work shall be deemed to have been included in the raise quoted in the Schedule
of prices.
11.1.5 The Agency shall, if so required by the Engineer-in-Charge, furnish drawings and design
of such false work, staging etc.
11.1.6 The Agency shall provide for the convenience of inspection/testing adequate temporary
and sufficiently strong and stable stairs and access ladders, gangways, etc. wherever
necessary at his own cost.
11.1.7 The Agency shall abide by the instructions and decisions of the Engineer-in-Charge at
any stage of execution of the job unless he can convince that the same goes against the
interest of satisfactory progress and completion of this work as per agreed schedule.

12. SHOP TESTS

12.1 Shop tests shall include all tests to be carried out at Agency works, works of his agents
at manufacturer’s works and at works where raw materials supplied for manufacture of
equipment.
12.2 The tests to be carried out shall include but not be limited to the tests mentioned below:
i. Composition of all materials, castings, forgings, etc.

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ii. Hydraulic test for pressure vessels, tanks, pump castings etc.
iii. Hydraulic tests for valves, specials etc.
iv. Test to check faults in rubber lining (as per IS: 4682) or its equivalent and painting.
v. Static and dynamic balancing test on all impellers.
vi. Static balancing test on agitators, stirrers, paddles etc.
vii. Performance test (Head, Capacity, BHP) on pump and blowers.
viii. Tests on motor as per IS: 4029.
ix. Any other test that may be provided in I. S. Specification and as required by the
Engineer-in-Charge.
12.3 All test certificates and reports shall be submitted to the superintending Engineer-in-
Charge for approval. All tests are normally to be carried out in presence of the Engineer-
in-Charge or his representative. However, waiver may be allowed in specific cases by
the Authority at his discretion.
12.4 The Authority’s representatives or his appointed agents shall be given full access to all
tests, The Agency shall inform the Superintending Engineer-in-Charge allowing ade-
quate time so that the Engineer-in-Charge or his appointed agents can witness the test, if
it is so desired by the Engineer-in-Charge.
12.5 No component or equipment shall be dispatched unless accompanied by approved test
certificates and reports. The approval shall be given provided the corresponding draw-
ings /technical particulars are already approved the Authority’s representatives or his
appointed agents have witnessed the tests or a letter of inspection waiver is issued by the
Engineer-in-Charge.

13. SITE TESTS

13.1 General
After erection at site, all components, equipment as Described below shall be tested to
prove satisfactory performance and/or fulfilment of functional requirement without
showing any sign of defect as individual equipment and as well as systems, The Agency
shall make all arrangements for testing and inform the Engineer-in-Charge for witness-
ing the tests.
i. All pipes, fittings and valves, after installation shall be tested hydraulically at a
pressure, at least 1.5 times the maximum attainable pressure in the system, to check

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against leak tightness. A higher factor shall have to be adopted in specific cases if
so specified by the I.S./B.S.
ii. All manually operated valves / gates shall be operated throughout 100% of the
travel and these shall function without any trouble.
iii. All pumps shall be run with the specified fluid form shut off conditions to valve
wide open condition. During the test, the pumps and drive motors shall run without
any undue vibration, leakage through gland, temperature rise in bearing parts,
noise, flow pulsation etc.
iv. Visual check on all structural components, welding, riveting, rubber lining, FRP
lining, painting etc. and if doubt arises shall be tested again.
v. All EOT and HOT hoists and its components shall be subjected to double the full
working load during all motions without showing any sign of defect.
vi. Water leakage test of all liquid retaining structures as per IS specifications.
vii. Load tests and integrity tests of piles.
viii. Load test of civil structures if desired by the Engineer-in-Charge.
ix. All test instruments and equipment shall be furnished by the Agency to the
satisfaction of the Engineer-in-Charge.

13.2 Mechanical Tests

All the rotating / moving components like agitators, paddles etc. shall be run at the rated
speed with water /chemicals up to the normal water /liquid level continuously for a pe-
riod of twenty-four (24) hours. During this period, all the components shall function
smoothly without any unbalance vibration, overheating at bearing parts, etc.

14. ERECTION SCHEDULE

14.1 The Agency shall prepare a time table for erection schedule of requirements of men and
material and tools & tackles or erections and outlines of erection methods together with
erection drawings and specifications and submit those for approval of the Engineer-in-
Charge. Such schedules shall be submitted well in advance. Any revisions to such sched-
ules shall only be effected after prior approval of the Engineer-in-Charge giving specific
reasons for such revisions.

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15. BLOCK GROUTINGS

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

16. SETTING OUT AND FOUNDATIONS

16.1 Where setting out and preparation of foundations are carried out by others, the Agency
shall approve the accuracy of the setting out before execution of foundation work. The
Agency shall be responsible also for the adequacy of such setting out a preparation of
foundations.

17. PROTECTION OF PLANT

17.1 All plant shall be afforded adequate protection against corrosion, mechanical damage,
deterioration etc. until the plant is taken over, The Agency shall submit his proposals for
achieving this protection for the approval of the Engineer-in-Charge.
17.2 The Agency shall make good to be satisfaction of the Engineer-in-Charge any deuteri-
ation of the protective coatings, paintwork, etc. which may occur during transportation,
erection, commissioning etc. until the plant is taken over.
17.3 Finish painting of the plant at site, as specified shall be carried out before the plant is
taken over.
17.4 Items of plant which are finished painted at the manufacturer’s works, such as switch
boards, etc. shall be suitably encased in crate or their protection before dispatch. This
plant may require to be returned to the works for making good of any deterioration of
the paintwork etc. at the Agency expense, which may have occurred during the period
until the plant is taken over.

18. TOOLS AND TACKLES

18.1 All tools and tackles, measuring and testing equipment etc. required for the successful
execution of all contract shall be provided by the Agency as part of his responsibility
with respect to erection and commissioning of the plant as per the terms of contract.
18.2 All tools and tackles supplied by him shall be taken back by him after completion of
works excepting special maintenance tools which shall be retained by the Authority till
the plant is taken over by him.

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19. DELIVERY AND ERECTION SCHEDULE

The tenderer shall quote his best schedules for delivery of equipment and plant, erection
and commissioning, and shall indicate the expected delivery schedule required for com-
ponents to suit the erection schedule of the plant.

20. COMPLIANCE WITH SATUTES, REGULATION ETC.

20.1. The Agency shall conform in all respect with the provision of any such state Ordinance
or Law as aforesaid and the regulations or Bye Laws of any local or other duly consti-
tuted Authority which may be applicable to the work or to any temporary work and with
such rules and regulations of public bodies and companies as aforesaid and shall keep
the Authority indemnified against all penalties and liability of every kind for breach of
any such statute ordinance or law regulation or bye law.

21. REMOVAL OF IMPROPER WORK AND MATERIALS.

21.1 The Engineer-in-Charge shall during the progress of the work have power to order in
writing from time to time.
a. The removal form the place of work of site within such time or times as may be
specified in the order of any materials which in the opinion of the Engineer-in-
Charge are not in accordance with the contract.
b. The substitution of in proper and the suitable materials, and
c. The removal and proper re-execution (notwithstanding any previous test thereof or
interim payment therefor) of any work which in respect of materials or workmanship
is not in accordance with the contract.

22 PACKING
22.1 Materials used for packing of the equipment shall be of sound timber of dimensions
proportional to the size the weight of contents. The seller shall not use second hand
packing materials, all package shall be steel strapped with at least two (2) straps on each
package to ensure a solid package and to prevent pilferage. Bundled materials shall be
rigidly steel strapped.
22.2 Fragile materials shall be securely packed within the containers or otherwise apply pro-
tected and packed to prevent shifting or rattling.

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22.3 The empty containers shall be fully covered by strong and durable water proof paper
inside, before putting the material, in order to protect the contents from damage, dust
and corrosion due to sea or rain water creeping into the cases and, in addition, they shall
be properly lined to withstand the elements while in transit or stored without cover.
22.4 Machined parts shall be thoroughly greased and amply protected against rust forming
and corrosive elements.
22.5 The Agency shall not use open type crates or fiber board cartons, unless permission is
received from the Authority.
22.6 The Agency shall not forward any articles without packing as specified herein, without
obtaining prior approval of Authority.
22.7 Spare parts shall be packaged separately, under no circumstances they shall be included
in the containers with the related commodity.

23. DAMAGE RISK AND INSURANCE

23.1 The Agency shall arrange the plant and equipment and each part thereof, to be insured
against loss, damage or destruction to fire, lightening, earthquake theft and such other
risks until it is handed over to the Authority after erection and trial run period as provided
for in the contract and shall from time to time, when so required by the Engineer-in-
Charge produce the policy and receipts for the premiums. All money received under any
of such policies shall be applied in or towards the replacement and repair of the plant
damaged or destroyed, but this provision shall not affect the Agency liabilities under the
contract.
Separate insurance policies shall be obtained to cover
i) rail and / or road etc. transit of equipment to site; and
ii) period of storage and erection and commissioning at site.

24. COMMISSIONING AND PERFORMANCE TESTS

24.1 The Agency shall undertake the complete responsibility for successful erection and com-
missioning of the plant and giving successful performance tests.
24.2 The commissioning of the plant shall involve the following steps of operations

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a) Testing of each unit on no load, to make complete check of its mechanical opera-
tions, alignment, clearance and rigidity and making necessary adjustments or alter-
ations required to make such unit properly operatable mechanically.
b) After the mechanical check has been made, as stated above, the equipment shall be
energized and run progressively from no load to full load.
c) Thereafter, trial operations of the units under completion shall be taken at normal
full load operating conditions for which the respective units are designed, further
the units shall be rechecked for operation under normal overload conditions and
necessary adjustments and alterations of the units shall be carried out to prevent
leakage, spillage, heating up, undue vibrations, etc. and ensure that the equipment
as erected to fulfill the design requirement. For this purpose, continuous 72 hr. op-
eration shall be demonstrated as a necessary prerequisite to commissioning vide
24.3 (d).
24.3 The initial performance tests shall involve the following steps of operations:
a) Necessary pumps shall be started and flow established through all the streams,
valves shall be adjusted so as to have rated distribution of flow through all streams.
b) Various units of the plant shall be started simultaneously. Samples of water shall
be drawn every hour in the presence of the Engineer-in-Charge or his authorized
representative from the outlets of flash mixers, flocculators, plate/tube settler clar-
ification units, filters and chlorinators and tested in the plant laboratory or in any
other laboratory approved by the Engineer-in-Charge. The test results shall be com-
pared against the required parameters.
c) Similarly, samples of raw water shall be collected in the presence of the Engineer-
in-Charge or his authorized representative and tested in order to determine the ef-
ficiency of treatment at different stages of treatment.
d) The initial performance tests shall be carried out at least for 72 hours continuous
operation.
e) The performance tests of the water treatment plant shall be deemed as a failure in
case performance as specified is not met regarding quality and flow.
All cost of the initial performance tests shall be borne by the Agency.
After the initial performance tests, the plant shall be subjected to Trial Run during which
performance tests shall be carried out further as specified in section F and other relevant
chapters.

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SECTION - VIII
General Provision for Operation & Maintenance

1. GENERAL
This section applies to carry out operation and maintenance of the facility in meeting
its objective. The section pertains to the specifications of water supply system and
equipment including materials to be used for operation and maintenance, the workman-
ship, period for routine maintenance, specifications for the satisfactory performance of
the entire proposed water supply system, maintenance of records, and responsibilities
during operation and maintenance period. The Agency shall be responsible for provid-
ing continuous operation of the Intake well-cum-raw water pumping station, water
treatment water supply system, clear water reservoir-cum-pumping station, GLSRs in
WDCs, instrumentation system, communication system, PLC/SCADA, water supply
system and machineries, all ancillary buildings, campus area, for a period of eight years,
and to prevent any sudden failure or breakdown through maintenance works on water
supply system operation and its operation works. It is essential that Authority and
Agency need to have sufficient information on operational issues under normal and
emergency conditions.

Notwithstanding as to what is specifically stated under Maintenance Schedule, it shall

be the responsibility of the successful bidder to attend to all the preventive & routine
maintenance and repairs and breakdown services including replacement of necessary
parts and components.

1.1 System Components for O & M

The system components for O&M shall comprise the following for the proposed water
supply system:
1. Intake well-cum-raw water pumping station,
2. Raw water pumping machineries
3. Raw water pumping main
4. Water treatment water supply system (Plate Settler, RGF, etc)
5. Clear water reservoir

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6. Clear water pumping station

7. Clear water rising main
8. Air management system
9. Tapping control system
10. Bypass management system
11. Semi-underground reservoirs in Water Distribution Centers (WDC)
12. All MEP services installed in Intake well, WTP, clear water pumping station ad-
ministrative building and guest house.
13. Electrical equipment in Intake well, WTP, clear water pumping station, adminis-
trative building and guest house
v. 33KV supply from two sources
w. 33KV Ring main unit
x. 33kV Switchgear Panel
y. 6.6KV switchgear panel
z. 33/6.6kV Oil Filled Power Transformers
aa. 6.6/0.415kV Dry type indoor Transformers for station auxiliaries
bb. 33/0.415KV CSS for WTP
cc. 6.6kV Neutral Earthing Resistors
dd. 6.6kV Pump Panels
ee. Main LT PCC Panel
ff. Pump Motors
gg. Pump MCC Panels
hh. Fresh air & Exhaust Panel
ii. AC Panel for cabin air condition
jj. Main Lighting & Power Panel DB
kk. Lighting Panel for Admin Building
ll. Variable Frequency Drive for Pumps (VFD)
mm. Capacitor and APFCR panel to maintain Power factor greater than 0.90
nn. UPS – 2 Nos with Battery Banks & Battery chargers
oo. DC Distribution Board
pp. UPS DB – 1 & UPS DB – 2
14. Fire Alarm System with Control Panel

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15. Lighting system

16. SCADA/ PLC system
17. Control & Power cables
18. Earthing & Lightning Protection system
19. Fire Fighting System
20. Hand Operated Hoist & Trolleys

The list of Mechanical & Electrical equipment applicable for Operation and Periodic
Maintenance activities are listed subsequently. The list of equipment is applicable for
Operation and Periodic Maintenance activities of the proposed water supply system and
associated systems, as listed above.

1.2 PERFORMANCE GUARANTEE

The Agency shall guarantee & maintain the design parameters of water supply on 24x7
basis as stated in Basis of Design, throughout the Operation & Maintenance Period of
8 years.

1.3 DUTIES & RESPONSIBILITIES

The Agency shall operate and maintain the proposed water supply system on regular
and systematic basis, in compliance with designed /calculated operational index. The
Agency shall manage water supply system operations to restrict power consumption
and chemical usage within the specified functional guarantees. The Agency shall ensure
satisfactory operation and maintenance of the whole works so that the water supply
system operation provides reliable, consistent performance and is economical at all
times.

1.4 DEFINITION OF MAINTENANCE

Maintenance covers all the techniques and systems which, by means of regular moni-
toring of equipment and scheduled maintenance procedures, prevent failures, predic-
tive, condition monitoring and, in the event of problems, enable repairs to be carried
out with the minimum disruption of the process. Maintenance is therefore a combina-
tion of technical, administrative, and management activities. Maintenance consists of

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preventive and corrective procedures. Maintenance also includes all civil structures,
pipeline, approach bridge & roads, storm water drainage network, sewerage network,
electrical installations, instrumentation & SCADA etc.

Preventive Maintenance
Preventive maintenance consists of all the regular work carried out in order to sustain
the conditions necessary or smooth operation of the water supply system and to keep
the performance of the equipment as close as possible to its original performance level.
Its purpose is to reduce the probabilities of failure of deterioration of equipment of the
water supply system. In simple terms, preventive maintenance involves the elementary
operations such as lubrication, mechanical servicing, electrical and instrumentation ser-
vicing.

Corrective or Remedial Maintenance

Corrective or remedial maintenance consists of all works needed to re-establish the
conditions necessary for an apparatus or set of equipment to operate properly subse-
quent to failure or deterioration of the results produced by the equipment. It includes
the following operations:
 Dismantling or equipment,
 Replacement of parts
The work may be scheduled for the short or medium term in accordance with the checks
carried out as part of the preventive maintenance procedure, the number of hours an
apparatus has been operating, or an alarm factor (abnormal noise, repeated cut-out,
weakening of the insulation, etc.), or may be dictated by an unexpected breakdown.

Condition Monitoring (Predictive Maintenance)

Condition Monitoring (Predictive Maintenance) consists of all the regular work carried
out in order to sustain the conditions necessary or smooth operation of the water supply
system and to keep the performance of the equipment as close as possible to its original
performance level. Its purpose is to reduce the probabilities of failure or deterioration
of equipment of the water supply system. All equipment vibration analysis and thermal

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analysis shall be monitored on continual basis; remedy action shall be planned to

achieve “zero unscheduled break down”.
Supply and maintain at WTP premises of Environment Temperature Vibration Analyzer
is a Class 1 ruggedly designed device for measuring sound and vibration caused due to
environmental factors, for e.g. in pumps, pump room etc. It shall boast of versatile soft-
ware applications to measure and record the Environment sound and vibration moni-
toring and analysis on the portable rugged system. This data can be exported for post-
processing and regression analysis. Contractor shall Supply the Vibration Analyzer as
specified below.

Type of Product Environmental Sound Vibration Analyzer

Speaker Amp. 1W

International Protection IP64

USB 1 Host, 1 Device

I/O Head-Phone, Speaker, LED, Power etc.

Input Signal Gain 2, 4, 8, 16, 32, 64

Input Channel 4 Channel (3-Vibration, 1-Sound)

Dynamic Range 134dB (50mV/Pa x 10Gain)

3 channels with 512Hz for vibration and

Sampling Frequency
channels with 32,768Hz for sound

LCD 3.5 " 240 * 320 TFT or LCD + TSP

Expandable Memory SD Card

System Memory DDR SDRAM 128MB

Temperature 4 C to +50 C

External Memory Slot SD/MMC Slot

A/D Converter 24 Bit

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Humidity 5 % to 95 % Non-condensing

Communication Serial, Wifi, CDMA

Operating System WinCE 5.0

CPU PXA320 (806MHz)

SNR More than 100dB

Sensor Type IEPE, AC, RPM, IR Temperature Sensor

Operating Temperature 4 C to +50 C

Storage Temperature 4 C to +70 C

3M CMOS Camera, 1D Bar-code Scan-

More Options
ner, IR Temp Sensor, Laser Macho

Flash NAND 128 MB

0.5 ~ 80Hz(3dB) for 3 ch. vibration and

Frequency Range (Hz)
0.5 ~ 16kHz(3dB) for 1 ch. sound

Keys Power, Reset, Menu, Navi etc.

Maintenance work
Maintenance work consists of inspection work and maintenance work as given below:
Inspection work includes physical appearance, inspection and measurement with test-
ing equipment to verify and survey the water supply system performance whether op-
eration is normal or not.
The inspection work shall be daily executed by each technical specialist as a routine
and/or regular inspection and shall be recorded each time. The evaluation on the col-
lected data shall be immediately reviewed by the chief operational Engineer-in-Charge
to instruct the staff member for operation on the same day and/or make a plan of detail
inspection and/or make repair schedule to make sure continuous water supply system
operation without any problem.

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Maintenance work shall include activities, such as lubrication, overhaul, replacement

of parts, repair, adjustment, detail examination and test, cleaning, to maintain the water
supply system in a good condition, performance consistent and low-cost operation
based on a regular and preventive maintenance schedule including attending sudden
Equipment breakdown and to achieve high operational efficiency, damage of civil struc-
tures, instrumentation and control etc.

Operation work
This work consists of operation work and monitoring work:
Operation work is executing the water supply system operation based on the scheduled
process and procedure to meet designed criteria including set-up or adjust the opera-
tional index or data according to the required characteristics of 24x7 water supply at
the Building Distribution Network.

Monitoring work is to confirm the operation data, and readout it’s measurement value
on panels, and check-up the working performance of water supply system appropriately,
as well as keep the records of the out-put.

2.0 SPECIFICATIONS
The specification of materials used for repairs shall be the same as have been used in
the original work. Specifications for any materials which were not used during con-
struction shall be approved by the Engineer-in-Charge prior to commencement of the
operation and maintenance period and must be incorporated in the O&M Register.
Without being limited by this clause, during O&M period, the Agency shall use appro-
priate material for repairs even if material required for such repairs has not been ap-
proved earlier, and no delay in making such repairs shall be subjected to such limitation.
Table 1: List of Execution Schedule
Items Description
List of unit process, Capacity of equipment,
Water supply maintenance of system/facilities
Method/Frequency of maintenance.
List of water supply system/equipment, Items to
be monitoring/operation.
Operation of water supply system/facilities
Preparation of chemical, Method of system con-
trol and its note, how to input data into computer,

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operation of backup, Period of Power failure

and communication method
Scope of monitoring, Method of Measurement and
Monitoring of water quality at water supply sys-
analysis, Place of monitoring and name of author-
tem & WDC Distribution Network
ized personnel
Damage prediction, Simulation of public rela-
Counter measure against accident and risk man-
tions, Method of recovery, Contact address, Res-
agement
cue activity and emergency team
Replace of pipes, Replace of equipment & Facili-
Renewal
ties
Method of contract out, Scope of works, limit of
Sub-contracting
responsibility
Method of data analysis, Evaluation of collected
Evaluation & Report
data, Improvement program, Reporting.
Executive organization chart, Segregation of du-
ties, List of staff members, Experience, Health
certificate of staff members, type of insurance,
Organization and administration
Criminal record, Personnel name of taking record
and make soft data, method of data control, Oper-
ation and maintenance cost.

The Agency shall deploy Qualified Staff having knowledge of entire water treatment
Water supply system and its Distribution Network.

3.0 WORKS COVERED UNDER O & M SCOPE

3.1 General
The Agency shall be responsible for, but not limited to, the following operation &
maintenance works:
 Providing & Maintaining water as per specified characteristics on 24x7 basis up to
WDC end as specified in the Basis of Design or as directed by the Engineer-in-
Charge.
 Providing the required staffs, but not less than the minimum specified numbers/
level, during operation and maintenance period and additional staffs as per require-
ment during periodic maintenance and in emergencies.
 Providing all required consumables such as spares, tools, tackles & equipment and
consumables required for functioning of all water supply systems and equipment.
 O & M of all functional and utility buildings, infrastructure and common areas
within the water-work campuses as listed in 1.1 above.

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 Entering into AMC contracts, if required, with system / equipment suppliers such
as treatment water supply system, Firefighting system, Ventilation Fans, Centri-
fuges, Air Blowers, Hoists and cranes, Valves and actuators, Sluice Gates and actu-
ators, pumps and mixers, and all proprietary equipment and others as necessary. It
is mandatory to enter into an agreement for 8-year maintenance contract with the
Controls & Instrumentation System, PLC and SCADA system supplier or the au-
thorized system integrator, whosoever has executed the work for this project. The
AMC contract shall include preventive maintenance and emergency corrective
maintenance programmers, so that breakdowns can be kept to absolute minimum in
frequency and duration.
 Establish work control procedures including preventive, predictive and corrective
maintenance so that the entire proposed water supply system /water supply systems
shall work in automatic mode and/or semi- automatic at all times.
 Maintenance of the lighting fixtures and the lighting system of all areas and replace-
ment of all non-functional lighting fixtures within 24 hours.
 Maintaining;
 Repair history of all mechanical, electrical and instrumentation control equipment
in the proposed water supply system and communication instruments;
 Every day power availability / power failures, hourly readings of input voltage and
current, frequency, power factor, kWh, kW in HT Switchgear cubicles at each pump
houses.
 Log books through PLC system; Daily log of operations of all the important equip-
ment such as VT pumps (Raw water), clarifier, RGF, Clear water pumps, blower,
compressor, Firefighting system, Ventilation Fans, filter, dosing, electrically actu-
ated valves, etc., with time tag;
 Hourly readings of temperature and pressure at Inlet & Outlet of all equipment; o
water quality test results as specified.
 chemical test results as specified.
 Daily list of alarms with time tag;
 Log book format and the data to be included in the log book shall be decided during
commissioning in consultation with the Authority;
 Last periodic maintenance done for all equipment/buildings of the system;
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 In addition to maintenance of above logbooks, the Agency is required to maintain

one inspection book at each process water supply system and machinery area. The
complaints entered in the complaint register must be investigated and remedial
measures must immediately be taken.
 Providing required spares, special tools and test equipment and maintaining ade-
quate inventory of required accessories or equipment itself for repair of system so
that the electrical, mechanical, instrumentation and control system, pipe and the
communication system can work efficiently as per the guarantees given or mini-
mum required efficiencies asked for in the Contract, without any additional costs to
Authority. The Agency may use spares and tools and tackles supplied with the Con-
tract as required by him. However, at the end of the Contract, the Agency shall hand
over the full spares, tools and tackles as supplied with the Contract by replacing the
used items with fresh supplies of the same specifications.
 Providing manpower for the required repairs of all facilities along with the man-
power and materials for repair of the roads, buildings and campus area utilities.
 Proper maintenance of Water Supply, Sewerage, Roads, Paths, lawns including
trimming and upkeep of gardens etc.
 Proper maintenance and housekeeping along with provision of all tools & equip-
ment.
 Maintaining stores for the electrical, mechanical and instrumentation and control
equipment as well as that for the chemicals and laboratory consumables. The
maintenance of stores will include but shall not be limited to:
i. Loading / unloading of materials received and issued for works;
ii. Proper arrangement of material in stores to ensure its safety and easy availa-
bility;
iii. Maintaining store areas in a neat and tidy condition;
iv. Keeping records and accounting for the incoming materials,
v. Keeping records and accounting for the consumed materials.
 The Agency shall be solely responsible for the safety and security of the goods in
the store and will be responsible for any loss or damages in stores for any reason.
 Periodic routine maintenance of structures/buildings. Such maintenance must en-
sure adequate cleanliness, ventilation, illumination and structural safety. In addition

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to this, the general hygienic standards must be maintained and adequate water sup-
ply system, horticultural activities must be taken up to maintain the total environ-
ment of the campus / building pleasant.
 Updating and periodic submissions of the operation and maintenance manual as
defined in specifications for O&M works. The Agency shall take up all periodic
maintenance works provided in the approved O&M manual.
 Submission of monthly report.
 Co-ordination with other Agencies and/ or agencies responsible for the execution,
operation and maintenance.
 The Engineer-in-Charge shall be entitled to audit any aspect of the system and the
Agency shall ensure remedial action as directed.
 Safety reporting: Brief reports of all accidents and hazardous incidents including
descriptions of causes, extent of injuries, action taken, and precautions instituted to
prevent repetition of such events.
 Insurance: The Agency shall, without limiting his or the Authority’s obligations and
responsibilities, undertake the following;
 The insurance shall be at the Agency cost and shall cover the Authority and the
Agency against all losses or damages from whatsoever cause arising from the start
of the O&M until the date of completion of O&M in respect of the facility or any
section or part thereof as the case may be.
 Insurance shall cover for all the civil, mechanical, electrical and instrumentation
works together with material and water supply system to the full replacement cost.
 Any amount not insured or not recovered from the insurer shall be borne by the
Agency.
 The agency shall maintain all civil structures, pipeline, boundary wall, approach
bridge & roads, storm water drainage network, sewerage network, electrical instal-
lations, instrumentation & SCADA etc. properly and keep in good working condi-
tion.

Maintenance of Civil structures

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The agency shall maintain all civil structures including pipeline, boundary wall, ap-
proach bridge & roads, storm water drainage network, sewerage network, electrical in-
stallations, instrumentation & SCADA etc. in good condition throughout the mainte-
nance period. There shall not be any sign of leakage in any water retaining structure,
any splashing of concrete, worn out plaster, moss blisters etc. over the surface of the
building. The agency shall maintain all sanitary plumbing installation properly. The
agency shall provide painting to all MS structures as per the provision of CPHEEO
manual. The agency shall provide painting to al civil structures at least twice during the
maintenance period.

3.2 General Obligation

The Agency shall operate and maintain the entire water supply system under this con-
tract for the period specified in this contract. The Agency will submit a detailed opera-
tion and maintenance plan for approval of the Engineer-in-Charge. All operation and
maintenance activities shall be carried out strictly in accordance with the approved plan.
The services shall include but not be limited to the following items.
 Operation and maintenance of the complete water supply system.
 Training for the O & M staffs designated by Authority’s requirement.
 Generation and maintenance of periodic reports.

3.3 Operational Services

 The Agency shall operate the complete water supply system, and other associated
services on a continuous 24- hour basis.
 The Agency shall operate and utilize the control and monitoring systems provided.
If found necessary, he shall make adjustments (within the operation range) of the
control
system and equipment, so that the Water supply system operation matches the
treatment process requirements.
 The Agency will be required to furnish the details of format for all water supply
system operation and monitoring including electricity consumption in the format
prescribed by the Engineer-in-Charge.

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Amaravati Development Corporation Limited

 Agency will be responsible for any penalty due to power factor, hence Agency has
to maintain power factor in the limit.
 The Agency shall provide all consumables and spare required operating and main-
taining the Water supply system in good condition. Any garbage generated in the
water supply system shall be removed from the site on daily basis. No accumulation
of such residues shall be permitted within the Water supply system campus without
express application by the Agency giving adequate reasons as well as permission of
Engineer-in-Charge. The Engineer-in-Charge may, if required, decide the mode and
timing of disposal of such residues in consultation with concerned Environmental
and Civic Authorities. Such directions shall be followed by the Agency promptly,
both in letter and spirit, without any reservations and without any increase in O&M
/other costs. The loading, unloading and transportation cost of these shall be borne
by the Department.
 The Agency shall provide all tools & special tools, equipment, testing and checking
instruments, monitors, safety items etc required for operation & maintenance of
complete electrical system, Lighting system & earthing system.
 The Agency at his own expense shall provide all tools, cleaning, and housekeeping
equipment, security and safety equipment.

3.4 Agency Care of Pumping Plant

The Agency shall take full responsibility for the care of the pumping plants and all other
systems like control rooms, pipelines, valves and other allied systems during the con-
tract period till it is handed over to the Authority at the end of 8 years of O&M.
If any loss or damage occurs to the treatment works or to any other system, during the
period for the Agency is responsible, the Agency shall rectify such loss or damage, at
his cost, so that all Pumping stations conforms to its condition when the Agency took
possession of the treatment works at the commencement of the contract.

4. Instrumentation, Control & Automation (ICA)

4.1 General Maintenance
A comprehensive maintenance program is critical to attaining long-term reliable per-
formance of SCADA Systems / ICA systems. Periodic device calibration, preventive
maintenance, and testing allow potential problems to be identified before they can
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cause mission failure. Prompt corrective maintenance assures reliability by minimiz-

ing downtime of redundant components.

4.2 Preventive Maintenance

The PLC/SCADA system shall be part of the overall preventive maintenance (PM) pro-
gram for the facility.
Table below provides a list of recommended maintenance activities and frequencies for
SCADA systems and their components.
Preventive maintenance schedules for SCADA components and subsystems shall be
coordinated with those for the mechanical/electrical systems they serve to minimize
overall scheduled down time.
Many components of SCADA systems, such as dead-bus relays, are not required to
function under normal system operating modes. For this reason, the system shall be
tested periodically under actual or simulated contingency conditions. These tests shall
approach as closely as possible the actual off- normal conditions in which the system
must operate. For example, SCADA for Dual Redundant system shall be tested by in-
terrupting the utility source as far upstream of the normal service as possible.
Periodic system testing procedures can duplicate or be derived from the functional per-
formance testing procedures.
The SCADA software maintenance shall include timely updates of any new versions
from the supplier and testing to verify proper installation on the SCADA computer. In
addition, software antivirus updates shall be maintained. This shall be performed any
time after the computer is connected to the Internet or the antivirus patch shall be down-
loaded as and when the updates are available. Normal operation requires that the
PLC/SCADA computer not be connected to the Internet. Faulty Instruments, sensors,
transmitters, communication modules, computer hardware shall be replaced with new
components. Repair of the failure items would not be accepted. Instruments, modules
would have to replace with a new instruments and components.

5.0 APPLICABLE STANDARDS

Operation & Maintenance Procedures of proposed Water supply system under this con-
tract shall conform to the latest applicable standards specified below. In case of conflict
between standards and this specification, this specification shall govern.

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Amaravati Development Corporation Limited

 Manual on EHV Substation Equipment maintenance - CBIP Publication No. 294

 Indian Electricity Rules - 1956 updated
 ASHRAE 2007 Systems and Application Handbook (with latest amendments) For
building & control room air conditioning.
Other sources of information must be consulted (e.g., manufacturer’s recommenda-
tions, unusual operating conditions, personal experience with the equipment, etc.) in
conjunction with the maintenance recommendations.

6.0 EXPERIENCE & QUALIFICATION OF STAFF

6.1 Requirements
Operation and maintenance staff shall have sufficient experience, good health condition
and adequate educational/technical qualification in addition to possessing best
knowledge, abilities and skills.
6.2 Knowledge and Abilities
 Knowledge of total Water supply system & Distribution Network of similar capac-
ity, unit operation;
 Knowledge of the method, materials, and equipment of Water supply system & Dis-
tribution Network operation;
 Knowledge of unit operation, maintenance, and servicing of pumps and other water
supply system equipment and machinery;
 Abilities to make repairs and/or adjustments to water treatment plant & Distribu-
tion Network equipment and to keep records and prepare reports;
 Abilities to read and interpret gauges and recording devices used in the Water Sup-
ply System & Distribution Network;
 Abilities to lift sacks of chemicals and to read and follow written and oral instruc-
tions;
 Abilities to work efficiently with others.
For all operation and maintenance works, the Agency shall provide skilled staff, which
has adequate qualifications and sufficient experience of similar works. CV of plant in
charge, Plant Supervisors, Shift-in-charge, Electrical Engineer-in-Charge and ICA/
SCADA Engineer-in-Charges etc. will have to be got approved from the Authority.

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Amaravati Development Corporation Limited

Operating Personnel
MINIMUM MANPOWER DURING OPERATION AND MAINTENANCE FOR
Intake well, WTP & WDC IN THE CONTRACT
Proposed Mini-
Sl. Minimum Qualifica- Experience
Position mum No. of
No. tion in Years
Posts
B.E. Environmental
1 Station In-charge 10-15 1
/Civil/Mechanical
B.E environmen-
2 Process In-charge 5-10 5
tal/Civil
Electro- Mechanical BE/Diploma
3 5-10 8
Shifts in Charge Mechanical/Civil
ITI
4 Operator 5-10 24
Fitter/Elec
5 Electrician ITI (Elec.) 3 8

6 Fitter ITI (Fitter) 3 8

7 Chemist BSC (Chem.) 3 1

8 Security Staff 10+2 -- 16

Operators cum In-
9 charge at Cushion ITI 3-5 200
tanks
Fitter/Electrician at
10 ITI 3-5 32
SUGRs
Operators cum In-
11 ITI 3-5 32
charge at SUGRs
Special Mainte-
As and when re-
12 nance, technical au- -- --
quired
dit team

6.3 Minimum levels of Staffing

The following paras describes the minimum levels of staffing, and their minimum qual-
ifications and experience in similar works. The Agency shall be required to deploy these
staffs for carrying out the O&M functions.
The Agency shall deploy the following persons as detailed in the General conditions of
contract.

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Plant in Charge:
An Engineer-in-Charge with Degree in Mechanical Engineer-in-Charge having
knowledge of related electrical equipment and system with at least 10 years of experi-
ence in operation and maintenance of similar kind of water treatment Water supply sys-
tem and Distribution Network. He shall be overall in charge for Pumps and Distribution
Network. He shall be posted in General/Day shift (9AM - 5:30PM) and responsible for
functioning of Water Treatment Plant and Distribution Network. Arranging shut downs,
programming for maintenance, co-ordination between Owner and other agencies in-
volved etc. Working knowledge in Telugu, English language is essential. Computer lit-
erate with knowledge of MS Word, Excel & MS Project.

Process in Charge:
Engineer-in-Charge Degree/Diploma of environmental/Civil Engineer-in-Charge hav-
ing knowledge of Water treatment process with at least 3 years of experience of shift
duties of similar kind of Water supply system and Distribution Network. He shall be
posted in shift of 8 hours. There will be three Engineer-in-Charges per day and one as
a Reliever. He shall be responsible for process monitoring of Water Treatment Plant and
Distribution Network. He shall be shift in charge. Responsible for reporting to the Sta-
tion in charge. Working knowledge in Telugu, English language is essential. Computer
literate with knowledge of MS Word, Excel & MS Project.

Electrical Mechanical Shifts in Charge:

Engineer-in-Charge Degree/Diploma of Mechanical/Electrical Engineer-in-Charge and
at least 5 years of experience of shift duties of similar kind of Water Treatment Plant.
He shall be posted in shift of 8 hours. There will be Six Engineer-in-Charge-ins (1 En-
gineer-in-Charge per shift for intake well and WTP) per day and Two as a Reliever. He
shall be responsible for operation of Water Treatment Plant. He shall be shift in charge.
Responsible for reporting to the Station in charge. Working knowledge in Telugu, Eng-
lish language is essential. Computer literate with knowledge of MS Word, Excel & MS
Project.

Operators:

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Amaravati Development Corporation Limited

The Operator is having Diploma of Mechanical Engineer or ITI having knowledge of

related electrical equipment and system and adequate experience of shift duties of sim-
ilar kind of Water Treatment Water supply system and Distribution Network. two oper-
ator intake well and four operators shall be posted in each shift of 8 hours. There will
be 18 operators per day and six relievers. He shall be responsible for maintaining log
books, operations during his shift. Working knowledge in Telugu, English language is
essential. Computer literate with knowledge of MS Word, Excel & MS Project.
Maintenance Crew
The maintenance crew would consist of
 Maintenance Engineer-in-Charge
Engineer-in-Charge having Degree or Diploma of Mechanical Engineer having
knowledge of related equipment and system and having adequate experience of Mainte-
nance of similar kind of WATER TREATMENT Water supply system and Distribution
Network. He shall be posted as and when required and responsible for routine and
breakdown maintenance of WATER TREATMENT Water supply system and Distribu-
tion Network.

 Electrical Maintenance Engineer-in-Charge:

Engineer-in-Charge having Degree or Diploma of Electrical Engineer-in-Charge and
having adequate experience of Maintenance of similar kind of WATER TREATMENT
Water supply system. He shall be posted as and when required and responsible for rou-
tine and breakdown maintenance of WATER TREATMENT Water supply system.

 Additional Staff
The additional staff comprising of skilled, unskilled workers headed by Engineer-in-
Charge shall be posted for routine, yearly, half yearly maintenance during break downs
and shut downs as per requirement and quantum of work. Apart from above, the Testing
Engineer-in-Charges along with skilled staff shall visit WATER TREATMENT Plant
and Distribution Network for annual relay testing and in event of emergency whenever
their services are required for smooth functioning of WATER TREATMENT Plant and
Distribution Network.

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Amaravati Development Corporation Limited

Operation staff shall be exclusive and not utilized for regular, periodic and breakdown
maintenance works. All the persons of the Agency shall have working interaction with
the Engineer-in-Charge to enable the Agency.
Operators cum In-charge at Cushion tanks & SUGRs:
The Operator shall have ITI having knowledge of system and adequate experience of
shift duties of similar kind of Water supply system and Distribution Network. Three
operators shall be posted in each shift of 8 hours and additional one operator shall be
posted as a standby at all WDC premises (including all cushion tanks & SUGRs com-
pounds). He shall be responsible for maintaining log books, operations during his shift,
landscaping activity, security for the entire compound area. Working knowledge in Tel-
ugu, English language is essential. Computer literate with knowledge of MS Word, Ex-
cel & MS Project.
Fitter/Electrician at SUGRs
Engineer-in-Charge having Degree or Diploma of Electrical Engineer and having ade-
quate experience of Maintenance of similar kind of water supply system. He shall be
posted as and when required and responsible for routine and breakdown maintenance
of Water supply system at all SUGR premises.
Note:
1. The above requirement is minimum only. The Agency will arrange extra work force,
as and when required, so as to smoothly run the operation and maintenance including
preventive maintenance, repairs etc. and general cleanliness of the installations.
2. The above staff strength is exclusive of leave reserve required for different category
of staff. The Agency shall ensure availability of the personnel given in the above table
for all seven days in a week.
3. The Agency shall make appropriate arrangements for maintenance of items like road
work, buildings, arboriculture, patrolling and maintenance of civil structures, vehicle
operations and other activities defined to fulfill its obligations under O&M Contract.
4. In the event of absent of staff during the O&M, the deduction of payment shall be
done on per day basis for the number of days absent, as per relevant Sub-clause.
5. The Agency shall provide manpower detail as per Annexure 3

7.0 DEFECT LIABILITY

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Amaravati Development Corporation Limited

A defect liability period of two years shall commence upon issue of the Construction
Completion Certificate by the Engineer-in-Charge/Authority. During defect liability pe-
riod, the Agency shall be responsible for the followings:
 Provide to Authority the advisory services and follow-up training required.
 Complete any outstanding work notified to Agency in Contract Completion Certif-
icate or Taking Back Certificate (as applicable as per contract), issued by the Engi-
neer-in-Charge under this clause.
 If during Defect Liability period, any defect shall be found in the system, the
Agency shall promptly, in consultation and agreement with the Authority/Authority
regarding appropriate remedying of the defects, and at its cost, repair, replace or
otherwise make good as the Agency shall determine at its discretion, such defect as
well as any damage to the facilities caused by such defect.

7.1 Extension of Defect Liability Period

The defect liability period shall be extended by the period during which any part of the
works could not be used by reasons of a defect or damage, for which Agency was liable.

7.2 Failure to Remedy Defects

 If the Agency fails to remedy any defect or damage within a reasonable time, a date
may be fixed by the Engineer-in-Charge, on or by which the defect or damage is to
be remedied.
 If the Agency fails to remedy the defect or damage by such date, the Authority may
carry out such works himself at the Agency risk and cost. Such cost, determined by
the Engineer-in-Charge, shall be final and binding.

7.3 Defect Liability Certificate

Within 28 days of the expiry of the defect liability period, Engineer-in-Charge shall
issue a Defect Liability Certificate stating the date by which the Agency completed all
his obligations under O & M, including remedying all the defects, to his satisfaction.
The decision of the Authority on all the sub clauses of this clause shall be final and
binding on the Agency.

8.0 OPERATION & MAINTENANCE EQUIPMENT

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All tools and tackles required for the safe and satisfactory operation and maintenance
including preventive and break down maintenance of the Water supply system and Dis-
tribution Network and related equipment covered under this tender shall be provided
by the Agency.

8.1 Tools and Tackles:

1. Sling psychrometer
2. Set of pocket hand thermometers
3. Refrigerant leak detector kit
4. Combustion testing kit
5. Voltage and community tester
6. Volt-ohm-milli-ammeter with temperature adapters
7. Stroboscope tachometer
8. Vibration meter
9. Temperature recorders
10. Air velocity meter
11. Sound level meter
12. CO2 monitor meter
13. CO monitor meter
14. Combustible gas detector set
15. Clamp-on volt-ohm meter
16. Inclined manometer
17. Automatic temperature control instrument testing: air regulators, air filters and con-
trol manufacturers test tools and instruments
18. Air balancing hoods
19. Ductwork leakage testers
20. Smoke gun/candles
21. Digital pressure gauges
22. Pressure and vacuum gauges
23. OSHA- approved oxygen/acetylene welder and arc welder
24. Grinder
25. Drills

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26. Grease pump

27. Vacuum pump
28. Ultrasonic flow meters
29. Refrigerant charging and testing unit
30. OSHA-approved ladders
31. Digital thermometers
32. Infrared thermometers
33. Humidity meter
34. Voltage recorder
35. Soldering gun kit
36. Combination wet/dry vacuum cleaner
37. Barrel with hand pump set
38. Electric short circuit locator
39. Megohmeter
40. Electrical cable testers
41. Hand oil pump
42. Punch and chisel set
43. Pipe wrenches
44. Flaring and swaging tool set
45. Tube bender
46. Inner-outer tube reamer
47. Tube cutter
48. Screwdrivers, Phillips head and Allen wrenches
49. Steel work benches
50. Inside and outside calipers
51. Bench vise
52. Claw hammer
53. Rubber mallet
54. Machinist’s square
55. Dividers
56. Level
57. Tap and die sets

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58. Files, cabinets and tool kits

59. Snips- straight, left and right
60. Wrecking bar
61. Ratchet wrench and socket set, multiple drives and depths
62. Set of open and box-ended wrenches
63. Pie and fitting chain wrenches
64. Strap wrenches
65. Heavy-duty pipe cutter
66. Locking pliers
67. Set of pipe taps
68. Pipe threader set
69. Pipe reamer
70. Pipe cutter and tri-stand
71. Gasket-cutting tool
72. High-pressure air hose and compressor set
73. High pressure portable fan for winterizing coils
74. Set of Discharge rods (Minimum six nos.)
75. Complete set of all sizes of Double ended, Ring, Tubular & box spanners - 2 sets.
76. Complete set of all sizes of screw drivers - 2 sets
77. Complete Tool Box -2 nos.
78. 1 No. Blower & Vacuum Cleaner.
79. One derrick capable of handling highest equipment of the Water supply system Guy
ropes suitable for hoisting above derrick.
80. Minimum two sets of heavy duty hand gloves of highest voltage rating available in
the market, 6 No Helmets, 6 No safety belts & Safety shoes.
81. 2 No of heavy duty dry cell or rechargeable (without acid) torches. Rain coats and
gum boots as required.
82. First aid box
83. 1 No. Insulation tester 5 kV capacity 1 No. Insulation tester 1 kV capacity 2 nos.
Multi meter Analog & Digital Tong tester
84. Temperature Gun

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85. Cable crimping tools of adequate capacity etc. Extension Power supply boards (sin-
gle phase) Phase Sequence meters
86. PC with printer
The above-mentioned tools & tackles shall be provided separately for Intake well and
WTP.

8.2 Consumables
1. Minimum 20 kg of Petroleum jelly.
2. Minimum 5 bottles of Carbon tetra chloride(CTC) Minimum 5 bottles of contact
cleaner spray
3. M seal, epoxy compound, sealing compound, paint, red oxide etc. Fuse wire, Insu-
lation tape, emery paper, HT tape etc.
4. 20 kg of Silica gel, Gaskets sheet, cotton tape, Teflon tape etc.
5. Cotton waste, muslin cloth, waste cloth, cleaning agents etc. Transformer oil for
topping up of Transformer, SF6 Gas Cylinder
6. All major consumable like Transformer oil, SF6 gas and its filling kit, indicating
lamps, Luminaries, control and power wires/ cables, Battery solution, etc.

9.0 MANDATORY SPARES

Proper preservation norms are to be adopted to perform periodic Condition Monitoring
tests on spares to keep them healthy and usable.
The practice of removing sub-assemblies from main spares during emergencies needs
to be regulated properly. Any component removed needs to be replenished as early as
possible so that the main spares are always kept complete. Proper transportation cases
also need to be kept at central stores to avoid transportation delays when transported to
the required destination.
All spares recommended by manufacturers of equipment as given in Appendix – E
shall be installed in the Plant.
Nuts, bolts, washers of sizes used in Water supply system and other systems.
Fuse holders and HRC fuses, terminal links, control wires and lugs of rating used in the
Water supply system and other systems.

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The Agency shall keep ready stock of all items/ consumables for day to day mainte-
nance/ repairing works.

10. MAINTENANCE SCHEDULES

Maintenance scope include both preventive and breakdown maintenance. Preventive
maintenance shall be routinely carried as per details provided herein below.
Breakdown maintenance shall be provided as and when situation warrants with a failure
or fault in the system. The breakdown maintenance shall be attended at the highest pri-
ority so to make good the faulted system and putting into operation. For breakdown
maintenance, the Agency shall coordinate/liaison with Engineer-in-Charge and the
original equipment manufacturer for replacement parts and services as necessary. In-
frastructure, tools and tackles and site support shall be provided by the Agency for such
jobs with priority and without unnecessary delays. OEM parts and services, if any, re-
quired for the completion of breakdown services shall be approved and cleared for ex-
ecution by appropriate authorities.
During the preventive (routine) maintenance, the Agency shall carry out the following
as listed for various system components given in Appendix D.
Though the list in Appendix D contains several individual jobs they could be executed
in a combined scope as in servicing or overhauling of the component.
The maintenance jobs which are specifically underlined in the following list shall be
carried out by OEM supplier or their authorized service provider only. The Agency shall
be required to provide proof for the same before executing the job.
In addition to the Equipment given in Appendix D, visual Inspections and Required
Periodic Maintenance shall also be carried out on the following:
 Control circuits
 Cranes and Hoists Motors and their wiring
 Electrical Drawings
 Emergency Lighting
 Fuses
 Motors
 Personnel Protective Equipment
 SCADA System
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Apart from the above Maintenance Schedules, Preventive Maintenance Procedures,

Condition Based maintenance, Residual life Assessment of all the Water supply system
& Distribution Network Equipment shall be carried out.

10.1 Operations
Hourly:
 Taking readings of all meters installed at control panel. ACDB, DCDB, Battery
Charger etc. Air and Gas pressures of Gas circuit breakers.
 Oil & Winding temperatures of Transformers.
 Taking the reading of surge arrestor counters of Lightning Arrestors, Checking any
sparking or flash over / hot spots in the Water supply system.

Daily:
 Checking the operation of Circuit breaker.
 Visual Checking contacts of Isolators are in proper position or not.
 Checking oil levels of all bushings, Main & OLTC Conservator, CTs and PTs, etc.
 Checking oil leakages if any for Transformers, CTs & PTs & taking appropriate
action for its timely repair
 Checking air / gas/ oil leakages if any for Circuit Breakers.
 Checking condition of Silica gel.
 Checking DC voltage & periodic maintenance of battery banks.
 Cleaning of premises, Control relay panels etc.
 Maintaining log books and daily check list.
 Checking Deposition of dust and dirt on Insulators.
 Checking Locks and doors of Water supply system are in good condition.
 Checking no leaks have developed in the roof, Ventilating systems.
 Checking the heating systems are working normally.
 Checking the prescribed safety aids are in place and in good order.
 Checking the earthing connections is unbroken.
 Checking the packing of cables entering and leaving the trenches or tunnels within
the premises are intact.

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 Checking the ventilating louvers are not damaged.

 Checking the access roads to the oil filled devices is not obstructed.
 Draining the air / moisture from air conservators of circuit breakers.
 Trouble shooting and repair of Electrical circuits components in case of any abnor-
mal conditions.

Monthly:
 Checking Auto/ Manual operations of OLTC.
 Checking earthing points and their contact, tighten wherever required.
 Preparation of monthly checklist and events log for the month.

Events:
 Logging auto / manual operations of OLTC.
 Logging the breakdown events with relay indications etc.
 Logging shut down events, log of operations during shut down period.
 Logging of on / off of feeders in the 33kV, 6.6kV and 415V distribution system.
Maintaining visitors registers along with their comments and details of their visits.

11.0 DOWN TIME

The Water supply system shall never be operated at less than its design capacity due to
maintenance and repair reasons.
The maximum downtime for any electro-mechanical equipment shall not exceed 8
hours, the periods for repairs and maintenance have to be communicated to the Engi-
neer-in-Charge at least one month in advance. For machinery and equipment which
requires maintenance to be carried out by manufacturer/ manufacturer’s authorized rep-
resentative. Authority reserves the right to impose Liquidated damages, shall there be
any default by Agency on this account. The Liquidated damages amount will be de-
ducted in the next O & M bill if adequate reasons are not furnished by the Agency for
delay.
Applicable rate for Liquidated damages have been given elsewhere in the document

12.0 PAYMENTS
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Amaravati Development Corporation Limited

The Agency, at the time of bidding, will be responsible to ensure the completeness and
adequacy of his Bid Price to fulfill the entire responsibilities as described above. His
bid price, shall include all costs for carrying out all O&M responsibilities. O&M pay-
ment shall be released according to the KPI mentioned elsewhere in the bid document.
The cost of electric power consumed, which will be paid directly by the Authority.

13.0 MAINTENANCE FORMATS

The Agency shall follow the Maintenance Formats of various system components as
listed out in Appendix – F

14.0 OPERATION & MAINTENANCE LABOUR REGULATIONS

The Agency shall follow the Operation & Maintenance Labour Regulations as stated in
Appendix – G

15.0 Key Performance Indicator (KPI)

The contractor/EPC Agency shall be subject to the following penalties for failure to
carry out its operations as indicated below during “Performance Based O&M period”
(10 years including DLP of 2 years) under Normal Operating Conditions. The Key Per-
formance Indicators (KPIs) are as follows. The KPIs will be monitored through the
sensors, PLC controlled SCADA system, Citizen Charter of Amaravati Capital or those
observed and recorded by the officers’ concerned in-charge of the project and accord-
ingly the EPC Agency will be penalized for not complying with the following KPIs.

15.1 Water Quality:

Failure to achieve the specified treated water quality parameter at the common delivery
manifold of the Clear Water Pump during the O&M period shall entail the following
penalties as % of the O&M Monthly payment for failure to pass the Tests during O&M
period for each additional “quantum” (as defined below) of the water quality parameter
or part thereof beyond the specified maximum concentration present in the actual water
produced during the Tests on Completion.

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Parameter Specified maxi- Measured Parame- Penalty/day as % of

(Monthly mum concentra- ter in excess of O&M Monthly Pay-
Avg.) tion Specified ment
1.01to 1.2 NTU 1.0%
Turbidity 1 NTU 1.21 to1.5 NTU 2%
(N.T.U.)
1.51 to 1.8 NTU 5%

6 1.0%
Colour (Units
on Platinum Co- 5 7 1.5%
balt Scale)
TCU 8 2.5%

6.8 or 8.7 0.5%

pH 6.5 to 8.5 6.7 or 8.8 1.0%

6.6 or 8.9 2.0%

0.04 mg/lit, 0.5%

Residual Alumi- Less than 0.03 0.045 mg/lit, 1.0%
num mg/l, Al
0.05 mg/lit, 2.0%

0.7 or 1.5 ppm 2%

Residual Chlo- 0.8 to 1 ppm
rine 0.6 or 2 ppm 4%

For the water quality and for a given water treatment plant, Performance Damages
shall not exceed 25% of the O&M Contract Price. However, for non-compliance of
the quality for more than one parameter, 25% Performance Damages limit shall apply
separately with an overall cap of 50% of monthly O&M payment.
Further, all remedies other than performance damages, including but not limited to
construction of additional facilities, additional equipment and repair and/or replace-
ment of the installed equipment shall continue to be fully available to the Employer,
and the Employer may choose to invoke any or all of them at any time in accordance
with the terms of the Contract.

Loss of Water
Entire water distribution system designed for Zero Discharge basis. Water losses be-
yond the contractual condition leads to penalization. O&M period shall entail the
following penalties as % of the O&M Monthly payment for failure to “Zero Discharge”

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during O&M period for each additional “quantum” (as defined below) of the water quan-
tity parameter
Parameter Specified maxi- Measured Parame- Penalty/day as % of
(Monthly mum concentra- ter in excess of O&M Monthly Pay-
Avg.) tion Specified ment
1.2 % 1.0%

Loss of Water 1% 1.5 % 2%

1.7 % 3.5%

15.2 Penalties against Excess Energy Consumption and low Power Factor:

15.2.1 Penalties for Excess Energy Consumption

The penalties for excess energy consumption for O&M of the constructed Works for
various treatment components of entire WTP shall be as under:

The Bidder shall guarantee that the electrical energy usage of various treatment,
pumping components of the Intake well, Raw water raising main, WTP, Clear water
pumping station, Clear water pumping main and WDCs (including auxiliary)
throughout the Operation and Maintenance Period. The bidder shall submit the energy
consumption detail for treatment of water per Million Litre per month as per Table-1
for EIC approval.

Bidder shall conduct energy audit every year and take necessary remedy action to
control within the approved guaranteed energy parameter. The energy audit report and
action plan shall submit for EIC approval.

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TABLE – 1
GUARANTEED POWER FOR OPERATION OF Intake well, Raw water raising main,
WTP, Clear water pumping station, Clear water pumping main and WDCs (including
auxiliary) UNDER DESIGN MONTHLY AVERAGE INFLUENT SEWAGE FLOW
AND BOD CONDITIONS

KWh/
Sl. No. O&M YEAR YEAR KWh/MONTH KWH/ML/Month

E1/(12*(ML of water
1 FIRST E1 E1/12
Produced in a month))
E2/(12*(ML of water
2 SECOND E2 E2/12
Produced in a month))
E3/(12*(ML of water
3 THIRD E3 E3//12
Produced in a month))
E4/(12*(ML of water
4 FOURTH E4 E4/12
Produced in a month))
E5/(12*(ML of water
5 FIFTH E5 E5/12
Produced in a month))
E6/(12*(ML of water
6 SIXTH E6 E6/12
Produced in a month))
E7/(12*(ML of water
7 SEVENTH E7 E7/12
Produced in a month))
E8/(12*(ML of water
8 EIGHTH E8 E8/12
Produced in a month))
E9/(12*(ML of water
9 NINTH E9 E9/12
Produced in a month))
E10/(12*(ML of water
10 TENTH E10 E10/12
Produced in a month))

The penalties for excess energy consumption for O&M of the constructed Works for
WTP and Pumping shall be as under:

Sl.
CONDITION RATE OF PENALTY
No.

If the power consumption

is lower than the Neither benefit nor deduction on account of power con-
a)
guaranteed / assessed sumption shall be made.
power consumption

If the actual power Damages payable by the Contractor to the Employer on a

consumption exceeds the monthly basis shall be equal to 2 times the cost of the ex-
b)
guaranteed / assessed cess energy used for O&M for WTP at the prevailing en-
power consumption ergy charges being paid by the Employer to APSPDCL.

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The Bidder shall guarantee that the energy usage of various components of the Works
will not exceed the values listed in the table above, as demonstrated by the Tests after
Completion and throughout the Operation and Maintenance Period. The actual
electrical energy usage shall be directly metered and compared to guaranteed numbers
on a monthly average basis.

15.2.2 Penalty for low Power Factor:

Penalty for low power factor shall be imposed on the contractor in case the APSPDCL
imposes the same on the Employer.

Sl. Penalty Value for each Parameter

Basis of Penalty Benchmark
No. specified in the bid document

Above 0.99 No penalty

Additional Units (kWH) will be charged to the

PF maintenance 0.95 & up to 0.9888
contractor with one-time penalty.
for H.T. Supply
pertaining to the
1
scope of work Below 0.95 & up to Additional Units (kWH) will be charged to the
contemplated in 0.90 contractor with two-time penalty.
this project
Additional Units (kWH) will be charged to the
Below 0.90 contractor with three times penalty or Termina-
tion of the contract.

15.3 Breakdown of Equipment:

In case of breakdown of equipment for more than the stipulated time period as below,
on discretion of Engineer-in-Charge, the Contractor shall be penalized as mentioned
below:

Equipment Breakdown Time Period Penalty Imposed

3% of Monthly O&M Cost
All Electro Mechanical Equipment and
beyond 48 hours i.e. 48 per day of default beyond
Instrumentation, online monitoring
hours permitted breakdown time
equipment, laboratory equipment
period
Semi-Critical Equipment

Safety Equipment

Filling of gas in safety equipment Within 24 hrs No penalty

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Equipment Breakdown Time Period Penalty Imposed

0.5% of Monthly O&M

24 hrs to 48 hrs cost

1.5% of Monthly O&M

48 hrs to 72 Hrs cost

No penalty
All safety Equipment Within 24 hrs

0.5% of Monthly O&M

24 hrs to 48 hrs cost

1.5% of Monthly O&M

48 hrs to 72 Hrs
cost

15.3.1 Penalty of Non Compliance Safety Measure, Explosive Licence and Public
Liability Insurance

Measure Time Period Penalty

Up to 2 occurrences/Month No penalty
Safety Measure
Not using PPE (Personal Protective >2 & up to 5 Occur-
Rs.1,0000/-per Occurrence
Equipment) devices, Noncompliance rences/Month
to Occupational Safety, Health & En- >5 & up to 10 Occur-
Rs.5,0000/-per Occurrence
vironment guidelines, Non-Compli- rences/Month
ance to State & Central Statutes in Rs.10,0000/- per complaint
Above 10 occur-
O&M (or) Termination of the
rences/Month
Contract
2 Days No Penalty
Double the penalty charged
Explosive License by Explossive Department
1 week
or 100000 whichever is
higher
Public Liability Insurance 2 Days No Penalty
Double the penalty charged
1 week by Insurance authority or
100000 whichever is higher

15.4 Additional Conditions:

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i. The analysis for the Plant Performance Evaluation for Commissioning Certificate,
Defects Liability Period and Operation & Maintenance, should be carried out at
the Third Party Reputed Laboratory as approved by the Engineer-In- Charge.
Note:

a. The above stated analysis requirements are in addition to the routine analysis for
commissioning or regular course of operation as per the tender document and
can be done at plant scale.
b. The Charges for the Third-Party Laboratory Testing shall be borne by the
Contractor.
c. The frequency of Sampling for
- Completion/ Commissioning – Three (03) Composite Samples per day, for
Three (03) Consecutive Days (72 Hours)
- Operation & Maintenance - Four (04) Nos. of Composite Samples on any
day (Weekly Once).
ii. The statutory Charges from APPCB / CPCB or any other Authority for any
Compliance/Liasoning should be paid by the Contractor on behalf of the Client
and would be reimbursed by the client at actual on production of proof of
payment.
iii. Any Penalty imposed by APPCB / or any other Authority for Non-compliance of
Effluent Discharge Standard/s shall be recovered from the Contractor at twice the
Penalty imposed by the above authority/(ies) on the Employer.

15.5 The KPIs will be monitored through the Sensors, PLC controlled SCADA, complaints
in the Citizen Charter of the concerned Corporation / Municipality / Department or
those observed and recorded by the officers in-charge of the project during their inspec-
tions and accordingly the contractor will be penalized in case of its non-compliance
with the above KPIs.

16.0 Biometric attendance

The agency has to show the record of 90% and above attendance of the approved or-
ganogram on monthly basis through biometric system. If the attendance record fall be-
low 90% the monthly payment shall be on prorate basis as per the attendance percent-
age. Biometric system will be connected with SCADA for attendance report generation.
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17.0 Maintenance of Civil structures

The agency shall maintain all civil structures in good condition throughout the mainte-
nance period. There shall not be any sign of leakage in any water retaining structure,
any splashing of concrete, worn out plaster, moss blisters etc. over the surface of the
building. The agency shall maintain all sanitary plumbing installation properly. Any
complaint from residents of quarters, officers/office staff, the agency shall take imme-
diate action and complete the work within 2 days. If the agency fails to attend any com-
plaint within 2 days, the agency shall be penalized. For noncompliance of the com-
plaints, deduction @ twice the expenditure incurred for rectification or Rs. 25,000/-
whichever is more shall be made from the agency bill for each incident.

18.0 Maintenance of pipelines & valves

The agency shall maintain entire pipe network and valves upto WDCs in Amaravati
capital city in god condition throughout the maintenance period. The agency shall take
immediate action on receipt of any leakages/damage in pipelines, valves and shall repair
the leakages/damages within 48 hrs (2 days) failing which the agency shall be penal-
ized. For noncompliance of the complaints, deduction @ twice the expenditure incurred
for rectification or Rs. 50,000/- whichever is more shall be made from the agency bill
for each incident.

Note: For all the complaints, rectifications etc., the online complaint redressal system
will be the basis for levying the penalties and also those observed and recorded by the
officers concerned.

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ANNEXURE - 3
RESOURCES: PERSONNEL
a. Name of Staff Technical Administrative

b. Please list names and present position of Technical Staff:

S No Name Position

c. Details of qualification and experience etc. of Technical Staff:

Name of
Nature of the pro- Date from which
Sr. Any other
Name Age Qualification Experience works jects han- in your organi-
No. remarks
handled dled and zation
cost

Note: Indicate other points, If any, to show your technical and managerial competency

Under Agency scope:

 Office space (one-room) for Engineer-in-Charge & safe storage will be provided.
 Spares for replacement as and when required.
 Boarding & lodging to his personnel.
 Medical facility & Insurance coverage.
 All tests, measuring instruments & tools with valid calibration certificate as mentioned
above. Any facility not mentioned in 'A'
 Uniform to staff.
 PC for data entry and printer for printout of technical reports.
 Safety gears like helmets, shoes and safety belts, aprons and gloves (general and insu-
lated type).
 Transport facility for Agency staff.
 Stationery as per work requirement.
 Equipment like Filter Machine.

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APPENDIX - D
MAINTENANCE SCHEDULES

D-Daily, W-Weekly, M-Monthly, QY-Quarterly, HY- Half Yearly, Y-Yearly, 2 Y- Once in 2 years, 3
Y- Once in 3 years, 4 Y- Once in 4 years, SOS - as and when required.

Always use a periodic maintenance program to ensure the best possible unit performance and effi-
ciency.

The maintenance schedules to be adopted by O & M Personnel are:

Sr. Recommended In-

Maintenance or test
No terval
1 Check pump’s rpm. D
2 Check for vibration or unusual sounds/ noise D
3 Check bearing temperature D
4 Check lubricating oil pressure/level D
5 Check for excessive generation of heat in gland D
6 Check for water leakage from gland packing D
7 Check pressure gauge readings D
8 Check position of valves D
9 Checkup no loose bolts/nuts/tighten D
Check bearing grease and lubricating oil level/deterioration.
10 M
Fill or change if necessary.
11 Check gland packing wear. M
12 Check pressure gauge readings. M
13 Adjustment/Checkup sensors, safety devices and its performance M
14 Re-tighten fastening bolts for stationary parts HY
Check flow relay, pressure switch, temperature switch (etc.) and other
15 HY
protective devices
16 Performance test. Y
17 Replace bearing grease and lubricating oil. Y
18 Replace gland packing. Y
19 Disassembly inspection Y
20 Overhaul and service unit Y

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Electrical motors
Sr. Recommended
Maintenance or test
No. Interval
1 Check for vibration or unusual sounds D
2 Check bearing temperature D
3 Check frame temperature D
Remove any dirt or debris from slip rings and brush holder
4 D
area
Check brush up/down movement, length and downward
5 M
pressure
Check bearing grease and lubricating oil levels and fill if
6 HY
necessary
7 Measure coil insulation resistance (MΩ). HY

8 Check working order of flow relays, pressure switches, and HY

temperature switch, protective devices, etc.
9 Performance test Y
10 Replace bearing grease and lubricating oil. Y
11 Terminal connection checking HY
12 Overhauling SOS

LT panels
Maintenance or test Recommended Interval
Cleaning of bus bars, insulators, etc. Y
Tightness of the connections Y

Sr. Maintenance or test Recommended Interval

No
1 Fan guard attached D
2 Fan fastened tightly to post M
3 Check fan orientation M
4 Clean fan guards HY
5 Clean motor and controls HY
6 Lubricate fans Y
7 Repaint corroded metal Y
8 Check total electrical circuit Y

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9 Cleaning of suction air filters QY

10 Check for unusual noise & vibration QY
11 Checking of all interlocks Y

TRANSFORMERS
Without shut down activities
Sr. No. Maintenance or test Recommended Interval
1 Checking of bushing oil level M
2 Checking of oil level in conservator M
3 Checking of oil level in OLTC conservator M
4 Manual actuation of cooler oil pumps and fans M
5 Checking of oil leaks M
6 Checking condition of silica gel in breather M
7 Checking of oil level in oil seal of breather M
8 Testing of oil for DGA and other oil parameters M

Shut down activities

Sr. Recommended
Maintenance or test
No. Interval
BDV, ppm of OLTC Diverter Switch compartment oil (Less fre-
1 Y
quently if operations are not more)
2 External cleaning of radiators Y
3 Cleaning of all bushings Y
4 Checking of auto starting of cooler pumps and fans Y
Marshalling boxes of transformer
(i) Cleaning of marshaling boxes of transformer Y
5
(ii) Tightening of terminators Y
(iii) Checking of Agency, space heaters, illumination, etc. Y
6 Maintenance of OLTC driving mechanisms Y
Checking of all remote indicators (WTI and Tap position indica-
7 Y
tor) and top up oil in pockets, if required
Electrical checking/testing of pressure relief device, Buchholz re-
8 lay, OLTC surge relay/checking of alarm/trip and checking/re- Y
placement of the gaskets of the terminal box
9 Checking/testing of Buchholz relay by oil draining Y
10 Frequency response analysis SOS
11 Tan measurement of bushings Y

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12 Recovery voltage measurement SOS

13 IR measurement of Windings (Polarization Index and D.A. Ratio) 2Y
14 Tan measurement of Windings 2Y
15 Checking and cleaning of diverter contacts 2Y
16 Checking and calibration of OTI, WTI 2Y
17 Measurement of Windings resistance at all tap positions 4Y
18 Filtration/degassing of main tank oil SOS
19 Testing of bushing CT’s SOS
20 Filtration/replacement of oil of OLTC SOS
21 Measurement of Windings Ratio SOS
22 Checking of earthing connections Y

Note:
(i) Insulation resistance measurement, tan delta of winding resistance at all taps
to be carried out once before expiry of warranty and then to be continued as
per schedule.
(ii) FRA at factory and during pre-commissioning is preferable to serve as base
signature.

CIRCUIT BREAKERS
Most breaker maintenance (except thermovision scanning) must be performed with equipment
de-energized.
Maintenance Schedule for Circuit Breakers:
(i) Breaker operations checks
Sr. Recommended
Maintenance or test
No. Interval
1 CB operating timings (Main, PIR, Aux.) Y
2 Static contact resistance measurement 2Y
Dynamic contact resistance (DCRM), contact travel, contact
3 2Y
speed, contact wipe, arcing contact length
4 Checking of pole discrepancy relay Y
Functional checks, duty cycle operations including rapid re-clos-
5 Y
ing (O-0.3s-CO)
Checking of all operation lock-outs including SF6 density moni-
6 Y
tor
7 Checking of all interlocks Y
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8 Checking of pressure settings Y

Cleaning of breaker interrupter, support insulators, PIRs and
9 Y
grading capacitors
(ii) Measurement/testing
Sr. Recommended
Maintenance or test
No. Interval
1 Checking of close/trip coil currents Y
2 Checking of healthiness of operation counter Y
3 Capacities and tan measurement of grading capacitors 4Y

(iii) Control cabinet

Sr. Recommended
Maintenance or test
No. Interval
1 Checking of tightness of all cable terminations in MB Y
2 Checking of door sealing gaskets and replacement, if necessary Y
3 Repainting of metallic surfaces SOS
4 Checking of space heater (before monsoon) Y

(iv) SF6 circuit breakers

Sr. Recommended
Maintenance or test
No. Interval
1 Checking of oil leaks from grading capacitors M
2 SF6 gas leakage test SOS
3 Dew point measurement of SF6 gas 3Y
4 Checking tightness of foundation bolts Y

(v) Vacuum circuit breakers

Sr. Recommended
Maintenance or test
No. Interval
1 Cleaning of control cubicle and checking for loose connections QY
Checking of ON/OFF indicator, spring charge indicator and
2 HY
Checking manual and electrical operation
Checking vacuum of interrupter by application of high voltage
3 Y
by disengaging with operation mechanism
Checking erosion of contacts by erosion mark on operation rod
4 or measurement of gap specified in closed position of contacts Y
(wherever provided)

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5 Checking tightness of foundation bolts Y

6 Replacement of vacuum interrupter SOS

(vi) Spring operated mechanism

Sr. Recommended
Maintenance or test
No. Interval
Oil leakages from close and open dashpots, replace the same if
1 Y
leakages observed
Greasing/lubrication of gears and various latches in the operat-
2 Y
ing mechanism
3 Checking of play of gaps in catch gears Y
Maintenance of spring charging motors, cleaning of carbon
4 Y
brushes and Agency
5 Replacement of oil in dashpot SOS

D) CURRENT TRANSFORMERS
Sr. Recommended
Maintenance or test
No. Interval
1 Checking of bellow expansion M
Visual inspection of CT for oil leakages and crack in insulator
2 M
etc.
3 Thermo vision scanning of CT Y
4 Checking of oil leakages in terminal box Y
5 Checking of primary connection strips, if provided externally Y
6 N2 pressure checking 2Y
7 Measurement of tan delta and capacitance 2Y*
8 I R measurement (DAR) 2Y
9 Checking of primary connection strips, if provided externally SOS
10 Measurement of CT secondary resistance SOS
11 Magnetization characteristics SOS
12 CT ratio test SOS
13 DGA and testing of other parameters of oil SOS
14 Checking of burden on the second winding SOS
*To be repeated before one year from commissioning and then as per schedule

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E) POTENTIAL TRANSFORMERS
Sr. Recommended
Maintenance or test
No. Interval
1 Checking of oil leaks M
2 Measurement of voltage at control room panel HY
3 Visual checking of earthing HF point Y
4 Checking for any breakage or cracks in cementing joint Y
5 Capacitance and Tan delta measurement 3Y*
6 Testing for EMU tank oil for BDV (if oil found discoloured) SOS
7 Checking for rust and painting SOS

*To be repeated before one year from commissioning and then as per schedule. This test is not pos-
sible to be conducted at site if isolation of neutral or immediate PT is not possible at site.

F) LIGHTNING ARRESTORS
Lightning arresters are static devices which require fairly infrequent maintenance. Most maintenance
must take place while the associated circuit is de-energized. However, crucial visual inspections and
thermovision scans can take place while energized.

Maintenance Schedule for Lightning Arrestors:

Sr. Recommended
Maintenance or test
No. Interval
Checking of leakage current (Third harmonic resistive cur-
1 Y
rent)
2 Testing of counters and leakage current meters Y
3 Cleaning of insulator Y
Checking of earth connection between surge arrester, surge
4 Y
monitor and earth
Measurement of capacitance and tan delta and IR of each
5 SOS
stack

G) BUS-BAR, WATER SUPPLY SYSTEM ILLUMINATION, ETC.

Except for thermovision scanning, bus maintenance must be conducted de-energized.
Sr. Recommended
Maintenance or test
No. Interval
1 Measurement of station earth resistance Y

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2 Cleaning of insulator Y
3 Cleaning of insulator for cracks Y
Thermovision scanning of all conductor joints, connect-
4 Y
ors/clamps, terminator
5 Removal of hot spots Y
6 De-weeding of substation SOS
7 Checking of earth connection of MOM box SOS
Repainting, rust removal of all structures, equipment,
8 SOS
etc.
9 Checking of Water supply system lighting SOS

H) PROTECTION SYSTEMS
Calibration and Periodic functional testing is recommended to ensure the integrity of protec-
tion circuits.
Sr. Recommended
Maintenance or test
No. Interval
1 Testing of DR/EL with time synchronization unit M
2 Calibration of tariff energy meters -
3 Checking of voltage (in service) for relays Y
Checking of DC logic circuits for trip and annunciations in-
4 Y
cluding timers by simulation
Calibration of panel meters (Indicating/recording instru-
5 4Y
ments along with the transducers)

(i) Bus bar protection

Sr. No. Maintenance or test Recommended Interval

1 Primary injection test SOS
2 Protection stability and sensitivity checks SOS
3 Relay and DC logic check 1Y

(To be done whenever the protection AC circuits are disturbed like addition of new feeder)

(ii) Differential relays

Sr. Recommended
Maintenance or test
No. Interval
1 Pick up current at the fixed/selected setting Y
Operation of high set element/instantaneous unit at the
2 Y
fixed/selected setting

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3 Operation of the relay at the selected restraint bias setting Y

4 Checking of 2nd harmonic current restraint feature Y
5 Operation of alarm and trip contacts Y
6 Through current stability checks on the existing load Y

(iii) Under voltage relay

Sr. Recommended
Maintenance or test
No. Interval
1 Starting and pick up of the relay as per plug setting Y
2 Relay Operating time as per relay characteristics Y
3 Operation of alarm and trip contacts Y
4 Verification of input voltage on relay terminals Y

(iv) Over voltage relay

Sr. Recommended
Maintenance or test
No. Interval
1 Starting and pick up of the relay as per plug setting Y
2 Relay Operating time as per relay characteristics Y
Operation of high set element/instantaneous unit at
3 Y
voltage setting, if applicable
4 Operation of alarm and trip contacts Y
5 Verification of input voltage on relay terminals Y

(v) Over current and earth fault relay

Sr. Recommended
Maintenance or test
No. Interval
1 Starting and pick up of the relay as per plug setting Y
2 Time of Operation as per relay characteristics Y
Operation of high set element/instantaneous unit at
3 Y
current setting, if applicable
4 Operation of alarm and trip contacts Y
5 Verification of input currents Y
6 Verification of directional feature, if applicable Y

(vi) Under frequency relay

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Sr. Recommended
Maintenance or test
No. Interval
Pick up value of the relay as its settings by slowly
1 Y
decreasing the frequency from 50 HZ
Drop off value of the relay as its settings by slowly
2 Y
increasing the frequency from pick up value
3 Verification of df/dt feature of the relay, if applicable Y
4 Operation of alarm and trip contacts Y
5 Verification of input voltage on relay terminals Y

 Local breaker back up protection, restricted earth fault (REF) and other in-
stantaneous current operated relays
Sr.
Maintenance or test Recommended Interval
No.
1 Pick up value of the relay at the selected setting Y
2 Operating time of the relay Y
3 Operation of alarm and trip contacts Y
4 Verification of input voltage on relay terminals Y
Through current stability checks on the existing
5 load in case of REF/circulating current differen- Y
tial protection

 Fuse failure relays

Sr. Recommended
Maintenance or test
No. Interval
Remove main fuse of each phase voltage input to the dis-
1 Y
tance protection scheme one by one in the relay panel
2 Checking that the “VT Fuse Fail Alarm” is received Y
3 Checking that the distance protection does not operate Y

 HT SWITCHGEAR, HT PANEL, ETC.

 HT panels

Sr. Recommended
Maintenance or test
No. Interval
1 Cleaning of bus bars, insulators, etc. Y

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2 Relays testing Y
3 Tightness of all electrical connections Y
4 Checking of indicating meters Y
5 Check for change-over facility, if provided Y
Check operation/Indications in Off-load conditions
6 Y
of VCB
7 Check spring charging of VCB Y

 HT switchgears

Sr. Recommended
Maintenance or test
No. Interval
1 Functional Checking (Trip, close, etc.) of 33/11kV CB’s Y
2 Measurement of operating timings Y
Cleaning of insulators and tightness of terminal connec-
3 Y
tions of CB’s, CT’s, PT’s, Isolators, etc.
4 Alignment Checking of isolators Y

I) TELEPHONE EXCHANGE
Sr. Recommended
Maintenance or test
No. Interval
Maintenance of EPAX as per recommen-
1 SOS
dations of the manufacturers

J) BATTERIES AND DC DISTRIBUTION SYSTEM

Battery system maintenance shall have highest priority. Computerized, online battery moni-
toring systems can greatly reduce maintenance required on battery systems and actually im-
prove battery reliability and increase battery life. Battery chargers, important to the health and
readiness of battery systems, require regular maintenance as well.
Maintenance Schedule for Batteries and DC Distribution system:
Sr. Recommended
Maintenance or test
No. Interval
1 Measurement of specific gravity and voltage of cell M
Checking electrolyte level and topping up with DM wa-
2 M
ter, if required
3 Checking of Emergency DC lightening to control Room M
4 Checking of any earth fault (If E/F relay not provided) M

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Checking of electrical connections of charger panel and

5 Y
DCDB panels for tightness and cleanliness
Checking of electrical connections for batteries and ap-
6 Y
plication of petroleum jelly on cell terminal, if required
Checking control cards of charger and measurement of
7 Y
test point voltage values
8 Battery impedance testing (Optional) Y
9 Testing of DC E/F and under voltage relays Y
10 IR measurement of charger transformer Y
11 Discharge test of battery set 3Y

K) FIRE PROTECTION SYSTEM

Compressor
Sr. Recommended In-
Maintenance or test
No. terval
1 Cleaning/replacement of air filter M
Checking of compressor oil and replace, if neces-
2 QY
sary
Maintenance and cleaning of compressor valves,
3 QY
gaskets, valve plates and replace, if necessary
4 Operation check of low oil level switch QY
Cleaning and Checking for seating of the breather
5 QY
valve
6 Cleaning of NRV/HP tank Y
7 General overhaul SOS

Fire alarm system

Sr. Recommended In-
Maintenance or test
No terval
Sequence test for annunciation in control room
1 M
panel
2 Smoke test M
3 Cleaning M
4 Battery electrolyte level checking M

Diesel engine
Sr. Recommended In-
Maintenance or test
No terval
1 Checking of auto starting of diesel engine M
2 Check oil level, top up if required M
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3 Checking/replacement of fuel oil/lube oil/air filter Y

Jockey pump
Sr. Recommended In-
Maintenance or test
No terval
1 Checking leakage and oil lubrication M
2 Pump overhauling SOS

V-belt drive
Sr. Recommended In-
Maintenance or test
No terval
1 Checking of belt tightness QY

Strainers
Sr. Recommended In-
Maintenance or test
No terval
1 Checking of oil strainer QY

Motors
Sr. Recommended In-
Maintenance or test
No terval
1 Checking of terminal connection HY

Pumps
Sr. Recommended In-
Maintenance or test
No terval
Checking of operation of hydrant pumps sump
1 M
pumps, jockey pumps
Adjustments of glands for leakages and tightening
2 HY
of nuts and bolts
3 Checking of alignment of pump set Y
4 Replenishment of grease SOS
5 Overhauling SOS

Hydrant system
Sr. Recommended
Maintenance or test
No Interval

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Checking of pressure of the hydrant system, at the

1 remotes end, auto starting of pumps, diesel engine, Y
etc.

Deluge system
Sr. Recommended
Maintenance or test
No. Interval
Operation of deluge system, check outlet pressure,
1 check alarm, check starting of diesel/electrical Y
pumps

Electrical panels
Recommended
Sr. No. Maintenance or test
Interval
1 Cleaning and tightening of terminals Y

General
Recommended
Sr. No. Maintenance or test
Interval
1 Greasing of all values HY
Painting of pipes, air lines, marshaling
2 SOS
box

Fire extinguishers
Sr.
Maintenance or test Recommended Interval
No.
1 Re-filling of fire extinguishers SOS

LT SWITCHGEAR, LT TRANSFORMER, LT PANEL, ETC.

LT panels
Sr. Recommended
Maintenance or test
No. Interval
1 Cleaning of bus bars, insulators, etc. Y
2 Relays testing Y
3 Tightness of all electrical connections Y
4 Checking of indicating meters Y
5 Check for change-over facility, if provided Y

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Check operation/Indications in Off-load con-

6 Y
ditions of air CB
7 Check spring charging of air CB Y

LT switchgears
Sr. Recommended
Maintenance or test
No. Interval
Functional Checking (Trip, close, etc.) of
1 Y
ACB’s, MCCB’s & MCB’s
2 Measurement of operating timings Y
Cleaning of insulators and tightness of terminal
3 Y
connections of CB’s, CT’s, PT’s, Isolators, etc.
4 Alignment Checking of isolators Y

LT transformers
Sr. Recommended
Maintenance or test
No. Interval
1 Testing of oil BDV Y
2 IR measurement Y
Testing/Checking of OTI, WTI and Buchholz (if
3 provided) Y
Checking healthiness of pressure relief dia-
4 phragm Y
5 Checking healthiness of Buchholz relay Y
6 Checking tightness of earthing connections Y

L) ANNUNCIATORS
Annunciators provide essential Switchyard condition status information to O&M
personnel. Two aspects must be considered:
 correct operation of the annunciator itself and
 integrity of the alarm devices and interconnected wiring.
Annunciator operation is easily tested using the “Test” button provided on most an-
nunciators and is considered an “operations” activity. Verifying integrity of the alarm
devices and interconnecting wiring requires a “functional test” of these circuits. Func-
tional testing is accomplished by
 resetting the annunciator,

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 closing (or opening) contacts at the alarm device, and

 verifying that the correct annunciator window is activated.

Maintenance Schedule for Annunciators:

Sr. No. Maintenance or test Recommended Interval

Each shift - staffed
1 Operational test
Each visit - unstaffed
2 Functional test Y

M) CABLES
Maintenance tests can detect problems in cables that are approaching failure without acceler-
ating the insulation deterioration process due to operational or environmental conditions. Ex-
cept for infrared scanning, de-energize the cable circuit before maintenance.

Maintenance Schedule for Cables:

Sr. Recommended
Maintenance or test
No. Interval
1 Equipment Ratings 5Y
2 Visual inspection of cables M
Checking and recording or IR values of all ca-
3 M
bles with megger of suitable range.
Checking all cable terminals & joins for over-
4 hauling / loose connections and tightening, ter- M
minating, rejoining, if required

N) EARTHING SYSTEM
Sr. Recommended
Maintenance or test
No. Interval
Checking of all earthing connections, joints and
1 QY
cleaning and tightening thereof
2 Putting adequate quality of water in earth pits. QY
Checking and recording of earth resistance of all
3 points, pits and taking corrective action to im- QY
prove it, if required.
Sr. Recommended
Maintenance or test
No. Interval

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Checking of each meter (analog/digital) for its

1 Y
correct operation
2 Calibration of indicating meter. M

O) SCADA SYSTEM
Sr. Recommended Inter-
Maintenance or test
No. val
Pneumatic Systems/Components/Instruments
1 Check Regulators and Filters M
2 Inspect Tubing and Piping M
3 Valve Actuators servicing M
4 Actuate Pressure Switches QY
5 Calibrate Switches and Sensors HY
HY
6 Calibrate Pressure Gauges
HY
7 Calibrate Level Transmitters
HY
8 Calibrate Flow transmitters
HY
9 Calibrate Pressure Transmitters
Calibrate Temperature transmitters, Vibra-
10 tion & bearing monitoring sensors HY
Electronic Systems
11 Verify Alarms W
12 Inter site Communication Network W
13 UPS setting with SCADA W
14 Network Redundancy W
15 Lamp Test/Verify Indicators M
16 Inspect Enclosures for Dirt, Water, Heat M
17 PLC Communication Modules M
18 Test Automatic Control Sequences M
19 Anti-virus Definition Updates M
20 Inspect Wire, Cable and Connections M
21 Communication Interface, Interface Panel M
22 PLC Redundant Power back up M
23 SCADA Redundancy M

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24 PLC Hot-Standby M
Historian Package & ODMS package
25 (Storage & archiving Capacity) M
26 General Data Archiving M
27 Run PLC Diagnostics QY
28 Software Maintenance and Patching QY
29 Dead Bus Relays QY
30 Calibrate Sensors and Transmitters HY
31 RTU Batteries HY
32 Calibrate Meters Y
33 PLC Batteries Y

TYPICAL TROUBLE-SHOOTING
Parameters Description

Higher /lower discharge rates, extra pump operation

System/operation to make up the flow, Overflows, Pump cavitations,
excess power consumption, water hammer, etc.
Unit process (Me- Power switch, Mechanical performance, Over load,
chanical) Noise, Vibration, etc
Transformers, Meters, Over load-Motors, Moisture
Unit process (Elec-
cut heaters, Overload protection, Wiring and con-
trical)
nection, Lamp test etc
Handling any accidents, its emergency meas-
Precaution, Safety &
ure/first-aid treatment, Handling heavy load, Physi-
Health
cal damage, Shock hazard, etc

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Appendix E – Mandatory spares

A) PUMPS
Sl.
Description of Equipment Quantity
No
(For each model/ capacity)
1 Pump Impeller 1
2 Pump bearings 1 set
3 Shaft sleeve 1 set
4 Shaft 1 set
5 Gaskets, dust seals and ‘O’ rings 2 sets
6 Motor 1 No.
7 VFD Drive 1 No.
8 Wearing rings 1 set
9 Nut and bolts etc. 2 sets
10 Mechanical Seals 2 sets
11 Couplings 1 set

B) DOSING PUMPS & ALUM AGITATOR

Sl.
Description of Equipment Quantity
No
1 Dosing pumps and drives 1 No. of each type and size
2 Agitator motor 1 No. of each type and size
3 Reduction gear assembly 1 No. of each type and size
4 Strainers 1 No. of each type and size
5 Valves 1 No. of each type and size

C) FLOCCULATOR
Sl. No Description of Equipment Quantity
1 Dosing pumps and drives 1 No. of each type and size
2 Agitator motor 1 No. of each type and size
3 Reduction gear assembly 1 No. of each type and size
4 Strainers 1 No. of each type and size
5 Alum strainer 1 No. of each type and size
6 Valves 1 No. of each type and size

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D) BLOWER

Sl. No Description of Equipment Quantity

1 Motor 1 No. of each type and size
2 Blower assembly 1 No. of each type and size
3 V belt/coupler 1 No. of each type and size
4 Air strainer 1 No. of each type and size
5 Valves 1 No. of each type and size

D) AIR CONDITIONING UNITS & VENTILATION FANS

Sl.
Description of Equipment Quantity
No
1 (For each model/ capacity) For each type & capacity
2 Indoor & outdoor unit 1 set
3 Copper tube 15 Rmt
4 Ventilation fan 1 set
5 Filters 4 sets

E. Electricals

Sl. No Description of Equipment Quantity

Modulating motor for face & by-
1 1 no for each type
pass damper - for this package.
Modulating motor for each type of
2 1 No
valve

F) VALVES
SI. No. Description Quantity
(for each type and size)
One (1) no. where total quantity of a particular type and size of valve is less than or equal to ten
1 (10).
Two (2) nos. where total quantity of a particular type and size of valve is less than 40 but more than
2 10.
10% of the total quantity (to nearest whole no. of a particular type and size where the total quantity
3 of a particular type and size of valve is more than 40.

G) VARIABLE FREQUENCY DRIVE (VFD) SYSTEM (IF APPLICABLE)

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SI. No. Description Quantity

1 Electrical cards
2 Nos. of each type and rat-
a Control modules
ing
2 Nos. of each type and rat-
b I/O module
ing
Power supply modules Thyris- 2 Nos. of each type and rat-
c
tor gate module including gate ing
d transformer 100% of installed quantity
e Exciter module 1 No.
2 Thyristor bridge leg 10%
Over voltage limiter and surge
3 2 sets
suppressor network
Semiconductor fuses for thy-
4 1 set
ristor
5 Power and control fuse 100% of installed quantity
6 Control transformer 1 No. of each type and rating
7 Contactor/ breaker 2 nos.
8 CT/VT 1 No. of each type and rating
9 Indicating lamps 100% of each type and rating
Auxiliary contactors and re-
10 15% of installed quantity
lays
11 Panel mounted meters 1 no. of each type and rating
12 Panel mounted printer 1 no.
13 Indicating lamp holder full set 15% of each type/colour
14 Parameter tuning device 1 no.
15 LT transformer (VFD)
Bushings with metal parts and Primary 3 nos. each rating
a
gaskets Secondary 3 nos. each rating
Winding temperature indicator
b 1 no.
with alarm and trip contacts
Oil temperature indicator with
c 1 no.
alarm and trip contacts
d Magnetic oil level gauge 1 no.
e Pressure relief device 1 no.
f Diaphragm for explosion vent 1 no.

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Buchholz relay/ sudden pres-

g 1 no.
sure relay (as applicable)
h Silica gel charge 3 charge
Floats with contacts for buch-
i 1 set
holz relay
j Set of gaskets 2 sets
k Contacts tap changer 1 set
l Set of valves 1 set
Pressure gauge (applicable for
m 1 no. each type
sealed tank)

n Set windings for one limb in a 1 for each rating

suitable oil container

H) MEASURING INSTRUMENTS
SI.
Description Quantity
No.
1 Electronic transmitters
Transmitters of all types, ranges and model no. (for
10% or 2 no. of each type and
a the measurement of Pressure, differential pressure
model, whichever is more
flow, level, etc.)
Electronic cards / PCB’s for each type and model 10% or 5 nos. of each type,
b
and model of transmitters whichever is more
2 Temperature Elements
a RTDs* of each type & length 10% or 2 nos. whichever is more
Thermocouples of each type like K-type, R-type,
b 10% or 2 nos. whichever is more
metal etc. and length *
c Cold junction compensation boxes of each model 10% or 2 nos. whichever is more
d Thermostatic units for each model 10% or 2 nos. whichever is more
e Thermo wells 10% or 2 nos. whichever is more
5% or 1 no. of each make, model
and type whichever is more (to
Local Indicators like temperature, pressure, differen-
3 be divided to various ranges in
tial pressure, flow gauges and flow meters etc.,
proportion to main of all make,
model, type population)
Process actuated switch devices including all types
5% or 1 no. of each type and
4 of pressure, differential pressure, flow, temperature,
model whichever is more
differential temperature, level switch devices.
5 Indicators/Recorders

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Digital Indicators of each model, type & range (in-

10% or 2 nos. min. whichever
a cluding relevant is digital indicators of electrical
more
system)
5% or 1 no. of each model
b Vertical Indicators of each type & model
whichever is more.
c Recorders for each type and model 5% or 1 no. whichever is more
25 rolls per recorder/ 25 nos. per
Consumables for continuous recorders Charts Ink
d recorder/ 20 nos. per recorder /
capsules
Ink Pads/Pens
e Consumables for multi-point recorders
5 nos. per recorder
• Charts
5 nos. per recorder
• Ink pads
10% or 5 nos. of each type
• Print mechanism/ print head assembly
whichever is more.
f Level transmitters (displacer type)
5% or 1 no. whichever is more
for each type and model
• Electronic cards / PCB’s of level transmitters
5% or 1 no. of each type, dis-
• Level transmitters
placer, length and model which-
ever is more
5% or 1 set of each type and
g PD type flow transmitters
model whichever is more

I) TRANSFORMERS

SI. No. Description Quantity

1 Bushings 1 No. of each type
2 Oil cooler pumps with motor 1 set
3 Gaskets and ‘O’ rings 1 set
4 Expansion joint 1 set
5 Buchholz relay 1 No
6 Local winding temp. indicator 1 No
Remote winding temp. indicator with sensing de-
7 1 No
vice and matching unit
8 Oil temp. indicator with contacts 1 set
9 Pressure relief device 1 No
10 Magnetic oil level gauge 1 No
11 Cooler fan with motor 1 No
12 Set of valves 1 set

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Set of starters, contactors, relays and switch for

13 1 set
electrical control panel
14 Remote tap position indicator 1 No
15 Oil flow indicator with flow switch 1 No
16 Diaphragm/air cell for conservator 1 No
17 Breather assembly for conservator and OLTC 1 set
18 Terminal connector 1 set
19 Motor operating mechanism assembly for OLTC 1 set
20 Oil surge relay for OLTC 1 No
Auxiliary transformer for control power for cooler
21 1 No
control cabinet
22 Transformer Oil 2 KI

J) SF6 CIRCUIT BREAKERS

SI. No. Description Quantity

One pole of circuit breaker with closet resistor and
grading capacitor complete with pole column and in-
1
terrupter with M.B. but without support structure and
operating mechanism
2 Rubber gaskets, ‘O’ rings and seals 1 set
3 Trip coils with resistor 6 Nos
4 Closing coils with resistor 6 Nos
5 Terminal pads and connectors 3 Nos
6 Molecular filter 3 Nos
7 Density/pressure monitoring systems (if applicable) 1 No.
8 Corona rings 1 No.
Relays, power contactors, switch fuse units, limit
9 1 Set
switches, push buttons, timers and MCB, etc.
10 Closing assembly/valve 1 Set
11 Trip assembly/valve 1 Set
12 Pressure switches 1 set
13 Pressure gauge and coupling 1 set
14 SF6 gas 20 % of the total qty.
15 Auxiliary switch assembly 1 set
16 Operation counter 1 No.

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K) Spring Operated Closing Mechanism

SI. No. Description Quantity

1 Closing dashpot 1 Set
2 Tripping dashpot 1 Set
3 Opening catchgear 1 Set
4 Closing catchgear 1 Set

L) CURRENT TRANSFORMER

SI. No. Description Quantity

1 Complete CT 1 No of each type
2 Terminal connectors 1 No
3 Primary Terminal bushings 1 Set

M) VOLTAGE TRANSFORMER
SI. No. Description Quantity
1 Complete PT 1 No
2 Terminal connectors 1 No

N) SURGE ARRESTOR
SI. No. Description Quantity
1 Complete LA with insulating base 1 set
2 Surge counter and accessories 1 set

O) FIRE PROTECTION SYSTEM

SI. No. Description Quantity
1 HVW spray pumps shaft sleeves 3 Sets
2 Diesel engine drive self-starter 1 Set
3 Shaft sleeves for hydrant pumps and jockey pumps 1 No
4 Grand packing for hydrant pumps and jockey pumps 1 Set
5 Quartzoid bulb detectors 10 % of population
6 Projectors (Merxles) 10 %
7 Smoke detectors 10 %
8 Heat detectors 10 %

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9 Deluge valve 1 set

10 Isolation valve 1 set
11 Annunciation printed circuit boards 1 No
12 Strainer 1 Set
13 Level switch 1 No
14 Safety Valve for hydro pneumatic system 1 No
12 Pressure switch 1 No
13 Bronze pipe fitted with nozzle and guide coupling 1 No
14 Hydrant Valve 1 No

P) BATTERIES AND BATTERY CHARGER

SI. No. Description Quantity

1 Spare battery cell without electrolyte 5 Nos
2 Terminator connectors with bolts and nuts 5 Nos
3 Float level indicators 10 Nos
4 Vent plugs 10 Nos
5 Set of control cards for charger 1 set

6 Set of relays 10% of total num-

ber of relays
7 Smoke detectors 1 No
8 Rectifier transformer 1 set
9 Control transformer 1 Set
10 Series inductor 1 Set
11 Micro-switches 1 Set
12 Filter capacitors 1 Set
13 Thristor/diode 1 Set
14 Set of switches 1 Set
15 Set of wound resistors 1 Set
16 Potentiometers 1 Set
17 Fuses of thyristor with indicators 2 Sets

Q) C&R PANELS
SI. No. Description Quantity
1 Main relay, Aux. relay 1 No. of each type
2 Timers and relays 10% of the total used

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Amaravati Development Corporation Limited

1 No of each type
3 PLC’s
PLC

4 I/O Cards 20% of total I/O

Cards used
5 Any Converters (Media, Power supply, etc) 2 No of each type
2 No of HMI loaded
6 HMI with all necessary
software’s
7 Over-voltage relay 1 No
8 Reactor REF (restricted earth fault) relay 1 No
9 Transformer differential relay 1 No
10 Transformer REF relay 1 No
11 Master trip relay and flag relay 1 Set
12 Switches, push-buttons and sockets (male and female) 1 Set
13 Meters with transcuders 5 No
14 Power supply module for all protective relay 1 Set
15 Metrocil (Nonlinear resistor) 1 Set
16 Interposing CT’s, PT’s etc 1 No
17 Panel indication lamp along with complete accessories 5 Nos
18 PT voltage changeover relay 1 No
19 Panel lamp and annunciation facia window lamps 50 Nos

R) L.T. SWITCHGEAR

SI. No. Description Quantity

1 Relays 1 set
2 CT’s and PT’s 2 sets
3 Switches, push-buttons and meters 1 set
4 TPN Switches/MCB 1 set
5 Spring charging motor for L.T. breaker 2 Nos
6 Aux. contact sets 1 set
7 Busbar seal off insulators 2 sets
8 Arc-chutes 1 set
9 Moving contacts 1 set
10 Arching contacts (fixed/moving) 1 set
11 Springs (closing/opening) 1 No

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12 Closing coil 2 Nos

13 Tripping oil 2 Nos
14 Aux. finger contact 1 No
15 Limit Switches 1 Set
16 Jaw contacts 1 Set
17 Busbar insulators 5 Nos
18 Interphase barrier 2 Nos
19 Bus bar strip (aluminum) 5 Mts

S) LIGHTING

SI. No. Description Quantity

1 Fluorescent tube set complete unit 10%
2 Sodium vapour/mercury vapour lamps unit 10%
3 Incandescent lamp complete fittings of all types 10%
4 Single pole MCB 2% of each rating
5 Triple pole MCB 2% of each rating
6 Switches and sockets 5%
7 Junction box 2%

T) CONTROL AND POWER CABLES

SI. No. Description Quantity
1 Power cables upto 185 mm square 500 mts
2 Power cables more than 185 mm square 250 mts
3 Control cables 5/10/19 crore 2.5 sq.mm 1000 mts each
4 Control Cables single core 1.5 sqmm 1000 mts each

U) STATION AUXILIARY SUPPLY

SI. No. Description Quantity
1 Transformer bushings 1 Set
2 Lightning arrestor 1 No
3 Clamps and connectors 1 Set
4 Complete isolator assembly for one phase 1 No
5 OTI and WTI with sensing device 1 Set
6 Tap changer contacts

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7 Buchholz relays 1 No
8 Explosion vent diaghram 1 No
9 Silicagel container 1 No

V) 6.6kV BREAKERS

SI. No. Description Quantity

1 Closing coil 1 No
2 Tripping oil 1 No
3 Aux. contact sets 1 No

W) BUS BAR ASSEMBLY

SI. No. Description Quantity

1 Al.Pipe bus 4” Dia 10 mts
2 Rigid connectors 10 Nos
3 Sliding connectors 5 Nos
4 Pipe to twin moose T-connectors 5 Nos
5 Double tension hardware with insulators 1 No
6 Suspension hardware with insulators 1 Set
7 T-connectors for conductor 10 Nos
8 Yard marshaling box 1 No
9 Spacers 10 Nos
10 PG clamps, other clamp and connectors 10 Nos
11 Corona bell 3 Nos

W) Tools & Testing Kits

S.No Description Quantity
1 Megger5 kv , Make-Fluke 2 No
2 Megger 1kv, Make-Fluke 2 No
Multi Meters with facility to measure DC mA,
3 5 No
Make-Fluke
4 Tong Testers 5 No
5 Fluke 725 Multi-Function Calibrator 2 No
6 Testing kits, Make-Omicron or equivalent 1 Kit for each
7 Zero voltage detector 1 Kit
Tool Kits for each Division (Electrical, Me-
8 2 Kits For each
chanical, SCADA), Make - Gedore
9 Earth Resistance measurement Kit 1 kit
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Note: The mandatory spares listed above are the minimum required, Agency shall update the same
for the satisfactory functioning of the system as per the instructions from EIC and final Spare list
shall be prepared by the Agency with prior approval from EIC and submitted.

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APPENDIX G

LABOUR REGULATIONS FOR OPERATION & MAINTENANCE

1. Working Hours
 Number of hours of work which shall constitute a normal working day:
The number of hours which shall constitute a normal working day for an adult shall be
EIGHT hours. The working day of an adult worker shall be so arranged that inclusive
of intervals, if any, for rest, it shall not spread over more than twelve hours on any day;
when an adult worker is made to work for more than EIGHT hours on any day or for
more than FORTY-EIGHT hours in any week, he shall, in respect of overtime work, be
paid wages at double at ordinary rate of wages.

 Weekly day or rest:

Every worker shall be given a weekly day of rest which shall be fixed and notified at
least TEN days in advance. A worker shall not be required or allowed to work on the
weekly rest day unless he has or will have a substituted rest day, on one of the five days
immediately before or after the rest day. Provided that no substitution shall be made
which will result in the worker working for more than ten days consecutively without
a rest day for a whole day.
Where in accordance with the foregoing provisions a worker works on the rest day and
has been given a substituted rest day he shall be paid wages for the work done on the
weekly rest day at the overtime rate of wages.

NOTE: The expression "ordinary rate of wages" means the fair wage the worker is entitled to.

2. Display of notice regarding Wages, Weekly Day of Rest etc.

The Agency shall, before he commences his work on Contract, display and correctly
maintain and continue to display and correctly maintain in a clean and legible condition
in conspicuous places on the works, notice in English and in the local Indian Language
spoken by majority of workers, giving the rate of fair wages, the hours of work for
which such wages are payable, the weekly rest days workers are entitled to and name

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and address of the Inspecting Officer. The Agency shall send a copy each of such no-
tices to the Inspecting Officers.
3. Fixation of Wage Periods
The Agency shall fix wage periods in respect of which wages shall be payable. No wage
period shall normally exceed one week.

4. Payment of Wages
a. Wages due to every worker shall be paid to him direct. All wages shall be
paid in current coins or currency or in both.
b. Wages of every worker employed on the Contract shall be paid where the wage
period is one week, within THREE days from the end of the Wage period; and in
any other case before the expiry of the 7th day from the end of the wage period
c. When employment of any worker is terminated by or on behalf of the Agency, the
wages earned by him shall be paid before expiry of the day succeeding the one on
which his employment is terminated.
Payment of wages shall be made at the work site on a working day except when the
work is completed before expiry of the wage period, in which case final payment shall
be made at the work site within 48 hours of the last working day and during normal
time.
NOTE: The term "working day" means a day on which the work on which labour is
employed, is in progress.

5. Register of Workmen
A register of workmen shall be maintained in the Form appended to these regulations
and kept at the work site or as near to it as possible, and relevant particulars of every
workman shall be entered therein within THREE days of his employment. (Ref. Form
4)

6. Employment Card
The Agency shall issue an employment card in the Form appended to these regulations
to each worker on the day of work or entry into his employment. If a worker already
has any such card with him issued by the previous Authority, the Agency shall merely

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Amaravati Development Corporation Limited

endorse that Employment Card with relevant entries. On termination of employment

the Employment Card shall again be endorsed by the Agency.

7. Register of Wages etc.

A Register of Wages-Cum-Muster Roll in the Form appended to these regulations shall
be maintained and kept at the work site or as near to it as possible. (Form 6)
A wage slip in the Form appended to these regulations shall be issued to every worker
employed by the Agency at least a day prior to disbursement of wages.

8. Fines and deductions which may be made from Wages

Wages of a worker shall be paid to him without any deduction of any kind except the
following:
i. fines;
ii. deductions for absence from duty; i.e. from the place of his employment he is
required to work. The amount of deduction shall be in proportion to the period
for which he was absent;
iii. deduction for damage to or loss of goods expressly entrusted to the employed
person for custody, or for loss of money which he is required to account for,
where such damage or loss is directly attributable to his neglect or default;
iv. deductions for recovery of advances or for adjustment or overpayment of wages,
Advance granted shall be entered in a register; and
v. any other deduction which the Institute may from time to time allows.
vi. No fines shall be imposed on any worker say in respect of such acts and omis-
sions on his part as has been approved by the Chief Labour Commissioner.
vii. No fine shall be imposed on a worker and no deductions for damage or loss shall
be made from his wages until the worker has been given an opportunity of show-
ing causes against such fines or deductions.
viii. The total amount of fines which may be imposed in anyone wage period on a
worker shall not exceed an amount equal to three paise in a rupee of the wages
payable to him in respect of that wage period.
ix. No fine imposed on a worker shall be recovered from him in installments, or
after expiry of sixty days from the date on which it was imposed. Every fine

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Amaravati Development Corporation Limited

shall be deemed to have been imposed on the day of the act or omission in re-
spect of which it was imposed.
x. The Agency shall maintain both in English & the local Indian language a list,
approved by the Chief Labour Commissioner, clearly stating the acts and omis-
sions for which penalty or fine may be imposed on a workman and display it in
a good condition in a conspicuous place on the work site.
xi. The Agency shall maintain a register of fines and the register of deductions for
damage or loss in the Forms appended to these regulations which shall be kept
at the place of work.

9. Register of Accidents:
The Agency shall maintain a register of accidents in such form as may be convenient
at the work place.
i. Preservation of Registers
The Register of workmen and the Register of Wages – cum - Muster Roll required to
be maintained under these Regulations shall be preserved for 3 years after the date on
which the last entry is made therein.
ii. Enforcement
The Inspecting Officer small either on his own motion or on a complaint received by
him carry out investigations, and send a report to the Engineer-in-Charge specifying
the amounts representing Workers' dues and amount of penalty to be imposed on the
Agency for breach of these Regulations, that have to be recovered from the Agency,
indicating full details of the recoveries proposed and the reasons therefore. It shall be
obligatory on the part of the Engineer-in-Charge on receipt of such a report to deduct
such amounts from payment due to the Agency.

10. Disposal of amounts recovered from the Agency

The Engineer-in-Charge shall arrange payment to workers concerned within FORTY-
FIVE days from receipt of a report from the Inspecting Officer except in cases where
the Agency had made an appeal under Regulation 16 of these Regulations. In cases
where there is an appeal, payment of workers dues would be arranged by the Engineer-

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Amaravati Development Corporation Limited

in-Charge, wherever such payments arise, within THIRTY days from the date of receipt
of the decision of the Regional Labour Commissioner (RLC).
a. Welfare Fund
All moneys that are recovered by the Engineer-in-Charge by way of workers dues,
which could not be disbursed to workers within the time limit prescribed above, due to
reasons such as whereabouts of workers not being known, death of workers, etc. and
also amounts recovered as penalty, shall be credited to a Fund to be kept under the
custody of GIFT for such benefit and welfare of workmen employed by Agency.
b. Appeal against decision of Inspecting Officer
Any person aggrieved by a decision of the Inspecting Officer may appeal against such
decision to the Regional Labour Commissioner concerned within THIRTY days from
the date of the decision, forwarding simultaneously a copy of his appeal to the Engi-
neer-in-Charge. The decision of the Regional Labour Commissioner shall be final and
binding upon the Agency and the workmen.
c. Representation of parties
A workman shall be entitled to be represented in any investigation or enquiry under
these Regulations by an officer of a registered trade union of which he is a member or
by an officer of a Federation of Trade Unions to which the said trade union is affiliated
or where the workman is not a member of any registered trade union, by an official of
a registered trade union, connected with, or by any other workman employed in, the
industry in which the worker is employed.
A Agency shall be entitled to be represented in any investigation enquiry under these
Regulations by an officer of an association of Agency of which he is a member or by
an officer of a Federation associations of Agency to which the said association is affil-
iated where the Agency is not a member of any association of Agency, by an officer of
association of Authoritys, connected with, or by any other Authority engaged in, the
industry in which the Agency is engaged.
No party shall be entitled to be represented by a legal practitioner in investigation or
enquiry under these Regulations.
d. Inspection of Books and other Documents

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Amaravati Development Corporation Limited

The Agency shall allow inspection of the Registers and other documents prescribed
under these Regulations by Inspecting Officers and the Engineer-in-Charge or his au-
thorised representative at any time and by the worker or his agent on receipt of due
notice at convenient time.
e. Interpretation etc.
On any question, as to the application interpretation or effect of these Regulations, the
decision of the Chief Labour Commissioner or Deputy Chief Labour Commissioner
(Central) shall be final and binding.
f. Amendments
Central Government may from time to time, add to or amend these Regulations and
issue such directions as it may consider necessary for the proper implementation of
these Regulations or for the purpose of removing any difficulty which may arise in the
administration thereof.
LIST OF DOCUMENTS AND SUBMITTAL
S. No. Items
1 4-Sets of Technical Literature
2 Performance Guarantee
3 All Permits/ Licenses
4 Technical Data
Manufacturer’s Certificates, Drawings, Catalogues & Pamphlets & Other Docu-
5
ments
6 Material submittals
7 Material inspections/ installation inspections
8 Nonconformance reports
9 Factory tests/ calibration tests etc.
10 Material safety data sheets
11 Spare parts list
12 Shop Drawings
13 Electrical Installation Certificate
14 Results of Summer & Monsoon Tests.
15 Operating Instructions & Maintenance Manual
16 Balancing, Testing, and Commissioning Reports
17 Training Modules and certificate
18 Guarantee
19 Quality Assurance Plan
20 List of subAgency, supplier and superintendents
21 Project Schedule
22 Construction Methodology

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23 Total Estimated Power & Water Requirement

Note:
(i) Soft copies of the above shall also be provided on CD or media as approved by
Engineer-in-Charge. All drawings shall be in AutoCAD format.
(ii) The above list is only for guide line of the Agency. The Agency shall thoroughly
check all the documents and submittals required as per the tender documents and
submit them in time as per the requirement.

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Amaravati Development Corporation Limited

SECTION - IX
Special Conditions of Contract
1. GENERAL

1.1 Extended Scope of the Contract

The contract comprises the planning, designing, drawing, supplying materials and
equipment, construction, testing of Intake, WTP, Clear Water Reservoir-cum-Pumping
Station and GLSRs at WDCs, trial run for three months and maintenance for a period
of ninety-six months upon completion of the works and commissioning and except in
so for as the contract otherwise provides, the provision of all labour, materials, con-
structional plant, temporary works and everything (whether on a temporary or perma-
nent nature) required in and for such planning, design, construction, completion and
maintenance so far as the necessity for providing the same in specified in or reasonably
to be inferred from the contract.

1.2 Store Shed

The Agency shall provide at his own cost a store shed of adequate capacity for storing
materials. The shed shall be of such construction that it must protect the materials
against deterioration. A raised platform well above the highest flood level (+21.5m)
shall be made for stacking cement in such a way that the cement received earlier can be
consumed first to avoid deterioration due to prolonged stacking. If any modifications
to the store shed is suggested by the Engineer-in-Charge for better storing of materials
that shall be carried out by the Agency at his own cost.

1.3 Land for Agency Establishment

For constructing Agency Store yard, godowns, site office and ancillaries, he may utilize
portion of the land belonging to the Authority at such location as would not interfere to
execute other co-works. For all these, the Agency shall have to obtain the requisite per-
mission of the Engineer-in-Charge. The Agency shall for this purpose submit to the
Engineer-in-Charge for his approval a plan of the proposed layouts for the site facilities.
The Engineer-in-Charge reserves the right to alter and modify the Agency proposals as
the Engineer-in-Charge may deem fit.

1.4 Water and Electricity for Construction

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Amaravati Development Corporation Limited

1.4.1 The Agency shall have to make his own arrangement for supply of water and for elec-
trical power that may be required for or regarding the works. No payment on this ac-
count shall be entertained. However, Authority may assist in getting power.

1.4.2 Water may be available from the Authority from a designated point as directed by the
Engineer-in-Charge. The Agency shall have to arrange for the necessary equipment and
labour, such as, pumps, valves, pipeline, storage facility etc. and as well as the connec-
tion with the existing source at his own cost. The Agency shall have to provide a water
meter of approved make at the delivery pipeline, which may be available from the Au-
thority, if stock is available. The Agency shall pay for the water at a rate designated for
industries. If arrangement for supply of piped water supply shall not be possible, the
Agency shall have to make arrangement for supply of drinking water and water required
for construction works by sinking tube wells or other suitable alternatives. The Tender-
ers shall investigate this matter during site inspection before submission of tenders. No
payment shall be entertained on this account.

1.4.3 Nevertheless, electrical power from usual supply agencies may not be continuously
available due to various reasons including load shedding. In case of non-availability of
electrical power, the Agency shall have to make his own arrangements for electrical
power through DG set. Agency shall include such aspects while quote his rate. No pay-
ment shall be entertained on this account. When drawing power from the AP-
TRANSCO’s electric power source, the Agency shall have to bear the cost of electrical
charges at a rate fixed by this Authority. The route of conveyance shall be subject to
approval by the Engineer-in-Charge and shall be in accordance with I.E. Rules.

1.5 First-Aid Facilities

The Agency shall arrange for medical attentions to be promptly available when neces-
sary. He shall for this purpose provide a number of First-Aid stations at suitable loca-
tions within easy reach of the workmen and other staff engaged in the Works. Each
First-Aid facility shall be properly equipped and shall remain in charge of a suitably
qualified person. The Agency shall also provide for transport of serious cases to the
nearest hospital. All these arrangements shall be to the approval of the Engineer-in-
Charge.

1.6 Fire Fighting Arrangement

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The Agency shall provide suitable arrangement for firefighting. For this purpose, he
shall provide requisite number of Fire-Extinguishers and adequate number of buckets,
some of which are to be always filled with sand and some with water. This equipment
shall be provided at suitable prominent and easily accessible places and shall be
properly maintained.

1.7 Safety Measures

The Agency shall be responsible for the safety of all workmen and other persons enter-
ing or in the works and shall at his own expense and to the approval of the Engineer-
in-Charge, take all measures necessary to ensure their safety.

Such measures shall include the provisions of helmets (specially where work at a height
is involved), provision of gum-boots to workers engaged in cement concrete or other
works. Scaffolding or other measures required for working at a height, shall be strong
and rigid and must be provided with suitable and convenient access. Shoring required
for deep excavation must be adequate and rigidly braced and strutted. Other safety
measure that the Engineer-in-Charge may direct, depending on the exigencies of the
location and nature of work and other relevant factors, shall be provided by the Agency.

1.8 Supervisory Staff

The Agency shall engage an experienced and qualified Site Manager to be in day to day
charge of the work and he shall be authorized to receive instructions from the Engineer-
in-Charge. He shall receive orders given by the Engineer-in-Charge from time to time
and shall act on them promptly. The Agency shall, during working hours, maintain En-
gineers and supervisors of sufficient training and experience to supervise the various
items and operations of the work. Orders and directions given to such Engineer-in-
Charges and supervisors or other staff of the Agency shall be deemed to have been given
to the Agency. The Chief Engineer of the Agency responsible for this work, by whatever
designation he may be known, but who shall be specified on award of the Contract shall
at least once in a fortnight inspect the works and shall discuss with the Engineer-in-
Charge the conduct and progress of the work.

1.9 Joint Survey

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The Agency shall satisfy himself regarding the correctness of the layouts, levels etc. as
are shown in the drawings or given in the specifications. Before starting the work, he
shall also carry out at his own cost, survey of the whole work site jointly with the rep-
resentative(s) of the Authority. Discrepancies noticed between drawings and the joint
survey shall be informed in writing to the Engineer-in-Charge and got set right before
execution of works. Such deviations as may arise out of the joint survey shall not vitiate
the provisions of contract or entitle the Agency to any extra claim in any way.

1.10 Layout and Checking

The Agency shall provide all labour, skilled and unskilled and all materials needed for
carrying out, as directed, survey, laying out, setting out, checking of works, taking
measurements, testing hydraulic and other structures, without any extra payment.

The Agency shall also provide approach and access to all the works and stores without
any extra cost.
1.11 Reference Points
After the joint survey has been plotted and approved by the Engineer-in-Charge, per-
manent base lines, cross line and bench marks shall be established by the Agency to
serve as reference points and "Dimensional Control Basis" of works. He shall prepare
and submit a plan showing such reference points with their full descriptions.

1.12 Cooperation with other Agencies

Some works in project site have been already done/are being done/shall be done through
other Agencies. In the event of any such work, the Agency shall have to work in full
co-operation and in close coordination with other Agency/Agencies. Any difficulty that
may arise in this connection shall have to be amicably settled by the Agencies amongst
themselves. If that is not possible, the matter shall be referred to the Engineer-in-Charge
whose decision shall be final and binding on all the parties.

The site allocated to the Agency may be fenced at the Agency cost, provided any nec-
essary access to others, as may be required, is given. The Agency shall be permitted to
use only the access to the site as indicated on the site plan in Tender Drawing.

1.13 Approval of Materials and Equipment to be used

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Samples in large enough quantity of materials and descriptive data requiring prior ap-
proval shall be furnished by the Agency to the Engineer-in-Charge in good time before
the collection of such materials and equipment so as to permit inspection and testing.
The samples shall be properly marked to show the name of the materials, name of the
manufacturer, place of origin and item for which it is to be used. Only upon approval,
the materials of approved quality shall be brought to site. Samples approved shall be on
exhibition always, properly stores and prevented from deterioration for the purpose of
comparison with the materials brought to site of work from time to time for use in work.

1.14 Testing & Testing Equipment

1.14.1 Testing of materials to be used in the permanent work, or of the quality of finished
items, shall have to be done from approved laboratory at the expense of the Agency.

The Agency shall afford at his own cost necessary facilities in providing the requisite
materials and other assistance that may be required by the Engineer-in-Charge includ-
ing transport of the test specimens to the laboratory referred to above.

1.14.2 The Agency shall provide at his own cost necessary equipment for such testing which
by the nature of work may have to be done at site or for taking samples for testing in
laboratories. These include sufficient number of slump cones, standard 150 mm metal
cube moulds, sets of I.S. sieves, weighing balances, graduated measuring cylinders,
complete set of equipment for in-situ density test, thermometers and any other miscel-
laneous equipment that may be required by the Engineer-in-Charge or his representa-
tive(s). The Agency shall also provide necessary arrangement for curing of concrete
cube specimens, as instructed by the Engineer-in-Charge.

1.15 Construction Records

The Agency shall keep and supply to the Engineer-in-Charge the up-to-date records of
the dimensions and positions of all permanent works (showing therein any approved
deviation between the drawing and the work as actually executed). The information
available from the records must be adequate and complete to enable preparation of "as-
made" drawing by the Agency from these records. A weekly report is mandatory for the
Agency describing the detailed status of the progress of work in a format as prescribed
by the Engineer-in-Charge.

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1.16 Progress Photographs

The Agency shall, at his own cost and expense, arrange to take periodic photographs to
show the progress of work or interesting features thereof. The time and the position
where from a photograph is to be taken shall be as per direction of the Engineer-in-
Charge or his Representative. Three copies of each of these photographs to an enlarged
size of about 25 cm x 20 cm together with the CD/DVD, shall be supplied to the Engi-
neer-in-Charge and these shall become the property of the Authority. Each photograph
shall be suitably captioned with the date of the photograph, location and other relevant
particulars. Further prints and CD of the photograph, location and other relevant partic-
ulars shall not be kept by the Agency or reproduced without written permission of the
Authority. Digital Camera with 6.0 Mega pixel shall be used for taking photos.

Restrictions to photography or security restrictions that may be applicable to any par-

ticular area, must be carefully and rigidly observed.

The number of photographs (each consisting of three prints and the CD/DVD as afore-
said) for the complete works is not expected to exceed 100 (one hundred). No photo-
graph of the plant and other installations shall be taken without prior approval of the
concerned officers.

1.17 Satisfactory completion of various items

The various items of the sub-work are to fit in perfectly in the whole plant in every
respect so as to form effective working parts of the whole plant as per satisfaction of
the Engineer-in-Charge. Each sub-work shall be considered as complete when it is com-
pleted as per specifications and put into commission, as per standards, as a successful
component part of the whole plant.

1.18 Checking Quality of Work

If the Engineer-in-Charge considers it necessary to satisfy himself as to the quality of
the work, the Agency shall, at any time during continuance of the contract, offer sample
of work done or if necessary pull down a reasonable part of the work enough for such
inspection and testing as the Engineer-in-Charge may direct and the Agency shall make
good the same at his cost and to the satisfaction of the Engineer-in-Charge without any
extra cost.

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1.19 Recording Measurements

Though the offer is on lump sum basis, the Agency shall give not less than five days’
notice, in writing to the Engineer-in-Charge, about the work which is proposed to be
covered or placed beyond the reach of measurements so that measurements may be
taken before the work is covered, bar bending schedule is to be provided five days be-
fore the casting date. If any work is covered without such written notice, the same shall
be uncovered at the cost of the Agency, and in default hereof, no payment or allowances
shall be made for such work. These requirements apply for all the component items
executed for the sub-work for which lump sum price is quoted.

1.20 Reports and Returns

The Agency shall maintain at site daily records of progress with regard to the works
carried out, labour engaged and construction equipment deployed. These shall form the
basis of preparing periodic reports and returns as may be required by the Engineer-in-
Charge and in the manner as directed by him.

These daily records shall be made accessible to the Engineer-in-Charge or his Repre-
sentative as and when desired by him.

1.21 Site Books

1.21.1 For the purpose of quick communication between the Engineer-in-Charge or his Rep-
resentative and the Agency or his Agent or Representative, Site Books shall be main-
tained at site in the manner described below. Any communication relating to the works
may be conveyed through records in the Site Books. Such a communication from one
party to the other shall be deemed to have been adequately served in terms of relevant
clause / sub-Clause of the General Conditions of Contract. Each Site Book shall have
machine-numbered pages in triplicate and shall be carefully maintained and preserved.

1.21.2 The Agency shall keep Site Books at various places Site work is being carried out so as
to be readily available to the Engineer-in-Charge or his Representative. Any instruction
or order which the Engineer-in-Charge or his Representative may like to issue to the
Agency may be recorded by him in the Site Book and two copies thereof taken by him
for his record. The Agency or his Agent or Representative may similarly maintain sep-
arate Site Book for any communication he may like to send to the Engineer-in-Charge

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or his Representative. Two copies thereof when sent to the Engineer-in-Charge's Rep-
resentative and receipt obtained thereof, shall constitute adequate service of the com-
munication to the Engineer-in-Charge.

1.21.3 It is mandatory to the Agency to submit a Weekly Report on every Monday morning
describing the progress of work till the night of the day before. The Weekly Report shall
include the volume of works done in all the categories like, earthwork, piling, concret-
ing, reinforcement works and all other miscellaneous works. As this report shall be the
basis of the Running Bills, the said bills may not be accepted by the Authority in ab-
sence of such regular report.

1.22 TECHNICAL ASSISTANCE

1.22.1 Training of Technical Personnel
The Agency shall undertake to train two Engineers selected and sent by the Authority
to the works of the Agency. These Engineers shall be given special training in the shop
and drawing office where the equipment shall be designed and manufactured, and
where possible, in any other plant where Agency manufactured equipment of similar
type is under installation, tests or maintenance, to enable them to become fully familiar
with the equipment being supplied by the Agency. The period of training shall be as
decided by the Authority but in any case, shall not exceed six months for any individual.
During the period of training, the Agency shall arrange for reasonable accommodation
of the Engineers and transport from the place of accommodation to the works or plant.

The Agency supervisory personnel at site shall continuously and intensively instruct
and train an adequate number of the Authority's authorized operating and maintenance
personnel at site during erection and commissioning of the plant to enable them to take
over the operation and maintenance of the plant after the maintenance period.

No extra payment shall be made by the Authority for the training of personnel under
this clause.

1.23 DISPOSAL OF THE EXCAVATED MATERIALS

All materials obtained from any excavation required to be carried out under this contract
shall be the property of the Authority and the Agency shall not have any claim on it. It

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shall not be used for any purpose other than refilling the excavations as needed or lev-
elling the compound or in construction of any embankment or in any manner as directed
by the Engineer-in-Charge. After completion of work or earlier, if so directed by the
Authority, the surplus excavated materials shall be disposed of by the Agency to any
distance without any extra cost, but only after being so directed by the Authority.

1.24 POSSESSION PRIOR TO COMPLETION

The Authority shall have the right to take possession for use of any completed or partly
completed part of the work. Such possession or use shall not be deemed to be an ac-
ceptance of any work not completed in accordance with the agreement.

1.25 TENDER TO STRICTLY COMPLY WITH SPECIFIED CONDITIONS AND

ALL OTHER SPECIFICATIONS
It shall be clearly noted that the tenderers shall strictly comply with the specifications
and other terms and conditions laid down in this document and no variations are per-
missible. This is necessary for the purposes of comparison of tenders received.

The Agency shall stand guarantee for producing potable water as per the standards laid
down in the Tender and for the works to be carried out under this contract.

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Annexure – I (C) - ii
Potable Water Supply

1.0 Water Supply Network

Standards and Specifications for the Design and Construction of Water Supply Network
are given in this section.
2.0 Applicable Codes & Standards
The manufacturing, testing, supplying, jointing and testing at work sites of pipes shall
comply with all currently applicable statutes, regulations, standards and codes. In par-
ticular, the following standards, unless otherwise specified herein, shall be referred. In
all cases, the latest revision of the Codes shall be referred. If requirements of this Spec-
ification conflict with the requirements of the Codes and standards, this Specification
shall govern. However, other codes as approved by Employers Engineer but not specif-
ically mentioned below pertaining to the use of MS, DI Pipes,Tytan gasket, welding ,
PLB HDPE Conduit shall form part of these specifications.

DI Pipes
Code Description

IS: 8329 Specification for Centrifugally Cast (spun) Ductile Iron pressure
pipes for water, gas and sewage specification.

IS: 5382 Specification for Rubber sealing ring for gas mains, water mains
and sewers
IS: 638 Sheet rubber jointing and rubber insertion jointing.
IS: 1387 General requirements for supply of metallurgical materials.
IS: 1500 Methods for Brinell hardness test for metallic materials.
IS: 9524 Ductile Iron fittings for pressure pipes for water, gas and sewage.
IS: 12820 Dimensional requirement of rubber gaskets for mechanical
Joints and push on joints for use with cast Iron pipes and fittings
for carrying water, gas and sewage.
ISO:4179 Ductile iron pipes for pressure and non-pressure-Centrifugal
cement mortar lining - General requirements.
ISO:2531 Ductile iron pipes, fitting and accessories for pressure pipe lines.
Code of Practice
IS: 12288 Code of practice for use & laying of Ductile iron pipes.
IS: 13382 Cast iron specials for mechanical and push-on-flexible joints for
pressure pipe lines for water, gas and sewage.

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MS Pipes
Code Description
IS: 2062-2011 Hot Rolled Medium and High Tensile Structural Steel-
Specification
IS: 814 Covered Electrodes for manual Metal Arc Welding of carbon and
C-Mn steel.
ASME B31.3 Pressure Piping Code for Process Piping
BS EN 499 Welding Consumables. Covered Electrodes for Manual Metal Arc
Welding of Non-Alloy and Fine Grain Steel. Classification
AWS: A-5.1 Specification for Mild Steel Covered Arc Welding Electrodes.
IS: 3613 Acceptance Tests for Wire Flux combinations for Submerged –
arc Welding.
AWS: A-5.17 Specification for Bare Mild Steel Electrodes and Fluxes for
Submerged Arc Welding. IS: 1377 - Technical Supply Conditions
for Threaded Fasteners
IS: 1367 Technical Supply Conditions for Threaded Steel Fasteners (Parts 1
to 3).
IS: 2074 Ready Mixed Paint, Air drying, Red Oxide Zinc Chrome and
Priming- specification.
IS: 102 Ready Mixed Paint, Brushing, Red Lead, non-setting, Priming.
IS: 816 Code of practice for use of Metal Arc Welding for General
Construction in mild steel.
IS: 4353 Submerged Arc Welding of Mild Steel & Low Alloy Steels –
Recommendations.
IS: 817 Code of practice for Training and Testing of Metal Arc Welders
IS: 1182 Recommended practice for Radiographic examination of Fusion
- Welded Butt Joints in steel plants
IS: 2595 Code of Practice for Radiographic Testing.
IS: 3658 Code of Practice for Liquid Penetrate Flaw Detection
IS: 5334 Code of practice for Magnetic Particle Flaw Detection of welds.
ASTM E 94 Guide for Radiographic Testing
IS: 3600 Methods of Testing Fusion Welded Joints and weld metal in steel
(Parts 1 to 9)
IS: 4853 Recommended Practice for Radiographic Inspection of Fusion
Welded Butt Joints in Steel Pipes
IS: 3589 Seamless or Electrically welded steel pipes for Water Gas and
Sewage (168.3 to 2540 Outside Diameter)
IS: 6631 Specification for Steel pipes for Hydraulic Purposes
IS: 7343 Code of practice for ultrasonic Testing of Ferrous Welded Pipes
and Tubular Products

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IS: 2598 Safety Code for Industrial Radiographic Practice

IS: 5822 Code of Practice for Laying of Electrically Welded steel pipes for
water supply
IS: 1608 Metallic material-tensile testing at ambient temperature
IS: 9595 Metal Arc welding of Carbon and Carbon-Manganese Steels –
Recommendations
IS: 2825 Code of unfired Pressure Vessels
IS: 5504 Specification for Spiral Welded pipes
IS: 10748 Hot-rolled Steel Strip for Welded Tubes and Pipes - Specification
IS: 228 Method of chemical analysis of steel (Second revision)
IS: 1599:1985 Method for Bend test (Second revision)
IS: 1608:1995 Mechanical testing of metals- Tensile testing
IS: 3803:1984 Steel conversion of elongation value part-I Carbon and low alloy
Steel (Second revision)
IS: 8910:1978 General Technical delivery requirements for steel and steel prod-
uct.
IS: 9595:1996 Metal arc welding of carbon and carbon manganese steels (First
revision) - Recommendation
IS: 1730:1989 Dimension for steel plates, sheets, strips & flats for general
engineering purposes (second revision)
IS: 1852:1985 Rolling & cutting tolerances for Hot re-rolled steel products.
(Forth revision)
BS 3900 Methods of Test of Paints
BS 7079 Preparation of Steel Substrates before Application
ANSI/AWWA C213 Standard for Fusion-bonded Epoxy Coating for the Interior and
Exterior of Steel Water Pipelines
AWWA C 200-97 Steel water pipe line
DIN 30670 Polyethylene Coatings of Steel pipes and Fittings – Requirements
and Testing.
DIN EN ISO 9001 Quality management systems – Requirements
2000
ANSI/AWWA C214 Standard for Tape Coating Systems for the Exterior of Steel Water
Pipelines
ANSI/AWWA C604 Installation of Buried Steel Water Pipe
ANSI/AWWA C209 Standard for cold applied tape coatings for the exterior of special
sections, connections and fittings for steel water pipelines.
ANSI /AWWA C210 Liquid Epoxy Coating systems for Exterior and Interior of Steel
Water Pipelines
ANSI/AWWA C 216 Standard for Heat - Shrinkable Cross-linked Polyolefin coatings
for exterior of special sections, connections and fittings of steel
water pipelines.
AWWA Manual M11 Steel Pipe – A Guide for Design and Installation

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PLB HDPE Ducts

TEC GR No. TEC/GR/TX/CDS-008/03/Mar-11: PLB HDPE Duct
Any other relevant codes required for the project will be applicable as per the directions of
Engineer-in-Charge.
General
Prior to the procurement of Pipes, the Contractor shall obtain the Engineer-in-charge
approval for the QAP & Data sheet. Shop inspection, Pressure testing of Pipes, Material
testing at manufacturer’s testing facility in presence of EIC/Representative of EIC fol-
lowed by a certificate from the manufacturer’s shop testing shall be provided for review
by the Engineer-in-charge.

PIPE LINE SPECIFICATIONS

DUCTILE IRON PIPES
1.1 Scope
This specification covers the requirements for manufacturing, testing, supplying, joint-
ing and testing at work site Ductile iron pipes (for potable - DI-K9 & DI-K7) and fit-
tings used for water conveyance. Schedule -B covers the specific requirement for the
project.
1.2 Applicable Codes
The manufacturing testing, supplying, jointing and testing at work sites of Ductile Iron
pipes and fittings shall comply with all currently applicable statutes, regulations, stand-
ards and codes. In particular, the following standards, unless specified herein shall be
referred. In all cases, the latest revision of the codes shall be referred to. If requirements
of specifications conflict with the requirements of the codes and standards, this speci-
fication shall govern.
1.3 References

Code Description
Specification for Centrifugally Cast (spun) Ductile Iron pressure pipes
IS: 8329
for water, gas and sewage specification.
Specification for Rubber sealing ring for gas mains, water mains and
IS: 5382
sewers
IS: 638 Sheet rubber jointing and rubber insertion jointing.
IS: 1387 General requirements for supply of metallurgical materials.
IS: 1500 Methods for Brinell hardness test for metallic materials.

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IS: 9524 Ductile Iron fittings for pressure pipes for water, gas and sewage.
Dimensional requirement of rubber gaskets for mechanical Joints and
IS: 12820 push on joints for use with cast Iron pipes and fittings for carrying wa-
ter, gas and sewage.
Ductile iron pipes for pressure and non-pressure-Centrifugal cement
ISO:4179
mortar lining - General requirements.
Ductile iron pipes, fitting and accessories for pressure pipe lines. Code
ISO:2531
of Practice
IS: 12288 Code of practice for use & laying of Ductile iron pipes.
Cast iron specials for mechanical and push-on-flexible joints for pres-
IS: 13382
sure pipe lines for water, gas and sewage.

Supply of Material

The General requirements relating to the supply of material shall be as laid down in
IS:1387. The material for DI fittings shall conform to IS:9523.
1.4 Manufacturing
The metal used for the manufacture of pipes shall be of good quality, commensurate
with the mechanical requirements laid down in 19. It shall be manufactured by any
method at the discretion of the manufacturer provided that the requirements defined in
this standard are complied with.
The pipes shall be stripped with all precautions to avoid warping or shrinkage defects,
detrimental to their good quality. The pipes shall be sound and free from surface or
other defects. Pipes showing small imperfections inherited with the method of manu-
facture, and which do not affect their serviceability, shall not be rejected on that account
alone. Minor defects arising out of manufacturing process may be rectified, for exam-
ple, by welding in order to remove surface imperfections and localized defects which
do not affect the entire wall thickness provided that the repairs are carried out in ac-
cordance with a written assurance system and the repaired pipes comply with all the
requirements of classes K9 and K7 with the approval of the purchaser.
Pipes centrifugally cast shall be heat-treated in order to achieve the necessary mechan-
ical properties and to relieve casting stresses caused due to the method of manufacture
and repair work.
If necessary, the pipes may be subjected to reheat treatment to ensure that Brinell hard-
ness does not exceed the specified value and the other mechanical properties specified
in the standard are achieved.

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1.5 Rubber Gasket

Rubber gaskets used with push-on-joints or mechanical joints shall conform to IS
5382.

Material of rubber gaskets for push-on mechanical or flanged joints shall be compatible
with the fluid to be conveyed at the working pressure and temperature.

Rubber gaskets for mechanical joint for conveyance of town gas may be suitably
protected so that the elastomer does not come in direct contact with the gas.

Rubber gaskets for use with flanged joints shall conform to IS:638.

While conveying potable water the gaskets should not deteriorate the quality of water
and should not impart any bad taste or foul odour.

1.6 Sampling
Sampling criteria for various tests, unless specified in this standard, shall be as laid
down in IS 11606.
The mechanical acceptance tests shall be carried out on samples of ductile iron pipes
which shall be grouped in following batch sizes.

DN (mm) Maximum Batch Size

80-250 200 pipes
300-600 100 pipes
700-1000 60 pipes
1100-1400 40 pipes
1600-2000 30 pipes

In order to check compliance with the requirements specified, a sample ring or bar shall
be taken from the spigot end of pipe.
1.7 Mechanical Tests
Mechanical tests shall be carried out during manufacture. One test shall be conducted
for every batch of production. The results obtained shall be taken to represent all the
pipes of that batch.

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1.7.1 Tensile Test

The thickness of the sample and the diameter

Castings Test Bar. Test bar Method B

Thickness Method A
mm Nominal Nominal Area Nominal Tolerance on
Diameter So Diameter Diameter
mm mm2 mm mm
Centrifugally
Cast Pipes
- less than 6 2.5 5.0 2.52 0.01
-6 up to but not 3.5 10.0 3.57 0.02
including 8
- 8 up to but not 5.0 20.0 5.05 0.02
including 12
- 12 and over 6.0 30.0 6.24 0.03

A Sample shall be cut from the spigot end of the pipe. This sample may be cut
perpendicular to or parallel with the pipe axis, but in case of dispute the parallel to axis
sample shall be used.

Test Specimen: A test bar shall be machined from each sample to be representative of
the metal at the mid-thickness of the sample, with a cylindrical part having the
diameters given in Data sheet.

The test bars shall have a guage length at least five times the nominal test bar diameter.
The ends of the test bars shall be such that they will fit the testing machine.

Two methods of measuring the tensile strength may be used at the manufacture’s
option:

Method A - Machine the test bar to its nominal diameter + 10 percent, measure the
actual diameter before the test with an accuracy of 0.01 mm and use this measured
diameter to calculate the cross-sectional area and the tensile strength; or:

Method B - Machine the test bar to its nominal area So within a specified tolerance on
diameter (see19.1.2) and use the nominal area to calculate the tensile strength.

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Equipment and Test Method: The sample shall be tested as per procedures laid down in
IS 1608. The tensile testing machine shall have suitable holders or grips to suit the test
bar ends so as to positively apply the test load axially.

1.7.2 Brinell Hardness Test

When tested in accordance with IS 1500, the Brinell hardness shall not exceed 240 HP
on the external un-machined surface.

1.7.3 Retest
If test piece representing a batch fails in the test in the first instance, two additional tests
shall be made on test pieces selected from two other pipes from the same batch. If both
the test results satisfy the specified requirements, the batch shall be accepted. Should
either of these additional test pieces fail in the test, the batch shall be deemed as not
complying with this standard.

1.7.4 Hydrostatic Test

All pipes shall be tested hydrostatically at a pressure specified in Table. To perform the
test, pressure shall be applied internally and shall be steadily maintained for a period of
10s. The pipes shall withstand the pressure test and shall not show any sign of leakage,
sweating or other defects of any kind.

It is recommended that the Hydrostatic test pressure at works ‘p’ be expressed in MPa
as a function of the coefficient K be calculated using the following formulae:

For DN 80 to 300 p = 0.05 (K+1)2

For DN 350 to 600 p = 0.05 (K)2

For DN 700 to 1000 p=0.05 (K-1)2

For DN 1100 to 2000 p = 0.05 (K-2)2

When pipes are required to be tested for higher pressure, the test pressures are subject
to agreement between the purchaser and the manufacturer at the time of enquiry and
order.

Test shall be carried out before the application of surface coating and lining.

Minimum Hydrostatic Test pressure at Works, MPa

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Nominal Centrifugally cast pipes Pipes with Screwed or welded on flanges

Diameter (DN) with flexible joints
Mm
Class K7 Class K9 PN10 Flange PN16 PN25 Flange
Flange
80 to 300 3.2 5.0 1.6 2.5 3.2
350 to 600 2.5 1.0 1.6 2.5 3.2
700 to 1000 1.8 3.2 1.6 2.5 3.2
1100 to 2000 1.2 2.5 1.6 2.5 2.5

1.8 Sizes
The standard nominal diameters DN, of pipes and flanges followed in this standard are
as follows: 150, 200, 250, 300, 350, 400, 450, 500, 600, 700, 4000, 800, 900, 1000 mm.

1.9 Dimensions
Length: The standard working length of socket and spigot pipes shall be 4m, 5m, 5.5m
and 6m and for flanged pipes shall be 4m, 5m and 5.5 m other lengths are available by
agreement between the manufacturer and the purchaser.

The internal diameter, thickness and length of barrel, dimensions of pipes and fittings
shall be as per the relevant tables of IS.8329/IS:9523 for different class of pipes and
fittings. The tolerances for pipes and fittings regarding dimensions and deviations from
straight line in case of pipes shall be as per relevant IS codes. The standard weight of
uncoated pipes and fittings and the permissible tolerances shall be per relevant IS codes.

1.10 Materials in contact with Potable water

When used under the conditions for which they are designed, in permanent or in
temporary contact with water intended for human consumption, ductile iron pipes
and their joints shall not have detrimental effects on the properties of the water for its
intended use.

1.11 Tolerances
1.11.1 Diameter
External Diameter: The values of the external diameter (DE) of the spigot end of socket
and spigot pipes and when measured circumferentially using a diameter tape shall
confirm to the requirements specified. The positive tolerance is +1 mm and applies to
all thickness classes of pipes.

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The negative tolerance of the external diameter depends on the design of each type of
joint and maximum negative tolerance is specified in this standard.

EXTERNAL DIAMETER DE (mm)

DN Nominal Tolerance
100 118 +1, -2.8
125 144 +1, -2.8
150 170 -1, -2.9
200 222 +1, -3
250 274 +1, -3.1
300 326 +1, -3.3

1.11.2 Tolerance on Ovality

Pipes shall be as far as possible circular internally and externally. In case of oval spigot
ends for push on joints (DE), the minor axis is permitted to be less than the minimum
allowable diameter by the value given below provided the mean diameter DE measured
by circumferential tape, comes within the minimum allowable dimensions of DE after
applying the tolerance.

Table-1: Allowable Ovality for Push-on-Joint Pipes.

Nominal Diameter DN Allowable Difference Between

mm Minor Axes and DE, Min
mm
80-300 1.0
350-600 1.75
700 2.0
4000-800 2.4
900-1000 3.5
1100-1200 4.0
1400 to 1600 4.5

Tolerance on Thickness: The tolerance on the wall thickness (e) and the flange
thickness (b) of the pipes shall be as follows:

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Dimensions Tolerance, mm

Wall Thickness (e) - (1.3 + 0.001 DN)

Flange thickness (b) + (2 + 0.05b)

The tolerance given is subject to minimum thickness against Classes K7 and K19 given.
No limit for the plus tolerance is specified.

Tolerance on Length: The tolerance on length of pipes shall be as follows:

Type of Casting Tolerance, mm

Socket and spigot and plain ended + 100

pipes

Flanged pipes + 10

1.12 Coating
1.12.1 Pipes shall be normally delivered internally and externally coated.

1.12.2 Internal Linings: By agreement between manufacturer and the purchaser, the following
lining may be applied depending on the internal conditions of use:

 Portland cement (with or without additives) mortar, as included in Annex A.

 Blast furnace slag cement mortar as included in Annex A.

 High alumina (calcium aluminate) cement mortar as included in Annex A.

 Cement mortar with seal-coat: as included in Annex A.

 Bituminous paint as included in Annex B.

1.13 Quality Assurance System

The manufacturer shall control the quality of the product during their manufacturing
process by a system of process control in order to comply with the technical
requirements contained in this standard. Wherever possible, statistical sampling
techniques should be used to control the process so that the product is produced within
the specified limits.

1.14 Marking

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Each pipe shall be marked with the logo of ADC along with month and year of Work
Order. Each pipe shall have as cast or stamped or legibly and indelibly painted on it
with the following appropriate marks.

a. Indication of the source of manufacture;

b. The nominal diameter;
c. Class reference;
d. The last two digits of the year of manufacturer;
e. The non-standard length of the pipe if specially ordered;
f. Where applicable, an indication of length over which the pipe is suitable for cutting
on site; and
g. A short white line at the spigot end of each pipe with push-on joint in sizes DN 700
and above, to indicate the major axis of the spigot.
Marking may be done:
i. on the socket faces of pipe centrifugally cast in metal mould, and

ii. on the outside of the socket or on the barrel of pipe centrifugally cast in sand mould.
BIS certification Marking:
The pipes may also be marked with the Standard Mark:
The use of Standard Mark is governed by the provisions of Bureau of Indian Standards
Act, 1986 and the Rules and Regulations made there under. The details of conditions
under which license for the use of Standard Mark may be granted to the manufacturers
or producer may be obtained from the Bureau of Indian Standards.
1.15 Jointing
Jointing of DI pipes and fittings shall be done as per the requirements of specifications
and as per the relevant IS code. After jointing, extraneous material, if any, shall be
removed from the inside of the pipe. In case, rubber sealing rings/gaskets are used for
Jointing these shall conform relevant IS codes.
1.16 Spigot and Socket Pipes
The Spigot and socket pipes and DI fittings shall have push on joints as specified in IS
code/ as recommended by manufacturer. The gaskets/sealant used for push on
joints/flanged joints shall be suitable for water conveyance. In jointing Ductile iron
spigot and socket pipes and fittings with tyton flexible joints the contractor shall take
into account the manufacturer's recommendations as to the methods and equipment to
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be used in assembling the joints. In particular the Contractor shall ensure that the spigot
end of the pipe to be jointed is smooth and has been properly chamfered, that the rubber
ring as per relevant IS code is correctly positioned in line, before the joint is made. The
rubber rings and any recommended lubricant shall be obtained only through the pipe
supplier or as otherwise directed by engineer.
1.17 Flanged Pipes
The gaskets used between flanges of pipes shall be compressed fibre board or
natural/synthetic rubber conforming to IS:638 of thickness between 1.5 to 3 mm
suitable for water conveyance and as specified by manufacturer. The fibre board shall
be impregnated with chemically neutral mineral oil and shall have a smooth and hard
surface. Its weight per square metre shall be not less than 112 g/mm thickness. Each
bolt should be tightened a little at a time taking care to tighten diametrically opposite
bolts alternatively. The practice of fully tightening the bolts one after another is highly
undesirable. The bolts shall be of mild steel unless otherwise specified. They shall be
coated with coal tar epoxy coating after tightening.
1.18 Cleaning of Pipes and Fittings
Contractor shall ascertain that each stretch of pipeline is absolutely clear and without
any obstruction by means of visual examination of the interior of pipeline suitably
lighted by projected sunlight or otherwise. The open end of an incomplete stretch of
pipeline shall be securely closed as may be directed by Owner/Engineer to prevent entry
of mud or silt etc. If as a result of the removal of any obstructions Owner/Engineer
considers that damages may have been caused to the pipeline, he shall be entitled to
order the stretch to be tested immediately. Should such test prove unsatisfactory,
contractor shall amend the work and carry out such further tests as are required by
Owner / Engineer.

1.19 Specials for Ductile Iron Pipes

This section covers the general requirements for Ductile Iron (DI) fittings suitable for
Tyton joints to be used with Ductile Iron pipes with flanged and Tyton jointing system.
1.19.1 Types of specials
The following types of DI fittings shall be manufactured and tested in accordance with
IS: 9523.

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 flanged socket
 flanged spigot
 double socket bends (900, 450, 22 1/20, 11 1/40)
 double socket branch flanged tee
 all socket tee
 double socket taper
 blind flange/dummy flange
1.19.2 Supply
All the DI fittings shall be supplied with one rubber ring for each socket. The rubber
ring shall conform to IS: 12820 and IS: 5382 as described in the preceding chapter.
Flanged fittings shall be supplied with one rubber gasket per flange and the required
number of nuts and bolts.
1.19.3 Lubricant for ductile iron pipes and specials
1.19.3.1 General
This section covers the requirements for lubricant for the assembly of Ductile Iron pipes
and specials suitable for Tyton push-in rubber ring joints
1.19.3.2 Specification
 The lubricant has to have the following characteristics:

 must have a paste like consistency and be ready for use

 has to adhere to wet and dry surfaces of DI pipes and rubber rings

 to be applied in hot and cold weather; ambient temperature 0 - 50 °C, temperature

of exposed pipes up to 70 °C

 must be non-toxic

 must be water soluble

 must not affect the properties of the drinking water carried in the pipes

 must not have an objectionable odour

 has to inhibit bacterial growth

 must not be harmful to the skin

 must have a shelf live not less than 2 years

Acceptance tests
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They shall be conducted in line with the provisions of the IS 9523

1.19.4 Packing
All the DI fittings shall be properly packed with jute cloth. Rubber rings shall be packed
in polyethylene bags. Rubber rings in PE bags and nuts, bolts etc. shall be supplied in
separate jute bags.
The fittings should also be supplied by the manufacturer of the pipes. They should
preferably be manufactured by the manufacturer of the pipes. The pipe manufacturer
will however be responsible for the compatibility and quality of the products.
1.20 Testing at Work Site
After the pipes and fittings are laid, jointed and the trench partially backfilled except at
the joints the stretch of pipe line as directed by Engineer shall be subjected to pressure
test and leakage test as per relevant BIS codes. Where any section of the pipeline is
provided with concrete thrust blocks or anchorages, the pressure test shall not be made
until at least five days have elapsed after the concrete was cast. If rapid hardening
cement has been used in these blocks or anchorages, the tests shall not be made until
atleast two days, have elapsed. Each section of' the pipe line shall be slowly filled with
water and all air shall be expelled from the pipe by tapping at points of highest elevation
before the test is made plugs inserted after the tests have been completed.
The duration of test shall be 8 hours. No pipe installation shall be accepted until the
leakage is less than the number cm3/hr as determined by the formula:
QL =ND √ P
3.3
Where, QL = the allowable leakage in cm3/hr
N = number of joints in the length of the pipeline.
D = diameter in mm, and
P = the average test pressure during the leakage test in kg/cm2

Should any test of pipe laid indicate leakage greater than that specified above, the
defective joints shall be repaired by Contractor at no extra cost to Owner/Engineer until
the leakage is within the specified allowance. Necessary equipment and water used for
testing shall be arranged by Contractor at his own cost. Damage during testing shall be
Contractor's responsibility and shall be rectified by him at no extra cost to

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Owner/Engineer. Water used for testing shall be removed from the pipe and not released
in the excavated trenches. After the tests mentioned above are completed to the
satisfaction of Owner/Engineer, the backfilling of trenches shall be done as per
specifications in layers.
Field Hydrostatic Testing
The entire pipeline shall be subjected to a hydraulic test as follows, to the required test
pressure as per Annexure E of IS: 8329 and as per the procedure laid down in IS: 12288.
The completed pipeline may be tested either in one length or in sections; the length of
section depending upon:
1) availability of suitable water,
2) number of joints to be inspected, and
3) difference in elevation between one part of the pipeline and another

Where the joints are left uncovered until after testing, sufficient material should be
backfilled over the centre of each pipe to prevent movement under the test pressure. It
is prudent to begin testing in comparatively short length of test section. Progressively
as experience is gained, lengths of about 1.5 km or more, are tested in one section,
subject to consideration of length of trench which can be left open in particular
circumstances.
Each section should be properly sealed-off, preferably with special stop ends secured
by adequate temporary anchors. The thrust on the stop ends should be calculated and
the anchors designed to resist it. All permanent anchors should be in position and, if of
concrete, should have developed adequate strength before testing begins. The section
undertest should be filled with water, taking care that all the air is displaced either
through vents at the high points or by using a pig or a sphere.
The test pressure to be applied should be not less than any of the following:
 The maximum pressure, sustained operating
 The maximum static pressure plus 5N/mm2, and
 The sum of the maximum sustained operating pressure (or the maximum static pres-
sure) and the maximum calculated surge pressure.
After filling, the pipeline should be pressurized to the specified operating pressure and
left for a period of time to achieve stable conditions. The length of this period of time
depends on many factors such as slight movement of the pipeline under pressure
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whether air is trapped in the pipeline or whether the pipeline has a concrete lining which
absorbs water.
The pipeline is then pressurized up to the full test pressure and the section under test
completely closed off. The test should be maintained for a period of not less than 10
minutes to reveal any defects in the pipes, joints or anchorages.
The test pressure should be measured at the lowest point of the section under test or
alternatively, an allowance should be made for the static head between the lowest point
and the point of measurement, to ensure that the required test pressure is not exceeded
at the lowest point. In case of extreme temperature conditions, there may be a tendency
of hydraulic pressure building up inside the pipeline because of expansion of water
during the high day time. This should normally not be of any major concern as the joints
and the pipes are manufactured to resist a much high pressure. However, sufficient care
should be taken to prevent floating bulging of the pipeline because of building up of
such high pressure during the temperature rise.
If the test is not satisfactory, the fault should be found and rectified. Where there is
difficulty in locating a fault, the section undertest should be sub-divided and each part
tested separately.
After all sections have been joined together on completion of section testing, a test on
the complete pipeline should be carried out. This test should be carried out at a pressure
not less than the maximum sustained operating pressure or the maximum static pressure
of the pipeline and, during the test, inspection made of all work which has not been
subject to section tests. During the test, the pressure at the lowest point in the pipeline
should not exceed the maximum hydraulic field test pressure. It is important to ensure
that proper arrangements are made for the disposal of water from the pipeline after
completion of hydrostatic testing and that all consents which may be required from
authorities have been obtained. In some cases, for example, heavily chlorinated water,
some treatment may be necessary before final disposal.

1.21 Measurement
All pipes shall be measured according to the work actually done and no allowance will
be made for any waste in cutting to the exact length required. Pipes and fittings shall be
described by their internal diameter and length measured in running meters. The

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measurement shall be taken along the centre line of pipe excluding fittings which shall
be measured separately. The lengths of pipes shall not include the portion of spigots
within the sockets of fittings and pipes.

The rate for providing, laying and jointing of DI pipes and fittings shall be deemed to
include the cost of jointing material and testing at work site.

Notes
If any damage is caused to the pipeline during the execution of work or while
cleaning/testing the pipeline as specified, Contractor shall be held responsible for the
same and shall replace the damaged pipeline and retest the same at his own cost of the
full satisfaction of Engineer. Water for testing of pipeline shall be arranged by
Contractor at his own cost.

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Annexure A
CEMENT MORTOR LINING

Materials

Cement: For internal lining of Ductile Iron pipes either blast furnish slag cement /
ordinary Portland cement may be used. The type of cement to be used is to be mutually
decided between the purchaser and manufacturer. Nominal recommendations are:

Portland cement (as per IS 8112 or IS 455) mortar lining perform rather well and have
an expected life of approximately 50 years in soft water with moderate amount of
aggressive CO2 and when pH is within 6 to 9. Longer service life can be obtained by
increasing the mortar lining thickness.

Where cement mortar lining may be exposed to sulphate attack, ordinary Portland
cement should be replaced by sulphate resisting Portland cement (as per IS 12430 or IS
6909). The sulphate concentration limit for sulphate resisting Portland cement is
approximately 3000 mg/litre, the same as blast furnace slag cement which naturally
possess a good resistance to sulphate attack. For sea water transmission blast furnace
slag cement which has C, A content below 3 percent can be used.

High alumina cement (as per IS 6452) mortar lining is suitable for continuous use of
pH between 4 and 12 and no severe damage occur after occasional exposure to pH 3 to
4 and 12 to 13.

Sand: The sand used shall have a controlled granulometric distribution from fine to
coarser elements; it shall be clean and shall be composed of inert, hard, strong and stable
granular particles.

The fine fraction comprising particles passing through a sieve of aperture size 0.125mm
shall not be more than 10 percent by mass.

The fraction comprising grains upto a maximum diameter equal to one third of the
normal thickness of the mortar lining shall not be less than 50 percent by mass.

The corsest fraction (Comprising particles which do not pass through a sieve of the
aperture size closest to half the normal thickness of the mortar lining) shall not exceed
5 percent by mass.

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Water: The water used for the preparation of the mortar shall not contain substances
deleterious to the mortar nor to the water it is eventually intended to transport in the
pipe. The presence of solid mineral particles is, however, admissible provided that
these requirements are still fulfilled.

Mortar: The mortar of the lining shall be composed of cement, sand and water.

Additives, which shall be specified, may be used, provided that they do not prejudice
the quality of the coating and that of the transported water.

The mortar shall be thoroughly mixed and shall have a consistency which results in a
dense and homogeneous lining.

The mortar shall contain by mass at least one part of cement to 3.5 parts of sand.

Application of the lining: The cement mortar lining at work is applied by a centrifugal
spinning process or a centrifuged sprinkler or a combination of both methods.

Apart from the inner surface of the joint, the parts of the pipe coming into contact with
the transported water shall be entirely covered with mortar.

Once centrifuging is finished, the lining shall be cured at temperatures greater than 4o
C. Any loss of water from the mortar by evaporation shall be sufficiently slow so that
hardening is not impeded.

Repair of Lining: Repairs to damaged or defective areas are not allowable. If any
defects are found in pipe at site contactor shall replace immediately.

For the repair operation, the mortar shall have a suitable consistency, if necessary;
additives may be included to obtain good adhesion against the side of the existing
undamaged mortar.

Thickness of the lining: The normal thickness of the lining and the minimum
permissible mean and local values are given in the Table A.

At the pipe ends, the lining may be reduced to values below the minimum thickness.
The length of the chamfer shall be as small as possible but, in any case, shall be less
than 50mm.

Determination of lining thickness: The thickness of the lining is checked on the freshly
centrifuged mortar by the insertion of a steel pin, or on the hardened mortar by means
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of a non-destructive method of measurement. The thickness of the lining shall be

measured at both ends of the pipe in at at least one section perpendicular to the pipe
axis.

Surface Condition of the Hardened lining: The surface of the cement mortar lining shall
be uniformly smooth. Only isolated grains of sand are allowed to appear on the surface
of the lining.

The lining shall be such that it cannot be dislodged with pressure of hand and shall be
free from corrugations or ridges that could reduce the thickness of the lining to less than
the minimum value at one point, as specified in the Table B.

Table-A Thickness of the Lining

DN (mm) Thickness (mm) Maximum Crack
Width / Radial
Nominal Value Tolerance
Displacement
80 to 300 3.0 -1.5 0/8
350 to 600 5.0 -2 1/0
700 to 1200 6.0 -2.5 1/2
400 to 2000 9.0 -3 1/5

Table-B Minimum Bore Clearance Cement

Mortar Lining of Ductile Iron Pipe

DN Minimum Bore of Cement Mortar

Lined Pipe (mm)
80 67.0
100 87.0
150 137.0
200 247.0
250 247.0
300 287.0

On contraction of the lining, the formation of cracks cannot be avoided. These cracks,
together with other isolated cracks which may result from manufacturer or may develop
during transportation, are acceptable up to a width given in the above.

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Seal Coat:

General: When specified the cement lining shall be given a seal-coat of bituminous
material or any other epoxy based material compatible with cement mortar lining.
Other seal-coat materials may be used, but they shall be agreed on at the time of
purchase and shall be specified on the purchase order.

The purpose of seal-coat is to minimize lime leaching of the cement mortar as well as
to restrict the unwanted rise in pH value of the transmitted water.

When the pipes are to be used for conveying potable water the inside coating shall not
contain any constituent soluble in such water or any ingredient which could impart any
taste or whatsoever to the potable water after sterilization and suitable washing of the
mains.

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Annexure B
1.0 Bituminous Coating

(a) General

Ductile iron pipes and fittings shall be zinc coated with bitumen over coating, all in
accordance with the following Specifications. Buried pipes and fittings shall also have
a site or factory applied polythene sleeving. Pipe coatings shall be inspected on site and
any damage or defective areas made good to the satisfaction of the Employers Engineer.

(b) Zinc Coating

Zinc coating shall comply with ISO 8179 and shall be applied as a spray coating. The
mass of sprayed metal shall not be less than 130 g/m2 as described in Clause 5.2 of ISO
8179.

(c) Bitumen Coating

Bitumen coating shall be of normal thickness 0.07 mm unless otherwise specified. It

shall be a cold applied compound complying with the requirements of BS 3416 Type
II, suitable for tropical climates, factory applied in accordance with the manufacturer's
instructions.

Damaged areas of coating shall be repainted on site after removing any remaining loose
coating and wire brushing any rusted areas of pipe.

2.0 SPIRALLY WELDED MILD STEEL PIPES

This specification covers the general requirements for design, supply, delivery of spi-
rally welded MS pipe , stacking at site, laying, jointing, testing and commissioning of
all spirally welded M.S pipeline, appurtenances, specials etc. above/below ground, in-
cluding Civil works required for the same. Schedule -B covers the specific requirement
for the project.
This specification covers the general requirements for design, supply, fabrication, de-
livery at site laying, stacking at site, jointing, testing and commissioning of all welded
M.S pipeline, appurtenances, specials etc. above/below ground, including Civil works
required for the same. Schedule -B covers the specific requirement for the project.

2.1 Applicable codes (Spirally welded M.S. pipes)

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The following standards and codes are made a part of the specification. All standards, tentative
specifications, codes of practice referred to herein shall be the latest editions including all ap-
plicable official amendments and revisions.
In case of discrepancy between this specification and those referred to herein, this specification
shall govern.

Code Description
Hot Rolled Medium and High Tensile Structural Steel-
IS: 2062-2011
Specification
Covered Electrodes for manual Metal Arc Welding of car-
IS: 814
bon and C-Mn steel.
ASME B31.3 Pressure Piping Code for Process Piping
Welding Consumables. Covered Electrodes for Manual
BS EN 499 Metal Arc Welding of Non-Alloy and Fine Grain Steel.
Classification
Specification for Mild Steel Covered Arc Welding Elec-
AWS: A-5.1
trodes.
Acceptance Tests for Wire Flux combinations for Sub-
IS: 3613
merged - arc Welding.
Specification for Bare Mild Steel Electrodes and Fluxes for
AWS: A-5.17 Submerged Arc Welding. IS: 1377 - Technical Supply Con-
ditions for Threaded Fasteners
Technical Supply Conditions for Threaded Steel Fasteners
IS: 1367
(Parts 1 to 3).
Ready Mixed Paint, Air drying, Red Oxide Zinc Chrome
IS: 2074
and Priming- specification
Ready Mixed Paint, Brushing, Red Lead, non-setting, Prim-
IS: 102
ing.
Code of practice for use of Metal Arc Welding for General
IS: 816
Construction in mild steel.
Submerged Arc Welding of Mild Steel & Low Alloy Steels -
IS: 4353
Recommendations.
Code of practice for Training and Testing of Metal Arc
IS: 817
Welders.
Recommended practice for Radiographic examination of
IS: 1182
Fusion - Welded Butt Joints in steel plants
IS: 2595 Code of Practice for Radiographic Testing.
IS: 3658 Code of Practice for Liquid Penetrate Flaw Detection
Code of practice for Magnetic Particle Flaw Detection of
IS: 5334
welds.
ASTM E 94 Guide for Radiographic Testing
ASTM E 709 Guide for Magnetic Particle Examination.

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ASTM E 165 Test Method for Liquid Penetrate Examination.

Methods of Testing Fusion Welded Joints and weld metal in
IS: 3600
steel (Parts 1 to 9)
Recommended Practice for Radiographic Inspection of Fu-
IS: 4853
sion Welded Butt Joints in Steel Pipes.
Seamless or Electrically welded steel pipes for Water Gas
IS: 3589
and Sewage (168.3 to 2540 Outside Diameter)
IS: 6631 Specification for Steel pipes for Hydraulic Purposes
Code of practice for ultrasonic Testing of Ferrous Welded
IS: 7343
Pipes and Tubular Products
IS: 2598 Safety Code for Industrial Radiographic Practice
Code of Practice for Laying of Electrically Welded steel
IS: 5822
pipes for water supply
IS: 1608 Metallic material-tensile testing at ambient temperature
Metal Arc welding of Carbon and Carbon-Manganese Steels
IS: 9595
- Recommendations
IS: 2825 Code of unfired Pressure Vessels
IS: 5504 Specification for Spiral Welded pipes
Hot-rolled Steel Strip for Welded Tubes and Pipes - Specifi-
IS: 10748
cation

2.2 Supplying, Delivery, Lowering, Laying, Jointing of SW MS Pipeline

2.2.1 Scope of Work

Manufacture, supply and delivery of Spirally welded Submerged Arc Welded (SAW)
M.S Pipe having bevelled ends from plate or coil conforming to IS-3589 and/or IS-
5504 with its latest revision/amendment with inside 406 micron thick solvent free
NSF/ANSI 61 approved High build liquid epoxy conforming to the specified thickness
& inner diameter of pipe at site with all type of specials, manholes, tees, bends &
flanges, lowering, laying and jointing the pipes with welding in prepared trench with
required excavation in all strata’s, RCC Encasing for the Pipe, breaking the road sur-
face/canal/existing structures & reinstating the same, necessary traffic diversion work,
refilling around the MS pipeline RCC Encasing after completion of work, disposal of
surplus excavated stuff, including hydro testing etc. complete with all taxes, insurance,
freight charges, inspection charges, transportation, etc. complete including all labour,
materials and ROU/ROW as per Standards.
Submerged Arc welded Hot finished mild steel Bevelled pipes to be manufactured sup-
plied and delivered under the scope of this contract shall be manufactured in accordance

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and conforming to IS-3589 and/or IS-5504. Pipes supplied shall be with inside 406-
micron epoxy coating as per detailed technical specification as per DIN-30670, 1991
or latest revision/amendments if any.
Pipe mill shall have valid management system certificates ISO 9001, 14001, 18001 and
IS 3589, IS 5504 license for product marking.

2.2.2 Marking
The methods of marking all the pipes to be delivered under scope of contract shall en-
sure that all the information will remain legible even after transportation storage in open
space etc. In general, the legible and marking upon the goods shall indicate the follow-
ing
Manufacturer’s brand name and / or trade mark.
Purchaser’s mark as “ADC” be stencilled
Diameter, Length and wall thickness.
Heat No., Pipe No., Pipe Designation
Date of manufacture
Any other important matter that the manufacturer deems fit to be inscribed.
All the MS pipes of diameter up to 2540mm shall be provided with ISI certification
mark on each pipe.
2.2.3 Packing and Handling
The materials shall always be packed separately dispatched from manufacturer’s works
with adequate protective measures to prevent damages and deterioration while in
transport or stored at any place. The pack shall always to be so neat and tidy that may
withstand any robust and rough handling.
The supplier shall use proper handing instruments / equipment and shall follow to a
suitable method of handing of pipes as may be approved by Engineer In-charge, while
unloading and stacking materials in the stores.

2.2.4 Workmanship
All pipes with internal solvent free NSF/ANSI 61 approved High build liquid epoxy
coating shall be finished and shall conform to detail specifications & relevant IS codes.

2.2.5 Test Certificate

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The contractor shall always provide manufacturer’s test certificate in accordance with
every batch / lot of goods as manufactured and supplied.
2.3 Materials
2.3.1 Steel Plates/H.R. coil
The steel plates for pipes, fittings, specials and stiffeners shall be of mild steel conform-
ing to IS: 2062, Grade-E250 BR or H.R. coil conforming to IS: 10748 grade III.
2.3.2 Welding Consumable
Such as electrodes, filler rods and wires shall conform to IS: 814, IS: 3613, IS: 6419
and IS: 7280.
2.4 Manufacturing
The spirally welded mild steel pipes shall be manufactured from H.R. coils conforming
to IS-10748 Grade-III or mild steel plate confirming to IS 2062-2011. The pipes are to
be shop or plant manufactured by continuous process in two step methods i.e., by
continuous Spiral Submerged Arc Welding (SAW) facility with at least one pass inside
and one pass out side welding with online testing sequentially as per terms and
conditions as laid down in IS-3589 and/or IS-5504. The pipe shall be manufactured
from Fe-410 grade steel.

The steel material viz. MS plate or coils having required thickness (with no negative
tolerance) and minimum 1500 mm width with no negative tolerance in trimmed condi-
tion having length & width as shown in the schedules of material should have been
manufactured and tested under ISI mark scheme or such license under other institution
valid for the respective country conforming to IS specification No: IS: 2062-2011
Grade-E250 BR for MS plates and IS 10748 Gr.-III for hot rolled steel coils.
The collection and testing of samples will be in accordance with the following Indian
Standard and para testing of samples. Imported steel plates and coils shall not be al-
lowed for manufacturing of pipeline.
Note:
For MS Plate: IS 2062 is to be read as IS: 2062; Gr. E250 BR
For H.R. Coil: IS 10748 is to be read as IS:10748 Gr. III

S. No. IS No. Title

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Amaravati Development Corporation Limited

1. 228 Method of chemical analysis of steel (Second revision)

2. 1599:1985 Method for Bend test (Second revision)

3. 1608:1995 Mechanical testing of metals- Tensile testing
4. 3803:1984 Steel conversion of elongation value part-I Carbon and low
alloy Steel (Second revision)
5. 8910:1978 General Technical delivery requirements for steel and steel
product.
6. 9595:1996 Metal arc welding of carbon and carbon manganese steels
(First revision) - Recommendation
7. 1730:1989 Dimension for steel plates, sheets, strips & flats for general
engineering purposes (second revision)
8. 1852:1985 Rolling & cutting tolerances for Hot re-rolled steel products.
(Forth revision)

In addition to above wherever necessary and suggested by inspecting agency, API or

other relevant standards will be used for testing and collecting of samples.
Unless otherwise specified, the MS plates supplied under this tender should conform to
the applicable requirements of the current addition of the IS specifications No. IS: 2062-
2011 Grade-E250 BR killed Quality or equivalent standard and or IS 10748, Gr. III for
hot rolled steel coils for manufacturer of spirally welded pipes.
The permissible variations in dimensions & tolerances applicable in length and width
of MS plates should be as per IS specification No 1852:1985 as applicable to rectangu-
lar, sheared cut MS plates but no negative tolerance in thickness will be acceptable.
The plates/HR coil older than 6 months from the date of manufacturing shall not be
allowed to manufacture pipes and these plates/ HR coil shall be free from any cracks,
surface flaws, laminations, scares, pits, splits, harmful scratches and other defects.
The MS plates shall be capable of forming operations and should not un-duly loose the
specified strength and property during various operations viz. drilling, threading, plug-
ging welding etc. and process adopted for fabrications & erection of pipe line. Also, the
plates shall be resistant to cleavage, fractures & effect of ageing.

2.4.1 Technical Advice

The contractor shall be fully responsible for proper liaison with the department to
evolve satisfactory welding procedure for fabrication & erection of pipe manufactured
from the plates / coil supplied by them. The contractor on receipt of a request from the
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dept. shall without any cost to the dept. arrange to furnish manufacturer’s technical
advice (with up to date instructions Booklet, technical literature etc. regarding any prob-
lem concerning fabrication in particular, suitability of welding, consumables, weld
grooves, design, heat treatment etc.) such advise shall be rendered till the expiry of
contract.
2.4.2 Acceptance of Goods
At the time of delivery of materials, the manufacturer will have to provide test results
in accordance with IS specification No. IS: 2062-2011 or equivalent standard of the MS
plates or IS: 10748 for hot rolled steel coils supplied along with the challans. The ma-
terial will not be accepted without test results of the manufacturer. If the test results of
the respective lots will be found satisfactory with respect to relevant IS or equivalent
standard specification and with no negative tolerance in thickness only then material
will be accepted by the department otherwise rejected.
Thus, in case of non-acceptance and return of materials by the department, the depart-
ment will not be responsible for the cost of materials and its transportation or any other
cost.
2.4.3 Inspection, Sampling & Testing
To have the quality assurance of the materials, the contractor shall arrange inspection
and testing in consultation with Engineer in charge. He may arrange inspection/testing
by him or his representative/consultant/third party inspection agency. The material un-
less inspected, passed and stamped for acceptance shall not be dispatched. The cost for
the inspection and testing shall be borne by the contractor.
2.4.4 Testing of HR Coils
The testing of HR coils shall be carried out by the steel manufacturer as per IS 2062.
The steel manufacturer shall submit the Hr coil MTC for review at the pipe manufac-
turer by client or its representative.
2.4.5 Wall Thickness
The wall thickness of pipes shall be as per the design requirement or minimum men-
tioned in the tender. No negative tolerance will be allowed, only positive tolerance will
be allowed. Thickness of sheet is enclosed.

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Diameter in mm Thickness in mm
1100 10
1400 12
1500 14
1600 14
1800 14
1900 16
2000 16
2400 20
2500 20

2.4.6 Pipe Ends

The pipe shall have bevelled ends to an angle of 30°+5° measured from a line drawn
perpendicular to the axis of the pipes. The root face shall be 1.6+0.8 mm. The root face
of the bevel may be prepared by hand finishing if required.
2.4.7 Length of Pipes
The random length of pipes shall be 10 to 12 meters. In specific locations, smaller
lengths can be accepted as per Engineer-in-charge
2.4.8 Straightness of Pipes
Finished pipes shall not deviate from straightness by more than 0.2% of the total length
checking for straightness shall be carried out using as taut string or wire from end to
end along the side of the pipe to measure, the greatest deviation.
2.4.9 Testing of Pipes
The main tests among others to be conducted on each pipe shall be as per IS-3589
and/or IS-5504 with its latest version.
2.4.10 Sampling of pipes
The sampling of pipes shall be as in IS:4711 with latest version/ or as directed by the
Engineer-in- charge.
2.4.11 Condition of Supply
The pipes with inside solvent free NSF/ANSI 61 approved High build liquid epoxy
shall be as per specifications.
2.4.12 Other Tolerances
As per IS-3589 and/or IS-5504 with latest version (Except for wall thickness). M.S.
Pipes shall be welded spirally. Before fabrication of pipes and specials / fittings is com-
menced, the copies of the mill sheets and the manufacturer’s test certificates for plates

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and other materials required for fabrication shall be submitted by the Contractor to the
Engineer In-charge for his approval.
When instructed by the Engineer In-charge, the Contractor shall supply free of charge
to the Engineer-in-charge for testing suitable samples of the materials to be used / used
in the Works.
2.4.13 Inspection
All materials will be subjected to inspection by the Engineer In-charge, his authorized
representative. The inspection charges shall be borne by the Government / Department.
However, in any case of re-inspection due to rejection / rework required of inspected
goods or inspection could not be carried out due to non-readiness of material called for
inspection etc., the additional charges for inspection will be borne by the contractor and
are required to be paid directly to the inspection agency. All such incidents will be re-
ported to the Engineer-in-charge in writing within a week.
The Contractor shall notify the Engineer In-charge, in advance of the production of
materials and fabrication thereof, in order that the Employer may arrange for mill and
shop inspection.
The Engineer In-charge may reject any or all materials or work that does not meet with
any of the requirements of this specification. The Contractor shall rectify or replace
such rejected material/performed work at his own cost, to the satisfaction of the Engi-
neer In-charge.
The Engineer In-charge shall have free access to those parts of all plants or any other
premises and sites that are concerned with the furnishing of materials or the perfor-
mance of work under this specification. The Contractor shall furnish to the Employer's
inspector reasonable facilities and space without charge for inspection, testing and ob-
taining of any information he desires in respect of the character of material used and
the progress and manner of the work.
2.5 Manufacturing of Spirally Welded MS Pipe
2.5.1 General
1. The pipes shall be truly cylindrical, and straight in axis. The ends shall be accurately
cut and prepared for field welding. The external circumference of the pipe pieces, which
are to be fixed adjacent to flange adapter with fixed outer diameter, shall not deviate
from theoretical one by more than 1 mm. To obtain this accuracy the pipe shall be rolled

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several times, if necessary, as pipe pieces should be truly cylindrical. The external lon-
gitudinal welding of this pipe shall be ground smooth flush with surface to the satisfac-
tion of the Engineer In-charge, for a length of 200 mm. No extra cost shall be charged
by the Contractor for this grinding work.
2. Minor repair by welding or otherwise shall be permitted at the discretion of the En-
gineer In-charge, but such repairs shall be done only after obtaining the previous per-
mission of the Engineer. Any pipe or part thereof which develops injurious defects dur-
ing shop welding or other operations shall be rejected.
2.5.2 Fabrication
Pipe shall be manufactured by continuous process, Spiral Submerged Arc Welding
(SAW) facility with on line testing sequentially, dust free environment, Real time
radiography (RTR) of the entire weld length of each pipe, X-ray, Ultrasonic testing,
adequate Hydraulic testing, etc.
The contractor shall get the MS pipe fabrication at well established, proven, having
adequate test facility, having pipe coating facility (inside-epoxy coating) and executed
at least three project and supplied 100 km of pipes with solvent free NSF/ANSI 61
approved High build liquid epoxy coating, having valid factory license. The contractor
shall propose such manufacturing unit/s for with credentials of manufacturing unit/s
approval by the department prior to placement of order. The department shall not be
responsible for non-acceptance of MS pipes manufactured/being manufactured in
absence of such approval from the department of particular manufacturing unit/s.
In no case manufacturing/fabrication of MS pipes shall be permitted at site. This man-
ufacturing unit/s should have the following minimum set-up viz.,
 Continuous Plate bending machines for rolling.
 By continuous Spiral Submerged Arc Welding (SAW) facility with at least one pass
inside and one pass out side welding with online testing sequentially.
 SAW (Submerged Arc Welding) machine & Automatic welding machines (suitable
for circumferential as well as longitudinal welding)- suitable for 3000 mm Dia
pipes.
 Automatic tracking of weld head in weld joint by Laser at forming for SAW weld
at final welding station

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 Pipe coating facility (inside-epoxy coating & outside - hot applied 3LPE/polyolefin
tape coating) set-up
 Hydraulic Testing Machines
 Travelling gantry or crane of suitable capacity
 Mobile cranes of suitable capacity for loading/unloading of HR/Plates and Pipes.
 Lathe for machining of the flanges rings, plates etc.
 Equipment for abrasive/ shot blasting and applying paint by spray gun.
 Equipment for cold forming of plates up to 25 mm thick to the required curvature
 Pipe hydro-testing set-up
 Testing equipment online and off line such as UT/ radiography/ DPT/ Chemical &
mechanical laboratory for DT & NDT etc.
 Real time radiography testing of spirally weld seam prior to Hydro test to ensure
the weld soundness and reduce repair work after hydro test.
 Valid management system certificates ISO 9001, 14001, 18001.
 Valid IS 3589, IS 5504 license for product marking.
 Valid license from AERB / BARC for X-ray testing facility.
In addition to above, the details such as company profile, manufacturing experience,
order in-hand, client list, quality certifications or other details pertaining to pipes fabri-
cation information as asked by the department.
2.5.3 Cutting plates to size
The plates shall be indented in such length as to have minimum wastage and so as to
make the pipe as far as possible with one longitudinal weld joints.
Before cutting, all the edges of the plates shall be cleaned by brushing/grinding on both
the sides.
After the plates are cut, the edges shall be made smooth and even by polishing with an
electrical or pneumatic grinder to remove all inequalities. Care shall be taken to see that
the cut edges of the plate are perfectly straight. Jigs to be used for this purpose shall
depend upon the types of cutting machine used. The plates cut to the required shape
shall be checked for correctness before they are rolled into pipe drums. If any correc-
tions are required, the Contractor shall do the same by re-cutting, if necessary. If any
plate or flat is found to be warped, to have corrugations, the defects shall be removed
by putting the plate or flat into a roller press, and no extra payment for this rectification

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work shall be made. The laminated or heavily corroded plate shall not be used in the
manufacturing of the pipe.
2.5.4 Rolling of Plates
The plates cut to the exact size shall be put into a rolling machine to form a pipe of the
required diameter. The Contractor shall adjust the rolling machine so as to give a uni-
form curvature to the pipe throughout its circumference. The curvature obtained shall
be checked by the Contractor's foreman during the process of rolling and if proper cur-
vature is not obtained at any place including the ends, the rolling operation shall be
repeated at this stage or even after the longitudinal welding of the drum where directed.
Heating of plates to obtain the desired curvature shall not be permitted.
2.5.5 Tacking the Drums
The rolled drums shall be kept on an assembly platform for tacking, care being taken
to ensure that the tacked drums have their end faces at right angles to the axis of the
pipe. While tacking the drum a gap of 2 mm to 4 mm shall be maintained where hand
welding is permitted. However, where the welding is to be done on automatic welding
machine, there is no need of maintaining such gap depending on the penetration through
complete thickness of the welding required. To achieve this objective, clamp spiders,
tightening rings and or any other approved gadgets shall be used. Each such drum, be-
fore being taken to the assembly platform, shall be numbered on the inside with oil
paint, stating the plate thickness as well.
2.5.6 Assembly of Drums into Pipes
The tacked drums shall then be transported to an assembly platform where they shall
be tack-welded together to form suitable pipe-lengths. Plate shall be bent in the maxi-
mum possible width to reduce the number of circumferential joints.
The longitudinal joints shall be staggered at 90 deg. The drums when tacked together
shall have no circumferential gap when the welding is done on automatic welding ma-
chine. But when hand welding is adopted, a gap of 2mm to 4mm shall be maintained to
obtain a good butt-welded joint.
The assembly shall be truly cylindrical and without any kinks. The faces shall be at
right angles to the axis of the cylinder. A suitable arrangement for testing the correctness
of the face shall be provided by the Contractor at the assembly platform.
Factory made spirally welded pipes are also permitted.
2.5.7 Welding

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Scope
This specification shall apply to site fabrication of all welded joints in carbon steel
(Mild steel), low alloy steel and stainless steel for plant piping systems. Site fabrication
also covers any fabrication in a shop set-up at site. The welded joints include the fol-
lowing:
a) All butt welding joints of the longitudinal and circumferential type for
attachments in piping, castings and forgings of all components

b) Socket welding and fillet joints

c) All types of branch welds

d) Any other joints not specifically covered above.

Codes and Standards

The welding of all piping systems including equipment, welding consumables, preheat-
ing, post-weld heat treatment, other auxiliary functions and welding personnel shall
comply with all currently applicable statutes, regulations and safety codes in the locality
where the systems are to be installed. Nothing in this specification shall be construed
to relieve the CONTRACTOR of this responsibility. Specifically, the latest editions of
the codes and standards listed in following paragraphs shall apply:
a) ASME B31.3 - Pressure Piping Code for Process Piping

b) Indian Boiler Regulations (IBR)

c) ASME Boiler and Pressure Vessel Code (BPV Code), Section II Part C -
Material Specifications for Welding Rods, Electrodes and Filler Materials

d) ASME Boiler and Pressure Vessel Code (BPV Code), Section V - Non-
Destructive Examination

e) ASME Boiler and Pressure Vessel Code (BPV Code), Section IX - Welding and
Brazing Qualifications

f) Standards of the Pipe Fabrication Institute

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g) BS 2633-Specification for Class I Arc Welding of Ferritic Steel Pipework for

Carrying Fluids

The codes and standards listed in are integral part of this specification. In the event of
conflict between this specification and the codes and standards, the more stringent shall
govern. If no specific requirements are given in this specification, the requirements of
the applicable code shall govern.
The following welding processes shall be used for shop-fabricated and field-fabricated
piping systems:
Shielded Metal Arc Welding (SMAW)
Gas Tungsten Metal Arc Welding (GTAW)
Welding by oxyacetylene process shall not be used.
All butt welds shall be considered as full penetration welds. Welding from inside of the
pipe after back gouging and chipping is not envisaged. However, if the Contractor pro-
poses to use such a method, a detailed written procedure shall be submitted for the
Engineer-In-Charge’s approval.
All components of a standard shell, either straight or bent etc. shall be welded, by use
of automatic arc welding machine by Submerged Arc welding process with alternating
current. Manual welding shall not be permitted except for sealing runs/ field weld joints
and such other minor works at the discretion of the Engineer In-charge. The strength of
the joint shall be at-least equal to that of the parent material.
Welding Qualifications:
Qualification of the welding procedures to be used and the performance of welders and
welding operators shall conform to the requirements of the BPV Code, Section IX. For
IBR systems, these shall also meet the requirements of IBR.
No production welds shall be undertaken until the qualification requirements are com-
pleted to the satisfaction of the ENGINEER-IN-CHARGE.
When impact testing is required by the code or by the specification, these requirements
shall be met in qualifying welding procedures.
The CONTRACTOR shall be responsible for qualifying any welding procedure and
welders intended to be used. The CONTRACTOR shall submit the Welding Procedure
Specification (WPS) for acceptance by the ENGINEER-IN-CHARGE. After approval
by the ENGINEER-IN-CHARGE, the procedure qualification test shall be carried out
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by the CONTRACTOR, at his own expense, duly witnessed by the ENGINEER-IN-

CHARGE. A complete set of test results shall be submitted to the ENGINEER-IN-
CHARGE for approval immediately after successful completion of procedure qualifi-
cation test. All tests as required by the BPV code Section IX or IBR shall be carried out.
The WPS shall require re-qualification if any of the essential variables or supplemen-
tary variables is altered.
Welders shall be qualified in accordance with BPV Code, Section IX or IBR, as appli-
cable. The qualification shall be carried out in the presence of the ENGINEER-IN-
CHARGE. Only those welders who are qualified and approved by the ENGINEER-IN-
CHARGE shall be used on the job. For IBR systems, approval of the local IBR inspec-
tor shall be obtained by the CONTRACTOR.
Welders shall always keep their identification cards with them and shall produce them
on demand. The CONTRACTOR shall issue the identity cards after the same are duly
certified by the ENGINEER-IN-CHARGE. Welder, who is not in possession of the
identity card, shall not be allowed to work.
The CONTRACTOR shall use forms as per BPV code, section IX, form QW-482, form
QW-483 and form QW-484. Other forms are also acceptable subject to approval by the
ENGINEER-IN-CHARGE.
Unless agreed otherwise, the CONTRACTOR shall advise the ENGINEER-IN-
CHARGE, in writing, at least three (3) weeks before any welder is employed on the
work, the names and qualifications of the proposed welders and welding supervisors. It
shall be the CONTRACTOR’s responsibility to ensure that all welders employed by
him or his SUB-CONTRACTORS, on any part of the CONTRACT either in the CON-
TRACTOR’s/his SUB-CONTRACTOR’s works or at site are fully qualified as re-
quired by the code. Each welder shall qualify for all types of welds, positions and ma-
terials or material combinations he may be called upon to weld.
Should the ENGINEER-IN-CHARGE require to test or retest any welder, the CON-
TRACTOR shall make available, at no extra cost to the ENGINEER-IN-CHARGE, the
men, equipment and materials for the tests. The cost of testing the welds shall be borne
by the CONTRACTOR.

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Welding supervisors shall have qualifications such as engineering degree or engineer-

ing diploma in welding technology with adequate knowledge of non-destructive testing
and a minimum of five (5) years of experience in supervising welding of pipe joints.
All welding, including the tacking up of all welds shall be carried out by approved
welders. Any weld made by other than an approved welder shall be cut out and re-
welded.
For purposes of identification and to enable tracing full history of each joint, each
welder employed on the work shall be given a designation. The welder’s designation
and the date on which the joint was made, shall be stamped on the relevant piping and
marked on the relevant drawings also. Copies of the drawings so marked shall be fur-
nished to the ENGINEER-IN-CHARGE for record purposes. For austenitic stainless
steels, welder’s designation shall be applied with water-proof paint that is not detri-
mental to the pipe. Alternatively, record charts may be used.
For each welder, a record card shall be maintained showing the procedures for which
he is qualified. These cards shall note the production welds, the date of the welding
done, the type of defects produced and their frequency. The record shall be reviewed
once in a week by the ENGINEER-IN-CHARGE and those welders whose work re-
quired a disproportionate amount of repair shall be disqualified from welding. Requal-
ification of welders disqualified more than three (3) times shall be entirely at the dis-
cretion of the ENGINEER-IN-CHARGE.
The ENGINEER-IN-CHARGE shall have free access to inspect welding or any other
related operations at any time and at any stage of fabrication. The ENGINEER-IN-
CHARGE may require non-destructive testing of any weld for reasons other than those
given in the specification. The responsibility for the cost of such testing shall be mutu-
ally decided between the ENGINEER-IN-CHARGE and the CONTRACTOR. The
CONTRACTOR shall inform the ENGINEER-IN-CHARGE when the weld prepara-
tion and setting up for welding of various members selected by the ENGINEER-IN-
CHARGE is in progress so that the ENGINEER-IN-CHARGE can inspect the assem-
bly before welding starts. The responsibilities of the ENGINEER-IN-CHARGE’s rep-
resentative shall in no way reduce the CONTRACTOR’s responsibilities to ensure that
the work is carried out in accordance with the specification. Any examination by non-

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destructive methods on low alloy steels shall be performed after post weld heat treat-
ment. For a welded branch connection, the examination of and any necessary repairs
shall be completed before any reinforcing pad is added.
Examination of Welds
Examination refers to the quality control functions performed by the CONTRACTOR
during fabrication, erection and testing. As a minimum, the following shall be examined
by visual examination:
a. Materials and components to ensure that these are as per the specification and are
free from defects. If defects are noticed on “free-issue” items, these shall be brought
to the notice of the ENGINEER-IN-CHARGE without delay.
b. Joint preparation and cleanliness
c. Preheating as applicable.
d. Fit-up, joint clearance, and internal alignment prior to joining.
e. Variables specified by the welding procedure, including filler material, position and
electrode.
f. Condition of the root pass after cleaning - external and where accessible, internal.
g. Slag removal and weld condition between passes.
h. Appearance of the finished joint Acceptance for the visual examination shall be as
per ASME B 31.3 or IBR as applicable.
The contractor shall use radiographic quality electrodes and to be carry-out the welding
procedure specification (WPS) and Pre-Qualification Requirement (PQR). For welding
the contractor shall ensure use with standard current and arc voltage required for the
machine. For this purpose, samples of welded joints shall be prepared and tested in the
presence of the Engineer in-charge. The values once determined shall be maintained
throughout the work and if any modifications are to be made, a written permission of
the Engineer In-charge shall be obtained. In the case of thin sheets, electric arc welding
may not give satisfactory results and gas welding shall be resorted to. Gas welding shall
be subject to the same specifications and tests as those for electric welds. Welding
should be carried out inside as well as outside.
Welder Qualification

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The contractor should engage all qualified welder for field welding at least having of
6G level qualification. The contractor should submit such qualified welders list prior
taking up welding work.
All welding shall conform to the requirements of IS 4353 latest version
All longitudinal and circumferential joints shall be double welded butt joints. Field
joints shall be from outside, with a sealing weld from inside. End preparation for such
welding shall conform to IS:2825.
All circumferential welds involving plates of unequal thickness shall be so kept that the
inside surfaces of plates match to provide stream lined joints without alteration in the
internal diameter. As far as practicable, welding of dissimilar thickness of shells shall
be carried out in the shops.
The welding shall be of the best workmanship free from flaws, burns, etc. and the Con-
tractor shall provide for his own electrodes and equipments, ovens to keep the elec-
trodes at the desired temperatures and dry. In order to maintain a good standard in weld-
ing, welders shall have to undergo for testing. Such testing shall be organized by the
Contractor before they are entrusted with the job. Qualification standard for welding
procedures, welders and welding operation shall conform to the requirements of
IS:7307 and IS: 7310 (latest) and/or ASME section-IX (latest). Periodical tests as re-
gards their efficiency shall also be taken at intervals of about 6 months and those found
inefficient shall be removed from the job. Only those who pass the test shall be posted
on the job. If an incompetent welder has already welded some pipes, all welding done
by him previously shall be fully checked by X-ray in addition to the regular X-ray in-
spections. The defects if any shall be set right to the satisfaction of the Engineer In-
charge. All such check tests and rectifications of defects shall be entirely at the cost of
the Contractor. No pipes or steel sections shall be erected unless the work of the welder
concerned has been proved to be satisfactory. Site welds shall be done by specially
selected welders.
A record shall be maintained showing the names of welders and operators who have
worked on each individual joint. Hand welding shall preferably be carried out by a pair
of welders so that, by observing proper sequence, distortion can be avoided. A joint
entrusted to a particular individual or a pair shall be as far as possible, completed by
them in all respects, including sealing run. No helper or other unauthorized person shall

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be permitted to do any welding whatsoever. In case of infringement of above, the per-

sons shall be punished as directed by the Engineer In-charge.
The welded joint after welding should not become brittle or sensitive to blows and there
should be no loss of toughness due to welding or heat treatment. The material after
welding and heat treatment is to be tougher than the base metal and is to retain its orig-
inal ductility. No allowance will be made for thinning of weld and the weld should in
no point be less than the nominal thickness of plate.
Upon receipt of the order and prior to the start of fabrication, the Contractor shall submit
to the Engineer In-charge for his approval the “welding procedure'' he intends to use in
the shop work. Similarly, prior to the start of the field welding, procedure for the field
welding must be submitted to the Engineer In-charge for his approval. Manual welding
shall be adopted only when machine welding is not possible.

2.5.8 Ultrasonic Test of Welded Joints

Minimum 15% of welded length in each pipe (well distributed along the pipe length) at
random shall be subjected to ultrasonic test at factory. The acceptance / rejection criteria
shall be as per API 5L (American Petroleum Institute). The ultrasonic test shall be con-
ducted as per relevant ASME code. (American Society of Mechanical Engineering) The
person who conducts the test shall have certificate as per ISNT or ASNT Level-2.
(American Standards and Testing)
2.5.9 Radiographic test of welded Joints
In case of field joints, minimum 10 % of weld length of each joint at random shall be
subjected to radiography test.
In case of shop / plant fabrication of pipes, minimum 200 mm of weld length of each
pipe end shall be subjected to radiography test.
In case of failure of joints, the contractor shall be required to carry out radiography of
thrice the number of segments failing during the radiography test. Even after such radi-
ography testing, if any one of the segment fails, the contractor shall be required to carry
out radiography of full joint.
The weld ripples or weld surface irregularities, on both inside and outside shall be re-
moved by any suitable mechanical process to a degree such that resulting radiographic
contact due to any remaining irregularities cannot mark or be confused with that of
objectionable defect. The radiograph shall be made in strict accordance with the latest

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requirements and as per the latest and most efficient technique either with X-ray or
Gamma ray equipment.
The photographs are to be marked in such a way that the corresponding portion of the
welded seam can be readily identified. All radiographs will be reviewed by the Engineer
to identify the defect and determine those which must be removed. Defects that are not
acceptable shall be removed by chipping, machining or flame gouging to sound metal
and the resulting cavities shall be welded. After rectification, the joint is to be radi-
ographed again to prove the quality of the repair. The radiographs will be judged as
acceptable or unacceptable by the Engineer In-charge based on the latest standards pre-
scribed by Indian Standard specification.
All X-ray shall be made with equipment and by personnel furnished by the Contractor.
Films shall be developed within 24 hours of exposure and be readily accessible at all
times for inspection by the Engineer In-charge. The Contractor shall provide for the use
of the Engineer In-charge suitable X-ray viewing equipment. X-ray films shall be
properly maintained by the Contractor and shall be handed over to the department on
completion of the Contract. All films shall be identified by the no. and chart prepared
indicating location of the joint each X-ray photo represents. In the event of additional
radiographic inspections required of any work associated with the pipe erection, such
inspection shall be performed by the Radiographer at the discretion of the Engineer In-
charge.
The Radiographic / X-ray test facility of the pipe manufacturer shall have valid license
/ approval from the AERB and in compliance with the requirements of the AERB.
2.5.9.1 Real Time Radiographic Inspection of Weld Seams
The entire weld length of pipes shall be tested by real time radiography (RTR) after the
SAW welding and prior to the Hydro test in accordance with the ISO 10893 – 7. All
unacceptable defects shall be repaired as per the approved repair procedure to enable to
reduce the repair of weld seams after hydro test.
2.5.9.2 Radiographic Inspection
1. General
The Engineer shall assure himself that the welding procedure employed in the construc-
tion of pipes has been qualified. The Contractor shall submit evidence to the Engineer
In-charge that the requirements have been met. The Contractor shall certify that the
welding of pipes has been done only by qualified welders and welding operators and
the Engineer In-charge shall ensure himself that only qualified welders and welding
operators have been used.
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The Contractor shall make available to the Engineer In-charge a certified copy of the
records of the qualification tests of each welder and welding operator. The Engineer In-
charge shall have the right at any time to call for and witness tests of welding procedure
or of the ability of any welder and welding operator.
2. Radiographic Inspection of Welded Joints
All welded joints are to be radio graphed and shall be examined in accordance with:
Code Description
IS: 2595-1978 Code of Practice for Radiographic Testing

IS:4853-1982 Recommended Practice for Radiographic Inspection of Fu-

sion Welded Butt joints in Steel Pipes
IS:1182-1983 Recommended Practice for Radiographic Examination of
Fusion Welded Butt-Joints in steel plates. (second revision)

IS:2598-1966 Safety Code for Industrial Radiographic Practice.

The reinforcement on each side of all butt-welded joints shall not exceed 1.5 mm.
A complete set of radiographs and records as described in IS:2595 Clause 14, for each
job shall be retained by the Contractor and kept on file for a period of at least five years.
Radiographers performing radiograph shall be qualified in accordance with SNT-TC-
1A. Supplements and Appendices “Recommended Practice for Non-destructive Test-
ing Personnel Qualification and Certification'' published by the American Society for
Non-destructive testing as applicable for the technique and methods used.
Final acceptance of radiographs shall be based on the ability to see the prescribed pen-
etrometer image and the specified hole.
Sections of welds that are shown by radiography to have any of the following types of
imperfections shall be judged unacceptable and shall be repaired.
 any type of crack, or zone of incomplete fusion or penetration,
 any elongated slag inclusion which has length greater than 6 mm,
 any group of slag inclusion in line that have an aggregate length greater than thick-
ness in a length of 12 times thickness, except when the distance between the suc-
cessive imperfections exceeds 6L where L is the length of the longest imperfection
in the group.
 Rounded indications in excess of that specified by the acceptance standards given
earlier
2.5.10 Tolerance

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The shell in the completed work shall be substantially round. The difference between
maximum and minimum inside diameters at any cross section shall not exceed 1% of
the nominal diameter of the cross section under consideration subject to a maximum of
10 mm. Straight pipes shall have their faces perpendicular to the axis of the section with
a maximum deviation of 2 mm on either side of the plane. Pipe ends shall be bevelled
as per IS-3589 and/or IS-5504.
For the shell thickness, no negative tolerances are acceptable.
2.5.11 Shop Testing
After fabrication, but before application of protective coatings all pipes and specials
shall be subjected to a shop hydraulic test. Standard lengths of pipes shall be directly
subjected to test and non-standard pipe and elbows can be tested as standard pipe before
being cut to size.
The Hydraulic test pressure for individual pipe in the factory shall be as per IS: 3589
(refer latest version).
Prior to testing, the pipe shall be inspected thoroughly by Real Time radiography (RTR)
and all the apparent defects in welding such as jumps, porosity etc. shall be repaired by
gouge and re-welding.
The hydraulic test shall be carried out under cover at the fabrication shop, in the pres-
ence of and to the satisfaction of the Engineer In-charge or the inspection agency ap-
pointed by the Employer.
For indicating the pressure inside the pipe an accurate pressure gauge of approved make
duly tested and calibrated for the accuracy of readings shall be mounted on one of the
closures, which close the pipe ends.
The pressures shall be applied gradually by approved means and shall be maintained
for at least 5 seconds or till the inspection of all welded joints is done during which time
the pipe shall be hammered throughout its length with sharp blows, by means of a 1 Kg
hand hammer.
The pipe shall withstand the test without showing any sign of weakness, leakage, oozing
or sweating. If any leak or sweating is observed in the welded joints, the same shall be
repaired by gouging and re-welding after dewatering the pipe. The repaired pipe shall
be re-tested to conform to the specified pressure.

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If any leak or sweating is observed in pipe shell the pipe under test shall be rejected
temporarily. The Contractor shall stack such rejected pipes separately in his yard. The
Engineer In-charge shall inspect the same and after taking cuts if necessary, shall deter-
mine the nature of repairs to be carried out thereon and shall then decide as to how and
where they shall be used. No payment shall be made for handling or carrying out re-
pairs, but, payment for the fabrication and hydraulic testing of the pipe shall be released
only after acceptance of the pipe with necessary repairs and subsequent testing etc. are
carried out by the Contractor to the satisfaction of the Engineer In-charge. The Engineer
In-charge shall be supplied with two copies of the results of all the tests carried out.
2.5.12 Submission of Daily Progress Report
The Contractor shall submit to the Engineer In-charge a daily progress report in the
Performa approved by the Engineer In-charge, wherein all the details of the work car-
ried out in the factory shall be fully recorded. Similarly, works done in the various units
in the factory shall be separately mentioned. The Contractor shall maintain a register of
all the finished materials giving dates of carrying out important operations such as test-
ing, transport, etc. The register shall be presented at least once a week to the Engineer
In-charge who shall initial the entries after verification.

2.6 Transportation of Pipes, Specials, etc.

All pipes and specials fabricated in the factory and temporarily stacked in the Contrac-
tor's yard shall be transported to the site of laying after cleaning them internally etc.
The loading in the factory shall be carried out by means of either a crane, gantry or
shear legs, so as not to cause any damage to the finished material. Similarly, while un-
loading and stacking, great care shall be taken to ensure that the material (pipe & spe-
cial) is not damaged or dented. The contrivances to be used for unloading will be dif-
ferent in different situations and in each case the one approved by the Engineer In-
charge shall be adopted. The material stacked at site shall be jointly inspected by the
Engineer In-charge and the Contractor and defect or damage noticed shall be repaired
to the satisfaction of the Engineer In-charge before payment is admitted.
Props of approved designs shall be fixed to the pipes during transit to avoid undue sag-
ging and consequent distortion. After the pipes are carefully stacked, props may be re-
moved and re-used for subsequent operations. The stacking ground, both in the Con-
tractor's yard and at the site of laying shall be selected in such a way as not to get

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waterlogged during monsoon. If this cannot be done, the pipes shall be supported on
sleepers to avoid contact with wet earth and subsequent rusting. In order to prevent
sagging during transit, savings of steel plates can be utilized by cutting to the required
length and tacking the same to the pipe ends, in place of props, if approved by the
Engineer In-charge.
As explained in earlier paragraphs, materials such as pipes, tapers, etc. may be trans-
ported to the site of laying as soon as the material is finished in all respects with the
permission of the Engineer In-charge to avoid congestion in the Contractor's yard. How-
ever, materials such as expansion joints, composite bends, ‘T' branches and other com-
plicated materials shall be stacked in the Contractor's yard until they are required for
laying in the field. In view of this, the work of fabrication of such materials shall be
properly synchronized as far as possible with the laying operations.
Fabricated materials such as manhole covers, appurtenances, bolts, nuts, distance pipes,
flanges, saddles, collars bypass arrangements etc. shall be transported to the site of lay-
ing from the fabrication shop according to the needs of the laying operations only. In
regards access roads, the Contractor shall note that access road may lead up to some
points on the alignment the Contractor shall have to make his own arrangement for
connecting approaches to transport the pipes cross country to the actual site of laying
at his own cost. Whatever may be the mode of transport he uses it shall be incumbent
on the Contractor to carry and stack the pipes and specials along the alignment as close
as possible to the site of laying.

2.7 Procedure for receiving Steel Pipes

2.7.1 General
To ensure that the work of erecting pipes is not held up at any stage and place, the
Contractor shall maintain an adequate stock of standard specials, flange rings, plug
plates, manhole covers, etc. and short length of smaller diameter pipelines, etc. at site
in his field stores, in consultation with the Engineer. Wherever possible, the Contractor
shall arrange one full month's requirement of pipes, specials, etc. stacked along the
alignment.

2.7.2 Stacking of pipes, etc. and Inspection

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The Contractor shall keep in each section a responsible representative to take delivery
of the pipes, specials and appurtenances, etc. transported from the fabricating stockyard
or received from any other work site to the site of laying and to stack along the route
on timber skids. Padding shall be provided between coated pipes and timber skids to
avoid damage to the coating. Suitable gaps in the pipes stacked shall be left at intervals
to permit access from one side to the other. The pipes, specials, appurtenances so re-
ceived on site shall be jointly inspected and defects recorded, if any, such as protrusions,
grooves, dents, notches, damage to the internal coating etc. shall be pointed out imme-
diately to the Engineer In-charge at the site and in the acknowledgement challans. Such
defects shall be rectified or repaired to the satisfaction of the Engineer In-charge en-
tirely at the Contractor's risk and cost.
2.7.3 Handling of Pipes, Specials, Appurtenances, etc.
It is essential to avoid damage to the pipes, fittings and specials, etc. or their coatings
at all stages during handling. The pipes and specials shall be handled in such a manner
as not to distort their circularity or cause any damage to their surface treatment. Pipes
shall not be thrown down from the trucks nor shall they be dragged or rolled along hard
surfaces. Slings of canvas or equally non-abrasive materials of suitable width of special
attachment shaped to fit the pipe ends shall be used to lift and lower coated pipes to
prevent damage to the coating.
Great care shall be taken in handling the pipe right from the first operation of manufac-
ture until they are laid and jointed. The Contractor will provide temporary props in order
to prevent any sagging of the pipes while they are stacked in their yard and while trans-
porting to the site of delivery, i.e. laying. The props shall be retained until the pipes are
laid. If at any time these props are found to be dislodged or disturbed, the Contractor
shall immediately reinstate them in such a way that the true shape of the pipe shell or
specials is maintained to the satisfaction of the Engineer In-charge. No defective or
damaged pipe or special shall be allowed to be used in the work without rectification to
the satisfaction of the Engineer In-charge. Any damage to the coating shall be repaired
by the Contractor at his own cost to the satisfaction of the Engineer In-charge.
2.7.4 Dents
Whenever any dent, i.e. a significant alteration of the curvature of the pipe shell is no-
ticed, the depth of the dent shall be measured between the lowest point of the dent and
the pipe shell curvature line. All dents exceeding 2 percent of the outer diameter of the
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pipe shall be removed by cutting out a cylindrical portion of the pipe and replacing the
same by an undamaged piece of the pipe. The Engineer In-charge may permit insert
patching if the diameter of the patch is less than 25 percent of the nominal diameter of
the pipe. Repairs by hammering with or without heating shall not be permitted. Any
damage to the coating shall also be carefully examined and rectified.
2.7.5 Marking
The component parts of the pipes shall be carefully marked for identification in the
field. The marking shall be on the side, which will be the inside of the pipe after bend-
ing.
The marking operation shall be conducted with full size rulers and templates. Only
blunt nose punches should be used.
The plates used for fabrication of pipes shall be laid out in such a way that when the
shells are completed one set of original identification markings for the material will be
plainly visible. In case these markings are unavoidably cut out, they shall be accurately
transferred by the Contractor to a location where these markings will be visible on the
completed work.
After hydraulic tests on the specials and other items, the number of the shell in the line
as it will be erected and the direction of flow shall be stamped in a prominent manner
on each piece.
A register shall be maintained in suitable proforma giving the following information for
each shell tested:
i. Serial No.
ii. Shell No.
iii. Date of test
iv. Thickness and specification of steel
v. Weight of shell tested
vi. Maximum test pressure
vii. Details of test performance
viii. Details of radiographic examination of welds
ix. Name of Engineer's representative witnessing tests
A copy of these details shall be furnished to the owner at free of cost. No separate
payment will be made for these markings and the rates for the items concerned shall be
deemed to include the cost of such markings.

2.8 Specification for liquid epoxy coating systems for drinking water steel pipelines
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Providing & applying internal coating to MS pipe with solvent free NSF / ANSI 61
approved High build liquid epoxy having dry film thickness of minimum 406 microns
including scrapping the surface of the pipe. Epoxy coating of supplied pipe shall be
carried out at factory, only field joint coating acceptable at site.
2.8.1 Scope
This specification is intended to establish the minimum criteria necessary for selection
of the coating material, supply of the materials and equipment, qualification, applica-
tion, inspection, testing, handling, storage and packaging of the materials that is re-
quired for protecting the internal surface of the drinking water carrying pipelines &
pipeline components that are coated in factory.
This specification covers chemically cured 2-part epoxy based solvent-free liquid coat-
ing material.
The specification has been designed for the said application and material, will be re-
vised periodically if needed, to meet environmental regulations & health-effects and to
modify procedures based on technological advances.
This specification makes restrictive amendments/modification to ANSI/AWWA C-210-
2015.

2.8.2 References
This specification makes reference to the documents listed below. Unless specified oth-
erwise, the latest editions of these documents including all addenda and revisions shall
apply.
Transco specification
 T/SP/CM1-Technical Specification for internal coating operations for steel line pipe &
fittings T/SP/CM2- Technical Specification for internal coating materials for steel line
pipe & fittings.
 ANSI/AWWA specification
 ANSI/AWWA C210-2015 - Standard for Liquid Epoxy coating systems for the interior
and exterior of steel water pipelines
ASTM standards
 ASTM D4060 - Standard Test Method for Abrasion Resistance of Organic Coatings
ASTM D2794 - Standard Test Method for Resistance of Organic Coatings to the effect
of Rapid Deformation (Impact)

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 ASTM D2485 - Standard Test Method for Evaluating Coating for High Temperature
Service ASTM D4541 - Standard Test Method for Pull-off Strength of Coatings
 ASTM D1653 - Standard Test Method for Water Vapor Transmission of Organic Coat-
ings ASTM D3363 - Standard Test Method for Film Hardness by Pencil Test
 ASTM B117 - Standard Process for Operating Salt Spray (fog) Testing ASTM D2486
- Standard Test Method for Scrub Resistance
 ASTM G8 - Standard Test Method for Cathodic Disbonding of Pipeline Coatings
 CSA.Z.245.20- Standard Test Method for Cathodic Disbonding of Pipeline Coatings
British Standards
 BS 3900 - Methods of Test of Paints
 BS 7079 - Preparation of Steel Substrates before Application
Others
 SSPC PA 3 – Guide to Safety in Paint Application

2.8.3 Definitions

Applicator: The “Applicator” is the organization responsible to the purchaser for the
application of the coating.

Purchaser: The “Purchaser” is the company or the authorized agency that buys the
coating or coated pipe.

Supplier: The “Supplier” is the manufacturer and/or distributor of the coating material
and its authorized qualified technician.

Inspector: The “Inspector” is the authorized agent appointed by the applicator or the
purchaser to carry out inspection of the coating material and the coated product.

Coating Material: “Coating material” indicates the liquid material prior to application
on the pipe or substrate.

Coating: “Coating” indicates the film formed by the coating material when applied on
the substrate.

Batch: A “Batch” is the quantity of coating material manufactured at one time and iden-
tified by a unique batch number.

Note: Other definitions shall be in accordance with the referenced standards.

2.8.4 General Requirements

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2.8.4.1 Coating Supplier Information

The coating material supplier shall furnish documents with the following information
for each batch of material supplied, to the purchaser and/or applicator.

a. Directions for application and use of the coating materials.

b. Directions for handling and storing of the coating materials.
c. Specification of the basic physical properties and performance test results of the
material. These basic physical properties and performance test results shall be
within the range permitted in the recommended practice
d. Certification of the specific physical properties for each batch of coating
material shipped.
2.8.5 Requirements for Quality
The applicator shall have established within his organization, and shall operate for the
contract, a documented quality system that ensures that the requirements of this speci-
fication are met in all aspects. The coating material suppliers should have Quality Sys-
tem certifications of ISO 9001-2008, ISO 14001, and OHSAS 18001.
The applicator shall have established quality assurance group within his organization
that shall be responsible for reviewing the quality system and ensuring that it is imple-
mented.
The applicator shall submit the procedures, which comprise the quality system, to the
purchaser for agreement.
The applicator’s quality system shall pay particular attention to the requirements for
quality control of suppliers. The applicator shall ensure that requirements of this spec-
ification are satisfied by its suppliers and is operating similar quality system in their
organization.
The applicator shall, prior to the commencement of work, prepare and issue a quality
plan for all of the activities required to satisfy the requirements of this specification.
The plan shall be sufficiently detailed to indicate sequentially for each discipline the
requisite quality control, inspection, testing and certification activities with reference to
the relevant procedures and acceptance standards.
The applicator’s quality system and associated procedures may, with due notice, be
subjected to formal audits. The appointed representative (s) (by purchaser/ applicator)
will monitor quality control implemented by the applicator. These representative(s) will

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also witness and accept the inspection, testing and associated work required by this
specification.
The applicator’s equipment for blast cleaning and coating shall be of such design, man-
ufacture and condition to permit the applicator to comply with the procedures and ob-
tain the results prescribed in this specification.

2.8.6 Compliance
The Applicator shall be responsible for complying with all applicable requirements of
ANSI/AWWA C210-2015 and this specification. The purchaser reserves the right to
make necessary investigation and in case of doubt, ask the applicator to conduct addi-
tional testing, batch sampling and manufacturing inspection, in order to be satisfied of
compliance by the applicator. Any material/coating that does not comply with the re-
quirements shall be rejected.

2.8.7 Safety
All necessary precautions should be taken to protect personnel and property from acci-
dents due to falls, hazardous materials, fire, explosion, and other dangers. The methods
and practices define in SSPC PA3 shall be followed.
2.8.8 Coating System
2.8.8.1 Two part, chemically cured, Solvent-free Epoxy Lining
Spray applied, impermeable, 100% solids, high build, primer-less, chemically cured
epoxy coating. The coating shall be capable of building wet film thickness that can give
406 microns dry film thickness in single coat application.

2.8.9 Shelf life

The component parts shall be stored in unopened original containers at conditions as
recommended by the supplier. They shall show no instability or settling beyond a state
permitting easy, complete dispersion to a smooth homogenous consistency. When
properly mixed and applied, acceptable drying and curing shall result. Shelf life of the
material shall be at least 1year from the date of manufacturing.

2.8.10 Physical and Performance Properties

The coating material used shall confirm to the performance standards explained in Table
2. The coating shall be suitable for a maximum in-service temperature of 60˚C.Unless
specified otherwise; design life of the internal epoxy coating shall be 40 years.

2.8.11 Drinking Water Approvals

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Buried steel pipeline shall be coated internally, with a single coat two part solvent free
high build liquid epoxy lining as per AWWA C210-2015 suitable for potable water ap-
plication. The coating material should have yearly approval and listed by NSF Interna-
tional Standard NSF/ANSI-61 and also should have certification by water regulations
advisory scheme (WRAS), UK suitable for contact with wholesome water for domestic
purposes having met the requirements of BS6920-1:2000 and/or 2014 'Suitability of
non-metallic products for use in contact with water intended for human consumption
with regard to their effect on the quality of the water.

In addition to above statements and requirements, applicator need to withdraw samples

randomly from the batches used during coating application, the picked samples after
consultation with pipeline owner / EPC are to be send to NSF Lab in Michigan, US for
testing to conform the compliance of NSF/ ANSI 61 certification. The tests report needs
to be submitted to purchaser by applicator.

Coating material should also comply with US FDA 175.300 Leachable and extractible
criteria for to be in contact with drinking water, and to be tested by a Government ac-
credited laboratory. Report to be submitted by the coating material manufacturer to ap-
plicator and purchaser.

The applicator shall perform all work in accordance with these specifications and the
latest pipeline coating practices, and shall complete the work in all respects to the full
satisfaction of the purchaser /purchaser’s representative

2.8.12 Coating Application

2.8.12.1 General
The pipe coating material shall be used and applied in accordance with the supplier’s
recommendation, application by hot plural feed air-less spray is preferred.

2.8.12.2 Pipe Surface Preparation

All surfaces should be free from oil, grease and other contamination prior to abrasive
blasting.

Surfaces should be blast cleaned to a minimum Sa2½ in accordance with BS7079 Part
A1 1989 or equivalent. Prior to blast cleaning any sharp protuberances, surface lamina-

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tions, weld spatter, etc. shall be removed by thorough grinding and cleaning. The abra-
sive used should be capable of producing a minimum profile of 50-90 microns corre-
sponding to 'medium' in accordance with BS7079 Part C4.

All dust, residues and debris left on the surface after the blast cleaning must be removed.

2.8.12.3 Surface Profile

The surface profile (anchor pattern) shall be as recommended by the coating supplier.

2.8.12.4 Profile Determination

Depth of profile shall be determined in the field by using a replica tape, a depth mi-
crometer, or a surface profile comparator.

2.8.12.5 Surface Inspection

The cleaned interior pipe surfaces shall be inspected for conformance to Sec 2.5.2. Sur-
face imperfections such as slivers, scabs, burrs, weld spatter, and gouges, shall be re-
moved by grinding. Inaccessible surface imperfections may dictate that the pipe be re-
jected.

2.8.12.6 Interior Cleaning

If abrasives or other loose foreign matter has entered the interior of the pipe, then clean,
dry and oil-free compressed air shall be used to remove the loose foreign matter in a
manner that does not adversely affect the cleaned surface. Alternatively, vacuum clean-
ing or other methods may be used in place of compressed air.

2.8.13 Coating Application

Blast-cleaned pipe surfaces shall be protected from conditions of high humidity, rain-
fall, or surface moisture. Pipe shall not be allowed to flash rust before coating.

2.8.13.1 Materials Preparation

Materials preparation shall be in accordance with the supplier’s recommendations.

2.8.13.2 Application Temperature

 Liquid epoxy coating can be spray coated on the blast cleaned surface, when substrate
temperature is in the range of 70C to 500C. If steel temperature is below 70C or
above 500C, spray coating shall be stopped, until the substrate (pipe) temperature is
brought in the range specified here.
 Spray coating application shall be performed only when the relative humidity is below
85%. If ambient relative humidity increases above 85% coating process is to be
stopped. Applicator is responsible to measure and record relative humidity at every
60 minute interval.
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 Spray coating application to be done, only when steel surface temperature is at least
300C above the dew point of ambient air, so that moisture from ambient air does not
condense on the steel surface or coated surface. Applicator shall be responsible to
measure and record the dew point of ambient air by using dew point indicator
 Applicator shall be responsible to use appropriate grade of spray nozzle (23 to 39 thou)
and regulator to achieve required tip pressure (about 4000psi), as recommended by
the coating material supplier.
 Both base and activator components need to be preheated (as per recommendation from
the supplier), so that material temperature at the spray tip is in the range of 40˚C to
65˚C, again it depends on fan width during application which can be established
during application.
2.8.13.3 Application of Coating Material
The epoxy coating system shall be applied as recommended by the coating manufac-
turer. If more than one coat is applied, the second coat shall be applied within the time
limits, surface conditions, and temperature recommended by the supplier. If the period
between the coats is exceeded, then a repair procedure shall be obtained from the coat-
ing material supplier and its recommendations to be followed.

2.8.14 Coating Repair and Touch Up

Defective coating shall be repaired in accordance with the following sections.

Accessible areas of pipe requiring coating repairs shall be cleaned to remove debris and
damaged coating using surface grinders or other means acceptable to the purchaser. The
adjacent coating shall be feathered by sanding, grinding or other methods approved by
the purchaser. Accumulated debris shall be removed by vacuum, blowing with dry air
or wiping with clean rag.

Areas not accessible for coating repair, such as interior surfaces of small diameter pipe,
shall be reprocessed and recoated.

Repairs shall be electrically inspected using a holiday detector.

2.8.15 Field Joints

2.8.15.1 Preparation
The weld joints shall be cleaned to be free from mud, oil, grease, welding flux, weld
spatter, and other foreign contaminants. The cleaned metal surfaces of the weld joint
shall then be abrasive blasted, or abraded to provide a surface in compliance with Sec

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1.8.12 The adjacent coating shall be feathered by abrading the coating surface for a
distance of 50-70mm.

2.8.15.2 Coating
The coating system shall be applied to the weld joint in accordance with Sec 1.8.12

2.8.15.3 Inspection
After curing, the coating system shall be electrically inspected using a holiday detector.

2.8.16 Inspection
The coating system shall be inspected for adhesion to the steel and between coats, thick-
ness, blisters, cracks, bubbles, under-film voids, holidays, pinholes, discontinuities, and
mechanical damage. All imperfections shall be identified and marked with for repair.

After curing but prior to installation, the coating system applied to the pipe shall tested
for holidays according to the procedures and using the high voltage settlings outlined
in NACE RP0188 for the specified thickness. Any holidays indicated by the detector
shall be identified and marked for repair.

2.8.17 Coating Qualification Testing

General
The coating system shall be qualified for production by coating applicator by testing
laboratory coated test specimen for each applicable test (see clause 7.3) and by meeting
the acceptance criteria as applicable. The applicator shall submit all test reports to the
purchaser for review and approval. The coating shall be re - qualified where there is a
change in one or more of the following:

a) Supplier
b) Coating formulation, and
c) Location of manufacture

Preparation of Test Panels

Prepare 4 in x 6 in x 1/8 in steel panels by blast cleaning one side in accordance with
Sec 2.5.2. Apply the coating without primer at the specified thickness and by the method
recommended by the supplier. Cure the coating according to the supplier`s recommen-
dations.

Coating Qualification Testing Requirements

Cure Test
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The coating supplier shall be consulted to ascertain the proper cure time of the coating
prior to testing. The cure test, whether performed on the coating system applied to the
test panels prepared as in Sec 7.2 or on the pipe in the shop or field, shall be performed
in accordance with solvent rub procedures as outlined in ASTM D4752 (Solvent Rub
Test), ASTM 3363 (Pencil Hardness) or both as required by purchaser. The coating sys-
tem that has not been cured in accordance with the manufacturer’s written instructions
may be rejected.

Adhesion Test
The adhesion or bond of the coating to the steel and the intercoat adhesion of succeeding
coats after curing shall be determined in the field after curing by making a V-shaped cut
through the coating with a sharp knife. The adhesion will be considered satisfactory if
the film can’t be peeled by the knife either from the steel or between coats for a maxi-
mum distance of 3.2mm from the intersection of the cut lines forming the “V”. Forcible
rupture of the coating that leaves potions of the film adhering tightly to the metal shall
not be cause for rejection. The adhesion of the coating to the test panel can also be
performed in the laboratory in accordance with ASTM D4541. The test can also be
performed in the field under the conditions set forth in the ASTM procedure.

Thickness Test
The thickness of each coat and of the final cured coating system shall be determined in
accordance with SSPC PA2.

QUALITY CONTROL TESTING

Applicator shall establish and maintain quality assurance system as are necessary to
ensure that goals or services supplied, comply in all respects with the requirements of
this specification. The quality assurance plan shall include following tests for quality
control:

Surface Preparation Stage

The standard of finish for cleaned pipe shall conform to near white metal finish to Sa2
½ of Swedish Standard SIS 055900 latest edition. Surface of pipe after abrasive
shot/grit blasting shall have an anchor pattern (surface profile measured from peak to
trough) of 50 to 90 microns (Rz) inclusive. This shall be measured for each pipe by a

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suitable instrument such as stylus gauge. In addition, the pipe surface after blast clean-
ing shall be checked for the degree of cleanliness (Say 2 ½) and degree of dust and
shape of profile

All pipes shall be preheated to a temperature of 55˚C to 65˚C, prior to abrasive blast
cleaning. The pipe surface shall be maintained at a temperature of at least 3˚C above
dew point of the ambient air. At no time, the blast cleaning be performed when the
relative humidity exceeds 85%. The applicator shall measure the ambient conditions at
regular intervals during blast cleaning and coating operations and keep records of pre-
vailing temperature, humidity and dew point of the air.

Application Stage
Wet Film thickness shall be checked at 3’ O clock, 6’ O clock” and 12’ O clock positions
at both the pipe ends. It is suggested to maintain appropriate wet film thickness (~ 506
μ) to ensure a minimum dry film thickness of 406μ.

Visual Assessment: No runs, sags, or bubbling

About10 minutes of spinning to be carried out to avoid sagging.

Surface hardness to be measured after full cure.

The internal epoxy lining shall consist of resin (epoxy) & hardener (curing agent),
mixed in the ratio as recommended by the supplier and applied to a dry film thickness
(DFT) of minimum 406μ. Physical properties of the internal lining shall be as per Table-
1

During PQT the coated specimens cut from coated pipes are to be tested as per AWWA
C 210-2015 compliance requirement.

Prior to regular production coating, supplier needs to submit their quality assurance
plan for approval from purchaser for the process and tests are to be carried out. At no
point, the DFT of cured coating should not be less than 406 μ while maximum can be
up to 606 μ.

Table-1 Physical Properties of the Coating

Property Requirement Test Method

Long term contact with No effects for human NSF / ANSI -61
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potable water consumption as certified by

NSF International
Thickness (applied min) 406μ SSPC-PA 2
Thickness deviation - 0 / + 200μ SSPC-PA 2
(min)
Dielectric strength (min) 450 V/mil (15 V/μm) ASTM D149
Hardness Shore D 85 (min) ASTM D2240
Adhesion to Steel (min) 1500 psi ASTM D4541
Tabor Abrasion 1560 cycles / mil ASTM D4060
Compressive strength 70 MPa ASTM C109

Check for Touch Dry after 24 hours

Dry Film thickness: DFT should be measured after full cure.

Wet Sponge Holiday Detection: ISO 15741 method to be used for holiday detection.
Depending upon actual Dry Film Thickness, Holiday Voltage to be set as per ISO
15741 requirements of Wet Sponge Test. All detected holidays need to be repaired.

2.8.18 Rejection
Pipe

The purchaser may reject pipe if the surface condition does not comply with the re-
quirements of this specification.

Coating Material

The coating material may be rejected if the coating materials does not comply with the
requirements specified in Table 1 & 2.

2.8.19 Packaging, Handling, Stacking & Storage

Coated pipe and other article shall be packaged, handled and stored in a manner that
will minimize damage. Pipe or coating damaged in handling or other operations shall
be repaired in accordance with the procedure mentioned in this specification.
All coating materials shall be supplied to the job site in the supplier’s original, unopened
containers. Each container shall be plainly marked with the name and address of the
supplier, type of material, batch or lot number, date of manufacturing, storage condi-
tions and information as required by federal, provincial and state laws.
Stacking of coated pipes shall be in accordance with industry-accepted safety practices
and in accordance with purchaser’s instructions.
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Table 2 - Physical & Performance Properties of Liquid Epoxy Coating

S No PROPERTY TEST METHOD SPECIFICATION

1 PHYSICAL PROPERTIES
Total Solid Content (by Volume), % API 5L2 100
Specific Gravity (Mix), gm/cc ASTM D1475 Min -1.40
V.O.C. (as supplied) NIL
Film Thickness, Microns 406 - 1000Microns in Single
Coat

Note: The thickness should be agreed between the specifier & manufacturer dependent on operational
performance criteria
Theoretical Coverage API 5 L2 Min 2 Sq meter per litre @ 500u
DFT
Thermal stability of cured coating Supplier’s Method 650C in contact with water.
Application Method Hot Plural Feed Air- Uniform thickness of coating
less Spray
Mixing Ratio (v/v) Part-A: Part-B Supplier’s Method As per Manufacturer product
recommendation
DRYING PROPERTIES @ 20 °C
2

Touch Dry API 5L2 4 Hrs Max

Hard Dry API 5L2 6 Hrs Max
Full Cure API 5L2 7 Days Max

3 PERFORMANCE PROPERTIES (500-600 Micron DFT)

Abrasion Resistance (1 kg load, 1000 Cycles, ASTM D4060 Max 80 mg

CS 17)
Impact Resistance ASTM G14 ˃ 5 Joule
Dry Heat Resistance, °C ASTM D2485 80
Pencil Hardness ASTM D3363 3H Min
Shore D Hardness ASTM D2240 Minimum 78
Water Vapor Permeability, perm.cm ASTM D1653 3.75 X 10-6
Direct Pull Adhesion, Grit-blasted Steel, PSI ASTM D4541 Minimum 10MPa
Cathodic Disbondment, mm ASTM G8 6 Max
Salt Fog Resistance, Cycles ASTM B117 Minimum 5000Hrs should Pass
Scratch Resistance, 2.5Kg load BS 3900 part E2 No failure
Humidity Resistance, Hrs BS 3900 part F2 5000 Min
Cathodic Disbondment Resistance- 28 Days CSA.Z.245.20 ≤ 13.5 mm
/ 1.5V / 3% NaCl/ 65 ± 2 0C

Hot Water Soak Adhesion at 65 0C CSA.Z.245.20 Rating 1-3

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Water Vapor Permeability ASTM D 1653 2.5 Max

Gm.mm/m2/24hrs -

2.9 Outside Coating – For underground pipe upto 1500mm diameter SWMS pipe 3 LPE
outside coating shall be provided and above 1500mm diameter pipe polyolefin tape out-
side coating shall be provided by the bidder:
For Over ground pipe outside coating shall be of 2 layer Epoxy Paint over a coat of primer.

3 Layer Polyethylene

2.9.1 Scope
This Specification defines the minimum requirements for the application of three- layer
polyethylene coating to the external surface of steel pipes.
For the factory applied coating the system shall comprise of a layer of fusion bonded
epoxy (FBE), overlaid with adhesive with an outer layer for high density polyethylene
(HDPE).
2.9.2 Codes and Standards
This latest edition of the following codes and standards shall establish the minimum
standards for the work
Codes and Standards
Codes Standards
ANSI/AWWA Standard for Fusion-bonded Epoxy Coating for the Interior and Exterior
C213 of Steel Water Pipelines
ASTM D149 Standard test method for dielectric breakdown voltage and dielectric
strength of solid electrical insulating materials at commercial power fre-
quencies.
ASTM D257 Standard Test methods for dc resistance or conductance of insulating ma-
terials.
ASTM D570 Standard test method for water absorption of plastics
ASTM D638 Standard test method for tensile properties of plastics
ASTM D746 Standard test method for brittleness temperature of plastics and elastomers
by impact.
ASTM D790 Standard test method for flexural properties of unreinforced and reinforced
plastics and electrical insulating materials
ASTM D1238 Standard test method for melt flow rates of thermoplastics by extrusion
plastometer.
ASTM D1505 Standard test method for Density of plastics by the Density-Gradient Tech-
nique.
ASTM D1525 Standard test method for Vicat softening temperature of plastics.
ASTM D1531 Standard test methods for relative permittivity (dielectric constant) and
dissipation factor by fluid displacement procedures.
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ASTM D1603 Standard test method for carbon black content in olefin in define plastics
ASTM D1928 Standard practice for preparation of compression- molded polyethylene
test sheets and test specimens.
ASTM D2240 Standard test method for rubber property - durometer hardness.
ASTM D3417 Standard test method for enthalpies of fusion and crystallization of poly-
mers by differential scanning calorimetry (dsc)
ASTM D4703 Standard test practice for compression Molding Thermoplastic Materials
into Test Specimen, Plaques or Sheets.
ASTM F372 Standard test method for water vapour transmission rate of flexible barrier
materials using an infrared detection technique
AWWA C 200-97 Steel water pipe line
ASTM G8 Standard test method for Cathodic Disbonding of pipeline Coatings.
CAN/CSA Z Internal fusion bond epoxy coating / lining of steel pipes
245:1
DIN 30670 Polyethylene Coatings of Steel pipes and Fittings – Requirements and
Testing.
DIN EN ISO 9001 Quality management systems – Requirements
2000
DIN EN ISO Preparation of steel substrates before application of paints and related
8501-1 products - Visual assessment of surface cleanliness - Part 1 : Rust grades
and preparation grades of uncoated steel substrates and of steel substrates
after overall removal of previous coatings.
DIN EN ISO Preparation of steel substrates before application of paints and related
8502-2 products - Tests for the assessment of surface cleanliness – Part 2 : Labor-
atory determination of chloride on cleaned surfaces.
DIN EN ISO Preparation of steel substrates before application of paints and related
8502-3 products - Tests for the assessment of surface cleanliness - Part 3 : Assess-
ment of dust on steel surfaces prepared for painting (pressure-sensitive
tape method)
DIN EN ISO Preparation of steel substrates before application of paints and related
8502-4 products – Tests for the assessment of surface cleanliness – Part 4 : Guid-
ance on the estimation of the probability of condensation prior to paint
application.
DIN EN ISO Preparation of steel substrates before application of paints and related
8502-9 products – Tests for the assessment of surface cleanliness – Part 9 : Field
method for the conductometric determination of water-soluble salts.
DIN EN ISO Preparation of steel surfaces before application of paints and related prod-
8503-1 ucts. Method for the grading of surface profile of abrasivety blast cleaned
steel using a comparator (1995)
DIN EN ISO Preparation of steel substrates before application of paints and related
8503-1 products - Surface roughness characteristics of blast-cleaned steel sub-
strates - Part 1: Specifications and definitions for ISO surface profile com-
parators for the assessment of abrasive blast cleaned surfaces.

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DIN EN ISO Preparation of steel substrates before application of paints and related
8503-2 products - Surface roughness characteristics of blast-cleaned steel sub-
strates - Part 2: Method for the grading of surface profile of abrasive blast-
cleaned steel - comparator procedure.
ISO 8502-5 Preparation of steel substrates before application of paints and related
products - Tests for the assessment of surface cleanliness - Part 5: Meas-
urement of chloride on steel surfaces prepared for painting (ion detection
tube method)
NACE RP0490 Holiday Detection of Fusion-Bonded Epoxy External Pipeline Coatings of
250 to 760mm (10 to 30 mils)
NACE RP-01-75 Recommended practice: control of International corrosion in steel pipe
line system.
SIS 05-5900 Preparation of steel substrates before application of paints and related
products - visual assessment of surface cleanliness - PT 1: rust grades and
preparation grades of uncoated steel substrates and of steel substrates after
overall removal of previous.

2.9.3 General
2.9.3.1 Environmental Conditions
The environmental conditions operating conditions, product data, etc. under which the
pipes shall operates and defined in Documents. Scope of Work, Project Design Data
and Site Conditions and Specification for Pipeline construction.
2.9.3.2 Abbreviations
ANSI American National Standards Institute
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
DIN German Standards Institute
ISO International Organisation for Standardisation
NACE National Association of Corrosion Engineers
NPS Nominal Pipe Size
MPI Magnetic Particle Inspection
UT Ultrasonic Testing
SIS Swiss standard
AWWA American Water Works Association
2.9.4 Handling of Coating Materials
2.9.4.1 General
Materials shall be handled and stored in accordance with the material manufacturer’s
recommendations, which shall be available for review by the Engineer In-charge at the
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Contractor’s premises. Materials shall be stored in temperature controlled environment

until required for use.
Coating materials shall be segregated by type and batch during storage and handling.
Materials from damaged containers shall be rejected unless otherwise agreed with the
Engineer In-charge.
As a minimum, all packages of the coating materials shall be marked with the fol-
lowing data:
a. Name of manufacturer
b. Complete material identification – trade name, chemical name and
c. type of product details
d. Batch number
e. Date of manufacture
f. Place of manufacture
g. Shelf life/expiry date (if appropriate)
h. Health and safety, and environmental instructions
i. Hazard Warnings
j. Storage instructions
k. Quantity
l. Manufacturing Standard
Any material not labelled with the above information shall not be used.
2.9.4.2 Abrasive Grit
The abrasive shall be steel grit, also in combination with steel shot of the required grade
to achieve the specified surface profile. The use of sand is not permitted.
Blasting abrasives shall be kept dry, clean and free from contamination. When recov-
ered metallic grit systems are used, a stabilized working mix of blast cleaning material
shall be established. This mix shall be maintained throughout the entire course of the
production, by frequent small additions from fresh or cleaned stock at a rate sufficient
to refurnish consumption. Blasting and other dust producing areas shall be kept separate
from coating application areas. The surface cleaning shall be degree of cleanliness as
per SA 2.5 & ISO 8502-3.
2.9.4.3 Fusion Bonded Epoxy (FBE) Powder
The FBE powder selected shall be suitable for use at the design temperatures in the
proposed environment and be suitable for a three-layer polyethylene coating system.

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The FBE shall be endorsed by the contractor of the adhesive and Polyethylene as being
compatible with these products under the specified service conditions.
Each batch of FBE shall be accompanied by a certificate stating the following tests have
been carried out on every batch and results are in accordance with the coating material
manufacturer’s product specifications;
 Gel Time
 Moisture content
 Particle size distribution
 Density
 Infrared Scan
 Thermal analysis
2.9.4.4 Adhesive
The adhesive selected shall be completely suitable for use at the design temperatures in
the proposed environment and be suitable for a three-layer polyethylene coating system.
Each batch of adhesive shall be accompanied by a certificate stating the following tests
have been carried out on every batch and results are in accordance with the coating
material manufacturer’s product specifications:
 Adhesion
 Density
 Melt flow index
2.9.4.5 Polyethylene
The polyethylene selected shall be high density meeting to Class B of ISO 21809-1 and
shall be completely suitable for use at the design temperatures in the described envi-
ronment. The polyethylene shall be suitable for a three-layer polyethylene can be sta-
bilized against UV-rays by incorporation of minimum 2% well dispersed Carbon black
of particle size 10-25 nm.
Each polyethylene batch shall be accompanied by a certificate stating the following
tests (as per below table) have been carried out on every batch and results are in accord-
ance with the coating material manufacturer’s product specification:
2.9.4.6 Properties of Epoxy Powder and Adhesive
i. The Contractor shall choose such a brand of epoxy powder and adhesive that will
achieve the functional requirement and properties of coating system as specified in this
specification. In addition, the coating material manufacturer shall also furnish Infra-red

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Scan for each batch of epoxy powder. The coating materials manufacturer shall issue
test certificates as per EN 10204, 3.1 for each batch of materials supplied to the con-
tractor and the same shall be submitted to the department for approval prior to their use.
Epoxy powder properties shall be as per CSA Z245.20.98 (latest version). The colour
of epoxy powder shall be either green or dark red or any other colour approved by the
department except grey colour. Copolymer grafted adhesive shall have the following
properties.

S. No. Properties Unit Requirement Test Method

a. Melt Flow Rate g/10 1.0 minute ASTM D 1238

(190°C/2.16 kg) minutes
b. Vicat Softening °C 100 min ASTM D 1525
Point
c. Specific Gravity - 0.926 min ASTM D 792

ii. Properties of Polyethylene compound

S. No Properties Unit Requirement Test Method

a. Melt Flow Rate g/10 1.0 minute ASTM D 1238

(190°C/2.16 kg) minutes
b. Vicat Softening °C 100 min ASTM D 1525
Point
c. Specific Gravity - 0.926 min ASTM D 792

S. No Properties Unit Requirement Test Method

a. Tensile Strength N/mm2 17 min ASTM D638
@ + 25 °C
b. Melt Flow Rate g/10 0.25 ASTM D 1238 or
(190°C / 2.16 kg) minutes DIN 53735
c. Specific Gravity - 0.926 min. (MDPE) ASTM D 792
+ 25°C 0.941 min.(HDPE)
d. Hardness @ + Shore D 50 min. ASTM D 2240
25°C
e. Water Absorp- % 0.05 max. ASTM D 570
tions, 24 hours @
+25°C
f. Volume Resistiv- Ohm-cm 1015 min. ASTM D 257
ity @ + 25 °C

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g. Dielectric with- Volts/mm 30,000 min. ASTM D 149

stand, 1000
Volt/sec
rise @ + 25°C
h. Vicat Softening °C 110 min. ASTM D 1525
Point
i. Elongation % 600 min. ASTM D 638
j. Oxidative Induc- Minutes ASTM D 3895
tion Time in Oxy- 10 min.
gen at 220°C,
Aluminum pan,
no screen
k. Environmental Hours ASTM D 1693
Stress Crack Re-
sistance (ESCR) 300
(for F50)
- Medium Den- 300
sity, Condition
"C"
- High Density,
Condition "B"
l. Carbon Black % 2 min. ASTM D 1603
Content

iii. In addition to vendor’s certificate, the contractor shall draw samples from each batch of
epoxy, adhesive and polyethylene in the presence of department’s representative and the test
for the following properties at the coating yard at least one week prior to its use, to establish
compliance with the Manufacturer’s test certificates.
a. Epoxy Powder: Gel Time, Cure Time, Moisture content, Thermal Characteristics (Tg1,
Tg2, ∆H).
b. Adhesive: Specific gravity, Melt Flow Rate, Vicat Softening Point.
c. Polyethylene: Melt Flow Rat, Specific Gravity, Vicat Softening Point, Moisture content,
Oxidative Induction Time.
In Case of the failure of any of the above tests in a batch, that batch of material shall be tested
for all other tests required as per this specification including the tests which failed. If all tests
pass, the batch shall be accepted for coating. If any of the tests fail, entire batch of material
shall be rejected and shall not be used for the coating.

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iv. The Contractor shall ensure that all coating materials are properly stored in accordance with
the Manufacturer’s recommendation at all times, to prevent damage and deterioration in quality
prior to use.
v. Properties of coating System
S. No. Properties Unit Requirement Test Method
a. Bond Strength (using Kg/cm 15 min ISO 21809-1
Type 2 test i.e. Dyna- 5 min
mometer) Assembly
@ 23°C
@ 80°C
b. Impact Strength Joules per mm of 7 min DIN 30670
(Mon. of 30 impacts coating thickness
on body along the
length. No breakdown
allowed when tested
at 25 Kv)
c. Indentation Hardness mm DIN 30670
@ 23 +/- 2°C 0.2 max
@ 70 +/- 2°C 0.3 max
d. Elongation at Failure % 400 min DIN 30670

e. Coating Resistivity Ohm-m2 108 min. DIN 30670

(*)
f. Heat Ageing (*) - Melt Flow rate shall
g. Light Ageing (*) - not deviate by more DIN 30670
than 35% of original
value
h. Cathodic Dis-bond- Min. radius of 7 max Annex H; ISO
ment Disbondment in mm 21809-1
7 max
-@ 23°C after 28 (**)
15 max
days, -1.5 V
-@ 65°C after 24 hrs,
-3.5 V
-@ 80°C after 28
days, -1.5 V
i. Degree of Cure of %°C 95 CSA Z 245.20
Epoxy +3/-2 – 98 (***)
- Percentage Cure, ΔH
- Δtg

(*) Test carried out in an independent laboratory of national / international recognition of PE

top coat is also acceptable.
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(**) Disbondment shall be equivalent circle radius of total unsealed area as per ASTM G42.
(***) Temperature to which the test specimens are to be heated during cyclic heating shall
however be as per the recommendations of epoxy powder manufacturer.
2.9.5 Acceptance of Pipe Materials
2.9.5.1 Identification and Tracking
Upon receipt at the coating factory, the Contractor shall record the following pipe information:
The unique pipe identification number, measured length, and measured weight (both to be
found stencilled in paint on one end or the pipe).
This data shall be used as a basis for monitoring pipe from the time of receipt until the delivery
of coated pipe.
The Contractor shall identify (or maintain identification of) every coated item, by using a
weatherproof mark on the inside of the pipe and on the outside of the coated item. The pipe
identification shall be the unique pipe identification number (the number required by the appli-
cable pipes specification). The contractor may use additional tracking numbers at his discretion
but these shall relate simply to the unique pipe number in the QC documentation.
Pipe tracking shall be carried out in accordance with approved procedures.
2.9.5.2 Preliminary Inspection
The Contractor shall carry out visual inspection of all pipes.
The Contractor shall record all external damage on pipes against the unique item serial number.
This damage shall be brought to the attention of the Engineer In-charge and the Pipe shall not
be coated without prior release by Engineer In-charge.
Bevel protectors at each end of every pipe joint shall not be removed unless showing signs of
damage or if removal is required to facilitate surface preparation, or they would be damaged
by coating operations. If the protectors are removed the conditions of the bevel shall be rec-
orded against the pipe serial number and any damage shall be brought to the attention of the
Engineer In-charge.
2.9.5.3 Damage to Pipe and Pipe Ends and Repair
No repair work shall proceed until a written procedure has been prepared by the Pipe Coating
Contractor and approved by the Engineer In-charge.
Minor damage to pipe and pipe ends/bevels, identified either at time of receipt or after abrasive
blasting shall be repaired by grinding. The number of such damages shall be not more than 3
per pipe. Repair by grinding on the pipe or pipe ends/ bevels outside diameter shall not reduce

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the wall thickness to less than the minimum requirements of the line pipe specification, when
measured using ultrasonic thickness measurement equipment.
All other damage to pipe ends/bevels shall be advised to the Engineer In-charge for review.
Subject to Engineer’s approval, these defects may be repaired by removal of damaged pipe
material and re-bevelling. No welding on the pipe surface shall be allowed.
Pipe identification numbers shall be preserved during repair. Any reduction in pipe lengths
shall be recorded in the relevant forms and files.
2.9.6 Prior to Coating Application
2.9.6.1 Stages
 The principle stages of pipe coating shall be as follows:
 Solvent cleaning followed by steam or hot bath cleaning (if required)
 Abrasive blasting
 Application of fusion bond epoxy (FBE) layer
 Application of adhesive layer
 Application of polyethylene layer
2.9.6.2 Cleaning Prior to Abrasive Blasting

All surface contaminants such as oil, grease, tar, salt, or other contaminants on the pipe shall
be removed by solvent cleaning followed by steam or hot bath cleaning, in accordance with a
procedure approved by the Engineer In-charge.
Following the steam or hot bath cleaning the pipe shall be tested for salt and chloride contam-
ination in accordance with the requirements of DIN EN ISO:8502-2, DIN EN ISO: 8502-5,
DIN EN ISO 8502-9.
The removal of hydrocarbon contamination shall be confirmed by a water spray test, where a
fine spray is applied to the surface and uniform wetting confirms the removal. This check shall
be performed before and after blasting, as a pre- qualification test and as a minimum, once per
100 items during production, or when necessary.
Items found to be contaminated shall be cleaned as above and re-blasted if testing after blasting
establishes that salt, chloride or hydrocarbon contamination is still present. The remainder of
the batch concerned shall all be checked individually.
All water used for rinsing or cleaning purposes shall be potable with less than 200 ppm total
dissolved solids and 50 ppm chlorides.

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2.9.6.3 Abrasive Blasting

Blasting and other dust producing areas shall be separate from coating application areas.
After cleaning and prior to abrasive blasting the pipe lengths shall be free from moisture, dust,
grease and free from other foreign materials.
Abrasive and dust, which entered the inside of the pipe during blasting operation, shall be re-
moved by suitable means.
Weld joints, sharp-edge projections, weld spatter and slag etc. shall be dressed prior to blast
cleaning.
Using dry blasting techniques only, the exterior surface of the pipe joints shall be abrasively
cleaned to remove all mill scale, and other impurities from the surface.
No blast cleaning shall take place when the prevailing relative humidity is higher than 85 per-
cent unless pipe is preheated to at least 3ºC above the dew point.
Twice per shift, samples of the abrasives mixture shall be removed from the hopper and
checked for hydrocarbon contamination. The sample shall be placed in a beaker to which de-
ionized water is added. The beaker shall then be sealed and shaken vigorously. Once the grit
has settled the surface of the water shall be examined for signs of hydrocarbon contamination.
If any signs are found all the abrasive in the hopper shall be rejected and not re-used.
Additionally, abrasive materials shall be checked at least once per shift to ensure that only
uncontaminated angular grit with an acceptable size distribution is used. As a minimum, the
following shall be carried out.
 Correct abrasive size distribution shall be carried out by sieve analysis.
 Placing a sample of abrasive on a clean, dry sheet of absorbent paper to determine
water contamination.
The surface of the pipes shall be blasted until a finish of Grade 2.5 to DIN EN ISO 8501-1 is
attained. The surface profile shall be between 50 to 100 microns, measured in accordance with
DIN EN ISO 8503-2. Profile measurements shall be made with a Keane Tator Profile Compar-
ator, Testex Press –O-Film or other Engineer In-charge approved method suitable for the abra-
sive being used.
Following abrasive blasting, the surface shall not be contaminated with dirt, dust, metal parti-
cles, hydrocarbons, water, chlorides, sulphates or any other foreign matter, which would be
detrimental to the coating.

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Prior to the coating application, the exterior surface shall be thoroughly inspected under ade-
quate lighting. Any damage such as surface imperfections, slivers, scabs, burrs, gouges, or
sharp-edged defects, shall be repaired in accordance with this specification. Pipes that have
damage repaired by grinding and have ground areas greater than 50 mm diameter shall be re-
blasted to meet the requirements of the clauses above. After grinding or mechanical repairs, the
wall thickness shall be ultrasonically examined and compared with the minimum requirements
of the applicable code / standard.
Any dust or loose residue that has accumulated during blasting and/ or grinding operations
shall be removed by the use of clean compressed air or by vacuum extraction. Alternative meth-
ods for removing dust and lint shall require approval of the Engineer In-charge.
The elapsed time between the start of blasting and the heating of pipe shall be indicated in the
application procedure submitted by the Contractor and shall be reflected on his plant scheme.
The total elapsed time between the start of blasting of any pipe and the heating of that pipe to
the specified temperature shall not exceed the following time- humidity table:
PERCENT RELATIVE ELAPSED TIME
HUMIDITY (HOURS)
85 0.5
80 1.0
70 2.0
60 2.0

Any pipe surface not processed within the above time-humidity table shall be completely re-
cleaned and re-blasted before coating.
The maximum time limit between blasting and coating for humidity below 60% shall be 4
hours.
2.9.7 Coating Application
2.9.7.1 General

The application of the coating shall be in accordance with the material manufacturer recom-
mendations and the procedure outlined below.
The Contractor shall perform coating Procedure Qualification Testing (PQT) prior to com-
mencing production or on his own risk at the start of production in accordance with this speci-
fication.

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Prior to start-up of the coating process the powder application and recovery systems shall be
thoroughly cleaned to remove any powder other than that is use, minimum once per day and
the collected powder shall be disposed off.
2.9.7.2 FBE Layer

The FBE shall be applied to a minimum thickness of 200 microns.

The pipe shall be uniformly preheated in accordance with the FBE manufacturer’s instructions.
This temperature shall have been confirmed during PQT. The surface temperature shall not
exceed 260ºC in accordance with AWWA C213, section 4.4.3.1 Preheating”.
Pipe temperature shall be checked periodically using pyrometer. The pyrometer shall be
checked for error not less than every four hours against a calibrated temperature measuring
instrument.
The coating shall be applied by electrostatic spray with the pipe at earth potential and the epoxy
powder charged to high potential.
The use of reclaimed FBE powder is only permitted if the reclaimed powder is screened to
remove foreign or deleterious material before being reintroduced into the powder application
system.
The clean reclaimed powder upto a maximum of 20% shall be introduced back into the fresh
virgin material by means of proportional weight.
During application, the bevelled ends and pipe bore shall be protected against mechanical dam-
age and from contamination with coating material.
2.9.7.3 Adhesive Layer

The adhesive shall be applied to a thickness of 200 microns.

The adhesive layer shall be applied before gel time of the FBE has expired. Application of the
adhesive shall not be permitted after the FBE has fully cured. The Contractor shall establish to
the satisfaction of the Engineer In-charge that the adhesive is applied within gel time window
of the FBE and at the temperature recommended by the adhesive manufacturer. The Contractor
shall state the proposed minimum and maximum time interval between FBE and adhesive ap-
plications at the proposed pre-heat temperature.
2.9.7.4 Polyethylene Layer/Cutback

The polyethylene layer shall be applied to a minimum thickness as per DIN 30670 over the
pipe body and to a minimum of 90% body thickness over the production welds.

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PIPE DN TOTAL THICKNESS

OF POLYETHYLENE
COATING
> DN 100 ≤ DN 250 2.7 mm

> DN 250 < DN 500 2.9 mm

≥ DN 500 < DN 800 3.2 mm
≥ DN 800 3.7 mm

The thickness may be less than the minimum thickness locally as long as these local areas do
not exceed 5cm2 per 1m length of pipe and the difference between the actual thickness and the
minimum thickness is not greater than 10%.
Inspection of Thickness:
 Inspection of thickness shall be as per Annexure A (normative) of DIN 30670.
 A polyethylene layer cutback of 150 mm (±20mm) shall be provided at pipe ends.
 The polyethylene shall be applied over the adhesive within the time limits established
during pre-production testing.
 The coating shall be cooled to below 60°C before handling.
 The ends of the coating shall be chamfered and bevelled to less than 30º.
 Immediately after the coating is fully cured, pipe identification marks shall be re-ap-
plied to the coated pipe using a method approved by Engineer In-charge
2.9.8 Inspection, Testing and Certification
2.9.8.1 General

In order to demonstrate that the manufacturer’s proposed coating procedure is capable of meet-
ing the specification, the Contractor shall undertake coating procedure qualification testing
(PQT) prior to commencing production, or at his own risk at the start of production. The Con-
tractor shall also be required to test the finished coating during production to demonstrate con-
tinued compliance with this specification. Details of all inspections and testing shall be fully
documented in accordance with this section.
All states of the surface preparation, coating and testing shall be subject to 100% inspection by
the Contractor. The Engineer In-charge shall be informed at least two weeks prior to the start
of surface preparation to allow scheduling of inspection supervision work

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2.9.8.2 Coating Procedure Qualification Testing (PQT)

Prior to commencing or at the start of full production five pipe of each diameter coated with
FBE only and five pipes of each diameter with the full coating system shall be selected for
PQT. All coating shall be in accordance with the coating procedure specifications and shall be
witnessed by the Engineer In-charge or its representative.
The produced pipes will not be released until the successful results of the PQT can be provided.
In case of long-term tests, the PQT report shall be updated once the results can be provided.
Any failure in meeting the specified acceptance criteria for the PQT will result in rejection of
the coated pipes. Engineer In-charge shall approve any remedial action, repairs or re-use.
The test methods for all tests required for PQT on the FBE and the complete coating system
shall be performed in the same manner as the production tests described in this specification.
Pipes selected for PQT testing shall pass all the criteria containing in 1.9.8.3 before production
commences.
Any change in the coating material or coating procedure shall require approval from Engineer
In-charge.
If any of the tests fails to meet the minimum acceptance criteria defined in this specification,
then the pre-qualification pipes shall be rejected. Further pipes may be prepared and coated
using revised procedures and further tests performed. Once acceptable results are obtained and
approved by Engineer In-charge, the Contractor’s quality plan and procedures shall be revised,
and submitted to the Engineer In-charge for approval. All items coated using the rejected pro-
cedures shall be striped and recoated to the revised procedures.
2.9.8.3 PQT Inspection and Test Summary
Inspection and testing summary for procedure qualification test (PQT) for three-layer coating
system for each pipe diameter:
Property Acceptable Values Frequency of Tests
On Arrival Minor damage/grinding Each Pipe
Pipe Damage <3 Per Pipe
After Cleaning Each Pipe
Chloride 2 mg/cm2
Oil No contamination
Salt 3 mg/cm2
After Abrasive Blast- Each Pipe
ing SA 2.5 acc to ISO 8501 Each Pipe
Cleanliness 50 – 100 um Each Pipe
Profile No contamination
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Contamination

Visual Inspection No surface defects Each Pipe

Holidays No holidays Each Pipe
Thickness Min/Max see Clause 10 per pipe
Adhesion 2.9.7.2 2 per pipe
See Clause 2.9.7.3
Holidays Visual In- No surface defects Each Pipe
spection 120+10/-0 mm width Each Pipe
Coating 10 to 40 mm width, Each Pipe
Bare steel at pipe Chamfered Each Pipe
ends 150 ±20 mm bevel <30º
Production FBE PE
cut
backs
Adhesion > 100 N/cm at 20 °C +5° 2 per Pipe
Peel Test > 50 N/cm at 50 °C +5° 2 per Pipe
Impact Resistance See Clause 2.9.8.4d 1 per pipe
% Elongation at Fail- See Clause 2.9.8.4f 2 per pipe
ure
Cathodic Disbond- See Clause 2.9.8.4h 2 per pipe
ment
DIN 30670 See Clause 2.9.8.4g 1 per pipe

2.9.8.4 Production Testing

a. Production testing shall be performed at the frequency shown below:
Property Acceptable Values Frequency of Tests
On Arrival Minor damage/grinding Each Pipe
Pipe Damage <3 Per Pipe
After Cleaning Each Pipe
Chloride 2 mg/cm2
Oil No contamination
Salt 3 mg/cm2
After Abrasive Blast- Each Pipe 20
ing SA 2.5 acc to ISO 8501 Each Pipe 20
Cleanliness 50 – 100 um
Profile No contamination
Contamination See clause 2.9.5
Pipe damage
FBE Layer No surface defects Each Pipe
Visual Inspection No holidays Each Pipe
Holidays Min/Max see Clause 10 per pipe
Thickness 2.9.7.2 2 per pipe
Adhesion See clause 2.9.7.3
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Holidays Visual No surface defects Each Pipe

Inspection 120+10/-0 mm width Each Pipe
Coating 10 to 40 mm width, Each Pipe
Bare steel at pipe Chamfered Each Pipe
ends 150 ±20 mm bevel <30°
Production FBE PE
cut
backs
Adhesion > 150 N/cm at 20° C +5° 1 Pipe per 25
Peel Test 2 per Pipe

Cathodic Disbond- See Clause 2.9.8.4h First pipe, last pipe

ment at Room Tem- and at intervals of
perature every 500 pipes

The frequency of tests shown in the table above will be for normal production operations. This
frequency of tests is subject to change at the discretion of the Engineer In-charge as a result of
change of materials or consistent poor production performance.
b. Holiday Detection
FBE Layer
The FBE coating shall be 100 % holiday tested with a pulse type DC holiday detector equipped
with audible signaling device. The test shall be carried out in accordance with NACE RP0490
or equivalent.
Final Coating
Each fully coated pipe shall be inspected for holidays over 100 percent of its coated surface
using a high voltage DC detector.
The detector shall be a type, which maintains complete contact with the coating. It may be
either constant or pulsed voltage type. If constant voltage type, holiday detection shall be car-
ried out on a dry coating. The operating voltage between electrode and pipe shall be checked
at least twice per working shift, and shall be maintained at 10 kilovolt/mm of coating thickness.
The Contractor shall demonstrate to the Engineer In-charge that the setting of the detector is
satisfactory for detecting pinhole defects. This setting shall be checked once every two hours.
The correct travel speed shall be determined by consistent detection of an artificial pinhole
made in a good coating sample but shall not exceed 300 mm/s.
All holidays and other detects shall be marked for subsequent repair and re-testing. On retest-
ing, no holidays shall be permitted in the final coating.

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The number of holidays for each pipe length shall be recorded. Coated pipe having holidays in
excess of 1 per 1 square meter shall be stripped and re-coated.
If there is an excess occurrence of holidays on successive pipes, the Contractor shall immedi-
ately stop the coating operation to determine the cause and remedy it.
c. Adhesion (Peel) Test
FBE Layer:

With a sharp narrow bladed knife, two incisions (approximately 13 mm long) shall be made, in
the form of an X. through to the metal substrate. At the intersection of the X. an attempt shall
be made to force the lining from the steel substrate with the knife point. The point of the knife
shall be inserted horizontally i,e., the flat of the blade under the lining at the point of intersection
of the X such that the blade point is on the metal surface. Using a levering action, the flat point
shall be forced away from the steel in an attempt to pry off the coating. Refusal of the lining to
disbond from the substrate shall be recorded as a pass. A pass shall also be recorded where the
lining fails cohesively. Partial or complete adhesive failure between the lining and the substrate
shall be recorded as a failure. Disbondment at the point of the intersection is common due to
the action of marking the 'X' cut. Therefore for 1 mm away from the tip of the intersection any
disbandment shall be ignored.
Final Coating:
The adhesion for the complete coating shall be determined in accordance with the requirements
for bond strength in DIN 30670. The relevant test temperature and acceptance criteria for these
tests shall be as detailed in procedure qualification and production testing of this specification.
Automatic chart recording equipment shall be used and the average peeling force shall be rec-
orded.
The failure mode shall be recorded. The failure should occur at the adhesive/polyethylene in-
terface or adhesive/FBE interface or cohesively in the polyethylene layer. If failure should oc-
cur at the FBE/steel interface this will be considered a total failure of the system.
d. Impact Test
A sample or coated pipe shall be impact tested in accordance with the procedures and ac-
ceptance criteria of DIN 30670.

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e. Resistance to Indentation Test (Indentation Hardness)

Once per shift (and when the FBE or polyethylene batch is changed), the indentation hardness
of two coated samples shall be measured (at 20○C ± 5°C and 70ºC ± 2ºC) in accordance with
DIN 30670.
Indentation depth shall not exceed 0.2mm at 20°C ± 5°C or 0.3mm at 70°C ± 2ºC.
f. Percentage Elongation at Failure
This test shall be conducted in accordance with DIN 30670 on each of the full system pre-
qualification pipes, but at least the coating of three pipes shall be tested for elongation at failure,
from which five test pieces shall be taken. The percentage elongation at failure shall be at least
400% on each of the full system pre-qualification pipes, 2 samples per pipe to the requirements
of DIN 30670.
g. Other DIN 30670 Tests
The Contractor shall demonstrate, for the same system to be applied for this order, attainment
of DIN 30670 requirements for Coating Resistivity, to Thermal Ageing and Light Ageing as
required by DIN 30670.
h. Cathodic Disbondment Test
Cathodic Disbondment testing shell be conducted:
as a pre-qualification test - 24 hours duration at 65 ± 2°C as a pre-qualification test - 28 days
duration at 23 ± 2°C
as a production test - 24 hours duration, at the frequency of one test per 50 coated pipes at 65
± 2°C
The test requirements shall be in accordance with ISO 21809-1.
The final unsealed diameter (including the initial holiday diameter of 6.35 mm) shall not exceed
15 mm. This shall apply to both, the 28-day test at 23 ± 2°C and the 2 days test at 65 ± 2°C.
The Contractor may propose alternative cathodic disbondment test standards provided the es-
sential requirements of this specification are retained. Any such alternatives shall be submitted
to the Engineer In-charge for review and approval.
Every 24 hours the applied voltage and current flow shall be recorded. Any drift from the spec-
ified voltage setting shall be corrected.

i. Destructive Tests

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A sufficient length of production pipe shall be cold cut to provide the required number of sam-
ples for conducting the coating destructive tests listed in this specification.
Items that fail individual tests and that cannot be repaired in accordance with this specification
shall be rejected. Subject to the approval of Engineer In-charge, the rejected coating shall be
stripped and the joint shall be re-blasted and coated in the manner specified for new pipe in this
specification.
Where a test relates to a quantity of coated items, e.g. 1 per 50 items or 1 per 100 items etc.,
the quantity or items represented by the item tested (e.g. 50 or 100) shall be considered to be a
batch.
If a test on an item in a batch fails then this item shall be rejected and two further items shall
be randomly selected from the batch for repeat testing. If either of these tests fails then the
whole batch shall be quarantined for review by Engineer In-charge. The cause of failure shall
be established and reported to the Engineer In-charge and if deemed necessary by the Engineer
the coating procedure shall be amended and re-qualified. The Engineer In-charge will decide
whether the whole batch is rejected and sent for re-blasting and re-coating or whether ac-
ceptance may be on the basis of acceptable tests carried out on individual items.
j. Coating Repairs

The Contractor shall submit detailed coating repair procedures for approval by Engineer in-
charge. These shall include procedures for repair or 'pin-hole', 'small area' and 'large area' de-
fects. The minimum and maximum areas for which each type of repair is applicable shall be
stated taking into consideration the below mentioned requirements.
The maximum number of coating defects allowable, before a joint of pipe shall be classed as
rejected and recoated, shall not exceed 1 per 1 square metre (exclusive of damage caused by
testing).
 Repair areas of sizes < 5 mm2
Pinhole damage shall be repaired by cleaning with an emery cloth followed by application of
a two (2) pack epoxy repay repair kit or an approved hot melt mastic smoothed flush with the
polyethylene surface. If the mastic is used, it shall be spread with the aid of a hot air or a
propane torch.

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 Repair areas of sizes < 5 mm2 upto < 250 mm2

The area shall be swabbed with solvent and abraided with an emery cloth to ensure that the
surrounding polyethylene is well bonded, the surface shall be roughened for a distance of at
least 25mm beyond the damage area. An approved hot melt mastic shall be applied to the dam-
age area and smoothed flush. The mastic and surrounding area shall be warmed with hot air or
propane torch until the surrounding polyethylene has as slight sheen. An approved polyethylene
patch material shall be applied overlapping the damage but not overlapping the pre-abraided
areas. Torch heat and smoothing pressure shall be applied to fuse the patch and ensure that no
blisters are formed.
 Repair areas of sizes 250 mm2 upto 625 mm2
Heat shrink-wrapping pipe sleeves shall be used for repair according to the following proce-
dure:
Thoroughly clean the area to be coated.
Bevel the extremities of the mill-coating with a rasp.
Pre-heat the area to be coated to a temperature of approximately 110-140°C.
Install the sleeve over the area to be coated.
Warm the shrink sleeve to a temperature above 150°C with a propane torch or a warm-air ring.
 Repair areas of sizes exceeding 625 mm2
No single defect shall exceed an area or 625 mm2. Pipes with a coating defect exceeding 625
mm2 shall be cause for rejection and shall be subsequently rejections and recoated. All rejec-
tions shall be recorded.
Repairs shall provide a finished coating equal in effectiveness to that of the parent coating. The
limit of the repair area shall be revised.
Each repaired area shall be holiday inspected as described in this specification.
The Pipe Coating Contractor shall submit coating stripping procedure for pipes rejected for
coating quality. The rejected coating may be stripped by heating in an oven. Under these cir-
cumstances, the temperature of the pipe joint shall not be allowed to rise above 400°C.
k. Handling, Transport and Storage Rules
The contractor shall be responsible for any damage occurring to the pipes from unloading to
reloading on the relevant transportation means.
 The contractor shall consequently:

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 inspect the bare pipes upon delivery to check that they have suffered no previous
damage,
 take all necessary precautionary measures to prevent any deterioration during the
following operations:
 handling,
 transfer to storage yards.
 storage,
 loading of pipes for shipment.
All repairs and inspections shall be carried-out at the contractor's expense.
l. Handling
The pipes shall be handled without causing damage to the pipe bevels and coating.
Direct contact steel or hamp slings or with any material whose shape or nature may deteriorate
the pipe coating shall be strictly prohibited. Polyamide slings or hooks fitted with thermoplastic
protection may be used.
Use of electromagnetic device is recommended.
m. Transfer to storage yard
During transport of pipes to the storage yard of the contractor, the latter shall take all their
required measures to avoid pipe and coating damage.
n. Storage yard of the contractor
Stockpiling of coated pipes shall be made so as to avoid any deterioration of coating. Coated
pipes, when non-concrete weight coated, shall be protected against ultraviolet rays action in
particular.
o. Pipe loading for shipment
When loading the coated pipes for shipment, the contractor shall take all necessary measures
to avoid the deterioration of pipes and coating during handling and transport.
p. Repair of Coating
The contractor shall submit to Department, its methods and materials proposed to be used for
executing a coating repair and shall receive approval from the department prior to use. In open
storage the repair materials must be able to withstand a temperature of at least (+) 80°C without
impairing its serviceability and properties. The contractor shall furnish manufacturer's test cer-
tificates for the repair materials clearly establishing the compliance of the repair materials with
the applicable coating requirements indicated in this specification.

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All pipe coating plan, shall have sound external with no holiday or porosity on 100% of the
surface.
Defects, repairs and acceptability criteria shall be as follows:
Pipes showing pororsity or very small damage not picked up during holiday test and having a
surface less than 0.5 cm2 or linear damage (cut) of not less than 3 mm shall be repaired bystick
using material of same quality.
Damages caused to coating by handling such as scratches, cuts, dents, gouges, not picked up
during holiday test, having a total reduced thickness on damaged portion not less than 2 mm
and an area not exceeding 20cm2 shall be rebuild as per approved method and without exposing
to bare metal.
Defects of size exceeding the above and mentioned area of or holidays of width less than
300mm shall be repaired as per approved method by exposing the bare metal surface.
Defect exceeding the above and in number not exceeding 2 per pipe and their length not ex-
ceeding 500 mm shall be repaired as per approved method.
Pipes with bigger damage shall be stripped and recoated.
In case of coating defect close to coating cut back, the contractor shall remove the coating
throughout the entire circumference of the pipe down to the steel surface and increase the coat-
ing cut back length. Now, if the coating cut back exceeds by 30 mm than the specified cut back
length, then the coating shall be repaired as per approved method thereby making up the coating
cut back length as per specification.
In case the defect exceeds 70 mm from the original coating cut back length, the entire coating
shall be removed and the pipe shall be recycled through the entire coating procedure.
Irrespective of type of repair, the maximum number of repair of coating shall be as follows:
 Holiday repair of size ≤ 100cm2 attributable to process of coating application shall be max-
imum one number per pipe.
 In addition to the above, defects to be repaired as per approved method shall be maximum
2 (two) per pipe.
Defects exceeding the above limits shall cause pipe coating rejection, stripping and recoating.
The above is exclusive of the repairs warranted due to testing as this specification.
All repairs carried out to the coating for whatever reason shall be to the account to the contrac-
tor.

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Cosmetic damages occurring in the polyethylene layer only need not be repaired by exposing
up to steel surface, as deemed fit by the department Engineer. In any case, the contractor shall
establish his material, methods and procedure of repair that result in an acceptable quality of
product by testing and shall receive approval from department prior to use.
Testing of repairs shall be in the same form as testing coating. All repairs shall result in a coat-
ing thickness not less than the parent coating thickness. The contractor shall test repairs to
coating as and when required by department.
Repair Material:
Heat Shrink Sleeves - Material to be qualified by the material manufacturer and approved by
department.
As applied coating system for repair shall comply the requirements of ISO 21809-1/DIN
30670 except as modified below:

i. Cathodic Disbondment Resistance at Tmax i.e. 80°C shall be 15 mm when tested as per ISO
21809-1. Test shall be carried out at (+) 80°C.

ii. Peel Strength shall be as follows

Peel Unit Requirement for
Strength Class-B
(minimum)
To Pipe @ 23 ±2 ºC N/mm 15
Surface @ Tmax N/mm 3
To Factory @ 23 ±2 ºC N/mm 15
Coating @ Tmax N/mm 3

Any combination of epoxy, adhesive and polyethylene shall be tested and certified by an inter-
nationally recognized agency.
In case the contractor proposed coating material other than above mentioned combination of
epoxy, adhesive and polyethylene, coating procedure and qualification need to be carried out
by an internationally recognized agency by the coating material Manufacturer.
All materials to be used shall be supplied in sealed, damage free containers and shall be suitable
marked with the following minimum information:
a. Name of the Manufacturer
b. Type of Materials
c. Batch Number

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d. Place and Date of Manufacture

e. Shelf Life/Expiry Date (if Applicable)
f. Quantity
All materials noted to be without above identification shall be deemed suspect and shall be
rejected by the department. Such materials shall not be used for coating and shall be removed
from site and replaced by the contractor at his expense.
LOFC: List of Operation of Fabrication and Control
Each LOFC must contain the following information as a minimum (all clearly marked and
separated):
a. Company name and references relating to the order;
b. All technical and other information required in order to define the items covered.
 The area of application will be limited to that item or those items considered in fabrication
and control as a natural unity.
 Details of plants, layout, capacity, production rate, testing equipment, yard facility.
c. A numerical sequence of operations with description will be built-up in a logical way
of work progress.
 The first operation will be the control over the incoming material(s) and documents.
 The last operation will be the control over the final documentation.
The following operations have to be included (not limited to):
 Procedure prior to the commencement of production shall be approved by the department
 Each step which call for own quality control (eventually QA);
 Each applicable examination as part of this specification;
 Document control-stamping and final documentation.
d. Each operation will be followed by the applicable specification or procedure number (with
the latest revision).
e. Columns to be provided for possible interventions of:
 the manufacture's fabrication control;
 the manufacturer's quality control (eventually QA);
 inspection Agency
 and place of intervention if not by the manufacturer.
The interventions will be indicated per operations with H or w and/or R.

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H = hold point - no further steps may be undertaken before the intervention of the designated
responsible takes place.
W = witness point - the designated responsible has to be notified of the operation in advance,
but production will continue whether the intervention took place or not.
R = point for which a control report or a recording has to be made.
The manufacturer will rill in his own H, W and R points. The inspection Agency will do the
same in its designated column, but this will not implicate a relaxation or waiving of the require-
ments of the manufacturer's controls.
Each intervention has to be signed and dated by person acting as controller. Only the original
documents will be presented for this purpose.
One column to be provided for report or record number (point marked R) and one for the review
or these documents by the Inspection Agency.
Two extra columns may give reference to non-conformity report if any and the resolution give
to it.
Completion of the LOFC does not automatically rise to a release of the material or it must be
stipulated otherwise in the contract.
The steps indicated in the LOFC must be executed following the sequence as stipulated in
LOFC.
2.10 EXTERNAL COATING - Polyolefin Tape Coating
General
Buried steel pipeline shall be coated externally, with prefabricated polyolefin tape coating as
per AWWA C 214-14. The Contractor shall perform all work in accordance with these specifi-
cations and the latest pipeline coating practices, and shall complete the work in all respects to
the full satisfaction of the Owner/Owner’s representative. The entire coating operation starting
from cleaning and surface preparation till coating shall be performed under the supervision of
skilled personnel who are well conversant with the work. Pipes which have been cleaned and
primed, or cleaned, primed and coated, without having been inspected and approved shall be
rejected.
This specification is not intended to be all inclusive and the use of guidelines set forth here
does not relieve the Contractor of his responsibility for the quality and performance of the
applied coating system, and to supply coating material capable of performing its intended ser-
vice.

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All steel special sections, connections and fittings to be used for underground steel pipeline
shall be coated with cold applied tape consisting of liquid adhesive and prefabricated tape as
described in AWWA C 209 and using Visco Elastic material as per ISO 21809 - 3 (2016) with
PE outer wrap only.
Referenced Standards:
The following standards (latest revision) referenced below are a part of this specification. In
case of conflict between this specification and the referenced standards, this specification shall
apply.
ANSI/AWWA C214: Standard for Tape Coating Systems for the Exterior of Steel Water
Pipelines
ANSI/AWWA C604: Installation of Buried Steel Water Pipe
ANSI /ASTM D149: Standard Test Method for Dielectric Breakdown Voltage and Dielectric
Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies.
ANSI/ASTM D570: Standard Test Method for Water Absorption of Plastics
ANSI/ASTM D4218: Standard Test Method for Determination of Carbon Black Content in
Polyethylene Compounds by the Muffle-Furnace Technique.
ASTM D1000 : Standard Test Method for Pressure-Sensitive Adhesive-Coated Tapes Used
for Electrical and Electronic Applications
ASTM E96: Standard Test Methods for Water Vapor Transmission of Materials
ASTM G8: Standard Test Method for Cathodic Disbonding of Pipeline Coatings
ASTM Gl4: Standard Test Method for Impact Resistance of Pipeline Coatings (Falling
Weight Test)
ASTM G17: Standard Test Method for Penetration Resistance of Pipeline Coatings
(Blunt Rod)
ANSI/AWWA C209: Standard for cold applied tape coatings for the exterior of special sections,
connections and fittings for steel water pipelines.
ANSI /AWWA C210: Liquid Epoxy Coating systems for Exterior and Interior of Steel Water
Pipelines
ANSI/AWWA C 216: Standard for Heat – Shrinkable cross-linked Polyolefin coatings for ex-
terior of special sections, connections and fittings of steel water pipelines.
NACE RP-O2-74: High-Voltage Electrical Inspection of Pipeline Coatings Prior to In-
stallation

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SSPC-PA 2: Measurement of Dry Paint Thickness with Magnetic Gauges

SSPC-SP l: Solvent Cleaning
SSPC-SP 6/NACE No. 3: Commercial Blast Cleaning

Tape Coating Systems for the Exterior of Steel Water Pipelines

General:
The buried steel pipeline shall be protected with cold applied tape protective coating conform-
ing to AWWA C214-14 (Cold Applied Tape Coating Systems for Exterior of Steel Water Pipe-
lines).
Protective coating shall consist of a coating system consisting of primer, inner tape wrap and
outer wraps.
Work or material that fails to conform to this standard may be rejected at any time before final
acceptance
Coating system:
The pre-fabricated polyolefin tape coating system shall consist of the following layers to pro-
vide an applied coating system thickness of 80 mils (2mm) on the exterior of the steel pipes.
 A liquid adhesive layer.
 An inner-layer tape for corrosion protection.
 An intermediate-layer tape for mechanical protection.
 An outer-layer tape for mechanical and UV protection.
The inner-layer tape and outer-layer tape shall be made of prefabricated tapes in rolls.
Liquid Adhesive layer:
The liquid adhesive layer shall consist of a mixture of suitable rubber and synthetic compounds
and solvent. The liquid adhesive layer shall be spray applied to the abrasive blasted prepared
pipe surface before application of the inner-layer tape. The function of the liquid adhesive is to
provide a bonding medium between the pipe surface and the inner-layer tape.
The liquid adhesive shall be supplied by the manufacturer that supplies the inner-layer tape.
The liquid adhesive shall not settle in the container forming a cake or sludge that cannot be
easily mixed by hand or mechanical agitation and it shall have good machine-application prop-
erties.

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Table-I Physical Properties of the Liquid Adhesive

Property Requirement
Minimum Maximum Test Method
(Ref AWWA
C214-14)
Width deviation -5% or -1/4 in. (-6 +5% Sec. 5.2.3
mm) whichever is
smaller
Nominal thickness 20mil 19 mil (0.48 mm) Sec. 5.2.4
(0.508 mm)
Ratio of adhesive to total in- 40% of total t 60% of total t Sec, 5.2.4
ner- layer tape thickness, t
Adhesion to prepared steel 15.9 lb/in. width - Sec. 5.2.5
(2.8 N/mm width)
Water absorption (24 h) - 0.2% by wt Sec. 5.2.6
Water-vapor transmission - 0.10 g/(h.m2) Sec. 5.2.7
Insulation resistance 500,000 megaohms Sec. 5.2.9
Tensile strength 30 lb / in width Sec. 5.2.10
(5.3 N/mm width)
Elongation 300% Sec. 5.2.11
Non-polyolefinic Material - 3.5% Sec. 5.2.12
Percent by Weight

Inner-layer tape:
The inner-layer tape shall be a two-layer tape consisting of a polyolefin backing layer with a
laminated butyl-based adhesive layer. The inner tape shall be compatible with the liquid adhe-
sive. The manufacturer shall certify that the backing material shall be polyolefin only, contain-
ing not more than 3.5 percent, by weight, of non-polyolefinic material consisting of carbon
black and antioxidants. The inner-layer tape shall be applied after the liquid adhesive and be-
fore the outer-layer tape.
The backing and adhesive shall be made from materials that provide high electrical resistivity,
resistance to corrosive environments, low moisture absorption and permeability, and shall pro-
vide an effective bond to a primed steel surface. The inner-layer tape shall be of material that
will resist excessive mechanical damage during normal application operations and shall be suf-
ficiently pliable for the intended use. The inner-layer tape shall withstand, without tearing, the
tensile force necessary to obtain a tightly wrapped inner coating free of voids. The inner-layer
tape shall be supplied in roll form wound on hollow cores with a minimum inside diameter of
75mm.

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To ensure a proper smooth coating, the inner-layer tape shall be provided in standard widths as
per manufacturer recommendations consistent with the pipe diameter. Width shall be approved
by Employer’s representative.

Table-2: Physical Properties of Inner Layer Tape

Color Base Weight Flash Point

Black Rubber and Flammable - 6 - 8 lb/gal (0.72 – 0.965g/l)
-
Synthetic 10oF(17oC)
Resins or greater
Nonflamma- - 10 - 12 lb/gal (1.20 – 1.44 none
ble kg/l)

Intermediate- layer tape / Outer-layer tape:

The intermediate -layer tape / outer-layer tape shall be a two-layer tape consisting of a poly-
olefin backing layer with a laminated butyl adhesive layer. The manufacturer shall certify that
the backing material shall be polyolefin only containing not more than 7.0 percent, by weight,
of non-polyolefinic material consisting of pigments, antioxidants and stabilizers. The interme-
diate -layer shall be compatible with the inner-layer tape and the outer-layer tape shall be com-
patible with the intermediate-layer tape. The primary function of the intermediate - layer tape
is to provide mechanical protection to the inner-layer tape and of outer-layer tape to provide
mechanical and outdoor weathering (UV) protection to the tape system, and secondarily, to
contribute to the overall corrosion-protection properties of the system. The outer-layer tape
backing shall be compounded so that it will be resistant to outdoor weathering. To distinguish
the intermediate- layer tape from outer-layer tape the colors of the two layers shall be different.
The intermediate- layer tape color shall be grey and the outer-layer tape color shall be white.
The outer-layer tape should be of suitable quality for the local environment, as follows:
Storage Temperature : 0 to 500C.
Over-ground Condition : 0 to 600C.
Under-ground Condition : 70C to 350C.
: Required in outer
Ultraviolet-ray Protection
layer.

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Materials used in the intermediate-layer & outer-layer tape shall have high electrical resistivity,
low moisture absorption and permeability, and shall provide mechanical protection during han-
dling and outdoor storage. The intermediate - layer & outer-layer tapes shall be sufficiently
pliable for normal application operations and shall form an effective bond to the inner-layer /
intermediate-tape layers. The intermediate- layer & outer-layer tape shall be supplied in roll
form wound on hollow cores with a minimum inside diameter of 75mm.
Dimensions: The intermediate- layer tape & outer-layer tape shall be provided in standard
widths and lengths. The width of the intermediate - layer & outer-layer tape shall be at least
equal to that of the inner-layer tape.
Table-3 Physical Property of Intermediate Layer Tape & Outer Layer Tape
Property Requirement
Minimum Maximum Test Method
(Ref AWWA
C214-14)
Width deviation -5% or -1/4 in. (-6 mm) +5% Sec. 5.2.3
whichever is smaller
Nominal thickness 30mil 28.5 mil (.724 mm) - Sec. 5.2.4
(0.762 mm)
Adhesion to Inner layer 3.71 lb /in. width - Sec. 5.2.5
(0.65 N/mm width)
Dielectric Strength 450 V/mil Sec. 5.2.8
Tensile strength 40 lb/in width - Sec. 5.2.10
(7.0 N/mm Width)
Elongation 300% - Sec. 5.2.11
Non polyole finic Material - 7.0% Sec. 5.2.12
Percent by Weight

Coating-system Thickness:
The installed coating system thickness shall not be less than 80 mils (2mm) and shall comprise
of the following.
 A liquid adhesive layer (50-75 microns)
 An inner-layer tape (Nominal 20 mils i.e. 0.50mm)
 An intermediate tape (Nominal 30 mils i.e. 0.75mm)
 An outer-layer tape (Nominal 30 mils i.e. 0.75mm)
The properties of the complete coating system shall conform to the following requirements.

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Table-4 Physical Properties of Total System

Property Requirement
Minimum Maximum Test Method (Ref
AWWA C214-07)
Thickness
80 mil, nominal 73 mil - Sec.5.5.4
(1,854 μm)
Dielectric strength 12000V Sec. 5.3.6
Impact resistance 25 lb * in. Sec. 5.2.13
(2.8 N*m)
Penetration/deformation re- - 25% with no Sec. 5.2.14
sistance holiday at 220C

Cathodic Disbondment - 12mm Sec 5.2.15

Coating Application:
General:
The coating application shall be a continuous operation starting with properly abrasive blasted
pipe surface. Longitudinal & spiral welds of the pipe shall not exceed a height of 3/32 inch
(2.4mm) above the pipe surface and shall be ground flush a full 18 inch (450mm) along the
length of the pipe from both ends prior to the coating process.
Four steps, which shall be performed consecutively, shall consist of
(1) liquid adhesive application;
(2) application of the inner-layer tape directly onto the prepared pipe surface;
(3) application of the intermediate-layer tape directly on top of the inner-layer tape and
(4) application of outer-layer tape directly on top of the intermediate-layer tape.
Pipe preparation:
Metal surface condition:
Bare pipe shall be free from mud, mill scale, mill lacquer, wax, coal tar, asphalt, oil, grease, or
any other foreign material. Before blast cleaning, surfaces shall be inspected and pre-cleaned
according to SSPC-SP 1 to remove oil, grease, and loosely adhering deposits. Visible oil and
grease spots shall be removed using a solvent. Only solvents that do not leave a residue shall
be used. Preheating to remove oil, grease, and mill scale may be used provided that all pipe is
preheated in a uniform manner to avoid distortion.
After drying and removing all loosely adhering foreign materials, the pipe surface shall be
cleaned by blasting with grit or steel shots to achieve a surface preparation at least equal to that
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specified in SSPC: SP6/NACE3. The blast anchor pattern or profile depth shall be 1.5 mil to
3 mils (38 µm to 75 µm) measured in accordance with ASTM D-4417.
For consistent surface finish, a stabilized working mix shall be maintained in abrasive recycling
blasting machines by frequent small additions of new grit, shot infrequent large editions shall
be avoided. The abrasive working mix, abrasive recycling blasting machines shall be main-
tained clean of contaminants by continuous effective operation of blasting machine scalping
and air-wash separators.
The cleaned exterior pipe surface shall be in inspected for adequate surface preparation. Sur-
face imperfections, such as slivers, scabs, burrs, weld spatter, and gouges, shall be removed by
hand filing or grinding if necessary to prevent holidays.
Blast-cleaned pipe surfaces shall be protected from conditions of high humidity, rainfall, or
surface moisture. No pipe shall be allowed to flash rust before coating. To ensure a dry pipe
surface at the time of liquid adhesive application, the minimum steel substrate temperature
shall be 30°C and at least 3°C above the dew point.

Coating Application:
Liquid adhesive application:
The liquid adhesive shall be applied in a uniform thin film at the coverage rate recommended
by the manufacturer. The liquid adhesive shall be thoroughly and continuously mixed and agi-
tated during application to prevent settling. The liquid adhesive shall be applied to the entire
exterior surface of the pipe by spray to cover the entire exterior surface of the pipe.
The liquid adhesive coat shall be uniform and free from floods, runs, sags, drips, or bare spots.
The liquid-adhesive-coated pipe surface shall be free of any foreign substances, such as sand,
grease, oil, grit, rust particles, or dirt.
Before applying the inner-layer tape, the liquid adhesive layer shall be allowed to touch dry in
accordance with the manufacturer's recommendation.
Application of inner-layer tape:
The inner-layer tape shall be applied directly onto the prepared pipe surface using mechanical
constant-tension coating equipment. The inner layer tape shall be spirally applied with neck
down tension as recommended by manufacturer. When applied to spirally welded pipe, the
direction of the tape spiral shall be generally parallel to the weld spiral. The minimum overlap
shall not be less than 25 mm. When a new roll of tape is started, the ends shall be overlapped
at least 150 mm measured circumferentially.

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Application of Intermediate-layer tape:

The intermediate-layer tape shall be applied over the inner-layer tape using the same type of
mechanical equipment used to apply the inner-layer tape. The intermediate- layer tape shall be
spirally applied with neck down tension as recommended by manufacturer. The overlap of the
intermediate -layer tape shall not coincide with the overlap of the inner-layer tape. The mini-
mum overlap shall not be less than 25 mm. When a new roll of tape is started, the ends shall be
overlapped at least 150 mm measured circumferentially. The intermediate-layer tape shall be
applied at a minimum roll body temperature of 21°C or as recommended by the tape manufac-
turer.
Application of outer-layer tape:
The outer-layer tape shall be applied over the intermediate-layer tape using the same type of
mechanical equipment used to apply the inner and intermediate layer tapes. The outer layer
tape shall be spirally applied with neck down tension as recommended by manufacturer. The
overlap of the outer-layer tape shall not coincide with the overlap of the intermediate-layer
tape. The minimum overlap shall not be less than 25 mm. When a new roll of tape is started,
the ends shall be overlapped at least 150 mm measured circumferentially. The outer-layer tape
shall be applied at a minimum roll temperature of 21°C or as recommended by the tape manu-
facturer.

Cutbacks
Coating cutbacks shall be 150 mm + 0 / - 25 mm.
Material acceptance, inspection and testing:
Material Acceptance
Proposed coating materials shall be approved by the Owner / Owner’s representative.
The recommendations of the manufacturer regarding coating process, repairs, etc, shall also be
provided by the contactor. The manufacturer should give guarantee to supply of the required
quantity as per the project time schedule and take responsibility for supervising the coating
application, repair works if required. Supporting documents shall be provided for the same.
When the material is supplied, acceptance of the material shall be based on submission of cer-
tificate of conformance of the coating system to AWWA C214-14 standard and properties spec-
ified in this specification superseding AWWA C 214-14 along with manufacturing acceptance
test certificates for various lots as per manufacturer’s quality assurance and quality control
requirements.

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Coating application inspection:

The entire coating operation by the Contractor will be supervised by qualified experts from the
manufacturer. The CV of the manufacturer's expert shall be approved by the Owner / Owner’s
representative. All coating work will be done in the presence of the Owner / Owner’s repre-
sentative. All lots shall be inspected at SGS/BV lab – Globally.
Coated-Pipe Tests:
Thickness:
The thickness of the coating system shall be checked in accordance with SSPC-PA 2. The
thickness shall be in accordance with the values given in the Table III and shall be checked at
a frequency specified by the Owner / Owner’s representative.
Holiday Testing:
Each coated pipe section shall be electrically tested for flaws in the coating using a suitable
holiday detector approved by the Owner / Owner’s representative. The detector shall impress
a minimum of 6,000 V. Reference should be made to NACE RP-02-74. The electrical inspec-
tion shall take place on the inner-layer tape before the intermediate -layer tape is applied. If a
holiday is detected, it shall be repaired as per specifications.
Peel strength:
The peel strength of the inner-layer tape to steel shall be checked in accordance with ASTM
D-1000. The average value below the limits stated in the Table I shall constitute a failure of
the system to meet the adhesion requirement. The peel test shall be conducted at a frequency
specified by the Owner/Owner’s representative.

Field procedures:
At all times during construction of the pipeline, the Contractor shall use caution to prevent
damage to the protective coating on the pipe. No metal tools or heavy objects shall be permitted
to unnecessarily contact the finished coating. Workmen shall not be permitted to walk on the
coating except when necessary. In these cases, they shall wear shoes with rubber or composi-
tion soles and heels or other suitable footwear that will not damage the coating. Any damage
to the pipe or the protective coating from any cause during the installation of the pipeline shall
be repaired.

Coating repair in field:

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All holidays visually or electrically discovered either at the coating plant or in the field shall
be repaired by peeling back and removing the outer, intermediate and inner layers from the
damaged area. The exposed areas shall then be coated with liquid adhesive and either (1) a
length of inner-layer tapes shall be wrapped around the pipe to cover the defective area; or (2)
a patch of inner-layer tape shall be applied directly to the defective area as specified by the
Owner / Owner’s representative. The minimum over-lap at the damaged area shall be 100 mm
all around. The repaired area shall be tested with a holiday detector as per specifications after
the repair is completed. If holidays are not found, the repaired area shall be covered with the
intermediate - layer & outer-layer tape with a minimum over-lap of 100 mm beyond the inner-
tape patch, Or as per the repair method recommended by the manufacturer of the tape.
Hoisting:
Pipe shall be hoisted using only wide-belt nylon slings or the equivalent. The use of caliper
clamps, metal chains, cables, tongs, or other equipment likely to cause damage to the coating
shall not be acceptable, nor shall dragging of the pipe be permitted. The Contractor shall allow
inspection of the coating on the underside of the pipe while the pipe is suspended from the
slings.
Shipping, handling and storage:
Coated pipe shall be handled, stored and shipped in a manner that will prevent damage to the
coating.
Pipe also shall be handled and stored in a manner to prevent damage to pipe walls and ends.
Pipe or coating damaged in handling or other operations shall be repaired. Handling during the
period of coating also shall be such as to avoid damage to the coating. Thermal expansion is a
characteristic of the coating that may cause uneven areas on the coated pipe surface, but does
not adversely affect the coating system's performance. These areas do not require any repair.

Stacking:
Sufficient spacers or padding shall be used to prevent damage to the pipe and coating.

Shipping:
Pipe shall be transported from the coating yard to the jobsite using sufficient shoring or ton-
nage, padding and banding to adequately protect the pipe and its coating.

Loading:

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Pipe shall be loaded for shipping in compliance with existing shipping standards and regula-
tions.
Trench-side Storage:
Pipe stored along the trench side shall be suitably supported off the ground to avoid damage to
the coating.
2.11 Specification for External Coating for Special Sections, Connections & Fittings of
Buried Steel Pipelines for Water - Polyolefin Tape Coating
General:
Special sections, miter bends, tees, connections, fittings in buried steel pipeline network shall
be coated externally, with prefabricated polyolefin tape coating as per AWWA C 209 Protective
coating shall consist of a coating system consisting of primer, inner - layer tape and outer-layer
tape or using Self - Healing Monolithic Polymer Wrap (Visco Elastic) material conforming to
ISO 21809 with PE backed outer tape.
Referenced Standards:
The following standards (latest revision) referenced below are a part of this specification. In
case of conflict between this specification and the referenced standards, this specification shall
apply.
ANSI/AWWA C 216: Standard for Heat - Shrinkable Cross-linked Polyolefin coatings for
exterior of special sections, connections and fittings of steel water pipelines.
ANSI/AWWA C214: Standard for Tape Coating Systems for the Exterior of Steel Water
Pipelines
AWWA Manual M11: Steel Pipe – A Guide for Design and Installation
ANSI /ASTM D149: Standard Test Method for Dielectric Breakdown Voltage and Dielectric
Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies.
ANSI/ASTM D257: Standard Test Method for DC Resistance or Conductance of Insulating
Materials.
ANSI/ASTM D570: Standard Test Method for Water Absorption of Plastics
ANSI/ASTM D638: Standard Test Method for Tensile Properties of Plastics.
ASTM D1000 : Standard Test Method for Pressure-Sensitive Adhesive-Coated Tapes
Used for Electrical and Electronic Applications.
ASTM D1002 : Standard Test Method for Apparent Shear Strength of Single Lap
Adhesively Bonded Metal Specimens by Tension Loading.
ASTM E96: Standard Test Methods for Water Vapor Transmission of Materials
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ASTM G14: Standard Test Method for Impact Resistance of Pipeline Coatings (Falling
Weight Test)
ASTM G17: Standard Test Method for Penetration Resistance of Pipeline Coatings
(Blunt Rod)
ANSI/AWWA C209: Standard for cold applied tape coatings for the exterior of special
sections, connections and fittings for steel water pipelines.
NACE RP-O2-74: High-Voltage Electrical Inspection of Pipeline Coatings Prior to
Installation
SSPC-SP 6/NACE No. 3: Commercial Blast Cleaning.
ISO 21809-3-2016

Coating system:
The pre-fabricated polyolefin tape coating system shall consist of the following layers to pro-
vide an applied coating system thickness of 100 mils (2.5mm) on the exterior of the special
sections of steel pipes.
 A liquid adhesive layer.
 An inner-layer tape for corrosion protection having thickness of 30mils and applied
with 50% overlap
 An outer-layer tape for mechanical and UV protection having thickness of 20mils
and applied with 50% overlap.
Liquid Adhesive layer:
The liquid adhesive layer shall consist of a mixture of suitable rubber and synthetic compounds
and solvent. The liquid adhesive layer shall be brush applied to the abrasive blasted prepared
pipe surface before application of the inner-layer tape.
Table-I Physical Properties of the Liquid Adhesive
Color Base Weight Flash Point
Black Rubber and Flammable - 6-8 lb/gal (0.72 – 0.965g/l)-
Synthetic 10oF(17oC)
Resins or greater
Non-flammable - 10 – 12 lb/gal (1.20 – 1.44 none
kg/l)

Inner-layer tape:
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The inner-layer tape shall be a two-layer tape consisting of a polyolefin backing layer with a
laminated butyl-based adhesive layer. The thickness of the inner tape shall be 30mils. To ensure
a proper smooth coating by hand or by manual hand wrapping machine, the inner-layer tape
shall be provided in standard widths of 4” or 6” as per manufacturer recommendations con-
sistent with the pipe diameter.
Outer-layer tape:
The outer-layer tape shall be a two-layer tape consisting of a polyolefin backing layer with a
laminated butyl adhesive layer. The outer-layer should be of suitable quality for the local envi-
ronment. The thickness of the outer-layer tape shall be 20mils. To ensure a proper smooth coat-
ing by hand or by manual hand wrapping machine, the outer-layer tape shall be provided in
standard widths of 4” or 6” as per manufacturer recommendations consistent with the pipe
diameter.
Coating-system Thickness:
The installed coating system thickness shall not be less than 100 mils (2.5mm) and shall com-
prise of the following.
i. A liquid adhesive layer (50-75 microns)
ii. An inner-layer tape (Nominal 30 mils i.e. 0.75mm) applied with 50% overlap
iii. An outer-layer tape (Nominal 20 mils i.e. 0.50mm) applied with 50% overlap
The properties of the tape & coating system shall conform to the following requirements.
Table 2 - Physical Properties of Total System
Property Requirement

Minimum Maxi- Test Method (Ref

mum AWWA C214/209-
07)
Thickness
100 mil, nominal 95 mil 105 mil
(2,413 μm) (2,267
μm)
Dielectric strength 12000V Sec. 5.2.8
AWWA C214
Impact resistance 25 lb * in. Sec. 5.2.13
(2.8 N*m) AWWA C214
Penetration/deformation 25% with no holiday at Sec. 5.2.14
resistance 72 0F (220C) AWWA C214
Water-vapor transmission 0.25 perms Sec 5.2.7
[1.44ng/ (Pa.s.m2)] AWWA C209

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Insulation resistance 500,000 mega ohms Sec 5.2.9 AWWA

(min) C209
Adhesion to Primed Steel 228 oz/inch Sec 5.2.4
(2500 N/m width) AWWA C214

Coating Repair:
Damages, Flawed areas, holidays, or mislaps to coatings applied to special sections, connec-
tions, and fittings from any cause during installation and before final acceptance shall be re-
paired by peeling back and removing the tape layers from the affected area. The repair area
shall be brushed with a primer, then a patch of tape covering a minimum of 4 inch (100mm)
around the affected area shall be applied by wrapping it around the pipe or by applying a patch
of tape as specified by the purchaser. After the repair is completed, the repaired area shall be
tested with a holiday detector.
Backfilling shall be conducted at all times in such a manner to avoid abrasion or other damage
to the coating. Unless otherwise specified, the following requirements shall be met:
Where the trench traverses rocky ground containing hard objects that could penetrate the pro-
tective coating, unless otherwise specified, a layer of screened earth, sand, or rounded river
gravel no less than 6 inch (152 mm) thick with a maximum particle size of 20mm shall be
placed in the bottom of the trench before installation of the coated item. Other bedding material
acceptable to the purchaser may be used in place of the earth, sand, or rounded river gravel.
Placement of backfill around the exterior of the coated item shall be done only in the manner
approved by the purchaser after final inspection and acceptance of the exterior coating. If rocks,
concrete chunks, or other hard objects are present in the backfill material along any section of
the pipeline, screened backfill or other approved materials shall be placed around the coated
item. When screened backfill is used, it shall be placed around the coated item to a minimum
depth of 152 mm before backfilling the remainder of the trench. Compaction of bedding and
backfill in the trench shall be done according to the best industry practices and ensures the full
integrity of the pipeline and coating.
INSPECTION:
Careful inspection of the coating shall include visual observation.
The coating shall be checked for any holidays using 12 kV holiday detector.
All holidays and all damages to coating shall be clearly marked and repaired immediately. The
repair shall be carried out by filling the damaged area with patch of tape and then wrapping the
tapes around the circumference to extend 100 mm beyond the damage.
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During the procedure qualification, peel test shall be carried out using hand peel test gauge.
The peel test shall be conducted on a strip 25 X 200mm long. The minimum peel value to be
recorded.
2.12 Coating of Field Joint, Special Sections & Connections Fittings of Steel Pipelines for
Water (3 Layer Poly Ethylene)
2.12.1 Scope
This specification establishes the minimum requirements of materials, equipment and installa-
tion of field joint anti-corrosion coating of buried onshore pipelines factory coated with three-
layer polyethylene coating, by heat shrink wrap around sleeves conforming to ISO 21809-3
Second Edition 2016 – “External coatings for buried or submerged pipelines used in pipeline
transportation systems” and the requirements of this specification. Unless modified/replaced
by this specification, all the requirements of ISO 21809-3 shall remain fully applicable and
complied with.
This specification shall be read in conjunction with the conditions of all specifications and
documents included in the Contract between Company and Contractor. Unless specified oth-
erwise, all sections of this specification shall apply to all specifications referred in this specifi-
cation.
2.12.2 Reference Documents
Reference has also been made to the latest edition (edition enforce at the time of issue of en-
quiry) of the following standards, codes and specifications:
a. ISO 8502-3 : Preparation of Steel Substrates before Application of Paints and Related
Products - Part 3 - Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure Sen-
sitive Tape)
b. ISO 8503-1 : Part 1: Specification and definitions for ISO surface profile comparator for
the assessment of abrasive blast cleaned surfaces.
c. ISO 8503-4 : Part 4: Methods for calibration of ISO surface profile comparator and for
the determination of surface profile-Stylus instrument procedure
d. SIS 055900 : Pictorial Surface Preparation Standard for Painting Steel surfaces.
e. SSPC-SP1: Steel Structure Painting Council.
In case of conflict between the requirements of this specification and that of above referred
documents, the requirements of this specification shall govern.

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The contractor shall be familiar with the requirements of these documents and shall make them
readily available at the site to all personnel concerned with carrying out the works specified in
this specification.
2.12.3 Materials and Equipment
2.12.3.1 Field Joint Coating Material:
Field joint anti-corrosion coating material shall be heat shrinkable wraparound sleeve suitable
for a maximum operating temperature of (+) 80°C (Tmax) and shall conform to ISO 21809-3;
2016 Table 17 Type 14B-2. In addition, the field joint anti-corrosion coating shall comply the
requirements specified in this specification.
a. Heat shrinkable wrap around sleeves:
Heat shrinkable wraparound sleeve shall consist of radiation cross-linked, thermally stabilized,
ultraviolet resistant semi-rigid polyolefin backing with a uniform thickness of high shear
strength thermoplastic/co-polymer hot melt adhesive. The joint coating system shall consist of
a solvent free epoxy primer applied to the pipe surface prior to sleeve application. The sleeve
shall be supplied in pre-cut sizes to suit the pipe diameter and the requirements of overlap.
The total thickness of heat shrinkable wraparound sleeve in the “As Applied” condition shall
be as follows:

Pipe Size (Specified Thickness (mm)

Outside Diameter)
On Pipe Body On Weld
Bead
Average Min. (Min.)
<30” (762.0mm) 2.0 1.8 1.6
>32” (813.0mm) 3.0 2.7 2.5

The heat shrink wraparound sleeve shall have the required adhesive properties when applied
on various commercial pipe-coating materials and shall be equivalent product to 3LPE main-
line coating. The pre-heat and application temperatures required for the application of the
shrink sleeve shall not cause loss of functional properties of the pipe coating.
The Contractor shall propose the manufacturer's details, heat shrinkable sleeve details/ prop-
erties and the specific grade of field joint coating system meeting the requirements of this
specification.
2.12.3.2 Functional Requirements of Field Joint Coating

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As applied field joint coating system shall comply the requirements of ISO 21809-3; 2016
Table 17
Contractor shall obtain prior approval from Employer regarding the Manufacturer of the joint
coating material and the specific grade of the joint coating system. Complete technical details
along with test certificates complying with the requirements shall be submitted to Employer
for this purpose. The Contractor shall furnish test certificates from an independent test labor-
atory for all the properties required for the specified field joint coating and the requirements
of this specification.

Functional Properties of Joint Coating System (As supplied)

As applied field joint coating system shall comply the requirements of ISO 21809-3, Table 17
except as modified below:
i. Cathodic Disbondment Resistance at Tmax i.e. 80°C shall be 10 mm .

ii. Peel Strength shall be as follows:

Peel Unit Requirement for 14 B-2

Strength (minimum)
To Pipe @ 23ºC N/mm 15
Surface @ Tmax N/mm 3
To Factory @ 23ºC N/mm 15
Coating @ Tmax N/mm 3

Contractor shall obtain prior approval from the department regarding the Manufacturer of the
joint coating material and the specific grade of the joint coating system. Complete technical
details along with test certificates complying with the requirements of this specification shall
be submitted to Employer for this purpose.
2.12.3.3 Cut back
Cut back length of the pre-coated pipes shall be 150mm +20, - 0mm.
2.12.3.4 Field joint coating system
Field joint coating system shall be of suitable width considering an overlap to the factory coated
pipe coating by minimum 50 mm on each side 3 LPE coated pipes.
2.12.4 Application Procedure
2.12.4.1 General
a. The application procedure shall be in accordance with manufacturer’s instructions and the
minimum requirements specified below whichever are the most stringent and shall be
demonstrated to and approved by the department. The contractor’s expert shall supervise
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the application and shall be available at site upon request during qualification of application
procedure and during construction at Contractor’s cost.
b. Operators for coating application shall be given necessary instructions and training before
start of work, by the Contractor. To verify and qualify the application procedures, all coat-
ing applied during the qualification test shall be removed for destructive testing as detailed
subsequently in this specification. Contractor shall only utilize those operators who have
been approved/ pre- qualified by the field joint coating manufacturer.
c. Oil, grease and salt shall be removed from steel surface by wiping with rags soaked with
suitable solvents such as naphtha or benzene. Kerosene shall not be used for this purpose.
Solvent cleaning procedure according to SSPC-SP1 shall be followed.
d. Each field joint shall be blast cleaned using a closed cycle blasting unit or open expandable
blasting equipment. With the first equipment type, steel or chilled shot and iron grit shall
be used and Garnet material with the second one (in case the authority having jurisdiction
have no objection, the contractor may adopt sand blasting instead of garnet material). Dur-
ing blast cleaning the pipe surface temperature shall be simultaneously more than 5°C and
more than 3°C above ambient Dew Point, while the ambient Relative Humidity shall not
be greater than 85%. Prior to surface cleaning the surfaces shall be completely dry. The
surface shall be cleaned to a grade Sa 2½ in accordance with Swedish Standard SIS-055900
with a roughness profile of 50-70 microns. Surface roughness profile shall be measured
using an approved profile comparator in accordance with ISO 8503-1 and shall be cali-
brated prior to the start of the work in accordance with ISO 8503 or ISO 8503-4. The blast
cleanliness shall be checked on every joint and the roughness profile shall be checked 1
every 10 joints.
Dust, grit or foreign matter shall be removed from the cleaned surface by an industrial
vacuum cleaner. The dust contamination allowed shall be of a rating max 2 as per ISO
8502-3. The frequency of checking for dust contamination shall be 1 every 10 joints.
Blast cleaned field joint shall be coated with 2-4 hours according to the conditions below:
 Relative Humidity (RH) >80% - 2 hours
 Relative Humidity (RH) 70-80% - 3 hours
 Relative Humidity (RH) <70% - 4 hours
Pipes delayed beyond this point or pipes showing any visible rust stain, shall be blast
cleaned again.

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e. The field joint surface shall be inspected immediately after blast cleaning and any feature
of the steel surface such as weld spatter, scabs, laminations or other imperfections consid-
ered injurious to the coating integrity, made visible during blast cleaning, shall be reported
to the Company Representative and on permission from Company Representative, such
defects shall be removed by filling or grinding. Pipes affected in this manner shall be then
re-blast cleaned if the defective area is larger than 50mm in diameter.
f. The ends of existing pipe protective coating shall be inspected and chamfered. Unbounded
portions of the coating shall be removed and then suitably trimmed. Portions where parent
coating is removed shall be thoroughly cleaned as specified. The adjacent chamfered areas
of the line pipe coating shall be cleaned and abraded, to expose a clean uniform fresh sur-
face of uncontaminated factory applied coating.
g. All steel joint surfaces shall be thoroughly examined before the application of the coating
in order to ensure the surfaces are free of oil, grease, rust, mud, earth or any other foreign
matter. All these substances shall be removed before coating, to the procedures herein de-
scribed.
h. Protection coating shall be applied on the joints immediately after the completion of clean-
ing operation.
2.12.4.2 Application Procedure for Heat Shrink Wraparound/Sleeves
In addition to the requirements stated above, following shall be complied with:
a. The wraparound sleeve shall be of a size such that a minimum overlap of 50mm is ensured
(after shrinking) on both sides of the yard applied corrosion coating of pipes.
b. In the cases where carrier pipe is installed by direct boring/jacking, the overlap on the mill
coating for the leading edges of the joints shall be minimum 200mm. When this extra over-
lap is achieved by providing an additional patch of heat shrink tape/ wraparound, it shall
be applied in such a manner that the square edge of the patch on the joint coating is in the
direction opposite to the direction of boring/ jacking.
c. Before centering the wraparound sleeve, the bare steel surface shall be preheated either
with a torch moved back and forth over the surface or by induction heating. The minimum
pre-heat temperature shall be as recommended by manufacturer and shall be checked by
means of contact type temperature-recording thermometer (Digital Pyrometer with flat
probe type contact). Temperature indicating crayons shall not be used. Pre-heat temperature
shall be checked on every joint. Care shall be taken to ensure that the entire circumference

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of the pipe is heated evenly. Temperature measuring instruments shall be calibrated imme-
diately before the start of the works and thereafter at intervals recommended by the manu-
facturer of the instrument.
d. Upon pre-heating, the pipe surface shall be applied with two pack epoxy primer of wet film
thickness 250 microns or as per manufacturer’s recommendation whichever is higher, to
cover the exposed bare metal of the welded field joint and 10mm min. onto the adjacent
pipe coating if recommended by the manufacturer. The wet film thickness of the primer
shall be checked on every joint with a wet film thickness gauge prior to installation of
sleeve. Thickness gauge shall be calibrated once per shift.
e. After application of epoxy primer, the wraparound sleeve shall be entirely wrapped around
the pipe, epoxy has to be forced cured using direct low flame before wrapping of sleeve
and shall be as per manufacture recommendation. To ensure the corrosion protection layer
is uniformly applied the Dry Film thickness of the epoxy needs to be checked in every 1 of
50 joints. Sleeve shall be positioned such that the closure patch is located to one side of the
pipe in 10 or 2 O’clock position, with the edge of the undergoing layer facing upward and
an overlap of min. 50mm. Gently heat by appropriate torch the backing and the adhesive
of the closure and press it firmly into place.
f. A heat shrinking procedure shall be applied to shrink the sleeve in such a manner to start
shrinkage of the sleeve beginning from the centre of the sleeve and heat circumferentially
around the pipe. Continue heating from the centre towards one end of the sleeve until re-
covery is completed. In a similar manner, heat and shrink the remaining side. Shrinking has
been completed when the adhesive begins to ooze at the sleeve edges all around the cir-
cumference.
The complete shrinking of the entire sleeves shall be obtained without undue heating of the
existing pipe coating and providing due bonding between pipe, sleeve and pipe coating. The
installed sleeve shall not be disturbed until the adhesive has solidified.

2.12.4.3 Joint Coating Application

Joint Coating Application shall be done under supervision of the contractor’s personnel during
the field trial demonstration and testing work. Presence of manufacturer’s representative is a
mandatory requirement and contractor shall be required to furnish specific commitment to this.
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Minimum 50 (fifty) field joint coating to be carried out under supervision of the joint coating
supplier’s representative. Application procedure and environment protection methodology
demonstrated at the time of field trial shall be strictly followed during the entire work.

2.12.5 Repairs
a. If a field joint is detected to be unacceptable after testing as per relevant QA section of this
specification the Contractor shall, at his own cost:
 Determine the cause of the faulty results of the field coating.
 Mobilise the expert of manufacturer, if required.
 Test to the complete satisfaction of Company, already completed field coatings.
 Stop the field coating works until remedial measures are taken against the causes of
such faults, to the entire satisfaction of the Company.
b. Contractor shall replace all joint coating found or expected to be unacceptable as per rele-
vant section of this specification.
c. Contractor shall, at his own cost, repair all areas where the coating has been removed for
testing by the Company.
d. After the coating work on welded joints and repairs to the coating have been completed the
coating as a whole shall be tested with a spark-tester before lowering or jacking the pipe-
line.
e. Employer shall be entitled to check the coating on buried pipelines or parts of pipelines
with equipment such as the “Pearson Meter” and the resistance meter. If coating defects are
established, the Contractor shall be responsible for excavation at such points, repairing the
coating, spark testing and backfilling the excavations without extra charge.
2.12.6 Documentation
a. Prior to procurement of coating materials, Contractor shall furnish the following information
for qualification of the Manufacturer and material.
i. Complete information of the Joint Coating Material along with descriptive technical
catalogues.
ii. Test certificates and results of previously conducted tests, for all properties listed in this
specification shall be submitted to the Engineer in Charge.
iii. Reference list of previous supplies, in last 5 years, of the similar material indicating the
project details such as diameter, quantity, operating temperature, year of supply, project
name, contact person and feedback on performance.

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Once the Employer’s approval has been given, any change in material or Manufacturer shall
be notified to Employer, whose approval in writing of all changes shall be obtained before the
materials are manufactured.
b. Prior to shipment of materials from the Manufacturer’s Works, Contractor shall furnish the
following documents:
 Test certificates/results as per Manufacturer’s Quality Control Procedure for each
batch of material.
 Specific application instructions with pictorial illustrations.
 Specific storage and handling instructions.
c. All documents shall be in English language only.
2.13 Lowering, laying & jointing of pipe
2.13.1 General
The pipeline shall be buried with minimum cover of 1.2 m at top, however pipeline shall be
laid as per detailed Engineering approved by Engineer In-charge. In case required cover is more
than 1.20m, contractor has to laid the pipeline accordingly.
Erection of fabricated shells shall be carried out by the Contractor who shall equip himself, at
his cost, with all necessary tools, machinery, labour etc. required for the purpose.
2.13.2 Welding
Except for routine welding of joints, no other work shall be done in the absence of Contractor's
engineer, either during the daytime or at night.
Chipping shall not be kept in arrears for more than 15 joints.
Saddle pieces shall be fixed in position after checking bolts holes, by means of templates. These
works shall be done together with the pipe laying work, if pipeline is to be laid above ground
in unavoidable circumstances.
2.13.3 Temperature
The components of the pipeline such as base plates, top plates and pedestals have been so
designed that the centres of the plates and pedestals shall coincide at the Mean Temperature
(30º).
For this reason, all works such as fixing flanges, base plate etc. in true alignment, and in correct
position and tack welding pipes shall be done at the mean temperature.
For ascertaining the temperature, the Contractor shall provide mercury cups and fix them to the
pipe shell from outside and shall also provide thermometers of the required type and range. No
extra payment shall be made for this.

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2.13.4 Saddle Supports

Unless otherwise specified pipeline shall be underground. However, at unavoidable reaches it
shall be on R.C.C. saddles spaced as per design. The material and construction of R.C.C./Steel
structures such as saddles, anchor blocks, crossings etc. associated with the work of pipe line
shall conform with the relevant I.S. codes, good engineering practice and as directed by the
Engineer In-charge. The pipes to be laid on saddle supports shall be erected at mean tempera-
ture. Saddle supports shall either be sliding type or fixed type. For both the types of supports a
10mm thick double plate shall be welded to the part circumference of the pipeline that will
make contact with the saddle and another similar plate shall also be embedded in the concrete
saddle with necessary arrangement to facilitate welding it to the double plate welded to the
pipe, in case of fixed support. In case of sliding support, the pipe shall be allowed to slide freely
over the plate embedded in the saddle. Alternatively, to achieve fixity, the pipe shall be an-
chored by providing suitable anchor block. The rate for laying the pipe on saddle support shall
include for laying, aligning, tack welding, provision of rigging screws with screw eyes etc.,
complete.
In addition to above, the pipe shall be held in position on saddles with two numbers 50mm x
8mm thick holding down traps fixed to the saddles with holding down bolts and nuts which
shall be paid separately under relevant item of bill of quantities.
2.13.5 Erection of Pipes
The erection shall be true to position, lines and grade as shown in the drawings or as modified
by the Engineer In-charge. The Contractor shall provide at his cost necessary saddles, pads,
spider etc., all necessary instruments and other materials and labour required for proper erection
of pipes in position and for the Engineer in checking the correctness of the erection.
Alignment of sections at edges to be butt welded shall be such that the maximum offset is not
greater than the values given below:

Thickness ‘t’ Offset in Longitudinal joints Offset in Girth joints

mm (mm) (mm)

Up to 12 0.25 t 0.25 t
12 to 20 3 mm 0.25 t

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Amaravati Development Corporation Limited

20 to 40 3 mm 5 mm
40 to 50 3 mm 1/8 t
Over 50 Lesser of 0.0625 t or 10 mm Lesser of 0.125 t or 20 mm

The best of welders as selected from their work in the Contractor's workshop shall be selected
for in-situ welding of the pipes. The relevant provision under welding such as qualification
standard for welding procedures, tests on welder's work and removal of defects etc., shall also
apply to in-situ welding.
2.13.6 General Sequence of Operations
Before commencing the work of pipe laying, the Contractor shall study the L-section of the
pipeline for the section concerned. He shall also study the details of laying i.e. underground or
aboveground. The underground pipeline shall be laid on sand cushioning/ bedding as shown
on the drawing. The difference in depth due to uneven excavations shall be made up by sand
cushioning.
Pipe laying shall generally start from the fixity points on either side, the expansion joints if
required for pipeline aboveground being provided last. Fixing points are at all anchor blocks.
Where such blocks are not required for long lengths, fixity shall be achieved by fixing the
pipeline to the special type of R.C.C. or steel saddles as directed. The distance between suc-
cessive fixity points shall not exceed 300 m.
Anchor blocks shall be constructed before commencing the pipe laying work in any section.
The construction of the blocks shall be carried out in 3 stages: In the first stage, the lower part
up to 150 mm below the invert of the pipeline including concrete chairs to support it shall be
constructed; in the second stage, the pipeline on this part of the block shall be laid; and lastly,
the remaining block around and over the pipeline shall be constructed. Necessary curing to
concrete shall be carried out for 14 days or as instructed Engineer in charge.
The fixity saddles and ordinary saddles if the pipeline is aboveground shall be cast-at least 3
weeks before the pipeline is laid on them. After all saddles between successive fixity points
have been cast, a line plan showing the actual position thereof shall be prepared, after taking
levels and measuring distances. In case of any errors in casting the pedestals, corrections shall
be applied. The pipe laying work shall then start from the fixity points and shall proceed to-
wards the expansion joints. The method of jointing the pipes and erecting them on previously

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cast R.C.C. saddles shall be determined by the Contractor depending upon the type of plant
equipment and personnel available with them.
The pipe stacking shall be assembled in position on the saddles either by the cranes, portable
gantries, shear legs or any other equipment approved by the Engineer In-charge. Normally, not
more than two pipes shall be aligned, tacked and kept in position on temporary supports. The
Contractor shall not proceed with further work, until the circumferential joints of these pipes
are fully welded. During assembly, the pipeline shall be supported on wooden sleepers and
wedges, with the free end of the pipeline held in position by slings to avoid deflection due to
temperature variations during the day. In general, the assembly of pipe stacking and one run of
welding shall be done during the day time while full welding including the external gouging
and sealing runs shall be done after 5 p.m. or so. The Contractor shall maintain the continuity
of the work by adding two more pipes on the second day in a similar manner, after full welding
of the previous joints is completed during the night. While this new work is being done, the
Contractor shall proceed with the work of providing permanent supports for the pipeline as-
sembled and welded previously.
2.13.7 Fixing Expansion Joint
The work of laying pipeline in aboveground, laying starts from the fixity points and proceeds
towards the expansion joints. It shall be continued until the gap between the pipe ends is less
than the lengths of the expansion joint plus pipe strake length. At this stage, the exact gap
between the pipe ends shall be measured at mean temperature of that locality. Let it be `X'.
Similarly, the exact length of the pipe strake and the expansion joint bought at site shall be
measured at the same temperature let these be `Y' and `Z' respectively. Normally, the length of
the expansion joint (`Z') is standard.
 Case when `Y' plus `Z' is more than `X' or equal to `X' (i.e. fixing of expansion joint
without strip)
At mean temperature, the exact gap between pipes shall be measured. Free ends of pipes shall
be brought in a correct line and level; lateral movement, if any, shall be corrected. Then the gap
between the free ends shall be made equal to the exact length of the expansion joint by cutting
one of the pipe ends. Choice of the end to be cut must be made from the point of view of
bringing the expansion joint to a central position.
The expansion joints are normally supplied without packing. The normal length of the expan-
sion joint shall be reduced by about 100 mm by cutting the inside locks and inserting the inner

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strake by means of turnbuckles. At mean temperature, this expansion joint shall be inserted
inside the gap (care being taken to keep the tapered portion on the down-stream side), and both
ends shall be tack welded to the pipe ends, after pulling the expansion joint. (Tacks of these
two joints shall be of longer length, approximately 100 mm long).
Welding of these two joints of the expansion joints shall be started only after it is ascertained
by taking observations that the expansion joint is functioning properly. The procedure to be
followed for taking observations is given in below observations.
 Case when `Y' plus `Z' is less than `X' (i.e. fixing of expansion joints with strap)
The expansion joint shall be laid in locked position. Before laying the pipes adjacent to the
expansion joint, the exact gap between the pipes shall be calculated by taking measurements
of the first pipe (upstream of the expansion joint), and the second pipe (downstream of the
expansion joint) at Mean Temperature.
If the gap is less than 100 mm, the second pipe shall be cut to make the desired gap of at least
100 mm. If the gap is more than 200 mm, suitable distance piece of not less than 700 mm shall
be inserted after cutting necessary length of the first pipe.
The second pipe shall then be laid in position. Then a strap of length equal to three times the
gap length shall be welded to the pipe, overlapping the second pipe by the gap length. The other
end of the strip shall be kept free.
At mean temperature, the other end of the strap shall be tacked to the first pipe, after checking
of the line and level. Simultaneously, all the locks of the expansion joint shall be removed and
chipped off properly.
Welding of the joints between the strap and the first pipe shall be started only after observations
are over and it is ascertained that the expansion joint is functioning properly.
Observations
Before fixing the expansion joint, two mercury cups - one on the left and the other on the right
side - shall be fixed on the pipe near the upstream side of the expansion joint.
Immediately after the expansion joint in case (a) above or the strap in case (b) above is tack
welded, observations for total expansion or contraction shall be started and continued for 48
hours round the clock. Similarly, the central and end fixity pedestals shall be kept constantly
under observation.

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The expansion and contraction shall be measured by making a temporary marking on the inner
strake (on the upstream side) and measuring the distance between this mark and the edge of the
gland of the expansion joint.
The observations shall be recorded in the following proforma;
Reading Time Pipe Temp Pipe Temp Atmos- Dist. between
No. on Up- on down- pheric edge of gland and
stream side stream side Tempera- marking
ture
1 2 3 4 5 6

2.14 Specials
2.14.1 General
Specials, such as tees, Y-pieces, bends (single or composite), tapers, etc. shall necessarily be
made from same pipe as used in straight reach shall be fabricated as per standards and tested
and laid in the same manner as the pipes. Small branches, single piece bends, etc. may be
fabricated at site, care being taken to ensure that the fabricated fittings have at least the same
strength as the pipeline to which they are to be jointed.
2.14.2 Bends
Bends shall be fabricated taking into account the vertical and horizontal angles for each case.
The bends shall have welded joints and the upstream and downstream ends of each bend shall
have a straight piece of variable lengths as required.
Bends shall be designed with suitable deflection angle between segments.
When the point of intersection of a horizontal angle coincides with that of a vertical angle, or
when these points can be made to coincide, a single combined or compound bend shall be used,
designed to accommodate both the angles. The combined bend should have a pipe angle equal
to the developed angle, arrived at from appropriate formula.
All joints in bends shall be thermally stress relieved as specified.
Details of thrust collars anchor bolts, holding down straps, saddle plates should be furnished
together with full specifications in Contractor's fabrication drawing.
Coating on bends has to be as per ISO 21809-1 (for 3 LPE coating)

2.14.3 Closing or Make up sections

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Closing or make up sections shall be furnished at appropriate locations on the line to permit
field adjustments in pipeline length to compensate for shrinkage in field welded joints, differ-
ences between actual and theoretical lengths and discrepancies in measurements.
2.14.4 Heads
Test heads may be ellipsoidal, standard dished as per ASME code or hemispherical heads. They
shall be welded in the shop and removed after the test. Allowance should be made in the length
of the pipe section receiving the test head for the welding and removal of the head and prepa-
ration of the plate edges for the final weld after testing.
The rate quoted for the hydraulic test shall be deemed to cover the cost of such installations.
2.14.5 Flanges
Flanges shall be provided at the end of pipes or special where, butterfly, air valve, scour valve,
sluice valves, blank flanges, tapers, etc. have to be introduced. The flanges received from the
manufacturers will have necessary bolt holes drilled. The Contractor shall assemble the flanges
in the exact position by marginal cutting, if necessary, so as to get the desired position of the
valves, etc. either vertical or horizontal and shall then fully weld the flanges from both sides in
such a way that no part of the welding protrudes beyond the face of the flanges. In case the
welding protrudes beyond the flanges and if the Engineer orders that such protrusions shall be
removed, the Contractor shall file or chip them off. If required and when ordered by the Engi-
neer In-charge, the Contractor shall provide and weld gusset stiffeners, as directed on site. The
drilling pattern shall be matching with the drilling pattern of flanges of valves.
2.14.6 Blank Flanges
Blank flanges shall be provided at all ends left unattended for the temporary closure of work
and also for commissioning a section of the pipeline or for testing the pipeline laid. For tem-
porary closures, non-pressure blank flanges consisting of mild steel plates, tack welded at the
pipe ends may be used. For pipes subjected to pressures, the blank flanges or domes suitably
designed as per Engineer's requirements shall be provided.
2.14.7 Stiffener Rings
The Contractor shall provide stiffener rings wherever required by design. The Contractor shall
weld the same to the pipes with one circumferential run on each side. All fillet welds shall have
a throat thickness of not less than 0.7 times the width of welding.

2.15 Field Hydraulic Test

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The entire pipeline shall be subjected to a hydraulic test as follows, to the required test pressure
as per Clause 11 of IS: 5822.
Hydrostatic test for the buried pipeline to be conducted for 1.5 times of working pressure (i.e.
1.5 * 50 = 75 m or 7.5 kg/cm2)
Water shall not spout, ooze or sweat either through joints-welded or bolted or the body of the
pipe. If any leakage noticed shall be repaired by the Contractor, which shall include coating
and repairing of the damaged portion. Repairs and replacements and further testing including
the cost of the plates and other raw materials shall be carried out by the Contractor at his own
cost. If any leakages are observed during the defects liability period due to defective workman-
ship or material supplied by the Contractor, he shall repair the same to the entire satisfaction of
the Employer, at his own cost.
After completion of field hydraulic test as specified above and if no leakage is found in the
entire pipeline/joints and all welded portion, then this may be considered as field hydraulic test.
2.16 Progress in laying
The contractor shall submit a detailed bar chart for manufacturing and laying of the pipeline.
While preparing this bar chart, the contractor shall plan all activities such that the laying of
pipes shall closely follow the manufacturing schedule and no pipes shall remain stacked in
factory or at site for a period more than one month.
2.16.1 Lowering and Jointing
The pipe shall be lowered into the trenches by removing only one or two struts at a time. It
shall be seen that no part of the shoring is disturbed or damaged and, if necessary, additional
temporary struts may be fixed during the lowering operations. It shall also be necessary to see
that the coating of pipe is not damaged in any way during the lowering and assembling. After
the pipe is lowered into the trench, it shall be laid in correct line and level by using the levelling
instruments, sight rails, theodolite, etc. Care shall be taken to see that the longitudinal joints of
two consecutive pipes at each circumferential joints are staggered by 90°. While assembling
the pipes, the ends shall have to be brought close enough to leave a uniform gap not exceeding
4mm. If necessary, a marginal cut may be taken to ensure a close fit of the pipe faces. For this
purpose, only experienced cutters who can make uniform and straight cuts shall be permitted
to cut the faces of the pipes. No extra payment shall be made for such marginal cutting. There
shall be no lateral displacement between the pipe faces to be joined. If necessary, spiders from
inside and tightening rings from outside shall be used to bring the two ends in perfect contact

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and alignment. It may also be necessary to use jacks for this purpose. In no case shall hammer-
ing or longitudinal slitting be permitted. When the pipe is properly assembled and checked for
correct line and level, it shall be firmly supported on wooden beams and wedges and tack
welded. Some portion of the trench may be refilled at this stage so as to prevent the pipeline
from losing its alignment. The tack welded circumferential joints shall then be welded fully.
Only experienced welders, who shall be tested from time to time shall be permitted to carry out
the welding work.
On completion of the pipe jointing and external protection, the trench and the welding pits shall
be cleaned. The welding pit shall be filled and compacted in 150mm layers with the bedding
material.
Backfilling shall be carried out as detailed here under.
Providing Steel Props inside the Pipeline (Dia. 1200 mm and above).
It is necessary that the roundness of the pipes is maintained circular. To achieve the same, steel
adjustable screw type props of screw or similar approved make consisting of minimum six
(three on each side) legs shall be fixed inside the pipe. The deflection of the pipe should be
limited to 1% of the average diameter. In no case shall the limit be exceeded, even under the
full load, in case of pipes laid underground. The design and drawings of the props that the
Contractor intends to use should be got approved by the Engineer In-charge before starting the
work. While laying the pipes underground. In case the Engineer In-charge finds it necessary,
they will have to be fixed in any position. The props should be kept in position at least for three
days after the encasing of the pipe in that section is completed or till refilling is done to the full
height of fill over the pipe in case the pipes are not encased. The props shall be removed only
after obtaining permission from the Engineer In-charge. The height of earth fill over the pipe
top shall normally be such as to avoid floatation under submerged conditions and to have a
minimum earth cushion of about 1.20 metres over the pipe whichever is greater. It is also nec-
essary that, in case of buried pipe, adequate side supports from the backfilled materials is de-
veloped to keep the diametrical deflection within the specified limits. Backfilling of the exca-
vated trenches, particularly below the pipe and along the sides shall, therefore, have to be done
with proper care and compaction as desired. No extra payment will be made for the above
work.

2.16.1.1 Precautions against Floatation

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Amaravati Development Corporation Limited

When the pipeline laid underground or above ground in a long narrow cutting gets submerged
in water collected in the trench of cutting it is subjected to an uplift pressure due to buoyancy
and is likely to float if completely or partly empty. In the design of pipelines, provision is to be
made to safeguard against floatation providing sufficient overburden or by providing sufficient
dead weight by means of blocks, etc. Factor of safety for calculations for check against floating
shall be taken as 1.2.
In the case of works extending over one or more monsoon seasons, however, special care and
precautions are necessary during the progress of work on this account. The Contractor shall
close down pipe laying operations well in time for the monsoon. The work of providing blocks,
refilling the earth to the required level, compacting the same, etc. shall always be done as soon
as the pipeline in the cutting has been laid.
The Contractor shall see that the water shall not be allowed to accumulate in open trenches.
Where work is in an incomplete stage, precautionary work, such as blank-flanging in the open
ends of the pipeline and filling the pipeline with water etc. shall be taken up as directed by the
Engineer In-charge.
Such works shall be to the Contractor's account and no separate payment shall be made for the
same. The Contractor's rate for pipe laying shall be deemed to include such precautionary
measures against floatation.
Protection of the pipeline against floatation during the Contract Period shall be the responsibil-
ity of the Contractor. Should any section of the pipeline float due to his negligence, etc. the
entire cost of laying it again to the correct line and level shall be to his account.
Pipeline will be laid by the contractor as per the drawings provided by the Client.
Alignment of pipeline may require to be changed on same route due to any obstructs or service
lines. No extra payment made to contractor.
All necessary actions required for diversion of the traffic on State high way, or any other routes
are to arrange by the contractor at his own cost as per the requirement of the traffic rules and
approval from concerned competent authority.
During the execution of work any damage occurred to the private/Govt. property is to be reim-
bursed by the contractor to the owner.

2.17 Specification for External Field Girth Weld Joint Coating for Buried Steel Pipelines
for Water Coated with Cold Applied Tape System

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General:
All girth weld joints of buried steel pipeline shall be coated externally with pre-fabricated heat
shrinkable cross-linked polyolefin coatings as per AWWA C216-07. The Contractor shall per-
form all work in accordance with these specifications and the latest pipeline coating practices,
and shall complete work in all respects to the full satisfaction of the Owner / Owner’s repre-
sentative. The entire field joint coating operation starting from cleaning and surface prepara-
tion till coating shall be performed under the supervision of skilled personnel who are well
conversant with the work.
This specification is not intended to be all inclusive and the use of guidelines set forth here
does not relieve the Contractor of his responsibility for the quality and performance of the
applied coating system, and to supply coating material capable of performing its intended ser-
vice
Referenced Standards:
The following standards (latest revision) referenced below are a part of this specification. In
case of conflict between this specification and the referenced standards, this specification shall
apply.
ANSI/AWWA C 216: Standard for Heat - Shrinkable Cross-linked Polyolefin coatings for
exterior of special sections, connections and fittings of steel water pipelines.
ANSI/AWWA C214: Standard for Tape Coating Systems for the Exterior of Steel Water
Pipelines
ANSI /ASTM D149: Standard Test Method for Dielectric Breakdown Voltage and Dielectric
Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies.
ANSI/ASTM D257: Standard Test Method for DC Resistance or Conductance of Insulating
Materials.
ANSI/ASTM D570: Standard Test Method for Water Absorption of Plastics
ANSI/ASTM D638: Standard Test Method for Tensile Properties of Plastics.
ASTM D1000 : Standard Test Method for Pressure-Sensitive Adhesive-Coated Tapes
Used for Electrical and Electronic Applications.
ASTM D1002 : Standard Test Method for Apparent Shear Strength of Single Lap
Adhesively Bonded Metal Specimens by Tension Loading.
ASTM E96: Standard Test Methods for Water Vapor Transmission of Materials
ASTM G14: Standard Test Method for Impact Resistance of Pipeline Coatings

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(Falling Weight Test)

ASTM G17: Standard Test Method for Penetration Resistance of Pipeline Coatings
(Blunt Rod)
ANSI/AWWA C209: Standard for cold applied tape coatings for the exterior of special
sections, connections and fittings for steel water pipelines.
NACE RP-O2-74: High-Voltage Electrical Inspection of Pipeline Coatings Prior to
Installation
SSPC-SP 6/NACE No. 3: Commercial Blast Cleaning.
Heat Shrinkable joint coating system:
General:
Heat shrinkable joint coating system shall consist of material fabricated from cross-linked pol-
yolefin backing, coated with a protective, heat-activated adhesive. The heat activated adhesive
can be of modified butyl rubber based or modified asphalt based. After installation, the heat
shrinkable coating shall conform to all surface contours of the pipe. Heat shrinkable sleeve will
be of wrap around design and shall be provided with a separate closure patch to secure the
overlap of the heat shrinkable sleeve during the shrinking process.
Dimensions:
The manufacturer shall provide pre-cut heat shrinkable sleeves to suit the diameter of the steel
pipe. The width of the sleeve shall meet the requirement of the coating cut back and shall over-
lap the main line coating by 100mm on either side. For coating cut back of mainline coating
150+ 0 /-25 mm, width of sleeve shall be 600mm.
Thickness:
The applied thickness of the heat shrinkable sleeve on the steel pipe body shall match the thick-
ness of the main line coating and the thickness on the apex of circumferential girth weld seam
shall not be less than 75% of the thickness of the heat shrinkable sleeve on the steel pipe body.
Applied thickness of the heat shrinkable sleeve shall be minimum 2.0 mm on the steel pipe
body and on the apex of circumferential girth weld shall be minimum 1.5 mm.
Table-I Physical and performance requirements for heat shrinkable coatings:
Property Requirement Test Method
(Ref. AWWA C216)
Width deviation (min) +0.25 inch (6mm) Sec.5.3.1
Thickness (as applied min) 2.0 mm Sec. 5.3.2
Water-vapor transmission 0.03 g/h/m2 Sec 5.3.3

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Dielectric strength (min) 400 V/mil (15 V/µm) Sec 5.3.4

Volume resistivity (min) 1014 ohm-centimeter Sec. 5.3.5
Adhesion to Steel (min) 15 lb/in width Sec. 5.3.6
Lap shear (min) 12 psi 83(kPa) Sec. 5.3.7
Heat shock (test for cross No visual cracking, flowing, or Sec. 5.3.8
linking of backing) dripping
Tensile strength 2,200 psi (15.2 Mpa) Sec. 5.3.9
Elongation 400% Sec. 5.3.10
Impact resistance 25 in-lb (282 cm-N) Sec. 5.3.11

Heat Shrinkable joint coating application:

Surface preparation:
Bare surface:
Bare surface shall be free from mud, mill scale, lacquer, wax, paint, coal tar, asphalt, oil, grease,
or any other foreign material. Before blast cleaning, surfaces shall be inspected and, if required,
pre-cleaned according to SSPC-SP1 to remove oil, grease, and loosely adhering deposits.
Welds shall be cleaned of all welding slag, spatter and scale and shall be allowed to cool before
the coating is applied. Sharp edges or burns that could puncture or cut the coating shall be
removed by grinding or filling.
Blast cleaning:
All metal surfaces shall be blast cleaned to achieve a surface preparation equivalent to SSPC-
SP 6/NACE No.3. Anchor profile shall be minimum 50 microns.
Protection from moisture:
Blast-cleaned surface shall be protected from conditions of high humidity, rainfall or surface
moisture and shall not be allowed to flash rust before the coating is applied. If rust occurs, the
surface must be prepared again by blast cleaning in the mill or shop or by either blast cleaning
or wire-brush cleaning in the field. At the time of coating/adhesive application the steel sub-
strate shall be at least 3°C above the dew point.
Application of heat shrink sleeve:
The application of heat shrink sleeve shall be in accordance with the manufacturer’s recom-
mendation and the procedures outlined below. The procedure shall be submitted to owner for
approval before start of work.
Heat shrink sleeve shall be clean, free from dust and dirt, moisture and chemical contamination
up to and during the time of application.

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Pipe surface shall be pre-heated to a temperature of 600C using LPG gas torches.
Heat shrink sleeve shall then be wrapped loosely around the pre-heated pipe, centering it over
the exposed weld area and evenly overlapping the adjacent pipe coating by 100mm. The closure
patch shall be positioned off to one side of the pipe in 10 o’clock or 2 o’clock position. Closure
patch shall be pressed into position and using a LPG torch with the flame adjusted according
to the manufacturer’s instructions, the closure patch shall be heated evenly until the pattern of
the reinforcement fabric is visible. Any wrinkles or entrapped air in the closure patch shall then
be smothed out using a gloved hand and or rollers.
LPG torches shall then be used to heat circumferentially around the joint heating from the
centre of the joint outwards, on one end of the joint only. When one end of the joint is fully
shrunk the other end shall be heated in the same manner. When fully shrunk adhesive flow shall
be visible at both ends of the sleeve and the dimples on the backing vanish.
After the joint sleeve is fully shrunk onto the field joint and while the sleeve is still warm and
soft, any wrinkles, creases or air bubbles shall be smoothed out with a gloved hand or small
roller. Sleeves showing signs of overheating or uneven shrinkage shall be removed and the
cleaning and surface preparation repeated for a new heat shrink.
Material acceptance, inspection and testing:
Material acceptance:
Proposed coating materials shall be approved by the Owner / Owner’s representative. The heat
shrink sleeve manufacturer proposed by the Contractor shall have supplied coating material for
a single water pipeline project with pipe diameter ≥ 2000mm and a length of minimum 100
Kms in the last seven years globally. The Work completion certificates from End User & coat-
ing applicator will be submitted by the Contractor while submitting credentials of the proposed
sleeve manufacturer to the Owner / Owner’s representative for approval.
The recommendations of the manufacturer regarding coating process, repairs, etc, shall also be
provided by the contactor. The manufacturer should give guarantee to supply of the required
quantity as per the project time schedule and take responsibility for supervising the coating
application, repair works and should have technical support team available in owners country.
Supporting documents shall be provided for the same.

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When the material is supplied, acceptance of the material shall be based on submission of cer-
tificate of conformance of the coating system to AWWA C216-07 standard and properties spec-
ified in this specification along with manufacturing acceptance test certificates for various lots
as per manufacturer’s quality assurance and quality control requirements.
Field joint coating application inspection:
The entire field joint coating operation by the Contractor will be supervised by qualified experts
from the manufacturer. The CV of the manufacturer's expert shall be approved by the
Owner/Owner’s representative. All field joint coating work will be done in the presence of the
Owner/Owner’s representative.
Thickness:
The thickness of the field joint coating system shall be checked in accordance with SSPC-PA
2. The thickness shall be in accordance with the values given in the Table I and shall be checked
at a frequency specified by the Owner / Owner’s representative.
Holiday testing:
Each field joint coating shall be electrically tested for flaws in the coating using a suitable
holiday detector approved by the Owner / Owner’s representative. The detector shall impress
a minimum of 12,000 V. Reference should be made to NACE RP-02-74. If a holiday is detected,
it shall be repaired as per specifications.
Peel strength:
The peel strength of the heat shrinkable sleeves shall be checked in accordance with ASTM D-
1000. The average value below the limits stated in the Table I shall constitute a failure of the
heat shrinkable sleeve to meet the adhesion requirement. The peel test shall be conducted at a
frequency specified by the Owner / Owner’s representative
Field procedures:
At all times during construction of the pipeline, the Contractor shall use caution to prevent
damage to the heat shrinkable field joint coating on the pipe. No metal tools or heavy objects
shall be permitted to unnecessarily contact the finished coating. Workmen shall not be permit-
ted to walk on the coating except when necessary. In these cases, they shall wear shoes with
rubber or composition soles and heels or other suitable footwear that will not damage the coat-
ing.
Coating repair in field:

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All holidays visually or electrically discovered and heat shrink sleeves damaged during peel
test shall be repaired using heat applied polyethylene adhesive lined repair patch. The patch
shall be applied as per manufacturer’s recommendation.

EXCAVATION
The ground shall be excavated by such methods and to such dimensions and depths as shall
allow for the proper construction of the works and safety of personnel and equipment used on
excavation. Slopes required for stable formation of sides shall be provided. The excavation
shall include excavation in earth and murrum and others shall be carried out to the correct levels
required and specified and no clearance, plus or minus (ie. no overcuts), shall be permitted as
per the authority.
Road crossing with the trench less technology / HDD (Horizontal directional drilling): Trench-
less technology tunneling work include the laying by hydraulic jacking and smooth controlled
pushing method in all types of soils including hard rock true to the alignment and gradient
under running traffic condition as per standards including carrying out the survey work at the
site for determining underground cable trenches like telephone, fiber optic cables , water sup-
ply pipes , irrigation pipes and resistivity test for finding the soil strata using necessary equip-
ments for completeness of works mobilizing of the machineries and specialized crews at con-
struction site etc, complete in all respects including the excavation of the driven pit and exit pit
with proper protection with shoring sheets and ISMB (providing and casting MS cutting edges
for front shield and construction thrust bed at designated level as directed by the engineer,
necessary dewatering and providing the concrete foundation at the base of the driven pit, crane
for holding the pipe and any other machinery, tools , tackle required, construction of the tem-
porary works as per the requirement and approval of the concerned authorities and engineering
in charge, as per the scope of work defined.

2.18 Back filling of trenches

On completion of the pipe laying operations in any section, for a length of about 100m and
while further work is still in progress, refilling of trenches shall be started by the Contractor
with a view of restricting the length of open trenches. Pipe laying shall closely follow the pro-
gress of Trench Excavation and the Contractor shall not permit unreasonably excessive lengths
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of trench excavation to remain open while awaiting testing of the pipeline. If the Engineer
considers that the Contractor is not complying with any of the foregoing requirements, he may
prohibit further trench excavation until he is satisfied with the progress of laying and testing of
pipes and refilling of trenches. Backfilling shall be carried out from bottom of pipe to 30 cm.
above top of pipe with useful excavated soil which do not damage the pipe surface. In case of
any damage to external surface (of pipe/joint/specials etc.), the damages shall be rectified by
the contractor at no extra cost. In case of failure in attending satisfactory repairs, entire
pipe/specials shall be replaced with new one at no extra cost. Filling from bottom of pipe line
up to centreline shall be done in layers not exceeding 225mm and compacted to 85 percent of
the maximum dry density by hand compaction as per part VII of IS:2720. Filling from centre
line of the pipe to a level 300mm above the top of pipe shall be done by hand or approved
mechanical methods in layer of 225mm as per IS 3114. Care shall be taken during backfilling,
not to injure or disturb the pipes, joints or coating. Filling shall be carried out simultaneously
on both sides of the pipes so that unequal pressure does not occur. Walking or working on the
completed pipeline unless the trench has been filled to height of at least 30 cm over the top of
the pipe except as may be necessary for tamping etc., during backfilling work.
Soil of excavated stuff which is to be used for refilling / backfilling work shall be got tested for
all chemical tests including SO3 %, sulphate as SO3 2:1 water soil extract as per I.S. 456:2000.
No swelling soils shall be used for backfilling work. For the purpose of back filling require-
ments of I.S. 3114:1994 shall be satisfied.
As per approval by EIC suitable material in backfilling may be use in lieu of earth, sand, or
rounded river-run gravel / crushed sand.
The trench shall be refilled so as to build up to the original ground level, keeping due allowance
for subsequent settlement likely to take place. No extra payment will be made for material
brought from outside. Backfill material shall be properly consolidated by watering and ram-
ming, taking due care so that no damage is caused to the pipes.
To prevent buckling of pipe shell diameters 1200 mm and above, pipes shall be strutted from
inside while the work of refilling is in progress, for which no separate payment shall be made.
Strutting shall be done by means of strong spiders having at least 6 arms which shall be suffi-
ciently stiff to resist all deformation. Spiders shall be provided at a maximum interval of 4 m.
If suitable material sand for back filling is not available from excavated stuff, it shall be brought
from borrow area for which no extra payment shall be made.

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The Engineer shall, at all times, have powers to decide which portion of the excavated materials
shall be for filling and in which portion of the site and in what manner it shall be so used.
If any material remains as surplus it shall be disposed of as directed by the Engineer In-charge,
which includes loading, unloading, transporting and spreading as directed. Contractor has to
make his own arrangement for disposal of surplus earth. Contractor has to identify and arrange
for dumping zone to dispose of the excess excavated stuff. No extra payment for such arrange-
ment shall be paid. If the Contractor fails to remove the earth from site within 7 days after the
period specified in a written notice, the Engineer may arrange to carry out such work at the
Contractor's risk and cost or may impose such fine for such omission as he may deem fit. Par-
ticular care shall be taken to keep the trench dry during the entire refilling operation.
If suitable material / Sand for refilling is not available from excavation the Contractor shall
bring selected material of approved quality as directed by the Engineer In-charge. No extra
payment will be made for material brought from outside.
No mechanical plant other than approved compacting equipment shall run over or operate
within the trench until backfilling has reached its final level or the approval of the Engineer In-
charge has been obtained.
Subsidence in filling in: Should any subsidence take place either in the filling of the trenches
or near about it up to completion of the Contract Works. The Contractor shall make good the
same at his own cost or the Engineer may make good the same in any way and with any material
that he may think proper, at the expense of the Contractor. The Engineer In-charge may also, if
he anticipates occurrence of any subsidence, employ persons to give him timely notice of the
necessity of making good the same, and the expenses on this account shall be charged to the
Contractor.
2.19 Distance indicators and Markings

The Contractor shall supply and fix indicators at all points of change of direction, at all valves
and at every one kilometre intervals along the buried pipe line. Indicators shall consist of 10
cm x 10 cm pre-cast concrete posts 1.25-metre-long, set 0.75 metre into the ground and painted
white above ground level. The description shall be written in blue at one face of the pre-cast
post.
In case of the pipeline laid above ground details such as chainage, Invert levels of pipe, appur-
tenance number, pedestal/saddle number, culvert number, anchor/thrust block number etc.,

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shall be suitably marked either on the pipeline or the supporting structure etc., in distinct colour.
The Contractor shall include the cost of this in his rates for the other items.
2.20 Responsibility of Contractor

The following responsibilities are under the scope of contractor

 Procurement of pipeline
 Stacking/storing of pipeline
 Remove of rust on Internal surface and external surface (BS-105 with A&C 2) before
lowering
 Excavation
 Lifting/Shifting of pipeline from yard (stacking place) to laying place.
 Lowering and laying of pipeline
 Welding and jointing of pipeline
 Closing of pipe ends
 Backfilling
 Compacting and testing.

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3. APPURTENANCES
3.1 Scope of Work

This chapter describes the minimum requirements for the provision of valves & valve cham-
bers. Prior to the procurement of valves, the Contractor shall obtain the Engineer in charge’s
approval for the QAP, Data sheet & drawings. General applicable Standards to be applied to
the Works under this Section shall be Indian Standards and British Standards or other approved
International Standard.
3.2 General

DI Resilient seated sluice valves shall be used as scour valves at following locations as men-
tioned in the Schedule – B, Table-4 of water supply scope. Shop inspection, Pressure testing of
valves, Material testing at manufacturer’s testing facility in presence of EIC/Representative of
EIC followed by a certificate from the manufacturer’s shop testing shall be provided for review
by the Engineer in charge. Before delivery to Site all working surfaces shall be thoroughly
cleaned and if metal protected with grease. The initial charges of oil, grease and similar mate-
rials necessary for the correct setting to work and operation of valves and penstocks shall be
provided by the Contractor. Packing must be sufficient to ensure complete protection of the
fitting during transit and storage and all valves are to have their openings sealed until installa-
tion.

3.3 Installation

All valves, operators and appurtenances shall be installed in accordance with the manufac-
turer’s recommendations and as per the specifications laid for pipe laying, and to the locations
indicated on the drawings. The installation shall be true to alignment and rigidly supported. As
soon as installation and operating conditions permit, all valves and appurtenances shall be
given a field test to be witnessed by the Engineer in charge to demonstrate that they meet all
requirements and operating conditions.
Valves shall be rated for PN 16 as minimum working pressure unless elsewhere defined as per
the requirement or in tender document.
3.4 Flanges

Valves shall be flanged and the flange face at right angles to the valve centerline. Backside of
valve flanges shall be machined or spot faced for proper seating of the head and nut. Flanges
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shall be machined on faces and edges to IS 6392 or BS 4504 for PN 16 nominal pressure rating
unless otherwise required. Flange drilling shall conform to IS 1538.
3.5 Operation

Scour valves shall be provided with extension spindle by contractor with supports for operation
from operating level / ground level. All valves shall be protected against corrosion. Provision
for indicator tags shall be made for identification / location of valves. Marking shall be either
cast on the bonnet or the body and shall show the following:
 Manufacturer’s name or mark
 Year of valve casting
 Size of valve
 Designation of working pressure
 Number of turns to open, with the direction of closing clearly indicated on the hand
wheel or body as appropriate.
Nuts and bolts shall be of the best quality bright steel, machined on the shank and under the
head and nut. Nuts and bolts shall be ISI Marked conform to IS 1363 and IS 1367, unless
otherwise specified. Nuts and bolts shall be hot dip galvanized or shall be chromium plated.
3.6 Construction of Scour Valve

The valve shall be constructed as per the arrangement drawing provided in the drawings and
the GFC drawing shall be provided by the contractor before installation/construction for ap-
proval of EIC.
Sluice Valves
3.6.1 Constructional Features
The valves shall be resilient seated, bubble-tight, straight and pocket less body passage, inside
stem screw and electrostatic epoxy powder (EP-P) coated INSIDE AND OUTSIDE. The face
to face dimensions shall conform to provisions of IS 14846/EN 558-1, Basic series F4/BS 5163.
All tests shall be carried out as per these standards.

Valves shall be of non-rising spindle type except for the bypass valves. The spindles shall be
of such lengths that when the valves are closed the bottom ends of the spindles engage fully in
the spindle nuts. The spindle collars of thrust plates shall be concentric and machined, suitable
for the specified test pressure. The thickness and bearing of the nut shoulders shall be adequate
to resist operating thrusts. Spindles shall be greased and supplied with a cap top. Valve shafts
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shall be a one-piece unit extending completely through the valve disc, or of the ‘stub shaft’
type, which comprise two separate shafts inserted into the valve disc hub. Valves of 400 mm
and above shall be provided with thrust bearing arrangement/Gear Arrangement for ease of
operation.

Valve of diameter 400 mm and above shall be provided with enclosed gear arrangement for
ease of operation. The operation gear of all valves shall be such that they can be opened and
closed by one man against an unbalanced head 15% in excess of the maximum specified rat-
ing. Valve and any gearing shall be such as to permit manual operation in a reasonable time
and not exceed a required rim pull of 200 N.

Valves spindles and hand wheels shall be positioned to give good access for operational per-
sonnel. Hand wheels shall be arranged to turn in a clockwise direction to close the valve, the
direction of rotation for opening and closing being indicated on the hand wheels.
Valves shall have two positions marked at the shut end of the scale, first one corresponding to
the position of the gate tangential to the bore of the seating and the second position below the
first, corresponding to the position of the gate as it sits on the seating after moving a further
distance equal to the depth of the seating.

The valves shall be so designed that the gates may be removed without removing the bodies
from the connecting pipe work. The gate guides shall be cast integrally with the valve bodies
and be of adequate strength and of sufficient length to guide the gates throughout their full
length of travel. In the fully open positions, the gates shall be fully withdrawn well clear of
the stream and the spindles shall not protrude into the bores of the valves.

All Sluice valves shall be open end tested. The Contractor shall provide test certificates for
materials, strength and leakage in accordance with BS 5163 / IS 750/International reputed
Standards.
3.6.2 Materials of Construction

Item Material of Construction

Body, Dome Spheroidal Graphite Iron IS 1865 Gr 400/12 or Gr500/7
Ductile Iron DIN 1693-GGG40 / GGG50
Wedge Spheroidal Graphite Iron IS 1865 Gr 400/12 or Gr500/7
Ductile Iron DIN 1693-GGG40 / GGG50
Rubber Vulcanized with EPDM/
Spindle / Stem SS: IS 6603 04 Cr17 Ni 12 M0 2 / AISI 316/SS 420
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Bonnet Gasket EPDM

Internal Fasteners Stainless steel SS316
Nuts, bolts & washers for High tensile steel Hot dip galvanized
pipe flanges
Coating Internal and external with powder or liquid food grade
Fusion Bonded Epoxy(FBE) coating with minimum dry
film thickness of 250 microns Or Thermoplastic-Powder
Coating Internal/External min 250 microns

4. PLB HDPE Duct

Optical Fiber Cables should be pulled though Permanently Lubricated HDPE Duct of 40
mm/33 mm size conforming to the specifications as per TEC GR No. TEC/GR/TX/CDS-
008/03/MAR-11 with latest Amendments. The Ducts shall be Orange in colour and have the
identification markings as per TEC GR.

4.1 Laying of PLB HDPE Duct

Purpose of PLB HDPE duct is for laying of optical fibre cables, networking/interconnect of
all accessories i.e., valves, control valves & WDC control management to C3 located at WTP
near Undavalli. PLB Duct shall be laid along with MS/DI K9 Pipes with minimum clearance
from the pipe line. Prior to the procurement of ducts, the Contractor shall obtain the Engineer
in charge’s approval for the QAP & Data sheet. The L-Section should show the water supply
profile, bends and appurtenances ie., Air valve, Scour valve, Isolation valve details (X, Y, Z
Coordinates), PLB HDPE duct profile for approval of Engineer-in-Charge.
4.2 PLB HDPE Duct Accessories

a. Push fit Coupler

Push Fit couplers shall be used for coupling PLB HDPE ducts/coils. The specifications of
the couplers shall be as per TEC GR no TEC/GR/TX/CDS-008/03/Mar11 with latest
amendment.
b. PP Rope
Should confirm to TEC GR No. TEC/GR/TX/CDS-008/03/MAR-11 with latest Amend-
ments. However, this is optional and EMPLOYERs may use the same on need basis. The
PP rope can be ordered along with the PLB duct as required. In this case PP rope is drawn
through the HDPE/PLB pipes/coils and safely tied to the end caps at either ends with hooks
to facilitate pulling of the OF cables at a later stage. The duct shall be supplied with pre-
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installed rope when so ordered by the purchasing authority. The rope shall be polypropyl-
ene, 4 mm in diameter for 40mm/33mm ducts and confirm to IS: 5175, with a minimum
slackness of 2%.
c. End Cap
End Cap shall be used for sealing the ends of the empty ducts, prior to installation of the
OF Cable and shall be fitted immediately after laying the duct to prevent the entry of any
dirt, water, moisture, insects/rodents etc. It should confirm to TEC GR No.
TEC/GR/TX/CDS-008/03/MAR-11 with latest amendments. The ends of the PLB HDPE
ducts/coils laid in the manholes should be closed with End Caps. The End Caps used should
be suitable for closing 40mm/33mm PLB HDPE ducts/coils. A suitable arrangement should
be provided in the End Cap to tie PP Rope.
d. Cable sealing Plug
This shall be used to seal the end of the ducts perfectly, after the OF cable is pulled in the
duct. For pulling the cable through the ducts, it is necessary to provide man holes at that
location and also at bends and corners wherever required. The ends of the PLB HDPE
ducts/coils are closed with Cable Sealing Plugs. The End Plugs used should be suitable for
closing 40mm/33mm PLB HDPE ducts/coils. The Cable sealing plug shall confirm to TEC
GR No. TEC/GR/TX/CDS-008/03/MAR-11 with latest amendments.

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Annexure – I (D)

Recycled Water Supply

1.0 Reuse Water Supply Network

Standards and Specifications for the Design and Construction of Recycled Water Sup-
ply Network are given in this section.

2.0 Applicable Codes & Standards

The manufacturing, testing, supplying, jointing, and testing at work sites of pipes shall
comply with all currently applicable statutes, regulations, standards and codes. In par-
ticular the following standards, unless otherwise specified herein, shall be referred. In
all cases, the latest revision of the Codes shall be referred to. If requirements of this
Specification conflict with the requirements of the Codes and standards, this Specifica-
tion shall govern. However, other codes as approved by Employers Engineer but not
specifically mentioned below pertaining to the use of DI and HDPE Pipes shall form
part of these specifications.
DI Pipes

Code Description
IS: 8329 Specification for Centrifugally Cast (spun) Ductile Iron
pressure pipes for water, gas and sewage specification.

IS: 5382 Specification for Rubber sealing ring for gas mains, wa-
ter mains and sewers
IS: 638 Sheet rubber jointing and rubber insertion jointing.

IS: 1387 General requirements for supply of metallurgical materi-

als.
IS: 1500 Methods for Brinell hardness test for metallic materials.

IS: 9524 Ductile Iron fittings for pressure pipes for water, gas and
sewage.
IS: 12820 Dimensional requirement of rubber gaskets for mechani-
cal Joints and push on joints for use with
cast Iron pipes and fittings for carrying water, gas and
sewage.
ISO:4179 Ductile iron pipes for pressure and non-pressure-Centrif-
ugal cement mortar lining - General requirements.
ISO:2531 Ductile iron pipes, fitting and accessories for pressure
pipe lines. Code of Practice
IS: 12288 Code of practice for use & laying of Ductile iron pipes.

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IS: 13382 Cast iron specials for mechanical and push-on-flexible

joints for pressure pipe lines for water, gas and sewage.

HDPE Pipes;
Code No. Description
IS 4984 – 1995 High Density Polyethylene Pipes for Water Supply
Specification.
IS 2530: 1963 Methods of test for polyethylene moulding materials and
polyethylene compounds
IS 4905: 1968 Methods for random sampling
IS 8360 (part- I): Specification for Fabricated High-Density Polyethylene
1977 Fittings for Potable Water Supplies – General Require-
ments
IS 8360 (part- Specification for Fabricated High-Density Polyethylene
II):1977 Fittings for Potable Water Supplies – Specific Require-
ments for 90 Deg. Tee
IS 8360(part- Specification for Fabricated High-Density Polyethylene
III):1977 Fittings for Potable Water Supplies – Specific Require-
ments for 90 Deg. Bends
IS 7634 (part- Code of Practice for Plastic Pipe Work for Potable Water
I):1975 Supplies – Choice of Materials and General Recommen-
dations
IS 7634 (part- Code of Practice for Plastic Pipe Work for Potable Water
II):1975 Supplies – Laying and Joining Polyethylene (PE) Pipes
IS 8008 (part-I): Injection Moulded / Machine High Density Polyethylene
2003 (HDPE) Fittings for Potable Water Supplies –Specifica-
tion – General Requirements for fittings
IS 8008 (part- Injection Moulded / Machine High Density Polyethylene
II):2003 (HDPE) Fittings for Potable Water Supplies – Specifica-
tion – Specific Requirements for 90 Deg. Bend.
IS 8008(Part Specification for injection moulded HDPE fittings for po-
III):2003 table water supplies: Part 3 Specification for 90-degree
tees
IS 8008(Part Specification for injection moulded HDPE fittings for po-
IV):2003 table water supplies: Part 4 Specific requirements for re-
ducers
IS 8008(Part Specification for injection moulded HDPE fittings for po-
VI):2003 table water supplies: Part 6 Specific requirements for
pipe ends

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IS 8008(Part Injection moulded/machined high density polyethylene

IX):2003 (HDPE) fittings for potable water supplies - Specification
Part 9 Specific requirements for ends caps (first revision)
IS 7328: 1992 High density polyethylene materials for moulding and
extrusion
IS 9845: 1986 Method of analysis for the determination of specific
and/or overall migration of constituents of plastics mate-
rials and articles intended to come into contact with food-
stuffs
IS 7328: 1992 High density polyethylene materials for moulding and
extrusion
IS 10141: 1982 Positive list of constituents of polyethylene in contact
with foodstuffs, pharmaceuticals and drinking water
IS 10146: 1982 Polyethylene for its safe use in contact with foodstuff,
pharmaceuticals and drinking water
IS 8112: 1989 Specification for 43 grade ordinary Portland cement
IS 4990:1993 Specification for plywood for concrete shuttering work

Any other relevant codes required for the project will be applicable as per the directions
of Engineer-in-Charge.

General

Prior to the procurement of Pipes, valves the Contractor shall obtain the Engineer-in-charge
approval for the QAP, GAD & Data sheet. Shop inspection, Pressure testing of Pipes, Material
testing at manufacturer’s testing facility in presence of EIC/Representative of EIC followed by
a certificate from the manufacturer’s shop testing shall be provided for review by the Engineer-
in-charge.

Excavation
The ground shall be excavated by such methods and to such dimensions and depths as shall
allow for the proper construction of the works and safety of personnel and equipment used on
excavation. Slopes required for stable formation of sides shall be provided. The excavation
shall include excavation in earth and murrum and others shall be carried out to the correct levels
required and specified and no clearance, plus or minus (ie. no overcuts), shall be permitted as
per the authority.
Road crossing with the trench less technology / HDD (Horizontal directional drilling): Trench-
less technology tunneling work include the laying by hydraulic jacking and smooth controlled
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pushing method in all types of soils including hard rock true to the alignment and gradient
under running traffic condition as per standards including carrying out the survey work at the
site for determining underground cable trenches like telephone, fiber optic cables , water sup-
ply pipes , irrigation pipes and resistivity test for finding the soil strata using necessary equip-
ments for completeness of works mobilizing of the machineries and specialized crews at con-
struction site etc, complete in all respects including the excavation of the driven pit and exit pit
with proper protection with shoring sheets and ISMB (providing and casting MS cutting edges
for front shield and construction thrust bed at designated level as directed by the engineer,
necessary dewatering and providing the concrete foundation at the base of the driven pit, crane
for holding the pipe and any other machinery, tools , tackle required, construction of the tem-
porary works as per the requirement and approval of the concerned authorities and engineering
in charge, as per the scope of work defined.

3. APPURTENANCES

3.1 Scope of Work

This chapter describes the minimum requirements for the provision of valves & valve
chambers.
Prior to the procurement of valves, the Contractor shall obtain the Engineer in charge’s
approval for the QAP, GAD, Data sheet & drawings. General applicable Standards to
be applied to the Works under this Section shall be Indian Standards and British Stand-
ards or other approved International Standard.

3.2 General

DI Resilient seated sluice valves shall be used as scour valves at following locations as
mentioned in the Schecule - B Table-4 of reuse water supply scope. Shop inspection,
Pressure testing of valves, Material testing at manufacturer’s testing facility in presence
of EIC/Representative of EIC followed by a certificate from the manufacturer’s shop
testing shall be provided for review by the Engineer in charge. Before delivery to Site
all working surfaces shall be thoroughly cleaned and if metal protected with grease.
The initial charges of oil, grease and similar materials necessary for the correct setting
to work and operation of valves and penstocks shall be provided by the Contractor.
Packing must be sufficient to ensure complete protection of the fitting during transit

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and storage and all valves are to have their openings sealed until installation.

3.3 Installation

All valves, operators and appurtenances shall be installed in accordance with the man-
ufacturer’s recommendations and as per the specifications laid for pipe laying, and to
the locations indicated on the drawings. The installation shall be true to alignment and
rigidly supported. As soon as installation and operating conditions permit, all valves
and appurtenances shall be given a field test to be witnessed by the Engineer in charge
to demonstrate that they meet all requirements and operating conditions.
Valves shall be rated for PN 16 as minimum working pressure unless elsewhere defined
as per the requirement or in tender document.

3.4 Flanges

Valves shall be flanged and the flange face at right angles to the valve centerline. Back-
side of valve flanges shall be machined or spot faced for proper seating of the head and
nut. Flanges shall be machined on faces and edges to IS 6392 or BS 4504 for PN 16
nominal pressure rating unless otherwise required. Flange drilling shall conform to IS
1538.

3.5 Fastener:

Add IS codes and specifications for fasteners.

3.6 Operation

3.6.1 Scour valve

Scour valves shall be provided with extension spindle by contractor with supports for
operation from operating level / ground level. All valves shall be protected against cor-
rosion. Provision for indicator tags shall be made for identification / location of valves.
Marking shall be either cast on the bonnet or the body and shall show the following:
 Manufacturer’s name or mark
 Year of valve casting
 Size of valve

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 Designation of working pressure

 Number of turns to open, with the direction of closing clearly indicated on the
hand wheel or body as appropriate.
Nuts and bolts shall be of the best quality bright steel, machined on the shank and under
the head and nut. Nuts and bolts shall be ISI Marked conform to IS 1363 and IS 1367,
unless otherwise specified. Nuts and bolts shall be hot dip galvanized or shall be chro-
mium plated.
3.6.1.1 Construction Scour Valve

The valve shall be constructed as per the arrangement drawing provided in the drawing.
GFC drawing shall be provided by the contractor before installation/construction for
approval of EIC.
Sluice Valves

3.6.1.2 Constructional Features

The valves shall be resilient seated, bubble-tight, straight and pocket less body passage,
inside stem screw and electrostatic epoxy powder (EP-P) coated INSIDE AND OUT-
SIDE. The face to face dimensions shall conform to provisions of IS 14846/EN 558-1,
Basic series F4/BS 5163. All tests shall be carried out as per these standards.

Valves shall be of non-rising spindle type except for the bypass valves. The spindles
shall be of such lengths that when the valves are closed the bottom ends of the spindles
engage fully in the spindle nuts. The spindle collars of thrust plates shall be concentric
and machined, suitable for the specified test pressure. The thickness and bearing of the
nut shoulders shall be adequate to resist operating thrusts. Spindles shall be greased and
supplied with a cap top. Valve shafts shall be a one-piece unit extending completely
through the valve disc, or of the ‘stub shaft’ type, which comprise two separate shafts
inserted into the valve disc hub. Valves of 400 mm and above shall be provided with
thrust bearing arrangement/Gear Arrangement for ease of operation.

Valve of diameter 400 mm and above shall be provided with enclosed gear arrangement
for ease of operation. The operation gear of all valves shall be such that they can be
opened and closed by one man against an unbalanced head 15% in excess of the maxi-
mum specified rating. Valve and any gearing shall be such as to permit manual opera-
tion in a reasonable time and not exceed a required rim pull of 200 N.
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Valves spindles and hand wheels shall be positioned to give good access for operational
personnel. Hand wheels shall be arranged to turn in a clockwise direction to close the
valve, the direction of rotation for opening and closing being indicated on the hand
wheels.
Valves shall have two positions marked at the shut end of the scale, first one corre-
sponding to the position of the gate tangential to the bore of the seating and the second
position below the first, corresponding to the position of the gate as it sits on the seating
after moving a further distance equal to the depth of the seating.

The valves shall be so designed that the gates may be removed without removing the
bodies from the connecting pipe work. The gate guides shall be cast integrally with the
valve bodies and be of adequate strength and of sufficient length to guide the gates
throughout their full length of travel. In the fully open positions, the gates shall be fully
withdrawn well clear of the stream and the spindles shall not protrude into the bores of
the valves.

All Sluice valves shall be open end tested. The Contractor shall provide test certificates
for materials, strength and leakage in accordance with BS 5163 / IS 750/International
reputed Standards.

3.6.1.3 Materials of Construction

Item Material of Construction

Body, Dome Spheroidal Graphite Iron IS 1865 Gr 400/12 or Gr500/7
Ductile Iron DIN 1693-GGG40 / GGG50
Wedge Spheroidal Graphite Iron IS 1865 Gr 400/12 or Gr500/7
Ductile Iron DIN 1693-GGG40 / GGG50
Rubber Vulcanized with EPDM/
Spindle / Stem SS : IS 6603 04 Cr17 Ni 12 M0 2 / AISI 316/SS 420
Bonnet Gasket EPDM
Internal Fasteners Stainless steel SS316
Nuts, bolts & washers for High tensile steel Hot dip galvanized
pipe flanges
Coating Internal and external with powder or liquid food grade Fu-
sion Bonded Epoxy(FBE) coating with minimum dry film
thickness of 250 microns Or Thermoplastic-Powder Coat-
ing Internal/External min 250 microns

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3.6.2 Air Valves

Air valves are used to protect the pipe line by filling air during draining, venting air
during filling and Continues venting of entrapped air during operation. Air valves
should match with the following specifications

3.6.2.1 Specifications:

 Air valve should be Single Chamber

 Body should be made of Ductile Iron ASTM A 536/ EN 1563/ GGG40
 Float should have made with Polypropylene
 Rolling Seal should be made with EPDM
 Gaskets and seals made of EPDM
 Valve should be Epoxy coating both inside and outside
 Flange Drilled as per DIN/ISO/BS/EN 1092

3.6.2.2 Material of Construction

Body (80 – 200 mm) : Ductile Iron ASTM A 536/ EN 1563/ GGG 40
Air & Vacuum Float : Polypropylene
Rolling Seal : EPDM
Automatic Float cover : Acetal
O-Ring : EPDM
Automatic Float : Polypropylene
Discharge Outlet : Polypropylene
Bolts and Nuts : Galvanized Steel
Body (50 mm) : Polypropylene

3.6.3 BUTTERFLY VALVES

3.6.3.1 Constructional Features

The valves shall be with integral body seat and bubble tight shut-off type, suitable for
ON-OFF operation. Compatible for motorized operation during selection. Spindle ar-
rangement for the wafer should be horizontal to the ground level.
Butterfly valves should be of double eccentric, design and Vulcanized type generally as
per EN 593, API 609, BS 5155 and IS 13095 or any equivalent international standards
approved by the end user. Underground Valves on transmission mains which are used
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for only isolation purposes shall be provided with stainless steel extension spindle /
telescopic arrangement so that valves can be operated from ground level.
Butterfly valves shall be suitable for mounting in any position. The valve shall be free
from induced vibrations.
Butterfly valves shall be suitable for bi-directional pressure testing with dead-tight shut
off even after long period of operation. The valves shall be of double flanged wafer
Short type.
The valve body seat shall be of Vulcanized Rubber design. When the valve is fully
closed, the seal shall seat firmly. All fasteners shall be set flush so as to offer the least
resistance possible to the flow through the valve.
The shaft shall be stainless steel with Bronze or equivalent seal with self-lubricating
bearings. Valve shafts shall be a one-piece unit extending completely through the valve
disc, or of the "stub shaft" type, which comprises two separate shafts inserted into the
valve disc hubs.
All valve spindles and hand wheels shall be positioned to give good access for opera-
tional personnel. Valve of diameter 400 mm and above shall be provided with enclosed
gear arrangement for ease of operation. The gear box shall be of worm and worm wheel
design type, totally enclosed, grease filled and weather proof. The operation with gear-
ing shall be such that they can be opened and closed by one man against an unbalanced
head of 1.15 times the specified rating. Valve and gearing shall be such as to permit
manual operation in a reasonable time and not exceed a required rim pull of 200 N. The
valve disc shall have a 90-degree turn.
The disc shall be designed to withstand the maximum pressure differential across the
valve in either direction of flow. The disc shall be contoured to ensure the lowest pos-
sible resistance to flow and shall be suitable for throttling operation.
It should be possible to open the valve with upstream pipe fully filled and downstream
pipe empty. The shaft shall be designed to withstand the maximum torque that will be
imposed by the operator. It shall be secured to the discs by tapered stainless steel cotter
pins.
Valves shall be provided with a continuous mechanical position indicator to show the
position of the disc, mounted on the driven shaft end.

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Rigid adjustable stop mechanism shall be provided within the gear box or elsewhere on
the valve to prevent movement of the disc beyond the fully open or closed position (i.e.
set points).
Valves shall be capable of closing against the maximum flow that can occur in practice.
The breakaway torque under maximum differential head conditions shall be within the
manufacturer’s limits.
All hand wheels shall be arranged to turn in a clockwise direction to close the valve,
the direction of rotation for opening and closing being indicated on the hand wheels.

3.6.3.2 Features of Construction

The requirement shall be as follow: -

Table 'A'
S. No Particulars Required specifications
(A) General requirements
1 Conforming to double eccen- BS 5155 Generally or IS: 13095/EN 593/API
tric 609
2 Fluid handled Clear Water
3 Rating (PN 1.0, 1.6, 2.0 and 2.5)
As per design pressure / surge analysis at the
point of installation
4 Temperature of fluid 4 to 45 degrees Celsius
(B) Service
5 Tight shut off Yes
(C) Modes of operation
6 Direction of rotation of hand Clock-wise for closing
wheel
7 Orientation of hand wheel w.r.t Perpendicular/Horizontal
pipeline
(D) Type of construction
8 Flanged or Wafer Double flanged/Wafer series
9 Face to face dimension As per BS 5155 or IS: 13095 or AWWA C
504 or EN 593/API 609
10 Whether lifting lugs and Yes
mounting feet are required
11 Valve installation Horizontal

3.6.3.3 Material of Construction

S. No Item Material of construction

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(1) Body and Flanges Spheroid Graphite Iron IS 1865 Gr 400/12

Ductile Iron DIN 1693/GGG 40/GGG 50
(2) Disc Spheroid Graphite Iron IS 1865 Gr 400/12
Ductile Iron DIN 1693/GGG 40/GGG 50
(3) Shaft Stainless steel IS :6603 -1972 Grade 316 or
AISI 410 or BS 970 Grade 431 S29 Or AISI
420
(4) Disc Seal Ring EPDM/Ductile Iron GGG 40/50
(5) Disc Seal Retaining Ring Ductile Iron DIN 1693 GGG-40
(6) Body Seat Stainless steel AISI 316/ Nickel weld overlay
micro finished/ integral micro finished seat
with valve body/Vulcanized EPDM Mini-
mum +60 Shore
(7) Shaft Bearing Bronze with EPDM `O’ ring seal
(8) Internal Fasteners Stainless steel SS 316
(9) Nuts, bolts & washers for pipe Stainless steel SS 316/Galvanized Steel
flanges
(10) Coating Internal and external with powder or liquid
food grade Fusion Bonded Epoxy coating
with minimum dry film thickness of 250 mi-
crons.

3.6.4 Electric Actuator

For Sluice/Butterfly valves installed on the Trunk network

Actuators shall be suitable for the medium, climatic, environmental and pressure conditions
of the system in which they are to be fitted.
Actuators shall be provided with:
a. AC Electric Motor.
b. Reduction gear unit.
c. Torque switch mechanism.
d. Limit switch mechanism complete with set of limit switches and additional two
spare sets for suitable position.
e. Hand wheel, for manual operation.
f. Valve position indicator.
g. Hand-auto lever with suitable locking arrangement.
h. 10 W single phase space heater in the switch compartment.
i. Blinking light throughout the valve operation.
j. Junction box for terminating power and control cables.
k. With additional accessories for integrating with PLC system.

The actuator shall be suitable for operation on 415V, 3 phase, 50 Hz power supply. The

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motor winding insulation shall conform to class B as per relevant BS and motor shall
be protected by suitable thermal overload relays. The actuator shall be capable of pro-
ducing not less than 1 1/2 times the required operator torque at the required time cycle
of valve operation. The transmission shaft connecting the actuator to the valve shall be
provided with 2 bearings one at actuator end and one at valve end with universal cou-
plings at suitable places. The required number of switch/contacts meet for requirements
for PLC system. The electrical actuator for butterfly valves acting as flow controllers
shall comprise of the additional necessary electronic card/ accessories required for gen-
erating a 4-20 ma signal and for integrating it with the PLC system.
The electric motors shall be of the squirrel cage type as per IS 325 with insulation to IS
1271 Class B. The windings shall be impregnated to render them non-hygroscopic and
oil resistant. All internal metal parts shall be painted. The motor shall be rated for 15
minutes. They shall also be suitable for operating on the specified electric supply and
shall satisfactorily open and close the valve under variations of electric supply speci-
fied.
Motor shall be protected by suitable overload protection device.
The reversing contactor starter and local controls shall be integral with the valve actu-
ator. The starter shall comprise mechanically and electrically interlocked reversing con-
tactors of appropriate rating fed from a 110 Volt control transformer. The common con-
nection of the contactor coils at the transformer shall be grounded. HRC cartridge type
primary and secondary fuses shall be provided.
Local control shall comprise pushbuttons for open, close and stop operations and a
Lockable Local/Remote/off selector switch. The control schematics shall be subject to
approval.
Internal wiring shall be of 650/1100-volt grade PVC insulated stranded copper conduc-
tor of minimum 1.5 sq. mm for control circuits and of minimum 4 sq.mm copper for
the power circuit. Each wire shall be number identified at each end. The terminals shall
be of stud type. Cable entries shall be suitable for PVC insulated/ sheathed, armored
cables. A separate terminal box shall be provided for the heater. A separate terminal box
shall be provided for cabling to control circuits.
The actuator enclosure shall be fully weatherproof and hose proof to IP 67 and shall be
fitted with an anti-condensation heater, which shall be switched off when the motor is

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running.
The torque switch mechanism shall function as follows to stop the motor on closing or
opening of the valve, or upon actuation by the torque when the valve disc is restricted
in its attempt to open or close.
The torque switch in the closing direction shall interrupt the control circuit if mechani-
cal overload occurs during the closing cycle or when the valve is fully closed.
The torque switch in the opening direction shall interrupt the control circuit if mechan-
ical overload occurs during the opening cycle or when the valve is fully open.
The mechanism shall facilitate adjustment of the torque at which the switches are re-
quired to operate.
Non-adjustable limit switches shall stop the motor and give indication when the disc
has attained the fully open or closed position.
The adjustable limit switches shall have control rated 2A, 48 V DC for specified system
interlock, at the desired value position in both the opening and closing directions.
Motor operators shall be provided with clearly visible local valve position indicators
mounted on the operator assembly to give an indication whether the valve is fully open,
fully closed or in an intermediate position.
Settings and emergency operation shall be possible with the use of a hand wheel. The
Hand wheel shall be of stainless steel and the drive mechanically independent of the
motor drive and any gearing should limit the operating torque at the hand wheel to less
than 15 kg and be such as to permit emergency manual operation in a reasonable time.
During electric operation, the hand wheel shall not rotate.
Actuators shall be adjusted at the manufacturer’s works to ensure that they provide the
correct, fully, open position and fully closed position. Mechanical adjustable stops shall
be provided to prevent over-travel of the valve in the open and closed positions.

3.7 Inspection and Tests

The following Inspection and Testing procedures shall be carried out for all the equip-
ment as applicable:
(a) Visual Inspection.
(b) Material Certificates for all the specified material shall be furnished.
(c) Welding Qualifications.
(d) Dimension Checking.
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(e) Stage Inspections (in process inspection).

(f) Hydrostatic / Leak testing for all pressure parts, Pneumatic Leak Test wherever ap-
plicable.
(g) Operation check.
(h) Liquid penetrating tests or magnetic particle tests for all machined surfaces of pres-
sure parts.
(i) Ultrasonic test for forging materials viz.,
(j) Plates of thickness 20mm and above for pressed / formed parts such as heads, etc.
(k) Plates, flanges and bars of thickness / diameter 40mm and above used for fabrica-
tion of pressure and load bearing members and rotating parts.
(l) Radiographic testing for all but welded parts, as per applicable codes.
(m) Hardness tests for all Hardened surfaces.
The Contractor shall maintain proper identification of all materials used, along with
reports for all internal / stage inspection work carried out, based on the specific job
requirement and or based on the datasheets / drawings / specifications.
Requirement of shop tests for Valves are listed below:
(a) During testing, there shall be no visible evidence of structural damage to any of the
valve components.
(b) Each valve operated actuator shall be shop-operated at least three times from the
fully closed to the fully opened position, and the reverse, under no-flow condition,
to demonstrate that complete assembly is workable.
The tests mentioned below shall be hold points and to be witnessed by a duty au-
thorized representative of the Employer:
The following tests shall be carried out for butterfly valves in line with IS 13095:
(a) Seat leakage test. Seat test shall be carried out in each direction and the valve shall
be drop tight.
(b) Body hydrostatic test
(c) Disc strength test at body test pressure in each direction.
(d) Valve operation with and without actuator
The following tests shall be carried out for sluice valves in line with IS 14846:
(a) Seat leakage test
(b) Body hydrostatic test
(c) Valve operation
The material certificates, physical properties, heat treatments and shop test certificates of valve
body, disc, wedge and shaft shall be duly approved and certified by the manufacturer and these
shall be subject to review & approval by the Engineer. Notwithstanding the above requirement
for inspection and quality control, the following inspection and quality control measures shall
be carried out by manufacturer:

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(a) Magnetic particle tests on body and disc/door.

(b) Dye penetration tests on metal seats.
(c) Ultrasonic tests on shafts.
(d) Overload Torque Test shall be carried out on the gear boxes of the valves. The test shall
be carried out by applying 1.5 times the rated torque.
3.8 Painting

The Contractor shall be responsible for the cleaning, preparation for painting, and prim-
ing or otherwise protecting of all parts at the place of manufacture prior to packing.Parts
may be cleaned but surface defects may not be filled in before testing at the manufac-
turer's works. Parts subject to hydraulic test shall be tested before any surface treatment.
After test, all surfaces shall be thoroughly cleaned and dried out if necessary by washing
with an approved de-watering fluid prior to surface treatment. Except where the Spec-
ification provides to the contrary all painting materials shall be applied in strict accord-
ance with the paint manufacturer's instructions. Protective coatings and painting shall
be in line with the Standards for the particular type of valve.

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Annexure – I (E)
SEWERAGE NETWORK

1.0 Sewerage Collection Network

Standards and Specifications for the Design and Construction of Sewer Network are
given in this section.

2.0 Scope of sewer collection system

The scope of work of includes, Providing, Laying, Testing and Commissioning of

Sewer Pipes of HDPE – DWC, Inner HAC lined DI K7 & K9 pipes, Inner HAC lined
RCC NP4 pipes and Construction of Manholes along the right of way and crossings of
Roads. The road wise sewer network details including Pipe Material, Diameter, Length
and Type and Number of Manholes are given in schedule B. In general, this work shall
include Earthwork in excavation, providing bedding (Sand/PCC), Supplying, laying,
jointing and testing of all pipeline and appurtenances.

This contract package includes supplying, laying, jointing, testing and commissioning
of sewers of Pipes of HDPE - DWC and HAC lined RCC NP4 pipes and Construction
of Manholes for the various sewer network diameters from 200 mm to 1600 mm in the
right of way of above mentioned roads.
This contract package includes supplying, laying, jointing, testing and commissioning
of sewers of Pipes of HDPE - DWC and Inner HAC lined DI K7 & K9 pipes with outer
polyethylene sleeves, Inner HAC lined RCC NP4 pipes. Inner HAC line DI K9 pipes
for Pumping mains. The total length of sewer pipeline is around 17.237 km.
The detailed scope of work includes:

i. Detailed design, Engineering and preparation of GFC including LS, CS, Layout, Plan
and CS of Manholes. On approval of design, detailed engineering & drawing from
EIC/Competent authority, Contractor shall start execution.

ii. Prior to the procurement of Pipes, the Contractor shall obtain the Engineer in charge’s
approval for the QAP & Data sheet. Supplying of pipes and specials at sites as per the
data sheet.

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iii. Prepare a detailed methodology for laying of pipeline and construction of manholes
taking into consideration of other utilities along the road and taking into consideration
of orientation and levels as given in data sheet and drawings.

iv. Carry out the survey and determine the alignment of sewer pipe line and location of
manholes.

v. Laying and Jointing and Testing of HDPE- DWC pipes, HAC lined DI K7 & K9 and
HAC lined RCC NP4 class pipes with diameter ranging from 200 mm to 1600 mm, as
per the quantities given in Schedule-B.

vi. HDPE-DWC pipes up to 490mm for total length of 10.792 km

vii. Inner HAC lined DI K7 & K9 pipes for total length of 6.095 km and at crossing
locations

viii. Inner HAC lined DI K9 pipes for Pumping mains for a length of 0.350 km.

ix. Design and Construction of Manholes considering buoyancy factors.

x. Testing of sewer lines including Manholes as per CPHEEO manual/ relevant IS Codes.

xi. Back filling of trenches up to FGL with consolidation to achieve maximum dry density
in layers not exceeding 150mm.

xii. Any work required for safe and satisfactory completion, testing and commissioning of
the above works.

xiii. Prepare & Submit “As Built Drawings”.

xiv. Removal of defects in all work components during defect liability period.

2.0 Sewer Pipes

2.1 Scope

This Specification covers the requirements for manufacturing, testing, supplying, low-
ering, laying, jointing, testing at work sites and commissioning of following pipes:
HDPE-DWC pipes (as per IS 16098 Part-2) up to 500 mm diameter

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HAC lined DI (K7/K9) as per IS 8329 up to 1200mm diameter and RCC pipes (SRC)
(HAC In-lining) (as per IS 458) above 1200 mm diameter.

2.2 Applicable Codes & Standards

The manufacturing, testing, supplying, jointing and testing at work sites of pipes shall
comply with all currently applicable statutes, regulations, standards and codes. In par-
ticular, the following standards, unless otherwise specified herein, shall be referred. In
all cases, the latest revision of the Codes shall be referred to. If requirements of this
Specification conflict with the requirements of the Codes and standards, this Specifica-
tion shall govern. However, other codes as approved by Authority’s Engineer but not
specifically mentioned below pertaining to the use of RCC, HDPE DWC Pipes shall
form part of these specifications.
Table-1 Applicable Codes

IS Code Description
IS: 458 Specification for Concrete Pipes (with and without Reinforce-
ment).
IS: 3597 Method of Tests for Concrete Pipes.
IS:432 Part Specification for mild steel and medium (tensile steel bars and
I & II hard drawn steel) wires for concrete reinforcement.
IS: 456 Code of Practice for Plain and Reinforced Concrete.
IS: 783 Code of Practice for Laying of Concrete Pipes.
IS: 516 Method for test for strength of concrete.
IS: 8329 Centrifugally cast (spun) Ductile Iron Pressure pipes for water,
gas and sewage.
IS: 9523 Ductile iron fittings for pressure pipes for water, gas and sew-
age.
IS: 12288 Code of practice for use and laying of ductile iron pipes.
IS: 5382 Specification for Rubber Sealing Rings for Gas Mains, Water
Mains and Sewers.
IS:16098 Structured wall plastics pipes for non-pressure drainage and
Part 2, Sewerage specifications
IS:7634 Code of practice for Laying and Jointing of High Density Poly-
Part 2 ethylene pipes (HDPE) piping system.
IS: 2530 Method of test for polyethylene moulding materials and polyeth-
ylene Compounds.
IS: 7328 High Density Polyethylene material for moulding and extrusion.
IS: 4905 Method for random sampling.

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2.3 HDPE-DWC Pipes

Scope

This Material Specification details the minimum requirements for the pipe procurement
of Double Walled Corrugated High-Density Polyethylene (HDPE) pipe and fittings to
be used for collection & conveyance of waste water.
Vendor has to substantiate the reason when he is deviating from any of the clause men-
tioned below and has to get approval for the same. The calculations for wall stress,
deflection, buckling, bending stress and bending strain for DWC PE pipe shall be car-
ried out by the vendor. The calculations performed shall be submitted for approval.
Specifications provided in this document is only for pipe procurement up to DN 500.
Requirements for Laying, and site inspections are not covered under this specification.
Applicable Standards and Codes

The following codes and standards, to the extent specified herein, form a part of this
specification. The latest edition of these codes and standards shall govern the work.

Table-2 Applicable Codes for DWC HDPE Pipes

Code No. Title/Specification

IS 4905-1968 Methods for random sampling
IS 5382:1985 Specification for rubber sealing rings for gas mains, water
mains and sewers (first revision). Type-I & Type-VI
IS 12235 Methods of test for thermoplastics pipes & fittings.
(Part 1): 1986 Method of measurement of outside diameter.
(Part 5):1986 Reversion test
(Part 8):1986 Internal hydrostatic pressure test
IS 16098 Part- 2 Structured wall plastics pipes for non-pressure drainage and
Sewerage specifications

Other Codes not specifically mentioned here but pertaining to the use of HDPE-DWC
pipes form part of these Specifications.
Pipes and fittings will be designated on the basis of its material/structure wall construc-
tion/nominal ID (DN/ID)/nominal ring stiffness, such as PE/DWC/ID/SN as per IS
16098:2013 (Part-2).
Material

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The material from which the pipe is produced shall consist substantially of polyethylene
(PE), to which may be added only those additives that are needed to facilitate the man-
ufacture of these pipes and fittings confirming to requirement of the standards as per
Tables 1, 2, 3 and 4 of IS: 16098
A pipe of fittings with a smooth internal & profiled external surface forming a finished
double walled profile shall come under this standard. When sealing rings are retained
by means of retaining devices (rings or caps), the devices may be made from polymers,
provided they conform to the same functional dimensions and test requirements as ap-
plied to sockets with either loose or fixed sealing rings.
The manufacturer ‘s own rework material conforming to the requirements given in 3.25
of IS: 16098 is permissible. No other rework material shall be used.
Dimensions
Mean inside Diameter
The mean inside diameter, at any point and tolerances shall be as given in Table 5 of
IS: 16098 and shall be measured according to the method given in IS 12358 (Part 8).
Wall Thickness
The nominal wall thickness, e, shall be in accordance with Table 5 of IS: 16098. Toler-
ances in inside diameters shall be those given in IS: 16098.
Length of pipe
Effective length of pipes (Le) with sockets shall be not less than that specified by the
manufacturer when measured as shown figure 2 of IS: 16098 2013. The lengths may be
supplied as agreed to between the purchaser and the manufacturer.

Dimensions of pipes & spigots of pipes & fittings

The nominal size and minimum mean inside diameter for DN-ID series are specified in
Table-5 (16098 Part2). The outside diameters of the DN-ID series pipes and spigots
intended to have jointing dimensions as pipes and /or fittings according to this standard
shall comply with the outside diameters and tolerances as specified by the manufacturer.
However, the guidelines for pipes, spigots and fittings not intended to have jointing
dimensions as pipes and /or fittings according to this standard, the tolerances of the
outside diameter of pipes and spigots fittings shall be + 0.3mm/ (-) 0.6mm of the nom-
inal size of outside diameter.
Inspection and Testing
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The material will be inspected and tested at manufacturers premises by the EIC/repre-
sentative of EIC prior to the delivery of pipes. The sampling procedure to be adopted
and the criteria for conformity shall be as given in IS: 16098. The following tests shall
be conducted:

Type Tests

Type tests are intended to prove the suitability, performance of a new technique or a
new size of pipe and water tightness. Type testing shall be in accordance with tables 15
to 18 as applicable of IS: 16098 part-2. All tests are to be carried out either in an in-
house laboratory or at an authorized third-party laboratory.
Physical Characteristics

Appearance

The structured outer layer of finished pipes and fittings shall be uniformly corrugated.
The inner layer shall be smooth and plain. Both layers shall be free from any visual
defects such as cracks, blisters, foreign inclusions and any other visual irregularities
which may cause harm to its construction integrities. The inner surface may reflect
slight shallow undulations. Color of Finished Pipes. The inner and outer layer of pipes
and fittings shall be coloured throughout. The outside layer of pipes and fittings should
preferably be black, orange brown or grey.
Mechanical Characteristics

The pipes shall be designated in the following nominal ring stiffness classes (SN) based
on detailed calculations for wall stress, deflection, bending stress and bending strain.
 DN ≤ 500: SN 8 or SN 16

 The manufacturer ‘s guaranteed minimum stiffness between the SN values, of a

component may be used for calculation purposes only. Such pipes shall be classified
and marked as the next lower stiffness class.

Ring Flexibility

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When tested in accordance with the test method using the indicated parameters, and
visually inspected without magnification, requirements in (a) and (b) shall be satisfied
during the test and requirements (c) to (d) shall be satisfied after the test.
a) There shall be no decrease of the measured force;

b) There shall be no cracking in any part of the wall structure;

c) There shall be no wall delamination except possible delamination between the outside
and inside wall of double wall pipes occurring in reduced welding zone in the ends of
test piece. Process aiding profile of material other than the pipe material is not subject
to this requirement;

d) There shall be no other types of rupture in the test piece; and

e) Permanent buckling in any part of the structure of the pipe wall including depressions
and craters, shall not occur in any direction.

Marking
General
Marking shall be labelled, printed or formed directly on the pipe or fitting, in such a
way that after storage, weathering and handling the legibility shall be maintained.
Marking shall not initiate cracks or other types of defects which adversely influence the
performance of the pipes or the fitting. Minimum Required Marking
Pipes
Each pipe shall be marked at intervals of maximum 3 m, at least once per pipe, with the
following information:
 Manufacturer ‘s name/Trade-mark:

 Diameter series, nominal size;

 Stiffness class;

 Material; and

 Lot number/batch number containing information regarding period of manufacture.

Fittings
Each fitting shall be marked with the following information:
 Manufacturer ‘s name/Trade-mark;
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 Nominal Angle;

 Diameter series, nominal size;

 Stiffness class;

 Material; and

 Lot number/batch number containing information regarding period of manufacture

The Contractor should submit the following data / certificates regarding HDPE-DWC
pipes along with the Qualification bid:
 Brand Name, Manufacturers capacity, previous supply details etc.

 Copy of valid ISO 9000 /14000 accreditation. (If any)

 Copy of valid BIS accreditation for manufacture of HDPE-DWC pipe as per IS 16098
2013.

 Manufacturer ‘s recommendation and Pressure testing procedure.

DUCTILE IRON PIPES

1.1 Scope
This specification covers the requirements for manufacturing, testing, supplying, joint-
ing and testing at work site Ductile iron pipes (Pumping Main - DI-K9) and fittings
used for Waste Water pumping. Schedule -B covers the specific requirement for the
project.
1.2 Applicable Codes
The manufacturing testing, supplying, jointing and testing at work sites of Ductile Iron
pipes and fittings shall comply with all currently applicable statutes, regulations, stand-
ards and codes. In particular, the following standards, unless specified herein shall be
referred. In all cases, the latest revision of the codes shall be referred to. If requirements
of specifications conflict with the requirements of the codes and standards, this speci-
fication shall govern.
1.4 References

Code Description
Specification for Centrifugally Cast (spun) Ductile Iron pressure pipes
IS: 8329
for water, gas and sewage specification.

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Specification for Rubber sealing ring for gas mains, water mains and
IS: 5382
sewers
IS: 638 Sheet rubber jointing and rubber insertion jointing.
IS: 1387 General requirements for supply of metallurgical materials.
IS: 1500 Methods for Brinell hardness test for metallic materials.
IS: 9524 Ductile Iron fittings for pressure pipes for water, gas and sewage.
Dimensional requirement of rubber gaskets for mechanical Joints and
IS: 12820 push on joints for use with cast Iron pipes and fittings for carrying wa-
ter, gas and sewage.
Ductile iron pipes for pressure and non-pressure-Centrifugal cement
ISO:4179
mortar lining - General requirements.
Ductile iron pipes, fitting and accessories for pressure pipe lines. Code
ISO:2531
of Practice
IS: 12288 Code of practice for use & laying of Ductile iron pipes.
Cast iron specials for mechanical and push-on-flexible joints for pres-
IS: 13382
sure pipe lines for water, gas and sewage.

Supply of Material

The General requirements relating to the supply of material shall be as laid down in
IS:1387. The material for DI fittings shall conform to IS:9523.
1.4 Manufacturing
The metal used for the manufacture of pipes shall be of good quality, commensurate
with the mechanical requirements laid down in 19. It shall be manufactured by any
method at the discretion of the manufacturer provided that the requirements defined in
this standard are complied with.
The pipes shall be stripped with all precautions to avoid warping or shrinkage defects,
detrimental to their good quality. The pipes shall be sound and free from surface or
other defects. Pipes showing small imperfections inherited with the method of manu-
facture, and which do not affect their serviceability, shall not be rejected on that account
alone. Minor defects arising out of manufacturing process may be rectified, for exam-
ple, by welding in order to remove surface imperfections and localized defects which
do not affect the entire wall thickness provided that the repairs are carried out in ac-
cordance with a written assurance system and the repaired pipes comply with all the
requirements of classes K9 and K7 with the approval of the purchaser.
Pipes centrifugally cast shall be heat-treated in order to achieve the necessary mechan-
ical properties and to relieve casting stresses caused due to the method of manufacture
and repair work.

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If necessary the pipes may be subjected to reheat treatment to ensure that Brinell hard-
ness does not exceed the specified value and the other mechanical properties specified
in the standard are achieved.

1.5 Rubber Gasket

Rubber gaskets used with push-on-joints or mechanical joints shall conform to IS
5382.

Material of rubber gaskets for push-on mechanical or flanged joints shall be compatible
with the fluid to be conveyed at the working pressure and temperature.

Rubber gaskets for mechanical joint for conveyance of town gas may be suitably
protected so that the elastomer does not come in direct contact with the gas.

Rubber gaskets for use with flanged joints shall conform to IS:638.

While conveying waste water the gaskets should not deteriorate the quality of sewage.

1.6 Sampling
Sampling criteria for various tests, unless specified in this standard, shall be as laid
down in IS 11606.
The mechanical acceptance tests shall be carried out on samples of ductile iron pipes
which shall be grouped in following batch sizes.

DN (mm) Maximum Batch Size

80-250 200 pipes
300-600 100 pipes
700-1000 60 pipes
1100-1400 40 pipes
1600-2000 30 pipes
In order to check compliance with the requirements specified, a sample ring or bar shall
be taken from the spigot end of pipe.

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1.7 Mechanical Tests

Mechanical tests shall be carried out during manufacture. One test shall be conducted
for every batch of production. The results obtained shall be taken to represent all the
pipes of that batch.

1.7.1 Tensile Test

The thickness of the sample and the diameter

Castings Test Bar. Test bar Method B

Thickness Method A
mm Nominal Nominal Area Nominal Tolerance on
Diameter So Diameter Diameter
mm mm2 mm mm
Centrifugally
Cast Pipes
- less than 6 2.5 5.0 2.52 0.01
-6 up to but not 3.5 10.0 3.57 0.02
including 8
- 8 up to but not 5.0 20.0 5.05 0.02
including 12
- 12 and over 6.0 30.0 6.24 0.03

A Sample shall be cut from the spigot end of the pipe. This sample may be cut
perpendicular to or parallel with the pipe axis, but in case of dispute the parallel to axis
sample shall be used.

Test Specimen: A test bar shall be machined from each sample to be representative of
the metal at the mid-thickness of the sample, with a cylindrical part having the
diameters given in Data sheet.

The test bars shall have a guage length at least five times the nominal test bar diameter.
The ends of the test bars shall be such that they will fit the testing machine.

Two methods of measuring the tensile strength may be used at the manufacture’s
option:

Method A - Machine the test bar to its nominal diameter + 10 percent, measure the
actual diameter before the test with an accuracy of 0.01 mm and use this measured
diameter to calculate the cross-sectional area and the tensile strength; or:

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Method B - Machine the test bar to its nominal area So within a specified tolerance on
diameter (see19.1.2) and use the nominal area to calculate the tensile strength.

Equipment and Test Method: The sample shall be tested as per procedures laid down in
IS 1608. The tensile testing machine shall have suitable holders or grips to suit the test
bar ends so as to positively apply the test load axially.

1.7.2 Brinell Hardness Test

When tested in accordance with IS 1500, the Brinell hardness shall not exceed 240 HP
on the external un-machined surface.

1.7.3 Retest
If test piece representing a batch fails in the test in the first instance, two additional tests
shall be made on test pieces selected from two other pipes from the same batch. If both
the test results satisfy the specified requirements, the batch shall be accepted. Should
either of these additional test pieces fail in the test, the batch shall be deemed as not
complying with this standard.

1.7.4 Hydrostatic Test

All pipes shall be tested hydrostatically at a pressure specified in Table. To perform the
test, pressure shall be applied internally and shall be steadily maintained for a period of
10s. The pipes shall withstand the pressure test and shall not show any sign of leakage,
sweating or other defects of any kind.

It is recommended that the Hydrostatic test pressure at works ‘p’ be expressed in MPa
as a function of the coefficient K be calculated using the following formulae:

For DN 80 to 300 p = 0.05 (K+1)2

For DN 350 to 600 p = 0.05 (K)2

For DN 700 to 1000 p=0.05 (K-1)2

For DN 1100 to 2000 p = 0.05 (K-2)2

When pipes are required to be tested for higher pressure, the test pressures are subject
to agreement between the purchaser and the manufacturer at the time of enquiry and
order.

Test shall be carried out before the application of surface coating and lining.

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Nominal Minimum Hydrostatic Test pressure at Works, MPa

Diameter (DN) Centrifugally cast pipes Pipes with Screwed or welded on flanges
Mm with flexible joints

Class K7 Class K9 PN10 Flange PN16 PN25 Flange

Flange
80 to 300 3.2 5.0 1.6 2.5 3.2
350 to 600 2.5 1.0 1.6 2.5 3.2
700 to 1000 1.8 3.2 1.6 2.5 3.2
1100 to 2000 1.2 2.5 1.6 2.5 2.5

1.8 Sizes
The standard nominal diameters DN, of pipes and flanges followed in this standard are
as follows: 150, 200, 250, 300, 350, 400, 450, 500, 600, 700, 4000, 800, 900, 1000 mm.

1.9 Dimensions
Length: The standard working length of socket and spigot pipes shall be 4m, 5m, 5.5m
and 6m and for flanged pipes shall be 4m, 5m and 5.5 m other lengths are available by
agreement between the manufacturer and the purchaser.

The internal diameter, thickness and length of barrel, dimensions of pipes and fittings
shall be as per the relevant tables of IS.8329/IS:9523 for different class of pipes and
fittings. The tolerances for pipes and fittings regarding dimensions and deviations from
straight line in case of pipes shall be as per relevant IS codes. The standard weight of
uncoated pipes and fittings and the permissible tolerances shall be per relevant IS codes.

1.10 Tolerances
1.10.1 Diameter
External Diameter: The values of the external diameter (DE) of the spigot end of socket
and spigot pipes and when measured circumferentially using a diameter tape shall
confirm to the requirements specified. The positive tolerance is +1 mm and applies to
all thickness classes of pipes.

The negative tolerance of the external diameter depends on the design of each type of
joint and maximum negative tolerance is specified in this standard.

EXTERNAL DIAMETER DE (mm)

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DN Nominal Tolerance
100 118 +1, -2.8
125 144 +1, -2.8
150 170 -1, -2.9
200 222 +1, -3
250 274 +1, -3.1
300 326 +1, -3.3

1.10.2 Tolerance on Ovality

Pipes shall be as far as possible circular internally and externally. In case of oval spigot
ends for push on joints (DE), the minor axis is permitted to be less than the minimum
allowable diameter by the value given below provided the mean diameter DE measured
by circumferential tape, comes within the minimum allowable dimensions of DE after
applying the tolerance.

Table-1: Allowable Ovality for Push-on-Joint Pipes.

Nominal Diameter DN Allowable Difference Between

mm Minor Axes and DE, Min
mm
80-300 1.0
350-600 1.75
700 2.0
4000-800 2.4
900-1000 3.5
1100-1200 4.0
1400 to 1600 4.5

Tolerance on Thickness: The tolerance on the wall thickness (e) and the flange
thickness (b) of the pipes shall be as follows:

Dimensions Tolerance, mm

Wall Thickness (e) - (1.3 + 0.001 DN)

Flange thickness (b) + (2 + 0.05b)

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The tolerance given is subject to minimum thickness against Classes K7 and K19 given.
No limit for the plus tolerance is specified.

Tolerance on Length: The tolerance on length of pipes shall be as follows:

Type of Casting Tolerance, mm

Socket and spigot and plain ended + 100

pipes

Flanged pipes + 10

1.12 Coating
1.12.1 Pipes shall be normally delivered internally and externally coated.

1.12.2 Internal Linings: By agreement between manufacturer and the purchaser, the following
lining may be applied depending on the internal conditions of use:

 Portland cement (with or without additives) mortar, as included in Annex A.

 Blast furnace slag cement mortar as included in Annex A.

 High alumina (calcium aluminate) cement mortar as included in Annex A.

 Cement mortar with seal-coat: as included in Annex A.

 Bituminous paint as included in Annex B.

1.13 Quality Assurance System

The manufacturer shall control the quality of the product during their manufacturing
process by a system of process control in order to comply with the technical
requirements contained in this standard. Wherever possible, statistical sampling
techniques should be used to control the process so that the product is produced within
the specified limits.

1.14 Marking
Each pipe shall be marked with the logo of ADC along with month and year of Work
Order. Each pipe shall have as cast or stamped or legibly and indelibly painted on it
with the following appropriate marks.

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h. Indication of the source of manufacture;

i. The nominal diameter;
j. Class reference;
k. The last two digits of the year of manufacturer;
l. The non-standard length of the pipe if specially ordered;
m. Where applicable, an indication of length over which the pipe is suitable for cutting
on site; and
n. A short white line at the spigot end of each pipe with push-on joint in sizes DN 700
and above, to indicate the major axis of the spigot.
Marking may be done:
iii. on the socket faces of pipe centrifugally cast in metal mould, and

iv. on the outside of the socket or on the barrel of pipe centrifugally cast in sand mould.
BIS certification Marking:
The pipes may also be marked with the Standard Mark:
The use of Standard Mark is governed by the provisions of Bureau of Indian Standards
Act, 1986 and the Rules and Regulations made there under. The details of conditions
under which license for the use of Standard Mark may be granted to the manufacturers
or producer may be obtained from the Bureau of Indian Standards.
1.15 Jointing
Jointing of DI pipes and fittings shall be done as per the requirements of specifications
and as per the relevant IS code. After jointing, extraneous material, if any, shall be
removed from the inside of the pipe. In case, rubber sealing rings/gaskets are used for
Jointing these shall conform relevant IS codes.
1.16 Spigot and Socket Pipes
The Spigot and socket pipes and DI fittings shall have push on joints as specified in IS
code/ as recommended by manufacturer. The gaskets/sealant used for push on
joints/flanged joints shall be suitable for Waste water conveyance. In jointing Ductile
iron spigot and socket pipes and fittings with tyton flexible joints the contractor shall
take into account the manufacturer's recommendations as to the methods and equipment
to be used in assembling the joints. In particular the Contractor shall ensure that the
spigot end of the pipe to be jointed is smooth and has been properly chamfered, that the
rubber ring as per relevant IS code is correctly positioned in line, before the joint is

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made. The rubber rings and any recommended lubricant shall be obtained only through
the pipe supplier or as otherwise directed by engineer.
1.17 Flanged Pipes
The gaskets used between flanges of pipes shall be compressed fibre board or
natural/synthetic rubber conforming to IS:638 of thickness between 1.5 to 3 mm
suitable for Waste water conveyance and as specified by manufacturer. The fibre board
shall be impregnated with chemically neutral mineral oil and shall have a smooth and
hard surface. Its weight per square metre shall be not less than 112 g/mm thickness.
Each bolt should be tightened a little at a time taking care to tighten diametrically
opposite bolts alternatively. The practice of fully tightening the bolts one after another
is highly undesirable. The bolts shall be of mild steel unless otherwise specified. They
shall be coated with coal tar epoxy coating after tightening.
1.18 Cleaning of Pipes and Fittings
Contractor shall ascertain that each stretch of pipeline is absolutely clear and without
any obstruction by means of visual examination of the interior of pipeline suitably
lighted by projected sunlight or otherwise. The open end of an incomplete stretch of
pipeline shall be securely closed as may be directed by Owner/Engineer to prevent entry
of mud or silt etc. If as a result of the removal of any obstructions Owner/Engineer
considers that damages may have been caused to the pipeline, he shall be entitled to
order the stretch to be tested immediately. Should such test prove unsatisfactory,
contractor shall amend the work and carry out such further tests as are required by
Owner / Engineer.

1.19 Specials for Ductile Iron Pipes

This section covers the general requirements for Ductile Iron (DI) fittings suitable for
Tyton joints to be used with Ductile Iron pipes with flanged and Tyton jointing system.
1.19.1 Types of specials
The following types of DI fittings shall be manufactured and tested in accordance with
IS: 9523.
 flanged socket
 flanged spigot
 double socket bends (900, 450, 22 1/20, 11 1/40)

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 double socket branch flanged tee

 all socket tee
 double socket taper
 blind flange/dummy flange
1.19.2 Supply
All the DI fittings shall be supplied with one rubber ring for each socket. The rubber
ring shall conform to IS: 12820 and IS: 5382 as described in the preceding chapter.
Flanged fittings shall be supplied with one rubber gasket per flange and the required
number of nuts and bolts.
1.19.3 Lubricant for ductile iron pipes and specials
1.19.3.1 General
This section covers the requirements for lubricant for the assembly of Ductile Iron pipes
and specials suitable for Tyton push-in rubber ring joints
1.19.3.2 Specification
The lubricant has to have the following characteristics:

 must have a paste like consistency and be ready for use

 has to adhere to wet and dry surfaces of DI pipes and rubber rings

 to be applied in hot and cold weather; ambient temperature 0 - 50 °C, temperature

of exposed pipes up to 70 °C

 must be non-toxic

 must be water soluble

 must not affect the properties of the drinking water carried in the pipes

 must not have an objectionable odour

 has to inhibit bacterial growth

 must not be harmful to the skin

 must have a shelf live not less than 2 years

Acceptance tests
They shall be conducted in line with the provisions of the IS 9523

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EXCAVATION
The ground shall be excavated by such methods and to such dimensions and depths as shall
allow for the proper construction of the works and safety of personnel and equipment used on
excavation. Slopes required for stable formation of sides shall be provided. The excavation
shall include excavation in earth and murrum and others shall be carried out to the correct levels
required and specified and no clearance, plus or minus (ie. no overcuts), shall be permitted as
per the authority.
Road crossing with the trench less technology / HDD (Horizontal directional drilling): Trench-
less technology tunneling work include the laying by hydraulic jacking and smooth controlled
pushing method in all types of soils including hard rock true to the alignment and gradient
under running traffic condition as per standards including carrying out the survey work at the
site for determining underground cable trenches like telephone, fiber optic cables , water sup-
ply pipes , irrigation pipes and resistivity test for finding the soil strata using necessary equip-
ments for completeness of works mobilizing of the machineries and specialized crews at con-
struction site etc, complete in all respects including the excavation of the driven pit and exit pit
with proper protection with shoring sheets and ISMB (providing and casting MS cutting edges
for front shield and construction thrust bed at designated level as directed by the engineer,
necessary dewatering and providing the concrete foundation at the base of the driven pit, crane
for holding the pipe and any other machinery, tools , tackle required, construction of the tem-
porary works as per the requirement and approval of the concerned authorities and engineering
in charge, as per the scope of work defined.

1.19.4 Packing
All the DI fittings shall be properly packed with jute cloth. Rubber rings shall be packed
in polyethylene bags. Rubber rings in PE bags and nuts, bolts etc. shall be supplied in
separate jute bags.
The fittings should also be supplied by the manufacturer of the pipes. They should
preferably be manufactured by the manufacturer of the pipes. The pipe manufacturer
will however be responsible for the compatibility and quality of the products.
1.20 Testing at Work Site
After the pipes and fittings are laid, jointed and the trench partially backfilled except at
the joints the stretch of pipe line as directed by Engineer shall be subjected to pressure
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test and leakage test as per relevant BIS codes. Where any section of the pipeline is
provided with concrete thrust blocks or anchorages, the pressure test shall not be made
until at least five days have elapsed after the concrete was cast. If rapid hardening
cement has been used in these blocks or anchorages, the tests shall not be made until
atleast two days, have elapsed. Each section of' the pipe line shall be slowly filled with
water and all air shall be expelled from the pipe by tapping at points of highest elevation
before the test is made plugs inserted after the tests have been completed.
The duration of test shall be 8 hours. No pipe installation shall be accepted until the
leakage is less than the number cm3/hr as determined by the formula:
QL =ND √ P
3.3
Where, QL = the allowable leakage in cm3/hr
N = number of joints in the length of the pipeline.
D = diameter in mm, and
P = the average test pressure during the leakage test in kg/cm2

Should any test of pipe laid indicate leakage greater than that specified above, the
defective joints shall be repaired by Contractor at no extra cost to Owner/Engineer until
the leakage is within the specified allowance. Necessary equipment and water used for
testing shall be arranged by Contractor at his own cost. Damage during testing shall be
Contractor's responsibility and shall be rectified by him at no extra cost to
Owner/Engineer. Water used for testing shall be removed from the pipe and not released
in the excavated trenches. After the tests mentioned above are completed to the
satisfaction of Owner/Engineer, the backfilling of trenches shall be done as per
specifications in layers.
Field Hydrostatic Testing
The entire pipeline shall be subjected to a hydraulic test as follows, to the required test
pressure as per Annexure E of IS: 8329 and as per the procedure laid down in IS: 12288.
The completed pipeline may be tested either in one length or in sections; the length of
section depending upon:
1) availability of suitable water,
2) number of joints to be inspected, and
3) difference in elevation between one part of the pipeline and another

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Where the joints are left uncovered until after testing, sufficient material should be
backfilled over the centre of each pipe to prevent movement under the test pressure. It
is prudent to begin testing in comparatively short length of test section. Progressively
as experience is gained, lengths of about 1.5 km or more, are tested in one section,
subject to consideration of length of trench which can be left open in particular
circumstances.
Each section should be properly sealed-off, preferably with special stop ends secured
by adequate temporary anchors. The thrust on the stop ends should be calculated and
the anchors designed to resist it. All permanent anchors should be in position and, if of
concrete, should have developed adequate strength before testing begins. The section
undertest should be filled with water, taking care that all the air is displaced either
through vents at the high points or by using a pig or a sphere.
The test pressure to be applied should be not less than any of the following:
 The maximum pressure, sustained operating
 The maximum static pressure plus 5N/mm2, and
 The sum of the maximum sustained operating pressure (or the maximum static pres-
sure) and the maximum calculated surge pressure.
After filling, the pipeline should be pressurized to the specified operating pressure and
left for a period of time to achieve stable conditions. The length of this period of time
depends on many factors such as slight movement of the pipeline under pressure
whether air is trapped in the pipeline or whether the pipeline has a concrete lining which
absorbs water.
The pipeline is then pressurized up to the full test pressure and the section under test
completely closed off. The test should be maintained for a period of not less than 10
minutes to reveal any defects in the pipes, joints or anchorages.
The test pressure should be measured at the lowest point of the section under test or
alternatively, an allowance should be made for the static head between the lowest point
and the point of measurement, to ensure that the required test pressure is not exceeded
at the lowest point. In case of extreme temperature conditions, there may be a tendency
of hydraulic pressure building up inside the pipeline because of expansion of water
during the high day time. This should normally not be of any major concern as the joints
and the pipes are manufactured to resist a much high pressure. However, sufficient care

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should be taken to prevent floating bulging of the pipeline because of building up of

such high pressure during the temperature rise.
If the test is not satisfactory, the fault should be found and rectified. Where there is
difficulty in locating a fault, the section undertest should be sub-divided and each part
tested separately.
After all sections have been joined together on completion of section testing, a test on
the complete pipeline should be carried out. This test should be carried out at a pressure
not less than the maximum sustained operating pressure or the maximum static pressure
of the pipeline and, during the test, inspection made of all work which has not been
subject to section tests. During the test, the pressure at the lowest point in the pipeline
should not exceed the maximum hydraulic field test pressure. It is important to ensure
that proper arrangements are made for the disposal of water from the pipeline after
completion of hydrostatic testing and that all consents which may be required from
authorities have been obtained. In some cases, for example, heavily chlorinated water,
some treatment may be necessary before final disposal.

1.21 Measurement
All pipes shall be measured according to the work actually done and no allowance will
be made for any waste in cutting to the exact length required. Pipes and fittings shall be
described by their internal diameter and length measured in running meters. The
measurement shall be taken along the centre line of pipe excluding fittings which shall
be measured separately. The lengths of pipes shall not include the portion of spigots
within the sockets of fittings and pipes.

The rate for providing, laying and jointing of DI pipes and fittings shall be deemed to
include the cost of jointing material and testing at work site.

Notes
If any damage is caused to the pipeline during the execution of work or while
cleaning/testing the pipeline as specified, Contractor shall be held responsible for the
same and shall replace the damaged pipeline and retest the same at his own cost of the
full satisfaction of Engineer. Water for testing of pipeline shall be arranged by
Contractor at his own cost.

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Annexure A
CEMENT MORTOR LINING

Materials

Cement: For internal lining of Ductile Iron pipes either blast furnish slag cement /
ordinary Portland cement may be used. The type of cement to be used is to be mutually
decided between the purchaser and manufacturer. Nominal recommendations are:

Portland cement (as per IS 8112 or IS 455) mortar lining perform rather well and have
an expected life of approximately 50 years in soft water with moderate amount of
aggressive CO2 and when pH is within 6 to 9. Longer service life can be obtained by
increasing the mortar lining thickness.

Where cement mortar lining may be exposed to sulphate attack, ordinary Portland
cement should be replaced by sulphate resisting Portland cement (as per IS 12430 or IS
6909). The sulphate concentration limit for sulphate resisting Portland cement is
approximately 3000 mg/litre, the same as blast furnace slag cement which naturally
possess a good resistance to sulphate attack. For sea water transmission blast furnace
slag cement which has C, A content below 3 percent can be used.

High alumina cement (as per IS 6452) mortar lining is suitable for continuous use of
pH between 4 and 12 and no severe damage occur after occasional exposure to pH 3 to
4 and 12 to 13.

Sand: The sand used shall have a controlled granulometric distribution from fine to
coarser elements; it shall be clean and shall be composed of inert, hard, strong and stable
granular particles.

The fine fraction comprising particles passing through a sieve of aperture size 0.125mm
shall not be more than 10 percent by mass.

The fraction comprising grains upto a maximum diameter equal to one third of the
normal thickness of the mortar lining shall not be less than 50 percent by mass.

The corsest fraction (Comprising particles which do not pass through a sieve of the
aperture size closest to half the normal thickness of the mortar lining) shall not exceed
5 percent by mass.

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Water: The water used for the preparation of the mortar shall not contain substances
deleterious to the mortar nor to the water it is eventually intended to transport in the
pipe. The presence of solid mineral particles is, however, admissible provided that
these requirements are still fulfilled.

Mortar: The mortar of the lining shall be composed of cement, sand and water.

Additives, which shall be specified, may be used, provided that they do not prejudice
the quality of the coating and that of the transported water.

The mortar shall be thoroughly mixed and shall have a consistency which results in a
dense and homogeneous lining.

The mortar shall contain by mass at least one part of cement to 3.5 parts of sand.

Application of the lining: The cement mortar lining at work is applied by a centrifugal
spinning process or a centrifuged sprinkler or a combination of both methods.

Apart from the inner surface of the joint, the parts of the pipe coming into contact with
the transported water shall be entirely covered with mortar.

Once centrifuging is finished, the lining shall be cured at temperatures greater than 4o
C. Any loss of water from the mortar by evaporation shall be sufficiently slow so that
hardening is not impeded.

Repair of Lining: Repairs to damaged or defective areas are allowable. The damaged
mortar shall first be removed from these areas. Then the defective part shall be repaired
by using, for example, a trowel with fresh mortar so that a continuous lining having a
constant thickness is again obtained.

For the repair operation, the mortar shall have a suitable consistency, if necessary;
additives may be included to obtain good adhesion against the side of the existing
undamaged mortar.

Thickness of the lining: The normal thickness of the lining and the minimum
permissible mean and local values are given in the Table A.

At the pipe ends, the lining may be reduced to values below the minimum thickness.
The length of the chamfer shall be as small as possible but, in any case, shall be less
than 50mm.

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Determination of lining thickness: The thickness of the lining is checked on the freshly
centrifuged mortar by the insertion of a steel pin, or on the hardened mortar by means
of a non-destructive method of measurement. The thickness of the lining shall be
measured at both ends of the pipe in at at least one section perpendicular to the pipe
axis.

Surface Condition of the Hardened lining: The surface of the cement mortar lining shall
be uniformly smooth. Only isolated grains of sand are allowed to appear on the surface
of the lining.

The lining shall be such that it cannot be dislodged with pressure of hand and shall be
free from corrugations or ridges that could reduce the thickness of the lining to less than
the minimum value at one point, as specified in the Table B.

Table-A Thickness of the Lining

DN (mm) Thickness (mm) Maximum Crack
Width / Radial
Nominal Value Tolerance
Displacement
80 to 300 3.0 -1.5 0/8
350 to 600 5.0 -2 1/0
700 to 1200 6.0 -2.5 1/2
400 to 2000 9.0 -3 1/5

Table-B Minimum Bore Clearance Cement

Mortar Lining of Ductile Iron Pipe

DN Minimum Bore of Cement Mortar

Lined Pipe (mm)
80 67.0
100 87.0
150 137.0
200 247.0
250 247.0
300 287.0

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On contraction of the lining, the formation of cracks cannot be avoided. These cracks,
together with other isolated cracks which may result from manufacturer or may develop
during transportation, are acceptable up to a width given in the above.

Seal Coat:

General: When specified the cement lining shall be given a seal-coat of bituminous
material or any other epoxy based material compatible with cement mortar lining.
Other seal-coat materials may be used, but they shall be agreed on at the time of
purchase and shall be specified on the purchase order.

The purpose of seal-coat is to minimize lime leaching of the cement mortar as well as
to restrict the unwanted rise in pH value of the transmitted water.

When the pipes are to be used for conveying potable water the inside coating shall not
contain any constituent soluble in such water or any ingredient which could impart any
taste or whatsoever to the potable water after sterilization and suitable washing of the
mains.

RCC (SRC) NP4 Pipes with HAC in lining Manufacturing

SCOPE
This Material Specification details the minimum requirements for the pipe procurement
of Reinforced Cement Concrete (RCC) non-pressure pipes shall be as per IS 458. Spec-
ifications provided in this document is only for pipe procurement. Requirements for
Laying, and site inspections are not covered under this specification.
ALIGNMENT AND GRADE
The sewer pipe shall be laid to alignment and gradient shown in the drawing. The align-
ment as proposed should be marked on ground with a line of white chalk and got ap-
proved from Engineer In-Charge. The contractor will the prepare an L-Section along
this alignment showing the location of proposed pipeline.

APPLICABLE STANDARDS AND CODES

The manufacturing, testing, supplying of pipes shall comply with all currently applica-
ble statutes, regulations, standards and codes. In particular, the following standards,
unless otherwise specified herein, shall be referred. In all cases, the latest revision of
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the Codes shall be referred to. If requirements of this Specification conflict with the
requirements of the Codes and standards, this Specification shall govern.
Table-3 Applicable Codes for RCC Pipes

IS Code Description
IS: 458 Specification for Concrete Pipes (with and without Reinforce-
ment).
IS: 3597 Method of Tests for Concrete Pipes.
IS: 432 Part Specification for mild steel and medium (tensile steel bars and
I & II hard drawn steel) wires for concrete reinforcement.
IS: 456 Code of Practice for Plain and Reinforced Concrete.
IS: 783 Code of Practice for Laying of Concrete Pipes.
IS: 516 Method for test for strength of concrete.
IS: 5382 Specification for Rubber Sealing Rings for Gas Mains, Water
Mains and Sewers.
IS: 4905 Method for random sampling.
*Latest revisions of all codes shall be followed

DESIGN

Design of RCC pipes, details of reinforcement and the ends of the pipe shall be in ac-
cordance with the relevant clauses of IS: 458.
Manufacturing
The method of manufacture shall be such that the form and the dimensions of the fin-
ished pipes are accurate within the limits specified in relevant IS: 458. The surfaces and
edges of the pipes shall be well defined and true, and their ends shall be square with the
longitudinal axis. The ends of the pipes shall be further reinforced by an extra ring of
reinforcement to avoid breakage during transportation.
The RCC pipes and rubber rings shall be systematically checked for any manufacturing
defects by experienced supervisors so as to maintain a high standard of quality.
ENGINEER-IN-CHARGE shall at all reasonable times have free access to the places
where the pipes and rubber rings are manufactured for the purpose of examining and
testing the pipes and rubber rings and of witnessing the test and manufacturing.
All tests shall be performed by Supplier / Contractor at his own cost and in presence of
EIC/Representative of EIC, if desired. For this, sufficient notice before testing of the
pipes shall be given to EIC/Representative of EIC.

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If the test is found unsatisfactory, EIC/Representative of EIC may reject any or all pipes
of that lot. The decision of ENGINEER-IN-CHARGE in this matter shall be final and
binding on Contractor and not subject to any arbitration or appeal.

Lining using High Alumina Cement Mortar

General:
The main purpose of using High Alumina Cement for lining is to protect the pipe against
sulphate attacks when it is used in sewer lines. All reinforced concrete pipes shall be of
spun concrete and lined with a 12mm thick High Alumina lining. (Test procedure for
measuring thickness to be as per the relevant standard IS codes-latest revision.
The normal proportion of the mix shall be as follows:

1. High Alumina cement - one part - as per IS: 6452

2. Granite dust passing through IS sieve 150 microns - one part
3. Fine aggregate passing through IS sieve 1.18mm as per IS 383
4. Water cement ratio of the lining mix shall not be more than 0.35 and shall be suffi-
cient to ensure maximum density.
Process of Manufacture: The pipes shall be made by spinning process. The centrifugal
force generated by spinning action will force the concrete against the mould, removing
excess resulting in a dense concrete. The mix for High alumina cement lining shall be
mixed in small separation mixer. All the ingredients shall be weighed. As soon as the
spinning of pipe is completed, the cement mortar shall be fed into the rotating mould
uniformly and the pipe shall be spun until the cement mortar is set.
Precaution to be taken for high alumina lining:
1. It is not desirable to mix and do the lining in high constant temperature (temperatures
more than 400 degrees.
2. Steam curing should not be used for curing pipes.
3. The high alumina lining shall be kept moist and cool for the first 24 hours. The curing
of lining shall be started after 3 to 4 hours after operation.
4. The water cement ratio of the lining shall not be more than 0.35
Materials: For all materials, Factory’s test result and written guarantee document with
necessary analysis data shall be submitted to obtain the approval of the ENGINEER-
IN-CHARGE before carrying to sites.

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Cement: Portland cement shall be used for the manufacture of RCC pipes and fittings
and shall conform to relevant IS codes.
Aggregates: Aggregates used for the manufacture of RCC pipes shall conform to IS:
383. The maximum size of aggregate should be 10mm for pipes of internal diameter
150 to 250mm but should not exceed one third thickness of the pipe or 20mm, which-
ever is smaller, for pipes of internal diameter above 250mm.
Mixing and Curing Water: Water used for mixing of concrete and curing of pipes
shall conform to IS: 456. Water shall be clean, colorless and free from objectionable
quantities of organic matter, alkali, acid, salts, or other impurities that might reduce the
strength, durability or other desirable qualities of concrete and mortar. CONTRACTOR
shall submit water quality report before using it.
Reinforcement: Reinforcement used for the manufacture of the spigot and socket RCC
pipes shall be mild steel Grade I or medium tensile steel bars conforming to IS: 432
(Part-1) or hard-drawn steel wire conforming to IS: 432 (part-2). A reinforcement cage
for pipes shall be as per relevant requirement of IS: 458.
Concrete: Concrete used for the manufacture of spigot and socket RCC pipes shall
conform to IS: 456. The minimum cement content and minimum compressive strength
of concrete shall be as per relevant requirements of IS: 458 and IS: 456. Compressive
strength tests shall be conducted on 15 cm cubes in accordance with the relevant re-
quirements of IS: 456 and IS: 516.
Curing: Pipes manufactured in compliance with IS: 458 shall be either water cured or
steam cured in accordance with the relevant requirements of IS: 458.
Workmanship and Finish
Pipes shall be straight and free from cracks except that craze cracks may be permitted.
The ends of the pipes shall be square with their longitudinal axis so that when placed
in a straight line in the trench no opening between ends in contact shall exceed 3mm in
pipes up to 600mm diameter (inclusive), and 6mm in pipes larger than 600mm diameter.
The outside and inside surfaces of the pipes shall be smooth, dense and hard, and shall
not be coated with cement wash. The pipes shall be free from defects resulting from
imperfect grading of the aggregate, mixing or molding.
The pipes shall be free from local dents or bulges greater than 3.00 mm in depth and
extending over a length in any direction greater than twice the thickness of barrel. The

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deviation from straight in any pipes throughout its effective length, tested by means of
a rigid straight edge parallel to the longitudinal axis of the pipe shall not exceed, for all
diameters, 3 mm for every meter run.
Dimensions and Tolerances
The internal diameter, wall thickness and length of barrel, reinforcement (longitudinal
and spiral), type of ends and minimum clear cover to reinforcement and strength test
requirements shall be as per the relevant clauses / tables of IS: 458.
The following tolerances shall be permitted:
Table-4 Tolerances

Dimensions Tolerances
Overall length ± 1 % of standard length
Internal diameter of pipes:
Up to and including 300 mm ± 3 mm
Over 300 mm and up to and including 600 mm ± 5 mm
Over 600 mm ± 10 mm
Barrel wall thickness:
Up to and including 30 mm + 2 mm
- 1 mm
Over 30 mm up to and including 50 mm + 3 mm
- 1.5 mm
Over 50 mm up to and including 65 mm + 4 mm
- 2 mm
Over 65mm up to and including 80 mm + 5 mm
- 2.5 mm
Over 80 mm up to and including 95 mm + 6 mm
- 3 mm
Over 95 mm + 7 mm
- 3.5 mm

Testing
All pipes for testing purposes shall be selected at random from the stock of the manu-
facturer and shall be such as would not otherwise be rejected under the criteria of tol-
erances as mentioned in IS: 458.
During manufacture, tests on concrete shall be carried out as per IS: 458. The manufac-
turer shall supply, when required to do so by ENGINEER-IN-CHARGE the results of
compressive tests of concrete cylinders or cubes made from the concrete used for the
pipes. For non-pressure pipes, 2 percent of the pipes shall be tested for hydrostatic test
pressure.

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The specimen of pipes for the following tests shall be selected in accordance with
Clause 10.1 of IS: 458 and tested in accordance with the methods described in IS:
3597.After laying and jointing of pipe is completed the pipe line shall be tested at work
site as per following specifications and as directed the EIC.
Sampling and inspection
In any consignment, all the pipes of same class and size and manufactured under similar
conditions of production shall be grouped together to constitute a lot. The conformity
of a lot to the requirements of this Specification shall be ascertained on the basis of tests
on pipes selected from it.
The number of pipes to be selected from the lot shall be in accordance Table 22 of IS:
458.
Pipes shall be selected at random. In order to ensure randomness, all the pipes in the lot
may be arranged in a serial order and starting from any pipe, every “rth” pipe be selected
till the requisite number is obtained, “r” being the integral part of N/n where “N” is the
lot size and “n” is the sample size.
All the pipes selected shall be inspected for dimensional requirements, finish and devi-
ation from straight. A pipe failing to satisfy one or more of these requirements shall be
considered as defective.
A lot shall be considered as conforming to the requirements of IS: 458 if the following
conditions are satisfied.
The number of defective pipes (those not satisfying one or more of the requirements for
dimensions, finish and deviation from straight) shall not be more than the permissible
number given in Column 3 of Table 22 of IS: 458.All the pipes tested for various tests
as per IS: 3597 shall satisfy corresponding requirements of the tests.
All result of tested data must be prepared by Contractor at site so that the ENGINEER-
IN-CHARGE shall make decision of “fail or pass” at once. All cost for the test shall be
borne by the Contractor.
Marking
The following information shall be clearly marked on pipe.
Name of manufacturer:
Class and size of pipe;
The words “SPUN PIPE” may be applicable, for Socket and Spigot pipes: and
Date of manufacture.
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Marking shall be clearly marked on outside only for pipes up to and including 350mm
internal diameter & both outside and inside for pipes above 350mm internal diameter.
The information shall be clearly marked on the outside of pipes. Each pipe may also be
marked with the Standard Mark.
Storage
Each stack of pipes shall contain only pipes of same class and size, with consignment
or batch number marked on it with particulars of suppliers wherever possible. Storage
shall be done on firm level and clean ground and wedges shall be provided at the bottom
layer to keep the stack stable. The stack shall be in pyramid shape or the pipes lay
lengthways and crosswise in alternate layers. The height of the stock shall not exceed
1.5 m. Rubber rings shall be stored in a clean, cool store away from windows, boiler,
electrical equipment and petrol, oils or other chemicals.
Steel Plate Shoring
Where the subsoil conditions are expected to be of a soft and unstable character in
trench/pit excavation, the normal method of timbering may prove insufficient to avoid
subsidence of the adjoining road surfaces and other services. In such circumstances, the
Contractor will be required to use steel trench sheeting or sheet piling adequately sup-
ported by timber struts, waling etc., as per the instructions, manner and method directed
by the Employers Engineer. Contractor shall supply pitch, drive and subsequently re-
move trench sheeting or piling in accordance with other items of the Employer Engi-
neer’s Requirements.
Bedding
For RCC (NP4 class) pipes bedding shall be of PCC with M10 Grade concrete. Bedding
shall be designed considering the required external loading conditions, geotechnical
requirements such as sub soil and bearing capacity of soil encountered in respective
sewer line, type, class and material of pipe used for the laying purposes as per CPHEEO
manual.
Manhole
Construction
The construction of RCC manholes shall be by Cast In-situ of Circular in shape or ap-
proved type Pre-Cast RCC, constructed using form vibrators of standard type, using
SRC/PPC/PSC Cement. The type of manhole to be constructed shall be as approved by
EIC, Contractor shall take prior approval for the Design and Process of manufacture of

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the Pre-cast RCC manholes, the type of vibration for compaction of concrete for precast
manholes shall be invariably of form or table vibrator type.
The work of Cast In-situ RCC manholes includes,
a). Providing and constructing of M-30 Grade of Cement Concrete foundation using
approved quality aggregates of 40mm and downsize with an offset as given in the draw-
ings.
b). Providing and laying Plain cement concrete of grade M-10 for beds of manholes
etc., using 20 mm nominal size graded stone aggregate including laying, tamping, etc.
for a depth, as per drawings, with water proof compound for top plaster in CM 1:3
curing and smooth finishing for exposed faces with necessary centering and form work
etc., complete as per specification, drawing and as directed by the EIC.
c). Providing and laying cement concrete of grade M-30 proportion for vertical walls
using 20 mm nominal size graded stone aggregate including laying, tamping, mixing of
required quantity of water proof compound for everyone bag of cement for plastering
in CM 1:3 curing and smooth finishing for exposed faces with necessary centering and
form work etc., complete as per specification, drawing and as directed by the EIC.
d). Providing and constructing benching with Cement Concrete of grade M-15 to the
dimensions as on drawings with 1: 12 slope in the concrete towards the central drain,
plastered with CM 1:3 proportion, 20mm thick and finished with smooth coat of neat
cement and fixing of inlet and outlet sewers in the walls with the internal periphery
protected with an arch M-15 grade Cement Concrete with graded metal of 10 mm to 20
mm size.
e). Providing and laying cement concrete of grade M-30 proportion with 12mm to
20mm I.S.I gauge of approved gradation hard broken granite/aggregate including cost
and conveyance of all materials with wood or steel shuttering form work including ma-
chine mixing, centering form work, scaffolding, tamping, vibrating , curing and smooth
finish with CM 1:3, 12mm thick for inside surface for RCC Covering Flat Slab with all
lead and lifts, etc. complete as per drawing, specification and as directed by the EIC.
f). Providing, Supplying and fabricating of TMT (Fe-415) reinforcement steel of all
sizes, including straightening, cutting, bending, hooking, lapping and/or welding wher-
ever required, placing in position, tying with binding wire of approved quality and
gauge including the cost of binding wire and anchoring to adjoining members wherever

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necessary including all laps and wastages etc., with all lead and lifts, complete as per
design, specification and directed by EIC.
g). Manholes shall be provided with CI rung ladder with epoxy painting having diam-
eter 16mm at a spacing of 300mm and providing and fixing of circular steel fiber rein-
forced concrete (SFRC) manhole frame and covers of not less than 560 mm diameter
conforming to IS 12592 and the payment for providing of SFRC manhole frame and
covers shall be paid separately as per quoted rate for the item in bill of quantities.
h). The RCC Manhole cost includes all materials, steel, curing, pouring tar over MH
frame and cover, cost of tar, engraving manhole number and flow direction on the inner
surfaces etc., with all lead and lifts, finishing etc. complete. The cement used for the
construction of RCC manhole and internal & external plastering works of manholes
shall be of sulphate resisting cement /PPC/PSC only.
The work of construction of Pre-cast RCC manhole includes,
a). Providing & laying mechanically mixed cement concrete of M-15 grade with stone
aggregate (with 20 mm nominal size graded stone aggregate) in benching, Neat cement
punning over PCC benching, as given in the drawings.
b). Construction of approved type vibrated Pre-Cast RCC Manhole Chambers con-
structed using Sulphate resistant Cement /PPC/PSC& form vibrator of standard type
for Circular Manhole Chambers of various internal dia. (as indicated in BOQ) at bottom
and 0.56 dia. at top made up of pre-cast monolithic base, modular riser and top cone in
M-30 grade concrete placed & aligned to provide vertical sides, with ring rubber gasket
at each joint, water tight & adjustment rings over top cone, complete and all connections
shall have, a water tight seal between the pipe and the manhole complete as per standard
design & drawing.
c). Providing, Supplying and fabricating of TMT (Fe-415) reinforcement steel of all
sizes, including straightening, cutting, bending, hooking, lapping and/or welding wher-
ever required, placing in position, tying with binding wire of approved quality and
gauge including the cost of binding wire and anchoring to adjoining members wherever
necessary including all laps and wastages etc., with all lead and lifts, complete as per
design, specification and directed by Engineer.
d). Manholes shall be provided with CI rung ladder with epoxy painting having diam-
eter 16mm at a spacing of 300mm and providing and fixing of heavy duty circular steel

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fiber reinforced concrete (SFRC)/Plastic fiber reinforced concrete (PFRC)/Polypropyl-

ene fiber reinforced concrete(PPFRC) manhole frame and covers of not less than 560
mm diameter conforming to IS 12592
f). The RCC Manhole cost includes providing danger lighting & use of sight rails &
boning roads shoring & strutting wherever required, including sand bedding, watering,
curing, cost of all materials, labor, supply & fabrication of steel, pouring tar over MH
frame and cover, cost of tar, engraving manhole number and flow direction on the inner
surfaces etc., with all lead and lifts, finishing etc. complete. The cement used for the
construction of RCC manhole and internal & external plastering works of manholes
shall be of sulphate resisting cement only, confirming to IS:12330/PPC/PSC.
Testing

All RCC Manholes and pipe lines shall be tested as in specifications CPHEEO Manual on
Sewerage and Sewage Treatment (latest edition), Relevant IS code (latest edition) for Testing
and commissioning.
Measurement & Payment

The depth of manhole shall be measured from the top of cover to the invert level of the deepest
outgoing sewer from the manhole. The quoted rate for the Manholes for various depths as per
the specifications and drawings shall include the cost of sulphate resisting cement/PSC/PPC,
bedding concrete, benching concrete, plastering, footsteps, fixing SFRC manhole frame with
cover, dewatering to keep the manhole dry until final testing etc. complete.
The Rates for any fractional variation (increase or decrease) in the depth of the manhole on
decimeter basis, shall be paid as per actual, by adding the difference in rates between the im-
mediately preceding and succeeding depths of such fractional depth of manhole on linear basis.
Drop manhole:

In a manhole, wherever the difference between the invert level of downstream sewer
and the invert level of the upstream sewer is greater than 60 cm, a drop manhole shall
be provided at that position. The locations and construction of the drop manholes shall
be provided as on drawings.
Depending upon the sewer material, the drop arrangement pipe shall be suitably sup-
ported with MS fasteners at 300 mm c/c. for diameters pipe line as per Bill of Quanti-
ties, construction drawings and as directed by EIC, specials conforming to IS:1729 shall

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be used for providing the drop in the manhole & a suitable expander/reducer T-Joint at
the top with incoming sewer and 45 degree bend at the bottom with similar incoming
sewer pipe specials to the direction of flow in the receiving sewer. The benching con-
crete in the manhole should surround the joint of the terminating bend and a neat chan-
nel shall be made in the benching concrete to direct the flow to the receiving sewer. A
continuation of the incoming sewer should be built through the shaft wall to form a
rodding and inspection eye, which should be provided with half blank flange as on
drawing. The drop manhole arrangements shall be tested along with sewer lines.

Table-5 Relevant Standards and Specifications:

S. No. Code or Standard Description

1 Manual for Water Supply & CPHEEO Manual for Water Supply &
Treatment Treatment – 1999-MoUD, GoI
2 Manual for Sewerage and Sewer- CPHEEO Manual for Sewerage – 2013-
age Treatment Plants. MoUD, GoI
3 SP 7 (Part-9 Section-1) 1983 National Building Code of India
4 SP 35:1987 Hand book on water supply & drainage
5 IS 1172 :1993 Code of Basic requirements for water sup-
ply, drainage and sanitation
6 IS. 3370 Part I to IV Code of practice for concrete structure for
the storage of liquids
7 IS 456-2000 Code of Practice for plain and reinforced
concrete
8 IS 1893-2002 part I to V Criteria for earthquake –resistant design of
structures
9 IS 13920-1993 Detailing of reinforced concrete Structures
subjected to seismic forces
10 IS 1992-1969 / IS 6403-1971 Code for exploration to find the safe bearing
capacity
11 IS 2309-1969 Code for Lighting arrestors
12 IS 875 part I to III,1987 Code of practice for design loads for build-
ing and structures
13 IS 7357 Code of practice for structural design of
tanks
14 IS 1786-1985 High strength deformed steel bars and wires
for concrete reinforcement
15 IS: 638 Specification for rubber and insertion joint-
ing.
16 IS. 226-1975 Specification for Structural steel
17 IS: 9523 Ductile iron fittings for pressure pipes for
water, gas and sewerage
18 IS: 1500 Code for Hardness test for DI pipes

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19 IS 3764-1966 Safety code of Excavation Works and re-

lated Drilling Operations
20 IS 11906:1986 Recommendations for cement mortar lining
for cast iron, Mild steel and Ductile Iron
pipes and fittings for transportation of water
21 IS 8062 Code of practice for cathodic protection for
steel structures
22 IS 12288:1987 Code of practice for laying of ductile iron
23 IS 14846:2000 Sluice valves for water Works purposes (50
to 1200 mm size)
24 IS 2906:1990 Sluice valves for water Works purposes
(350 to 1200 mm size)
25 IS 2685:1971 Code of practice for selection, installation
and Maintenance of sluice valves
26 IS 3950:1979 Surface boxes for sluice valves
27 IS 5312 Swing check type reflux(non-return) valves
for water Works purposes
28 IS 10446:1983 Glossary of terms relating to water supply
and sanitation
29 IS 2951-1965 Recommendation for estimation of flow of
liquids in closed conduits.
30 Advisory note on improving Ur- Guidelines for preparation of DPRs for wa-
ban Water Supply & Sanitation ter supply system by MoUD, 2013
Services
31 Is :4733-1972 Indian Standard Code: Methods of Sam-
pling Test Sewage Effluent
32 IS: 6908-1975 Indian Standard Code: Sewage and Drain-
age
33 IS :7022 (PT 11)-i 979 Indian Standard Code: Glossary of Terms
Relating to Water Sewage and Industrial Ef-
fluents PT II
34 IS:1538-(PT-XXIV)-1 982 Indian Standard Code: Pressure Pipes for
Water. Gas and Sewage
35 IS 5600: 2002 Indian Standard Code: Pumps-sewage and
Drainage-Specification
36 IS 5611 :1987 Indian Standard Code: Code of practice for
waste stabilization ponds (facultative type)
(first revision)
37 IS: 5600-1970 Indian Standard Code: Specification for
Sewage and Drainage Building Elements
38 IS: 4764-1973 Indian Standard Code: Tolerance Limits for
Sewage Effluents Discharged into Inland
Surface Water
39 IS 6279 :1971 Indian Standard Code: Equipment for gnt
removal devices
40 IS 6280:1971 Sewage screens

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41 IS 7232:1974 Indian Standard Code: Method for lmhoff

cone test
42 IS 7784: Part 1 & 2: Sec 1 to 5 Indian Standard Code: Code of practice for
design of cross drainage work Part 1 Gen-
eral features
43 IS 4111(Part 1):1986 Code of practice for ancillary Structures in
sewerage system: Part I Manholes
44 IS 4111(Part 4):1968 Code of practice for ancillary Structures in
sewerage system: Part 4 Pumping stations
and pumping mains (rising mains)
45 IS 12251:1987 Code of practice for drainage of building
46 IS 12288:1987 Code of practice for use and laying of duc-
tile iron
47 SP 35(S&T): 1987 Handbook on water supply and drainage
with special emphasis on plumbing.
48 IS 458 Pre-cast Concrete Pipes (with and without
reinforcement).
49 IS 651 Specification for Salt Glazed Stoneware
Pipes and Fittings.
50 IS 783 Code of Practice for Laying Concrete Pipes
51 IS 1729 Cast Iron /Ductile Iron Drainage Pipes and
Pipe Fittings Socket and Spigot Series for
Over-ground Non-Pressure Pipe Line.
52 IS 4885 Specifications for Sewer Bricks
53 IS 12592 (Part I & II) Pre-cast Concrete Manhole Covers and
Frames – Specifications
54 IS-8112: 2013 Specification for 43 grade ordinary Portland
cement
55 IS-383: 1970 Specification for Coarse and Fine Aggre-
gates from Natural Sources For Concrete
56 IS:3597 (1998) Concrete Pipes: Methods of Test
57 IS: 783 Code of Practice for laying of Concrete
Pipes
58 IS:376 Safety code for Excavation work
59 IS: 1077 Common Burnt Clay Building Bricks
60 IS:3102 Classification of Burnt Clay Bricks
61 IS: 395 Method of Sampling and Testing Clay
Building Bricks
62 IS: 2212 Code of practice for brick work

TESTING AND COMMISSIONING

Testing at site
All sewers and appurtenances shall be tested before commissioning and trial run as per
the specifications in this section. After laying and jointing of sewer pipes and before
backfilling the trenches, the complete length of the sewer is to be checked for water

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tightness and the sole responsibility of arranging the necessary equipment and apparatus
lies with the Contractor at his own cost. Any damage during testing shall be Contractor
‘s responsibility and shall be rectified by him free of cost. Water for testing shall be
arranged by the Contractor ‘s at his own cost.
Water test for Sewers

After laying and jointing of sewer pipes and before backfilling the trenches, the com-
plete length of the sewer is to be checked for water tightness. Owner may exempt water
test for lateral sewers, where house service connections are to be connected immedi-
ately.
The procedure for testing is as detailed below,
a) Each section of sewer shall be tested for water tightness from manhole to manhole
to prevent change in alignment and disturbance after the pipes have been laid, it is de-
sirable to backfill the pipes up to the top keeping at least 90cm length of the pipe open
at the joints in case of longer length pipes.
b) In case of concrete and stoneware pipes with cement mortar joints, pipes shall be
tested three days after cement mortar joints have been made. It is necessary that the
pipelines are filled with water for about a week before commencing the application of
pressure to allow for the absorption by pipe wall.
c) The sewers are tested by plugging the upper end with a provision for an air outlet
pipe with stop cock. The water is filled through a funnel connected at the lower end
provided with a plug. After the air has been expelled through the air outlet, the stop
cock is closed and the water level in the funnel is raised to 2.50m above the invert at
the upper end. Water level in the funnel is noted after 30 minutes and quantity of water
required to restore the original water level in the funnel is determined. The pipeline
under pressure is then inspected while the funnel is still in position. There shall not be
any leaks in the pipe or the joints (small sweating on the pipe surface is permitted). Any
sewer or part there of that does not meet the test shall be emptied and repaired or re-
laid as required and tested again.
d) The leakage or quantity of water to be supplied to maintain the test pressure during
the period of 10 minutes shall not exceed 0.2 lit/mm dia. of pipe per kilometer length
per day.

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e) Ex filtration test for detection of leakage shall be carried out at a time when the
ground water table is low.
f) For concrete, R.C.C. pipes of more than 600mm dia. the quantity of water inflow can
be increased by 10% for each additional 100mm of pipe dia.
g) After completion of the test all temporary seals shall be removed, the test water shall
be drained out / pumped out and the line cleaned properly.
Test for straightness & obstruction
As soon as a stretch of sewer is laid and tested, before commissioning the cleanliness
of the pipeline is to be checked by the following tests as applicable and as decided by
the Engineer In-Charge.
Torch & Mirror Test
In this method of testing, a torch will be held one end of the pipeline inside a manhole
and its image through the pipeline will be reflected and seen on a mirror held at the
opposite end of the pipeline, inside the next manhole. Any obstruction / debris / major
misalignment will not give a clear image in which case the pipeline will again be
cleaned /rectified and the tests re-done.
Ring Test
In this method of testing two steel/ wooden rings of suitable thickness and design shall
be fixed facing each other at a distance of 2 feet or more. The block of rings shall be
inserted from one end of the pipeline, inside manhole and pulled by a rope fixed to the
block from the other end of the pipeline, inside the next manhole. The rings shall be of
dia. 75 mm less than the inside diameter of pipe under testing. The rope used for pulling
the ring block may be inserted in the pipeline by suitable means. Any construction /
debris / major misalignment will prevent the ring to pass through the pipeline in which
case the pipeline will again be cleaned / rectified and the test redone, and no extra pay-
ment will be made.
Alternately upon the approval of the Engineer, the sewer may be tested by inserting at
the high end of the sewer, a smooth ball of a diameter 13 mm less than the pipe bore.
In the absence of obstruction, such as yarn or mortar projecting through the joints, the
ball should roll down the invert of the pipe and emerge at the lower end. Any construc-
tion / debris / major misalignment that prevent the ball to pass through the pipeline in
which case, the pipeline shall be again cleaned / rectified and the tests redone, and no
extra payment will be made.

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Water test for Manholes

The entire height of Brick and RCC manhole shall be tested for water-tightness by clos-
ing both the incoming and outgoing ends of the sewers and filling the manhole with
water. A drop-in water level not more than 50mm per 24 hours shall be permitted. In
case of high subsoil water, it should be ensured that there is no leakage of ground water
into the manhole by observing the manhole for 24 hours after emptying it.
Test records
Complete test records shall be maintained for all tests carried out for sewers both during
construction and after being in service. The tests carried out as in specifications, ap-
proved QAP shall be documented in the formats as approved by the Contractor and
shall be carried out in the presence of the Engineer or his representative and shall be
certified by the Engineer In-Charge or his representative. All completed Test rec-
ords/documents shall be submitted to the Engineer In-Charge before submission of
bills.
Commissioning
After satisfactory completion of works and Testing of the sewer lines and appurtenances
as per specifications in above clauses, the system shall be commissioned for trial run
and operation.
Final finishing
The Contractor will ensure that the entire structure along with all its installations is in
finished and in new and fully operative condition when handed over. He shall have
repaired and removed all signs of damage that might have been done during the course
of construction of manholes and laying of sewers. He shall also see that the entire ex-
terior has been finished properly and the entire site is cleared of all extra construction
material, debris, and excavated soil. This shall have to be done to the satisfaction of the
Engineer In-Charge.

As Built Drawings
The Contractor shall submit to the Engineer In-Charge within two months of actual
completion of the work, “As Built” Drawings as specified below and operation and
maintenance instructions for the whole of the Works. These Drawings shall be accurate
and correct in all respects, including the existing sewer network for which the Contrac-
tor has done the condition assessment survey, shall be submitted to, and approved by

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the Engineer In-Charge. Completion Drawings as below on two prints and one polyester
film shall be supplied by the Operator, along with a soft copy in CD. These drawings
shall be developed in Auto CAD. Drawing shall be of standard size as below,
i) . Strip Plans and L-sections of Sewerage Network system showing pipe work in pack-
age area on scale as per standard practices to the satisfaction of the Engineer, showing
sewer alignments, levels, appurtenances, sizes and material of pipe etc. complete.
ii). Structural Drawings showing reinforcement details of all the components covered
under this contract as per standard practices.

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Annexure - I (F)
Pipe Conduits and RCC ducts for power Cables
General:

This specification envisages manufacturing, testing at works, transport to site, insur-

ance, storage, erection and commissioning of High-Density polyethylene primarily in-
tended for buried for laying of underground Power cables up to 400 mm2 as per NEMA
TC-7 or any equivalent Indian standard with latest amendment. The expected service
life of HDPE pipe and accessories shall not be less than 50 years.

1.1 Detail Requirements of HDPE Pipe.

Three-layer construction:

The HDPE pipe shall have three concentric layers viz. outer layer, middle layer and
inner layer with ribs. The outer layer shall be made of HDPE material in red colour,
middle layer shall be made of HDPE in translucent (natural) and the inner ribbed layer
of solid permanent lubricant (PLB) i.e. Silicore. These concentric layers shall be con-
tinuous, co-extruded and integral part with HDPE outer/middle layer and shall distinc-
tively visible in cross-section under normal lighting conditions and outer layer gener-
ally conform to IS-9938.
The inner layer of solid permanent lubricant shall not come out during storage, usage
and throughout the life of the pipe. The colour of HDPE pipe shall be as per CRDA
requirement and shall be uniform throughout the length of the pipe.
The HDPE pipe shall Inner Ribbed of standard make and shall have the outer diameter
as fallows.

S No Type of Cable Outer Diameter of Pipe

in mm
1 33 kV 225, 200
2 LV cable 160
3 Service Cable 110

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1.2 Standards:

The PLB (Permeant Lubricant) HDPE pipe shall conform to the following standard and
the technical specifications described below.

S. No Properties Test Method Requirements

Density of Raw
1 ISO 1183 ≥ 930 Kg/m³
Material
The melt flow rate of the duct should
2 Melt Flow Rate ISO 1133 be 0.2 to 1.1 Grams/10 Minutes
@5kg.
Tensile Strength
3 ISO 6259 - 1 & 3 Min 18 N/mm²
at Yield
There should be no crack or split
Environmental
when tested with 10% IGEPAL - CO
4 Stress Crack Re- ASTM D 1693
– 630 solution at 50 ± 1º C for 96
sistance
hours.
5 Ovality IS 4984-1995 Maximum 2% of outer diameter.
6 Reversion IS 4984-1995 3.00% Max
7 Elongation ISO 6259 - 1 & 3 Min 350%
Colour Pigment
ISO 4427 /
8 Dispersion (Outer ≤ Rating A3
ISO 18553
Layer)
Ash Content of
9 Outer Layer of ASTM D5630 ≤ 0.3%
the Duct
There should be no crack / split when
10 Kg load dropped from 1.50 Meter
10 Impact Strength IS 12235 (Part 9)
height after conditioning at 0º C for 1
hour.
Outside diameter at cut end of the
conduit shall not be more than 1.5%
11 Toe- in ASTM F 2160 smaller than outside diameter that
measured at 300mm away from the
cut end of the conduit.
Lubrication materials shall be com-
Friction redution ASTM F 2160 patible with the conduit & any cable
12
jacketing.

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1.3 Material:

The raw material used for the HDPE pipe shall meet the following requirements

i. The anti-oxidant establishers, color master batch and other additive used
shall be physiologically harmless and shall be used only to minimum
extent necessary to meet the specification.
ii. Usage of any additives used separately or together should not impair the
long-term physical and chemical properties of the HDPE pipe.
iii. Suitable Ultra-Violet stabilizers may be used for manufacture of the
HDPE pipe to protect against UV degradation when stored in open for a
minimum period of 8 months.
iv. In case of HDPE pipe of three concentric layer construction, the friction
reducing, polymeric material to be used as the inner layer lubrication
material shall be integral with HDPE layer.
Tests on Material of HDPE pipe:
The base HDPE resin material shall be subjected to following tests and shall satisfy
i. Melt flow Index: ISO 1133
ii. Density: ISO 1183
1.4 Dimension of pipe:
Duct shall have Nominal Diameter of either 110mm,160mm 200mm and 225mm
and shall have a dimensional ratio of 13.5 (SDR)
1.4.1 Dimensions of inner Ribbed HDPE Duct:

S. No Description 225 DIA 200 DIA 160 DIA 110 DIA

1 Outer Diameter of Pipe 200 + 1.50 160 + 1.00 110.0 +1.00

(mm) 225 +
1.5
2 Wall Thickness (mm) 16.70 to 14.80 to 11.90 to 8.20 to 9.20
(Excluding rib height) 18.50 16.50 13.2

3 Ovality Max 4.5 Max 4 Max 3.2 Max 2.2

Pipe Length shall be 6 or 12 meters, length of supply preferred to be 12 mtrs

1.4.2 HDPE Ducts should be sourced from the manufacturer with ISO 9001 accredited
manufacturing facility.

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1.5 Accessories:

The following accessories are required for jointing the pipe and shall be supplied along
with the pipe. The manufactures shall provide complete design details, procedure for
method of installation and type of the material used for the accessories.

Plastic coupler: The coupler shall be used to join two HDPE pipes. The coupling shall
be able to provide a durable water tight joint between two pipes without deteriorating
the strength of the pipes. The strength of coupler shall match the primary strength of the
HDPE pipe. It should either snap fit or Split type. The jointing shall meet the air pressure
test of 2 kg/cm2 for a minimum period of 2 hours without any leakage.

1.6 Workmanship:
The pipe shall be free of blisters, shrink holes, break and other defects. The HDPE pipe
ends shall be cut as square as possible to longitudinal aspects. The external HDPE pipe
surfaces shall be smooth and inner ribbed layer. The color of outer surface should be
Red uniform throughout.
1.6 Marking:

Each straight length of pipe shall be clearly marked hot embossed on white base or ink
jet in black on straight length of the pipe at every meter of pipe with the following
information:

a) Employer’s name,
b) Manufacturer’s name/Trade-mark,
c) Designation of pipe,
d) Lot number/Batch number,

1.8 Tests on finished HDPE pipe:

1.8.1 Visual Inspection: The external surfaces of the pipes shall be smooth and inner surface
of the pipe shall be ribbed, clean and free from grooving and other defects. The pipe
shall be cleanly cut and shall be square with axis of the pipes. Slight shallow longitudi-
nal grooves or irregularities in the wall thickness shall be permissible, if the wall thick-
ness remains within the permissible limits.

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1.8.2 Dimensions: The wall thickness and diameter of the pipe, shall be measured by a
dial Vernier or ball ended micrometer. The diameter shall be measured with mi-
crometer and shall conform to the figures given in the clause 1.4.1.

1.8.3 Reversion Test: This test shall be carried out as per IS: 4984. The dimension of
inner layer or outer layer shall not change by more than 3% in the longitudinal di-
rection when a sample pipe placed (sample length 200mm approx..) horizontally in
an air-oven at 110+/-2o C for 60 minutes and cooled to the room temperature.

1.8.4 Tensile Strength at yield and Elongation at break Test: The tensile strength and
elongation of the HDPE pipe shall be carried out as per ISO: 6259 1& 3.The tensile
strength for finished material shall be minimum 18 N/mm2 and elongation at break
shall be 350%.

1.8.5 Environmental Stress Crack Test: The test shall be conducted as per ASTM D
1693 with the specimen prepared from HDPE pipe after making compression
moulding sheet. The specimen shall be immersed in 10% IGPAL (CO 630) Solution
at 50± 1o C for 96 hrs. There shall be no crack or split.

1.8.6 Impact Strength Test: The test shall be carried out as per IS:12235 (Part 9). A
sample HDPE pipe 150mm in length shall be conditioned at 0◦C for one hour and
placed on a heavy rigid block whose faces are at angle of 120o. A striker with a total
weight of 10kg shall be allowed to fall freely in a suitable vertical guides through a
height of 1.5m. The HDPE pipe shall not crack or split.

1.8.7 Crush Resistance: The test shall be in a sample of 200± 2 mm length of HDPE
pipe which shall be subjected to crush load as specified below with compression
speed 12.5 mm per minute. The deflection with crush load on period shall not ex-
ceed 5%.
i) 225 mm: 1700 N Minimum
ii) 200 mm: 1500 N Minimum
iii) 160 mm: 1200 N Minimum
iv) 110 mm: 800 N Minimum

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1.8.8 Ovality test: The ovality is the difference between maximum outside diameter and the
minimum outside diameter of the HDPE pipe at same cross section of the duct at
300mm away from the cut end. The same shall be measured as per IS-4984 as described
above.
Raw Material: HDPE Virgin material shall be used. No other reworked or recycled
material shall be used

1.9 Packing and condition of delivery:

1.9.1 The pipe may be supplied in loose sticks.

All materials furnished and all work performed shall be inspected and tested. Deliver-
ables shall not be shipped until all required inspections and tests have been completed,
and all deficiencies have been corrected to comply with this Specification and approved
for shipment by the Employer.

Except where otherwise specified, the Contractor shall furnish all manpower and ma-
terials for tests, including testing facilities, power and instrumentation, and replacement
of damaged parts. The costs shall be borne by the Contractor and shall be deemed to be
included in the contract price.

The entire cost of testing for factory & site acceptance, routine tests, production tests
and other test during manufacture & site activities specified herein including the ex-
penses of Inspector/Employer’s representative shall be treated as included in the quoted
unit price of materials.

Acceptance or waiver of tests will not relieve the Contractor from the responsibility to
furnish material in accordance with the specifications.

All tests shall be witnessed by the Employer and/or its authorized representative (here-
inafter referred to as the Employer) unless the Employer authorizes testing to proceed
without witness. The Employer representative shall sign the test form indicating ap-
proval of successful tests.

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Should any inspections or tests indicate that specific item does not meet Specification
requirements, the appropriate items shall be replaced, upgraded, or added by the Con-
tractor as necessary to correct the noted deficiencies at no cost to the Employer. After
correction of a deficiency, all necessary retests shall be performed to verify the effec-
tiveness of the corrective action.

The Employer reserves the right to require the Contractor to perform, at the Employer’s
expense, any other reasonable test(s) at the Contractor’s premises, on site, or elsewhere
in addition to the specified type. Acceptance, Routine or Manufacturing tests to assure
the Employer of specification compliance.

The Employer also reserves the right to require any retesting of previously approved
tests at the Employer’s expenses. However, if the retest(s) reveal non-compliance to the
specification, the Contractor shall bear the expenses for the retesting and remedial ac-
tion at no cost to the employer.

1.10 Factory Acceptance Test:

Factory acceptance tests shall be conducted on randomly selected final assemblies of

all equipment to be supplied. Visual inspection shall be carried out on 100% basis for
all the equipment/items offered. Factory acceptance testing shall be carried out on
HDPE and accessories.
Material shall not be dispatched to the Employer until required factory tests are com-
pleted satisfactory all variances are resolved, full test documentation has been delivered
to the Employer, and the Employer has issued Material Inspection & Clearance Certif-
icate (MICC). Successful completion of the factory tests and the Employer approval to
dispatch shall in no way constitute final acceptance of the system or any portion thereof.
These tests shall be carried out in the presence of the Employer’s authorized represent-
atives.
Factory acceptance tests shall not proceed without the prior delivery to and approval of
all test documentation by the Employer.
The factory acceptance test shall demonstrate the technical characteristics of the equip-
ment in relation to this specifications and approved drawings and documents. The fac-
tory acceptance test for items shall be proposed by the Contractor in accord-

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ance with technical specifications and Contractor’s (including Subcontractor’s/sup-

plier’s) standard FAT testing program. For Test equipment, FAT tests shall include sup-
ply of proper calibration certificates, demonstration of satisfactory performance, evi-
dence of correct equipment configuration and manufacturer’s final inspection certifi-
cate/report.

1.10.1 Sampling for FAT:

From each batch HDPE pipe presented by the Contractor for Factory acceptance testing,
the Employer shall select random sample (s). For HDPE pipes, following sampling
plans shall be followed.

B. Sampling plan for Visual inspection and dimensional test

Scale of sampling for Visual inspection and dimensional test shall be as per below table:

No of Pipes in Sample Sample Cumulative Acceptance Rejec-

the Lot No A Size Sample Size No tion No

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

Up to 150 First 13 13 0 2
Second 13 26 1 2
151 to 280 First 20 20 0 3
Second 20 40 3 4
281 to 500 First 32 32 1 4
Second 32 64 4 5
501 to 1200 First 50 50 2 5
Second 50 100 6 7
1201 to 3500 First 80 80 3 7
Second 80 160 8 9
3501 to above First 125 125 5 9
Second 125 250 12 13

The number of pipes given for the first sample in col 3 of above Table shall be examined
for dimensional and visual requirements given in clause 1.8.1 & 1.8.2. A pipe failing to
satisfy any of these requirements shall be considered as defective. The lot shall be
deemed to have satisfied these requirements, if the number of detectives found in the
first sample are less than or equal to the corresponding acceptance number given in col
5 of above Table. The lot shall be deemed not to have met these requirements if the

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number of detectives found in the first sample is greater than or equal to the correspond-
ing rejection numbers given in column 6 of above Table.
If, however, the number of detectives found in the first sample lies between the corre-
sponding acceptance and rejection numbers given in col 5 and 6 of above Table, the
second sample of the size given in col 3 of above Table shall be taken and examined for
these requirements. The lot shall be considered to have satisfied these, requirements, if
the number of detectives found in the cumulative sample is less than or equal to the
corresponding acceptance number given in col 5 of above Table; otherwise not.

B. Sampling Plan for performance test

The lot having satisfied dimensional and visual requirements shall be tested for other
requirements with the sample size selected as per below Table from the lot. The lot shall
be considered to have met the requirements of these tests, if none of samples tested
fails.

No. of pips in the lot Sample size

Up to 150 3
151 to 1200 5
1201 and 3500 8
3501 and above 12

Since FAT testing provides a measure of assurance that the Quality Control objectives
are being met during all phases of production, the Employer reserves the right to require
the Contractor to investigate and report on the cause of FAT failures and to suspend
further testing/approvals until such a report is made and remedial actions taken, as ap-
plicable.

1.10.2 SITE ACCEPTANCE TESTS

 Randoms checks somewhere in the middle of the pipe, by cutting the duct, will be
made at site to ensure that ducts supplied are of correct dimension and thickness
and there is no compromise on thickness in intermediate length, for saving in ma-
terials cost.
 100% Duct pipe being supplied would be measured length to cross check the length
of the duct pipe.

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 To keep a check on the use of filler material, ash contents would be determined on
randomly selected samples as per ASTM D 1603 method and the value of ash con-
tent, thus determined, shall not exceed 0.3% (outer coloured layer).
 UV Stabilise Content: UV Stabiliser content of finished duct shall not be less than
0.15%
 Third party inspection on above, in addition to inspection at factory, would be car-
ried out by independent agencies. on randomly picked up samples from field for
testing of relevant parameters, thereby ensuring right quality of ducts. Failure of
samples to pass any of the prescribed tests/parameters would result in immediate
invoking of PBG/Blacklisting of the Vendor.

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DATA REQUIREMENTS SHEETS for

HDPE CONDUIT

S.N. Parameter Units Guaranteed Value

HDPE Pipe parameters

1 Manufacturer
2 Pipe diameter (outside)
nominal mm
tolerance mm
3 Wall thickness
nominal mm
tolerance mm
4 Standard Length
nominal mm
tolerance mm
5
6 Three concentric layers type Con-
struction.
7
8 Construction material of outer layer
Construction material of middle
layer
9 Construction material of inner layer
10 Pipe color
a Outer Layer
b Middle Layer
c Inner layer
12 Base HDPE Resin:
a. Density at 27oC Kg/m3 g/10 minutes
b. Melt flow rate at 190oC & 5 kg
load.
13 Service life span year

UG Cable. DRS

Date ……………… Signature ………….

Place …………….. Name ………………

Seal Designation …………..

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DATA REQUIREMENTS SHEETS for

HDPE CONDUIT

S.N. Parameter Units Guaranteed Value

15 Suitable for laying in trenches by- Y/N
a. Directly burying

16 Tensile strength N/mm2

17 Elongation at break %
18 Bend radius
---- End of Table ----

UG Cable. DRS

Date ……………… Signature ………….

Place …………….. Name ………………

Seal Designation ……………

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Annexure- I (G)
Pipe Ducts for ICT
Specification for Multi-Channel
For Fiber Optic Cable and Communication Cable Installations

1.0 General:

Multiple Bundled PLB (Permanent solidly Lubricated Silicore) HDPE ducts provides
pathways & the ability to install fiber optic cables and communication cables for the
Fiber optic network, all within the same multi-channel construction. The multiple chan-
nels enables to install OF cables for present needs and a provision for futuristic use as
when demand grows. Thus, Bundled Multi Channel pathway gives maximum cost ef-
fective builds and good return on investment for existing and future networks.
This specification envisages manufacturing, testing at works, transport to site, insur-
ance, storage, erection and commissioning of Bundled HDPE (High-Density polyeth-
ylene) multi-channel primarily intended for buried for laying of underground Fiber Op-
tic Cable up to 16mm outer diameter.
This contract package includes providing, laying, jointing, testing and commissioning
of DWC HDPE ducts (IS: 14930 Part-2) of 160 mm diameter as per the details furnished
in the drawing. Double-wall corrugated pipe is a kind of pipe material with ring-
structure external wall and smooth internal wall at a length of 6 m each piece.

1.1 Bundled Multi Channel Requirement

Construction:

Bundled HDPE multi channel consists of multiple pathways in different colours for
identification and in specific sizes all bound together with an over sheath for ease of
placement. All of the multi channels shall have internal spiral ribs with a solid perma-
nent solidly lubricated material i.e. Silicore to reduce friction during cable placement
installations.
The inner layer of solid permanent lubricant shall not come out during storage, usage
and throughout the life of the duct. The colour of HDPE duct shall be as per requirement
and shall be uniform throughout the length of the duct.
The PLB multi channel shall have Inner spiral Ribbed and shall have the dimensions of
outer diameter as per project requirement.
1.2 Standards:

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1.2.1 PLB HDPE DUCTS:

The PLB (Permanent Lubricant) HDPE duct shall conform to the following standard
and the technical specifications described below:

S. No Properties Test Method Requirements

The Co-extruded layers of duct/conduit
shall be homogeneous throughout & es-
sentially uniform in colour, opacity,
density & other properties. The outside
1 Workmanship ASTM F 2160
surfaces shall be free from visible
cracks, holes, blisters, voids, foreign in-
clusions, or other deleterious. The inner
surface shall be Spiral ribbed.
Density of Raw
2 ISO 1183 0.940 - 0.958 g/cc
Material
The melt flow rate of the duct should be
3 Melt Flow Rate ISO 1133
0.2 to 1.1 grams/10 Minutes @5kg.
ASTM F 2160/
Tensile Strength
4 ASTMD 638 Type Min 20 N/mm²
At Yield
IV
ASTM F 2160/
5 Elongation ASTMD 638 Type Min 500%
IV
No cracking when tested with 10% Ige-
Environmental
pal Solution at 50 ± 1º C for 96 Hours.
6 Stress Crack Re- ASTM D 1693
(Type Test shall be for minimum 500
sistance
Hours.)
Oxidation Induc- Oxidation Induction time should not be
7 ISO 11357-6
tion test less than 30 minutes.
Reversion of duct shall not be more than
8 Reversion ISO 2505
3%
No swelling leakage or bursting ob-
Hydraulic Char-
served after 48 Hours at a Induced stress
acteristics
9 IS 4984 of 4.9Mpa @ 80ºC
(Acceptance
(Type for 165 hrs at a Induced stress of
Test)
4.6Mpa @ 80ºC)
Deflection shall be < 15% when 1000N
Crush Resistance load applied on 200mm length of the
10 Standard
test sample. Sample should not crack or split
after the test.
There should be no crack / split when
9.1 Kgs load (Tup B) dropped from 1.5
11 Impact Strength ASTM D 2444
Meters. Height after conditioning at 0ºC
for 1 hour.

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The Inner Surface shall be spirally

Inner Surface of
12 ribbed and shall be of a configuration
the Duct
for faster installation of Cable.

1.2.2 BUNDLED MULTI CHANNEL SHEATHING:

S. No Properties Test Method Requirements

Density of Raw
1 ISO 1183 0.940 - 0.958 g/cc
Material
The melt flow rate of the duct should
2 Melt Flow Rate ISO 1133 be 0.2 to 1.1 Grams/10 Minutes
@5kg.
This is bundle of seven PLB HDPE
ducts where external Sheath shall be
in Orange Color and shall be free from
3 Workmanship Standard
visual defects like blisters, shrink
holes, flaking, scratches, groove lines
& surface roughness.
Colour of PLB The Color of the Ducts shall be Green,
4 HDPE ducts in Blue, Yellow, Brown, Violet, Grey,
Bundle Red
Outer Sheath
5 Standard 1.2 mm ± 0.2 mm
Thickness
Outer sheath of Bundled PLB Multi
Channel shall be complied with Anti
termite property as per Standard test-
Outer Sheathing: ing procedure/protocol of IICT, Hy-
6
Anti Termite derabad. Certificate of Anti Termite
shall be submitted for from IICT, Hy-
derabad or any reputed government
testing laboratory. (Type Test)
Minimum Bending
7 Diameter IN Standard 3000 mm
FIELD installation
Additional Re-
A Locatable tracing feature/ mecha-
8 quirement (Op- Standard
nism shall be provided
tional)

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1.3 Material:

The raw material used for the Bundled PLB Multi Channel shall meet the following
requirements

i.The anti-oxidant establishers, color master batch and other additive used shall be phys-
iologically harmless and shall be used only to minimum extent necessary to meet the
specification.
ii.Usage of any additives used separately or together should not impair the long-term
physical and chemical properties of the HDPE duct.
iii.Suitable Ultra-Violent stabilizers may be used for manufacture of the HDPE duct to
protect against UV degradation when stored in open for a minimum period of 8 months.
iv.Suitable anti-termite master batch shall be used in outer sheath of Bundled PLB Multi
Channel to protect damages of the duct from anti-termite when using for underground
application.
v.In case of PLB Multi Channel duct with inner spiral ribs construction, the friction re-
ducing, polymeric material to be used as the inner layer lubrication material shall be
integral with HDPE layer.
vi.HDPE Virgin material shall be used. No other reworked or recycled material shall be
used
Tests on Material of HDPE duct:
The base HDPE resin material shall be subjected to following tests and shall satisfy
i. Melt flow Index: ISO 1133
ii. Density: ISO 1183
1.3 Dimension of duct:
Bundled PLB Multi Channel should consist seven 40mm PLB HDPE ducts with
inner spiral ribs in colour sequence of Green, Blue, Yellow, Brown, Violet, Grey,
Red colors clockwise when viewed from outer end of the coil.

1.4. Dimensions of PLB HDPE Duct:

S. No Description 40 PLB HDPE

duct
1 Outer Diameter of duct (mm) 40 + 0.4 mm
2 Wall Thickness (mm) (Ex- 2.9mm ± 0.3mm
cluding rib height)
3 Ovality before bundling Max 1.4

The Bundled PLB HDPE duct should be supplied in length of 100 meters of coil. HDPE Ducts
should be sourced from the manufacturer with ISO 9001, 14001 and 18001 accredited manu-
facturing facilities.

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1.5 Accessories:

The following accessories are required for jointing the PLB Multi Channel and shall be
supplied along with the duct. The manufactures shall provide procedure for method of
installation and type of the material used for the accessories.

a) Plastic coupler: Plastic Coupler (Push-fit type type): It is used to couple two ducts.
The design of this shall be simple, easy to install and shall ensure that the two ducts are
butted smoothly without any step formation in the inner surface. The jointing shall meet
the air pressure test of 15 kg/cm² for a minimum period of 2 hours without any leakage.
Note: Both sides of the coupler shall be marked with the manufacturers name by en-
graving and that the ends of the opening (for entry of duct) shall be covered with paper
sticker, to prevent the entry of foreign matter while not in use.
b) End Plug: This is for scaling the ends of the empty ducts, prior to installation of the
OF cable and shall be fitted immediately after laying of the duct, to prevent the entry of
any dirt, water, moisture, insects/rodents etc.

1.6 Workmanship:
The outer sheath of Bundled PLB Multi Channel shall be free of blisters, shrink holes,
break and other defects... The external surface of PLB Multi Channel shall be smooth
and free from visual defects like blisters, shrink holes, flaking, scratches, groove lines
& surface roughness and inner ribbed layer. The color of outer sheath surface should be
uniform throughout.
1.7 Marking:
Each coil length of Bundled PLB Multi Channel shall be clearly marked with ink jet in
black and contrast to outer surface colour on length of the duct at every meter of duct
with the following minimum information:
a) Employer’s name,
b) Manufacturer’s name/Trade-mark,
c) Description of duct,
d) Coil Number/Batch number,
e) Sequential meter making at every one meter

1.8 TESTS ON PLB MULTI CHANNEL:

(Each of the test shall be carried out individually on the HDPE Duct)

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1.8.1 Visual Inspection: The external surfaces of the Bundled PLB Multi Channel shall
be smooth and inner surface of the PLB Multi Channel shall be spirally ribbed,
clean and free from grooving and other defects.
1.8.2 Dimensions: The wall thickness and diameter of the PLB Multi Channel, shall be
measured by a dial Vernier or ball ended micrometer and shall conform to the clause
1.4.1.
1.8.3 Reversion Test: This test shall be carried out as per ISO 2505. The dimension of
inner layer or outer layer shall not change by more than 3% in the longitudinal di-
rection when a sample duct placed (sample length 200mm approx..) horizontally in
an air-oven at 110+/-2o C for 60 minutes and cooled to the room temperature.
1.8.4 Tensile Strength at yield and Elongation at break Test: The tensile strength and
elongation of the HDPE duct shall be carried out as per ASTM D 638 Type IV. The
tensile strength for finished material shall be minimum 20 N/mm2 and elongation
at break shall be 500%.
1.8.5 Environmental Stress Crack Test: The test shall be conducted as per ASTM D
1693 with the specimen prepared from HDPE duct sample. The specimen shall be
immersed in 10% IGPAL (CO 630) Solution at 50± 1o C for 96 hrs. There shall be
no crack or split.
1.8.6 Impact Strength Test: The test shall be carried out as per ASTM D 2444. A sample
HDPE duct 150mm in length shall be conditioned at 0◦C for one hour and placed
on a heavy rigid flat block. A striker as per Tup B and loaded to a total weight of
9.1kg shall be allowed to fall freely in a suitable vertical guides through a height of
1.5m. The HDPE duct shall not crack or split.
1.8.7 Crush Resistance: The test shall be in a sample of 200± 2 mm length of HDPE
duct which shall be subjected to 1000N crush load with compression speed 12.5
mm per minute. The deflection shell be < 15% on PLB HDPE duct.
1.8.8 Ovality test: The ovality is the difference between maximum outside diameter and
the minimum outside diameter of the PLB HDPE duct at same cross section of the
duct at 300mm away from the cut end.

1.8.9 Hydraulic Characteristics: The duct shall be tested for internal pressure creep
rupture test as per the test method outlined in IS: 4984. For this purpose, a sample
length of 10 times the outside diameter of the duct shall be taken. At the end of the

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test, the sample shall not show signs of localized swelling or leakage and shall not
burst during the test duration. The test showing failure within a distance equivalent
to the length of end cap from the end shall be disregarded and the test repeated.
This test temperatures and the duration of the test shall be as follows:

Test Test Temp. °C Test Duration (Hrs.) Induced Stress

(Min. holding time) (Mpa)
Type Test 80 165 4.6
Acceptance Test 80 48 4.9

1.8.10 Oxidation Induction Test: The induction time oxygen when tested as per method
in Annexure-I, shall not be less than 30 minutes. Testing should be carried out on
computerized machine and graphs should be submitted along with the test results.

1.9 TEST ON BUNDLED PLB HDPE DUCTS

1.9.1 Visual Inspection: The external surfaces of the Bundled PLB HDPE ducts/ PLB HDPE
duct shall be smooth and clean and free from grooving and other defects...

1.9.2 Dimensions: The outer sheath thickness of the Bundled PLB HDPE duct, shall be
measured by a dial Vernier or ball ended micrometer and shall conform to the clause
1.2.2.
1.9.3 Tracing mechanism: PE insulated copper wire with nominal diameter 0.63mm and
overall nominal 1.2mm diameter with PE insulation should be used during bundling of
PLB HDPE ducts...
1.9.4 Outer Sheathing: Outer sheath of Bundled PLB HDPE duct should complied to Anti
termite property as per Standard testing procedure of IICT, Hyderabad. Certificate of
Anti Termite shall be submitted for from IICT, Hyderabad or any reputed government
testing laboratory

2.0 Packing and condition of delivery:

2.1 The duct should be supplied in coils of 100 meters.

All materials furnished and all work performed shall be inspected and tested. Deliver-
ables shall not be shipped until all required inspections and tests have been completed,
and all deficiencies have been corrected to comply with this Specification and approved
for shipment by the Employer.
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Except where otherwise specified, the Contractor shall furnish all manpower and ma-
terials for tests, including testing facilities, power and instrumentation, and replacement
of damaged parts. The costs shall be borne by the Contractor and shall be deemed to be
included in the contract price.
The entire cost of testing for factory & site acceptance, routine tests, production tests
and other test during manufacture & site activities specified herein including the ex-
penses of Inspector/Employer’s representative shall be treated as included in the quoted
unit price of materials.
Acceptance or waiver of tests will not relieve the Contractor from the responsibility to
furnish material in accordance with the specifications.
All tests shall be witnessed by the Employer and/or its authorised representative (here-
inafter referred to as the Employer) unless the Employer authorises testing to proceed
without witness. The Employer representative shall sign the test form indicating ap-
proval of successful tests.
Should any inspections or tests indicate that specific item does not meet Specification
requirements, the appropriate items shall be replaced, upgraded, or added by the Con-
tractor as necessary to correct the noted deficiencies at no cost to the Employer. After
correction of a deficiency, all necessary retests shall be performed to verify the effec-
tiveness of the corrective action.
The Employer reserves the right to require the Contractor to perform, at the Employer’s
expense, any other reasonable test(s) at the Contractor’s premises, on site, or elsewhere
in addition to the specified type. Acceptance, Routine or Manufacturing tests to assure
the Employer of specification compliance.
The Employer also reserves the right to require any retesting of previously approved
tests at the Employer’s expenses. However, if the retest(s) reveal non-compliance to the
specification, the Contractor shall bear the expenses for the retesting and remedial ac-
tion at no cost to the employer.

3.0 Factory Acceptance Test:

Factory acceptance tests shall be conducted on randomly selected final assemblies of

all equipment to be supplied. Visual inspection shall be carried out on 100% basis for
all the equipment/items offered. Factory acceptance testing shall be carried out on
HDPE and accessories.

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Material shall not be dispatched to the Employer until required factory tests are com-
pleted satisfactory all variances are resolved, full test documentation has been delivered
to the Employer, and the Employer has issued Material Inspection & Clearance Certif-
icate (MICC). Successful completion of the factory tests and the Employer approval to
dispatch shall in no way constitute final acceptance of the system or any portion thereof.
These tests shall be carried out in the presence of the Employer’s authorized represent-
atives.
Factory acceptance tests shall not proceed without the prior delivery to and approval of
all test documentation by the Employer.
The factory acceptance test shall demonstrate the technical characteristics of the equip-
ment in relation to this specifications and approved drawings and documents. The fac-
tory acceptance test for items shall be proposed by the Contractor in accordance with
technical specifications and Contractor’s (including Sub-Contractor’s/supplier’s)
standard FAT testing program. For Test equipment, FAT tests shall include supply of
proper calibration certificates, demonstration of satisfactory performance, evidence of
correct equipment configuration and manufacturer’s final inspection certificate/report.

3.0.1 Sampling for FAT:

From each batch Bundled PLB Multi Channel presented by the Contractor for Factory
acceptance testing, the Employer shall select random sample (s). For HDPE ducts,
following sampling plans shall be followed.

A. Sampling plan for Visual inspection and dimensional test

Scale of sampling for Visual inspection and dimensional test shall be as per below table:

No of Ducts in Sample Sample Cumulative Acceptance Rejec-

the Lot No A Size Sample Size No tion No

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

Up to 150 First 13 13 0 2
Second 13 26 1 2
151 to 280 First 20 20 0 3
Second 20 40 3 4
281 to 500 First 32 32 1 4
Second 32 64 4 5
501 to 1200 First 50 50 2 5
Second 50 100 6 7
1201 to 3500 First 80 80 3 7

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Second 80 160 8 9
3501 to above First 125 125 5 9
Second 125 250 12 13

The number of ducts given for the first sample in col 3 of above Table shall be examined
for dimensional and visual requirements given in clause 1.8.1 & 1.8.2. A duct failing to
satisfy any of these requirements shall be considered as defective. The lot shall be
deemed to have satisfied these requirements, if the number of detectives found in the
first sample are less than or equal to the corresponding acceptance number given in col
5 of above Table. The lot shall be deemed not to have met these requirements if the
number of detectives found in the first sample is greater than or equal to the correspond-
ing rejection numbers given in column 6 of above Table.
If, however, the number of detectives found in the first sample lies between the corre-
sponding acceptance and rejection numbers given in col 5 and 6 of above Table, the
second sample of the size given in col 3 of above Table shall be taken and examined for
these requirements. The lot shall be considered to have satisfied these, requirements, if
the number of detectives found in the cumulative sample is less than or equal to the
corresponding acceptance number given in col 5 of above Table; otherwise not.

B. Sampling Plan for performance test

The lot having satisfied dimensional and visual requirements shall be tested for other
requirements with the sample size selected as per below Table from the lot. The lot shall
be considered to have met the requirements of these tests, if none of samples tested
fails.

No. of coils in the lot Sample size

Up to 150 3
151 to 1200 5
1201 and 3500 8
3501 and above 12

Since FAT testing provides a measure of assurance that the Quality Control objectives
are being met during all phases of production, the Employer reserves the right to require
the Contractor to investigate and report on the cause of FAT failures and to suspend
further testing/approvals until such a report is made and remedial actions taken, as ap-
plicable.

3.0.2 SITE ACCEPTANCE TESTS

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 Randoms checks somewhere in the middle of the PLB Multi Channel, by cutting
the single duct, will be made at site to ensure that ducts supplied are of correct
dimension and thickness and there is no compromise on thickness in intermediate
length, for saving in materials cost.
 100% Duct being supplied would be measured length to cross check the length of
the duct.
 Third party inspection on above, in addition to inspection at factory, would be car-
ried out by independent agencies. on randomly picked up samples from field for
testing of relevant parameters, thereby ensuring right quality of ducts. Failure of
samples to pass any of the prescribed tests/parameters would result in immediate
invoking of PBG/Blacklisting of the Vendor.

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DATA REQUIREMENTS SHEETS FOR

BUNDLED PLB HDPE DUCT

S.N. Parameter Units Guaranteed Value

Bundled PLB Multi Channel parameters

1 Manufacturer
2 No of PLB Multi Channel in Bundled Nos.
HDPE duct
2 Outer Sheath thickness of Bundled PLB
Multi Channel
3 PLB Multi Channel diameter
nominal mm
tolerance mm
4 Wall thickness (Excluding inner ribs
nominal mm
tolerance mm
5 Standard Length of Bundled Multi Chan-
nel mm
nominal mm
tolerance
6 Construction material of outer sheath of
Bundled Multi Channel
7 Construction material of PLB Multi
Channel
8 Construction material of inner layer of
PLB Multi Channel
9 Outer Sheath color of Bundled Multi
Channel
10 Colours of all seven PLB Multi Channels
11 Base Duct Resin:
c. Density at 27oC Kg/m3 g/10
d. Melt flow rate at 190oC & 5 kg load. minutes

Date ……………… Signature ………….

Place …………….. Name ………………

Seal Designation …………..

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DATA REQUIREMENTS SHEETS FOR

SILICORE MULTI CHANNEL

S.N. Parameter Units Guaranteed Value

12 Suitable for laying in trenches by- Y/N
b. Directly burying

13 Tensile strength N/mm2

14 Elongation at break %

15 Minimum Bend diameter for field

installation
---- End of Table ----

UG Cable. DRS

Date ……………… Signature ………….

Place …………….. Name ………………

Seal Designation ……………

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Annexure - 1
OXIDATION INDUCTION TEST

1.0 A short length of completed duct (approximately 30 cm) shall be sealed at the ends and
placed in an oven at temperature of 68 ± 1° C for 8 hours. The sample shall then be
allowed to cool at room temperature for at least 16 hours. The sample shall be clean
and dry. The sample shall then be tested by means of a Differential Scanning Calorim-
eter (DSC) or by Differential Thermal Analyser (DTA).
2.0 Instrument Test Procedure:

2.1 Cell Cleaning: The cell shall be held at approximately 400° C for 10 minutes in Nitro-
gen. The cell shall be cleaned after standing over night and between testing of different
formulations.

2.2 Temperature Calibration: This has to be done according to the instrument manual. The
temperature scale should be adjusted until the determined melting point of pure Indium
metal is 156.6° C at a heat rate of 5° C per minute or any other heat rate as indicated in
the manual of the equipment is permitted.

2.3 Aluminium Pan Preparation: Standard aluminium DSC pans as per ASTM D 4565 are
required to hold specimens during testing. A fresh pan shall be used for each test.

2.4 Sample Preparation: Take the sample weighing about 5 mg from the duct conditioned
as indicated above. Position the sample in the center of the pan.

2.5 Nitrogen Purge: Place the sample pan and reference pan in instrument cell. Flush for 5
minutes with cylinder of nitrogen (99.6% extra dry grade) at 60 ± 10 cc per minute.

2.6 Oxidation Test: Rapidly increase the temperature of the sample (20° C/min or greater)
from 100° C or lower initial temperature to 199 ± 1° C. After thermal equilibrium is
obtained (steady recorder signal) switch to 80 ± 20 cc per minute oxygen flow and
simultaneously start time-base recording. The oxygen used for the test should be equiv-
alent to or better than 99.6% extra dry grade.

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2.7 Induction Period: The oxygen induction point shall be recorded as time zero, and the
chart speed shall be sufficient to provide a clearly discernible slope at the start of the
exothermic reaction. The test in the pure dry oxygen atmosphere shall continue until
the exothermic peak is produced. The intersection of the tangent of the exothermic
sloped line with the extended base line will be drawn. The time zero to this intersection
point is read from the base line and recorded as the oxidative induction time.

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TECHNICAL SPECIFICATIONS FOR LAYING OF ICT DUCTS

Relevant NHAI guidelines and other guidelines referred in this document shall be followed.

CLASSIFICATION OF SOIL:

The excavation work generally involves various soil conditions on such routes like soft soil,
hard muram soil, hard rocks requiring chiseling/blasting as per relevant specification.

EXCAVATION
The ground shall be excavated by such methods and to such dimensions and depths as shall
allow for the proper construction of the works and safety of personnel and equipment used on
excavation. Slopes required for stable formation of sides shall be provided. The excavation
shall include excavation in earth and murrum and others shall be carried out to the correct levels
required and specified and no clearance, plus or minus (ie. no overcuts), shall be permitted as
per the authority.
Road crossing with the trench less technology / HDD (Horizontal directional drilling): Trench-
less technology tunneling work include the laying by hydraulic jacking and smooth controlled
pushing method in all types of soils including hard rock true to the alignment and gradient
under running traffic condition as per standards including carrying out the survey work at the
site for determining underground cable trenches like telephone, fiber optic cables , water sup-
ply pipes , irrigation pipes and resistivity test for finding the soil strata using necessary equip-
ments for completeness of works mobilizing of the machineries and specialized crews at con-
struction site etc, complete in all respects including the excavation of the driven pit and exit pit
with proper protection with shoring sheets and ISMB (providing and casting MS cutting edges
for front shield and construction thrust bed at designated level as directed by the engineer,
necessary dewatering and providing the concrete foundation at the base of the driven pit, crane
for holding the pipe and any other machinery, tools , tackle required, construction of the tem-
porary works as per the requirement and approval of the concerned authorities and engineering
in charge, as per the scope of work defined.

ALIGNMENT OF THE TRENCH:

Contractor shall carry out detailed survey of route and submit the final survey report for ap-
proval before implementation. The final survey report shall include the following:

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 A drawing of the proposed ICT duct route indicating all details including relevant
details of soil strata, bridges, culverts, & other utilities & other important landmarks,
etc.

 The distance of the ICT duct route from the center of the median of road shall be
indicated on the route maps as well as documented in tables.

 Sections where RCC manholes are required.

 Location and number of manholes as proposed.

 Location of all turns, bends and major landmarks.

 The final LS, CS and Plans have to be approved by the Engineer-in-Charge.

The Contractor shall prepare and submit for approval by the Employer, specific construction
drawings for all types of soil strata/crossings taking into consideration the guidelines given in
this specification. The construction/implementation shall be carried out as per the approved
drawings. The Construction drawings shall interalia include the longitudinal sectional diagram
of the trench for different soil strata and detail arrangement of crossings, number of pipes, size
of pipe, locations and position of manholes, other details as per the technical specifications.
Route maps shall be drawn to the scale as required by the authority.

The trench will normally follow the alignment in the ROW permitted by Authority. The Engi-
neer-in-charge will decide the alignment of the trench, which shall be proposed by the contrac-
tor in consultation with the Engineer-in-Charge. While marking the alignment, only the center
line will be marked and given, and the contractor shall set out all other work to ensure that the
excavated trench is as straight as possible.

The contractor shall provide efficient staff for the purpose of this marking and the contractor
shall solely be responsible for accuracy of such setting out.

The contractor shall clear, prepare and grade the right of way to facilitate the making of the
alignment of the trench. Contractor shall remove all bushes, undergrowth, slumps, rocks and
other obstacles to facilitate marking the central line.

TRENCHING DEPTH & WIDTH:

The standard depth as specified is subject to the following conditions: -

It is likely that, due to uneven ground condition if 1.65 m is adopted as the uniform depth
throughout, the bottom of the trench will also follow the same unevenness as the surrounding

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terrain. This should not be the case and the bottom of the trench has to be at uniform level. In
this process, it is possible that in some locations the depth of excavation may be more. How-
ever, it is to be ensured that at no location, the depth is less than 1.65 meter.

DEWATERING:

The contractor shall be responsible for all necessary arrangements to remove or pump out water
from trench. The contractor should survey the soil condition encountering the section for which
he is trenching and make his own assessment about de-watering arrangements that may be
necessary. No extra payment shall be admissible for this and the tendered rate may take care of
this aspect.

The contractor shall provide sufficient width of the trench and all such places where it is likely
to cave in due to soil conditions and for this no extra payment will be made.

A minimum free clearance as per standards defined in Schedule-D should be maintained above
or below any existing/Proposed underground metallic or non-metallic lines or utility lines
crossing the trench. No extra payment will be made towards this.

TRENCH EXCAVATION AND BACKFILLING:

The contractor shall carry out excavation and backfilling of trenches in all kinds of soil strata
for proposed duct bank as per the indicative drawings.

EXCAVATION:

The cable trenches shall be dug as per route plan and detailed trench drawings (indicating the
various dimensions and other details of the trench) approved by the Engineer-in-Charge for
each type of soil strata. The Contractor shall take due care and precaution during excavation to
avoid possible damage of other underground plans/facilities in the proposed underground ICT
Duct route and shall indemnify the Employer for all damages and shall be solely responsible
for all the damages and losses. The Employer shall not be liable for any damages/losses.

Depth of cover shall be at least 800 mm up to chequered tile from top level.

During the construction of trench, the Contractor shall be responsible for shoring and strutting
the walls of the trench on either side by using suitable means such as wooden planks to avoid
subsidence of soil. The Contractor shall also be responsible for supporting the exposed plant/fa-
cilities of other utilities such as water, gas and oil pipes, electric, telephone or fiber optic cables,
etc. to avoid any possible damage. The contractor shall also be responsible for any dewatering
of trench during digging and installation of pipes.

BACK FILLING AND DRESSING THE TRENCH:

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Provided that the pipe has been properly laid and jointed in the trench, and the back-filling
operation shall follow as closely as practicable. The back-filling operation shall be performed
in such a manner as to provide firm support under and above the pipe and to avoid bend or
deformation of the pipe, when the pipe gets loaded with the back filled with sand. Where in
any location the back filling is unevenly centered over the trench due to carelessness or any
other cause it shall be redressed at the contractor’s expenses. No debris shall be allowed in
backfill at any time.

The backfill shall be maintained by the contractor against wash out settlement below original
levels and rotting until final completion of the works and until reinstated to the original surface
conditions as acceptable to the Engineer-In-charge.

Wherever, the duct is laid at a depth less than 1.65 meters the contractor shall obtain the site
instructions from Engineer-In-charge in writing.

ROAD CROSSINGS:

Road crossings: RCC encasing pipes of NP4 to be laid for the crossing of the HDPE-DWC
ICT conduits with reference to the drawing.

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Annexure - I (H)

DESIGN LIFE

Design Life
Design
S.
Items Period Code Reference Note
No.
in years
A Road layers

1 Bituminous layers 10 IRC 37: 2012

Base, Sub-base and Em-
2 20 IRC 37: 2012
bankments

3 Concrete Roads 20 IRC 67: 2014

B Drainage Structures
Cross Drainage Works - Clause no.7.2(iii) of
1 100 IRC 84: 2014
HP drains page no 60
Cross Drainage Works - Clause no.7.2(iii) of
2 100 IRC 84: 2014
Box drains page no 60
3 RCC Side Drains 30 CPHEEO Manual

C Misc. Items

1 High mast - GS 25 CPWD Manual

2 Light poles - GS 25 CPWD Manual

3 Underground cabling 20 CPWD Manual

D Pumping and Pipes

Electric motors - single
1 15 CPHEEO Manual
phase
Electric motors - Three
2 15 CPHEEO Manual
phase
3 Electric Pump 15 CPHEEO Manual

4 Diesel Pump 10 CPWD Manual

5 Diesel Generator 12 CPWD Manual

6 Sewage Pump 15 CPHEEO Manual

F Civil Structures

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Design Life
Design
S.
Items Period Code Reference Note
No.
in years
Pumping station - Pump
2 30 CPHEEO Manual
house- Civil Structure
3 Sewage Treatment Plant

a) Civil Structures 30 CPHEEO Manual

Electrical & Mechanical
b) 15 CPHEEO Manual
Components
4 Water treatment units 15 CPHEEO Manual
Pipes and distribution sys-
5 30 CPHEEO Manual
tems
Reservoirs - Overhead and
6 30 CPHEEO Manual
ground level

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Annexure – I (I)
Clash Analysis

Resolving the clashes during designs will avoid the cost overruns and time overruns during
execution. While submitting construction drawings for each utility the following has to be
maintained
 All clashes between utilities should be resolved during designs and accordingly final
LS has to be prepared for each individual utility.

 Spacing between each utility should be maintained as given in table 1.

 Gravity systems should be given first priority and all other utilities which are
colliding with them shall bend.

 Priority matrix for resolving the clashes between utilities are given in table 2.

 All joints should be away from crossings as far as possible.

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ANNEXURE I (I)II
Minimum Depth from Ground Level, horizontal and vertical spacing requirements between
utilities
Utility Minimum Horizontal Spacing (m) Vertical Spacing (m)
Vertical depth
from ground
level
Water Waste Reuse Storm Power Power Power Gas ICT Water Waste Reuse Storm Power Power Power Gas ICT
(m)
supply water Drain 220KV 33KV 415V supply Water Water Drain 220KV 33KV 415V

Water sup- 0.6 0.3 0.2

ply

Waste Wa- 1 3 0.5 0.2 0.2

ter

Reuse Wa- 1 0.6 0.5 0.5 0.2 0.2 0.2

ter

Storm - 0.6 0.5 0.5 0.5 0.2 0.2 0.2 0.2

Drain

Power 1.2 0.6 0.5 0.5 0.5 0.2 0.2 0.2 0.2 0.2 0.2
220KV

Power 1.05 0.3 0.3 0.3 0.3 0.2 0.25 0.2 0.2 0.2 0.2 0.2 0.2
33KV
Power 0.75 0.3 0.3 0.3 0.3 0.2 0.15 0.1 0.2 0.2 0.2 0.2 0.2 0.15 0.1
415V

Gas 1 0.6 0.5 0.5 0.5 1 0.3 0.3 0.15 0.4 0.4 0.4 0.4 0.5 0.3 0.3 0.6

ICT (Opti- 0.75 0.6 0.5 0.5 0.5 0.5 0.3 0.3 0.2 0.2 0.2 0.2 0.2 0.2 0.4 0.2 0.2 0.2 0.2
cal Fibre)

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ANNEXURE I (I)III
S. No Utility Water supply Sewerage Reuse Storm Power Power 33KV Power 415V Gas ICT
220KV
1 Water supply minor size pipe has to
bend
2 Sewerage Water supply line has to Merge / Pumping
bend main line has to
bend
3 Reuse reuse pipe has to bend Reuse pipe has to minor size
bend pipe has to
bend
4 Storm Drain Water supply line has to Sewerage line has Reuse pipe Minor Drain
bend to bend has to merges with Ma-
bend jor Drain
5 Power 220KV Water supply line has to Power lines has to Reuse pipe Power lines has to Merge
bend bend has to bend
bend
6 Power 33KV For water supply trunk- Power lines has to Power Power lines has to 33KV Lines Merge/Any one
33KV lines has to bend bend lines has bend has to bend can bend
For Water supply distri- to bend
bution- water supply
lines has to bend
7 Power 415V Power lines has to bend Power lines has to Reuse pipe Power lines has to 415V Lines 415V Lines has to Merge/Any one can
bend has to bend has to bend bend bend
bend
8 Gas Gas line has to bend Gas line has to Reuse pipe Gas line has to Power lines Gas line has to Gas line has to bend Merge/ mi-
bend has to bend has to bend bend nor size pipe
bend has to bend

9 ICT (Optical Fi- ICT lines has to bend ICT lines has to Reuse pipe ICT lines has to Power lines ICT lines has to ICT lines has to bend ICT lines has Merge/
bre) bend has to bend has to bend bend to bend Any one
bend can bend

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Annexure – I (J)
List of Drawings
TABLE OF CONTENTS

PACKAGE -XV (E3-SEED ACCESS ROAD)

S.NO. DESCRIPTION DWG NO.
ROADS
TYPICAL CROSS SECTIONS
1 TYPICAL CROSS SECTION OF SEED ACCESS ROAD-E3 CRDA-ADC-ROAD-TCS-01
PLAN AND PROFILES
2 PLAN & PROFILES FROM Km 0+000 TO 18+270 – E3 ROAD CRDA-AR-PKG1-PP-01 OF 19
STANDARD DRAWINGS
3 TYPICAL DETAILS OF MANDATORY / REGULATORY TYPE ROAD SIGNS 1957-CRDA-ADC-ROAD-MISC-01
4 TYPICAL DETAILS OF CAUTIONARY / WARNING TYPE ROAD SIGNS 1957-CRDA-ADC-ROAD-MISC-02 TO 03
5 INFORMATORY ROAD SIGNS 1957-CRDA-ADC-ROAD-MISC-04
6 FACILITY INFORMATORY ROAD SIGNS 1957-CRDA-ADC-ROAD-MISC-05
7 ROAD MARKINGS 1957-CRDA-ADC-ROAD-MISC-06 TO 07
8 TYPICAL DETAILS OF ROAD MARKINGS 1957-CRDA-ADC-ROAD-MISC-08
9 FOUNDATION DETAILS FOR TRAFFIC SIGNS 1957-CRDA-ADC-ROAD-MISC-09
10 TYPICAL DETAILS OF ROADWAY DELINEATOR ON HORIZONTAL CURVES 1957-CRDA-ADC-ROAD-MISC-10
11 SOLAR LIGHT 1957-CRDA-ADC-ROAD-MISC-11
12 TYPICAL DETAILS OF METAL BEAM CRASH BARRIER 1957-CRDA-ADC-ROAD-MISC-12

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PACKAGE -XV (E3-SEED ACCESS ROAD)

S.NO. DESCRIPTION DWG NO.
13 DETAILS OF KILOMETER STONE AND KERB 1957-CRDA-ADC-ROAD-MISC-13
14 ELECTRICAL STREET LIGHT POLE DETAILS 1957-CRDA-ADC-ROAD-MISC-14
15 DETAILS OF CURVE COMPONENTS 1957-CRDA-ADC-ROAD-MISC-15
UTILITIES
CHAINAGE WISE UTILITY TCS
16 TYPICAL CROSS SECTION WITH UTILITIES ARRANGEMENT FOR E3 ROAD AG-1957-DDR-AM-UT-TCS-E3-001 OF 024
UTILITY PLANS
17 UTILITIES ARRANGEMENT WITH DETAILS FOR E3 ROAD AG-1957-DDR-AM-UT-LP-E3-001 OF 019
18 STORM WATER DRAINAGE NETWORK PLAN FOR E3 ROAD AG-1957-AM-DPR-E3-DR-DL-001 OF 010
19 WASTE WATER NETWORK WITH DETAILS FOR E3 ROAD AG-1957-DDR-AM-WW-DL-E3-001 OF 013
UTILITY JUNCTIONS
20 UTILITIES ARRANGEMENT WITH DETAILS FOR E3-N4 ROAD JUNCTION AG-1957-DDR-AM-UT-JUN-E3/N4-001
21 UTILITIES ARRANGEMENT WITH DETAILS FOR E3-N9 ROAD JUNCTION AG-1957-DDR-AM-UT-JUN-E3/N9-002
22 UTILITIES ARRANGEMENT WITH DETAILS FOR E3-N14 ROAD JUNCTION AG-1957-DDR-AM-UT-JUN-E3/N14-003
23 UTILITIES ARRANGEMENT WITH DETAILS FOR E3-N16 ROAD JUNCTION AG-1957-DDR-AM-UT-JUN-E3/N16-004
WATER SUPPLY - HEAD WORKS
GENERAL DRAWINGS
24 MAP SHOWING PROPOSED WATER SUPPLY ZONES WITH UTILITY LOCATIONS FOR AMARAVATI CAPITAL CITY AG-1957-DDR-AM-WS-GL-001
25 MAP SHOWING WATER DISTRIBUTION CENTERS WITH CUSHION TANKS FOR AMARAVATI CAPITAL CITY AG-1957-DDR-AM-WS-GL-002

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PACKAGE -XV (E3-SEED ACCESS ROAD)

S.NO. DESCRIPTION DWG NO.
26 MAP SHOWING WATER DISTRIBUTION CENTERS WITH SUGR'S FOR AMARAVATI CAPITAL CITY AG-1957-DDR-AM-WS-GL-003
27 DETAILED LAYOUT OF PROPOSED WATER SUPPLY SCHEME OF AMARAVATI CAPITAL CITY AG-1957-DDR-AM-WS-DL-001
28 PROPOSED WATER SUPPLY NETWORK CONNECTIVITIES TO WDCs OUT OF ROAD BATTERY LIMIT AG-1957-DDR-AM-WS-DL-002
29 SCHEMATIC FLOW DIAGRAM OF PROPOSED WATER SUPPLY SYSTEM FOR AMARAVATI CAPITAL CITY AG-1957-DDR-AM-WS-SLD-001
30 SITE LAYOUT OF INTAKE WELL CUM RAW WATER PUMPING STATION AND APPROACH ROAD AG-1957-DDR-AM-WS-IW-SL-001
GAD OF INTAKE WELL CUM PUMP HOUSE AND APPROACH ROAD/BRIDGE OF AMARAVATI CAPITAL CITY -
31 AG-1957-DDR-AM-WS-IW-GAD-001
PHASE-I
32 LAYOUT PLAN OF WATER TREATMENT PLANT FOR AMARATAVI CAPITAL CITY – PHASE-I AG-1957-DDR-AM-WS-WTP-LP-001
33 PROCESS FLOW DIAGRAM OF WATER TREATMENT PLANT FOR AMARAVATI CAPITAL CITY AG-1957-DDR-AM-WS-WTP-SLD-001
34 GAD OF CLEAR WATER PUMPHOUSE AT WTP OF AMARAVATI CAPITAL CITY AG-1957-DDR-AM-WS-CW-GAD-001
35 GAD OF SUGR CUM PUMP HOUSE AT WDC OF AMARAVATI CAPITAL CITY AG-1957-DDR-AM-WS-SUGR-GAD-001
36 TYPICAL CAMPUS LAYOUT OF WDC WITH CUSHION TANK AG-1957-DDR-AM-WS-WDC-CL-001
37 TYPICAL CAMPUS LAYOUT OF WDC WITH SUGR CUM PUMP HOUSE AG-1957-DDR-AM-WS-WDC-CL-002
SCADA DRAWINGS
38 SYSTEM ARCHITECTURE DRAWING OF PROPOSED WATER SUPPLY SYSTEM AG-1957-DDR-AM-WS-SD-SCA-001
39 WDC INSTALATION DRAWING FOR CUSHION TANK LOCATION AG-1957-DDR-AM-WS-SD-SCA-002
40 TYPICAL CONFIGURATION DRAWING OF ISOLATION VALVE AG-1957-DDR-AM-WS-SD-SCA-003
41 OVER ALL P & ID OF PROPOSED WATER SUPPLY SYSTEM AG-1957-DDR-AM-WS-SD-SCA-004
42 TYPICAL P & ID OF RAW WATER PUMPING MACHINERY AT INTAKE WELL CUM PUMP HOUSE AG-1957-DDR-AM-WS-SD-SCA-005

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PACKAGE -XV (E3-SEED ACCESS ROAD)

S.NO. DESCRIPTION DWG NO.
43 TYPICAL P & ID OF CLEAR WATER PUMPING MACHINERY AT WTP AG-1957-DDR-AM-WS-SD-SCA-006
44 TYPICAL LAYOUT OF COMMAND CONTROL CENTER (C3) AT WTP AG-1957-DDR-AM-WS-SD-SCA-007
E & M DRAWINGS
45 SCHEMATIC DRAWING OF INDOOR SUB STATION AT INTAKE WELL AG-1957-DDR-AM-WS-ELE-SLD-001
46 ELECTRICAL SINGLE LINE DIAGRAM OF PROPOSED PUMP HOUSE AT INTAKEWELL AG-1957-DDR-AM-WS-ELE-SLD-002
47 SCHEMATIC DRAWING OF INDOOR SUB STATION AT WTP PUMPING STATION AG-1957-DDR-AM-WS-ELE-SLD-003
48 ELECTRICAL SINGLE LINE DIAGRAM OF PROPOSED PUMP HOUSE AT WTP AG-1957-DDR-AM-WS-ELE-SLD-004
49 TYPICAL ELECTRICAL SINGLE LINE DIAGRAM OF PROPOSED PUMP HOUSE AT WDC (SUGR cum PUMP AG-1957-DDR-AM-WS-ELE-SLD-005
HOUSE)
50 TYPICAL ELECTRICAL SINGLE LINE DIAGRAM OF ISOLATION VALVE AG-1957-DDR-AM-WS-ELE-SLD-006
STANDARD DRAWINGS
51 TYPICAL DETAILS OF PIPE TRENCH EXCAVATION AG-1957-DDR-AM-UT-SD-001
52 TYPICAL DETAILS OF UTILITY CROSSINGS FOR WATER SUPPLY AG-1957-DDR-AM-UT-SD-002
53 TYPICAL DETAILS OF UTILITY CROSSINGS FOR REUSE AG-1957-DDR-AM-UT-SD-003
54 TYPICAL DETAILS OF UTILITY CROSSINGS FOR WASTE WATER AG-1957-DDR-AM-UT-SD-004
55 TYPICAL DETAILS OF RCC VALVE CHAMBERS FOR ISOLATION VALVES AG-1957-DDR-AM-WS-ST-ISV-001
56 GENERAL ARRANGEMENT OF SCOUR VALVE INSTALLATION AG-1957-DDR-AM-WS-ST-SCV-001 OF 002
57 TYPICAL DETAILS OF RCC VALVE CHAMBERS FOR SCOUR VALVE ARRANGEMENT AG-1957-DDR-AM-WS-ST-SCV-002 OF 002
58 TYPICAL DETAILS OF SEWER PIPE BEDDING AG-1957-DDR-AM-WW-SD-PB-001
59 TYPICAL DETAILS OF RCC SEWER MANHOLE (TYPE-A) AG-1957-DDR-AM-WW-SD-MH-002 (001 OF 005)

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PACKAGE -XV (E3-SEED ACCESS ROAD)

S.NO. DESCRIPTION DWG NO.
60 TYPICAL DETAILS OF RCC SEWER MANHOLE (TYPE-B) AG-1957-DDR-AM-WW-SD-MH-002 (002 OF 005)
61 TYPICAL DETAILS OF RCC SEWER MANHOLE (TYPE-C) AG-1957-DDR-AM-WW-SD-MH-002 (003 OF 005)
62 TYPICAL DETAILS OF RCC SEWER MANHOLE (TYPE-D) AG-1957-DDR-AM-WW-SD-MH-002 (004 OF 005)
63 TYPICAL DETAILS OF RCC SEWER MANHOLE (TYPE-E) AG-1957-DDR-AM-WW-SD-MH-002 (005 OF 005)
64 TYPICAL DETAILS SEWER DROP MANHOLE AG-1957-DDR-AM-WW-SD-DM-003
65 TYPICAL DETAILS OF UTILITY CROSSINGS AND PIPE BEDDING FOR POWER AG-1957-DDR-AM-PW-UT-SD-PB-001
66 TYPICAL DETAILS OF MV & LV HDPE CONDUITS AG-1957-DDR-AM-PW-ST-CD-001 OF 005
67 TYPICAL DETAILS OF MV & LV HDPE CONDUITS AG-1957-DDR-AM-PW-ST-CD-002 OF 005
68 TYPICAL DETAILS OF MV & LV HDPE CONDUITS AG-1957-DDR-AM-PW-ST-CD-003 OF 005
69 TYPICAL DETAILS OF MV & LV HDPE CONDUITS AG-1957-DDR-AM-PW-ST-CD-004 OF 005
70 TYPICAL DETAILS OF MV & LV HDPE CONDUITS AG-1957-DDR-AM-PW-ST-CD-005 OF 005
71 TYPICAL MANHOLE DRAWINGS FOR POWER 33KV HDPE CONDUITS COMING IN JUNCTION & ALONG THE AG-1957-DDR-AM-PW-SD-MH-001
ROAD
72 TYPICAL MANHOLE DRAWINGS FOR POWER 33KV HDPE CONDUITS COMING IN JUNCTION & ALONG THE AG-1957-DDR-AM-PW-SD-MH-002
ROAD
73 TYPICAL MANHOLE DRAWINGS FOR POWER 33KV HDPE CONDUITS COMING IN JUNCTION & ALONG THE AG-1957-DDR-AM-PW-SD-MH-003
ROAD
74 TYPICAL MANHOLE DRAWINGS FOR POWER 33KV HDPE CONDUITS COMING IN MEDIAN AG-1957-DDR-AM-PW-SD-MH-004
75 TYPICAL MANHOLE DRAWINGS FOR POWER 33KV HDPE CONDUITS COMING IN MEDIAN AG-1957-DDR-AM-PW-SD-MH-005
76 TYPICAL MANHOLE DRAWINGS FOR POWER 33KV HDPE CONDUITS COMING IN MEDIAN AG-1957-DDR-AM-PW-SD-MH-006
77 TYPICAL MANHOLE DRAWINGS FOR POWER 33KV HDPE CONDUITS COMING IN MEDIAN AG-1957-DDR-AM-PW-SD-MH-007
78 TYPICAL MANHOLE DRAWINGS FOR POWER 33KV HDPE CONDUITS COMING IN MEDIAN AG-1957-DDR-AM-PW-SD-MH-008

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PACKAGE -XV (E3-SEED ACCESS ROAD)

S.NO. DESCRIPTION DWG NO.
79 TYPICAL MANHOLE DRAWINGS FOR POWER 33KV HDPE CONDUITS COMING IN MEDIAN AG-1957-DDR-AM-PW-SD-MH-009
80 TYPICAL MANHOLE DRAWINGS FOR POWER 33KV HDPE CONDUITS COMING IN MEDIAN AG-1957-DDR-AM-PW-SD-MH-010
81 TYPICAL DETAILS OF UTILITY CROSSINGS AND PIPE BEDDING FOR ICT AG-1957-DDR-AM-ICT-UT-SD-PB-001
82 TYPICAL DETAIS OF ICT HDPE CONDUITS FOR 50 & 60M ROW AG-1957-DDR-AM-ICT-SD-CS-001 OF 002
83 TYPICAL DETAIS OF ICT HDPE CONDUITS FOR 50 & 60M ROW AG-1957-DDR-AM-ICT-SD-CS-002 OF 002
84 TYPICAL MANHOLE DRAWINGS FOR ICT AG-1957-DDR-AM-ICT-SD-MH-001 OF 003
85 TYPICAL MANHOLE DRAWINGS FOR ICT AG-1957-DDR-AM-ICT-SD-MH-002 OF 003
86 TYPICAL MANHOLE DRAWINGS FOR ICT AG-1957-DDR-AM-ICT-SD-MH-003 OF 003
87 TYPICAL HANDHOLE DRAWINGS FOR ICT AG-1957-DDR-AM-ICT-SD-HH-001
88 TYPICAL DETAILS OF UTILITY CROSSINGS AND PIPE BEDDING FOR GAS AG-1957-DDR-AM-GAS-UT-SD-PB-001
89 TYPICAL SECTION OF STORM WATER DRAIN AG-1957-SWD-STR-GAD-001
90 TYPICAL AARANGEMENT OF INLET CHAMBER/CATCH PITS AG-1957-SWD-STR-IC-001
91 TYPICAL AARANGEMENT OF ACCESS MANHOLES AG-1957-SWD-STR-AMC-001
92 TYPICAL AARANGEMENT OF SLIT PIT AG-1957-SWD-STR-SP-001
93 TYPICAL AARANGEMENT OF OUTFALL STRUCTURE AG-1957-SWD-STR-OF-001
94 GENERAL ARRANGEMENT DRAWING FOR PIPE CARRYING BRIDGE 1957-CRDA-ADC-STR-PCB-001 TO 002
OTHER DRAWINGS
95 MAP SHOWING PHASE WISE BATTERY LIMIT FOR AMARAVATI CAPITAL CITY AG-1957-DDR-AM-UT-BL-GL-001
96 PROPOSED VALVE LOCATIONS OF WATER SUPPLY TRUNK NETWORK FOR AMARAVATI CAPITAL CITY AG-1957-DDR-AM-WS-VL-GL-001

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PACKAGE -XV (E3-SEED ACCESS ROAD)

S.NO. DESCRIPTION DWG NO.
97 PROPOSED POWER MANHOLE LOCATIONS OF SEED ACCESS ROAD-E3 FOR AMARAVATI CAPITAL CITY AG-1957-DDR-AM-PW-MH-GL-001
98 PROPOSED ICT MANHOLE LOCATIONS OF SEED ACCESS ROAD-E3 FOR AMARAVATI CAPITAL CITY AG-1957-DDR-AM-ICT-MH-GL-001
99 DETAILS OF UTILITY CROSSING CANALS THROUGH UTILITY DUCTS IN BRIDGE @ Km 3+979 - E3 ROAD AG-1957-DDR-AM-UT-E3-MJB-001
100 DETAILS OF UTILITY CROSSING CANALS THROUGH UTILITY DUCTS IN BRIDGE @ Km 8+740 - E3 ROAD AG-1957-DDR-AM-UT-E3-MJB-002
101 TYPICAL STREET LIGHTING ARRANGEMENT IN SEED ACCESS ROAD-E3 AG-1957-DDR-AM-UT-E3-SL-001

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Schedule - E Maintenance Requirements

1.0 Maintenance Requirements

1.1 The Contractor shall maintain the Project Works for a period of [10 years] as
per Schedule-B and Schedule-D commencing from the date of the completion.
However, contractor to note that the maintenance for Water supply system
including head works (Intake well, Raw water pumping main, Water treatment
plant, transmission and distribution supply lines, Cushion tanks and Semi
underground reservoirs, Integration with entire water supply and other
Ancillary works to WDC’s ) shall commence only after the commissioning of
this network integrating with total supply network the payment for the
maintained of these networks shall commence from the year on which the
maintenance starts in accordance with the price quoted in the price break up.
For the performance of its Maintenance obligation, shall be paid on Quarterly
basis not exceeding the O&M amount set forth in the Price Bid.

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Schedule F – Applicable Permits

Contents

Applicable Permits.........................................................................................................

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Applicable Permits

1.1 The Contractor shall obtain, as required under the Applicable Laws, the following
Applicable Permits and any other permits defined in the Schedule-D:
(a) Permission of the State Government for extraction of boulders from quarry;

(b) Permission of Pollution Control Board for installation of crushers;

(c) License for use of explosives;

(d) Permission of the State Government for Drawing water from river/reservoir;

(e) License from inspector of factories or other competent authority for setting

up batching plant;

(f) Clearance of Pollution Control Board for setting up batching plant;

(g) Clearance of Pollution Control Board for setting up asphalt plant;

(h) Permission of State Government for borrow earth; and

(i) Any other permits, clearances or approvals required under Applicable Laws.

(j) Contractor has to coordinate with different govt. officials of all type of clear-

ances/permissions as per the requirement of the project.

1.2 Applicable permits, as required, relating to environmental protection and conserva-

tion shall have been procured by the Authority i n accordance with the provisions
of this Agreement.

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Schedule G – Form of Bank Guarantee

(See Clause 7.1.1, 7.5.3 and 19.2)

Contents

Annex-I – Performance Security

Annex-II – Form for Guarantee for Withdrawal of Retention Money

Annex-III – Form for Guarantee for Advance Payment

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Annex-I
(See Clause 7.1.1)
Performance Security

…………………
Authority………
Vijayawada.

WHEREAS:

(A) _______________________________ [name and address of contractor] (“herein-

after called as Contractor”) and [name and address of the Authority ], (“the
Authority ”) have entered into an Agreement (the “Agreement”) for “ Survey, Inves-
tigation, Design, Construction, Testing, Commissioning of smart infrastructure works
of Additional lanes of Roads, Storm water Drains, Culverts, minor/major Bridges ,Wa-
ter Supply including Headworks (Intake well, Raw water pumping main, Water treat-
ment Plant, Cushion tanks , semi underground reservoirs, Integration with entire water
supply and other Ancillary works), Sewerage Network, Power & ICT conduits, RCC
duct for Power cables, Reuse water network ,Gas lines crossings, Cycle track, Street
furniture and Avenue Plantation & 10 years O&M for Water supply including Head-
works for Road E3 on EPC basis under Package-XV in Amaravati, the new Capital City
of Andhra Pradesh state, India.

(B) The Agreement requires the Contractor to furnish a Performance Security for due and
faithful performance of its obligations, under and in accordance with the Agreement,
during the Construction Period and Defects Liability Period (as defined in the Agree-
ment) in a sum of Rs. …. Crore (Rupees …. Crore) (the “Guarantee Amount”).

(C) We, ……………...through our branch at …………………………. (the “Bank”) have

agreed to furnish this Bank guarantee (hereinafter called the “Guarantee”) by way of
Performance Security.

NOW, THEREFORE, the Bank hereby, unconditionally and irrevocably, guarantees and
affirms as follows:

1. The Bank hereby unconditionally and irrevocably guarantees the due and faithful perfor-
mance of the Contractor’s obligations during and under and in accordance with the
Agreement, and agrees and undertakes to pay to the Authority, upon its mere first written
demand, and without any demur, reservation, recourse, contest or protest, and without any
reference to the Contractor, such sum or sums up to an aggregate sum of the guarantee
amount as the Authority shall claim, without the Authority being required to prove or to
show grounds or reasons for its demand and/or for the sum specified therein.
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2. A letter from the Authority, under the hand of an officer not below the rank of
[…………….of Authority ], that the Contractor has committed default in the due and
faithful performance of all or any of its obligations under and in accordance with the
Agreement shall be conclusive, final and binding on the Bank. The Bank further agrees
that the Authority shall be the sole judge as to whether the Contractor is in default in due
and faithful performance of its obligations during and under the Agreement and its deci-
sion that the Contractor is in default shall be final, and binding on the Bank,
notwithstanding any difference between the Authority and the Contractor, or any Dispute
between them pending before any court, tribunal, arbitrators or any other authority
or body, or by the discharge of the Contractor for any reason whatsoever.

3. In order to give effect to this Guarantee, the Authority shall be entitled to act as if the
Bank were the principal debtor and any change in the constitution of the Contractor
and/or the Bank, whether by their absorption with any other body or corporation or
otherwise, shall not in any way or manner affect the liability or obligation of the Bank
under this Guarantee.

4. It shall not be necessary, and the Bank hereby waives any necessity, for the Authority to
proceed against the Contractor before presenting to the Bank its demand under this Guar-
antee.

5. The Authority shall have the liberty, without affecting in any manner the liability of
the Bank under this Guarantee, to vary at any time, the terms and conditions of the
Agreement or to extend the time or period for the compliance with, fulfillment and/or
performance of all or any of the obligations of the Contractor contained in the Agreement
or to postpone for any time, and from time to time, any of the rights and powers
exercisable by the Authority against the Contractor, and either to enforce or forbear from
enforcing any of the terms and conditions contained in the Agreement and/or the securi-
ties available to the Authority , and the Bank shall not be released from its liability and
obligation under these presents by any exercise by the Authority of the liberty with
reference to the matters aforesaid or by reason of time being given to the Contractor or
any other forbearance, indulgence, act or omission on the part of the Authority or
of any other matter or thing whatsoever which under any law relating to sureties and
guarantors would but for this provision have the effect of releasing the Bank from its
liability and obligation under this Guarantee and the Bank hereby waives all of its rights
under any such law.

6. This Guarantee is in addition to and not in substitution of any other guarantee or security
now or which may hereafter be held by the Authority in respect of or relating to the
Agreement or for the fulfillment, compliance and/or performance of all or any of the
obligations of the Contractor under the Agreement.

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7. Notwithstanding anything contained herein before, the liability of the Bank under this
Guarantee is restricted to the Guarantee amount and this Guarantee will remain in force
for the period specified in paragraph 8 below and unless a demand or claim in writing is
made by the Authority on the Bank under this Guarantee all rights of the Authority
under this Guarantee shall be forfeited and the Bank shall be relieved from its liabilities
hereunder.

8. The Performance Security shall cease to be in force and effect 90 (ninety) days after the
end of the Defects Liability Period as set forth in Clauses 7.1

9. The Bank undertakes not to revoke this Guarantee during its currency, except with
the previous express consent of the Authority in writing, and declares and warrants that
it has the power to issue this Guarantee and the undersigned has full powers to do so on
behalf of the Bank.

10. Any notice by way of request, demand or otherwise hereunder may be sent by post
addressed to the Bank at its above referred branch, which shall be deemed to have been
duly authorized to receive such notice and to effect payment thereof forthwith, and if sent
by post it shall be deemed to have been given at the time when it ought to have been
delivered in due course of post and in proving such notice, when given by post, it shall
be sufficient to prove that the envelope containing the notice was posted and a certificate
signed by an officer of the Authority that the envelope was so posted shall be
conclusive.

11. This Guarantee shall come into force with immediate effect and shall remain in force and
effect for up to the end **** month in the year ***** or until it is released earlier by the
Authority pursuant to the provisions of the Agreement.

Signed and Sealed this……. Day of ………. 20………….. at………….

SIGNED, SEALED AND DELIVERED

For and on behalf of the bank

By:(Signature)

Name Designation:

Code Number:

Address NOTES:

(i) The Bank guarantee should contain the name, designation and code number of the
officer(s) signing the guarantee.

1052
Amaravati Development Corporation Limited

(ii) The address, telephone number and other details of the head office of the Bank as well
as of issuing branch should be mentioned on the covering letter of issuing branch.

1053
Amaravati Development Corporation Limited

Annex-II
(See Clause 7.5.3)
Form for Guarantee for Withdrawal of Retention

……………..,
……………...Authority,
Vijayawada

WHEREAS:

[Name and address of contractor] (hereinafter called “the Contractor”) has executed
an Agreement (hereinafter called the “Agreement”) with the [name and address of the
Authority ], (hereinafter called “the Authority ”) for the “ Survey, Investigation, De-
sign, Construction, Testing, Commissioning of smart infrastructure works of Additional
lanes of Roads, Storm water Drains, Culverts, minor/major Bridges ,Water Supply in-
cluding Headworks (Intake well, Raw water pumping main, Water treatment Plant,
Cushion tanks , semi underground reservoirs, Integration with entire water supply and
other Ancillary works), Sewerage Network, Power & ICT conduits, RCC duct for
Power cables, Reuse water network ,Gas lines crossings, Cycle track, Street furniture
and Avenue Plantation & 10 years O&M for Water supply including Headworks for
Road E3 on EPC basis under Package-XV in Amaravati, the new Capital City of Andhra
Pradesh state, India.

A. In accordance with the Clause 7.5.3 of the Agreement, whenever the amount of the
retention money (hereinafter called “Retention Money”) held by the Authority exceeds
1% (one per cent) of the Contract Price, the Contractor may, at its option, withdraw
the Retention Money after furnishing to the Authority a Bank guarantee for an amount
equal to the proposed withdrawal.

B. We, ……………..through our branch at …………………………. (the “Bank”) have agreed

to furnish this Bank guarantee (hereinafter called the “Guarantee”) for the amount of Rs.
…………. (………. in words) (the “Guarantee Amount”).

NOW, THEREFORE, the Bank hereby, unconditionally and irrevocably, guarantees and
affirms as follows:

1. The Bank hereby unconditionally and irrevocably undertakes to pay to the Authority,
upon its mere first written demand, and without any demur, reservation, recourse, contest
or protest, and without any reference to the Contractor, such sum or sums up to an ag-
gregate sum of the Guarantee Amount as the Authority shall claim, without the Authority
being required to prove or to show grounds or reasons for its demand and/or for the sum
specified therein.

1054
Amaravati Development Corporation Limited

2. A letter from the Authority, under the hand of an officer not below the rank of
[………………….of Authority ], that the Contractor has committed default in the due
and faithful performance of all or any of its obligations under and in accordance with the
Agreement shall be conclusive, final and binding on the Bank. The Bank further agrees
that the Authority shall be the sole judge as to whether the Contractor is in default in due
and faithful performance of its obligations during and under the Agreement and its
decision that the Contractor is in default shall be final, and binding on the Bank, notwith-
standing any difference between the Authority and the Contractor, or any Dispute be-
tween them pending before any court, tribunal, arbitrators or any other authority or body,
or by the discharge of the Contractor for any reason whatsoever.

3. In order to give effect to this Guarantee, the Authority shall be entitled to act as if the
Bank were the principal debtor and any change in the constitution of the Contractor
and/or the Bank, whether by their absorption with any other body or corporation or
otherwise, shall not in any way or manner affect the liability or obligation of the Bank
under this Guarantee.

4. It shall not be necessary, and the Bank hereby waives any necessity, for the Authority to
proceed against the Contractor before presenting to the Bank its demand under this Guar-
antee.

5. The Authority shall have the liberty, without affecting in any manner the liability of
the Bank under this Guarantee, to vary at any time, the terms and conditions of the
Retention Money and any of the rights and powers exercisable by the Authority
against the Contractor, and either to enforce or forbear from enforcing any of the terms
and conditions contained in the Agreement and/or the securities available to the Authority
, and the Bank shall not be released from its liability and obligation under these presents
by any exercise by the Authority of the liberty with reference to the matters aforesaid
or by reason of time being given to the Contractor or any other forbearance, indulgence,
act or omission on the part of the Authority or of any other matter or thing whatsoever
which under any law relating to sureties and guarantors would but for this provision have
the effect of releasing the Bank from its liability and obligation under this Guarantee and
the Bank hereby waives all of its rights under any such law.

6. This Guarantee is in addition to and not in substitution of any other guarantee or security
now or which may hereafter be held by the Authority in respect of or relating to the
Retention Money.

7. Notwithstanding anything contained hereinbefore, the liability of the Bank under this
Guarantee is restricted to the Guarantee amount and this Guarantee will remain in force
for the period specified in paragraph 8 below and unless a demand or claim in writing is
made by the Authority on the Bank under this Guarantee all rights of the Authority

1055
Amaravati Development Corporation Limited

under this Guarantee shall be forfeited and the Bank shall be relieved from its liabilities
hereunder.

8. The guarantee shall cease to be in force and effect 90 (ninety) days after the end of
then Defects Liability Period specified in Clauses 17.1 of the Agreement.

9. The Bank undertakes not to revoke this Guarantee during its currency, except with
the previous express consent of the Authority in writing, and declares and warrants that
it has the power to issue this Guarantee and the undersigned has full powers to do so on
behalf of the Bank.

10. Any notice by way of request, demand or otherwise hereunder may be sent by post
addressed to the Bank at its above referred branch, which shall be deemed to have been
duly authorized to receive such notice and to effect payment thereof forthwith, and if sent
by post it shall be deemed to have been given at the time when it ought to have been
delivered in due course of post and in proving such notice, when given by post, it shall
be sufficient to prove that the envelope containing the notice was posted and a certificate
signed by an officer of the Authority that the envelope was so posted shall be
conclusive.

11. This Guarantee shall come into force with immediate effect and shall remain in force and
effect up to the end **** month in the year ***** or until it is released earlier by the
Authority pursuant to the provisions of the Agreement.

Signed and Sealed this……. Day of ………. 20…………. at………….

SIGNED,SEALED AND DELIVERED

For and on behalf of the bank

By:(Signature)

Name Designation:

Code Number:

Address NOTES:

(i) The Ba n k guarantee should contain the name, designation and code number of the
officer(s) signing the guarantee.

1056
Amaravati Development Corporation Limited

(ii) The address, telephone number and other details of the head office of the Bank as
well as of issuing branch should be mentioned on the covering letter of issuing
branch.

1057
 Amaravati Development Corporation Limited

Annex-III
(See Clause 19.2)
Form for Guarantee for Advance Payment

………………………………..,
………………. Authority,
Vijayawada

WHEREAS:
 [name and address of contractor] (hereinafter called “the Contractor”) has executed an
Agreement (hereinafter called the “Agreement”) with the [name and address of the
Authority ], (hereinafter called “the Authority ”) for the Survey, Investigation, Design,
Construction, Testing, Commissioning of smart infrastructure works of Additional lanes
of Roads, Storm water Drains, Culverts, minor/major Bridges ,Water Supply including
Headworks (Intake well, Raw water pumping main, Water treatment Plant, Cushion
tanks , semi underground reservoirs, Integration with entire water supply and other
Ancillary works), Sewerage Network, Power & ICT conduits, RCC duct for Power
cables, Reuse water network ,Gas lines crossings, Cycle track, Street furniture and
Avenue Plantation & 10 years O&M for Water supply including Headworks for Road
E3 on EPC basis under Package-XV in Amaravati, the new Capital City of Andhra
Pradesh state, India.

i. Engineering Procurement and Construction (the “EPC”) basis, subject to and in accord-
ance with the provisions of the Agreement.
ii. in accordance with the Clause 19.2 of the Agreement the Authority shall make to the
Contractor an interest bearing Advance Payment (hereinafter called “Advance
Payment”) equal to 10% (ten per cent) of the contract price for mobilization expenses
and acquisition of equipment; and that the Advance Payment shall be made in three
installments subject to the Contractor furnishing an irrevocable and unconditional guar-
antee by a scheduled Bank for an amount equal to the 110% amount of each install-
ment to remain effective till the complete and full repayment of the installment of the
Advance Payment as security for compliance with its obligations in accordance with
the Agreement; and the amount of (first/second/third) installment of the Advance Pay-
ment is Rs. **** cr. (Rupees ***** crore) (the “Guarantee Amount”).

iii. We, ……………...through our branch at …………………………. (the “Bank”) have

agreed to furnish this Bank guarantee (hereinafter called the “Guarantee”) for the Guar-
antee Amount.

NOW, THEREFORE, the Bank hereby, unconditionally and irrevocably, guarantees

and affirms as follows:

1058
Amaravati Development Corporation Limited

1. The Bank hereby unconditionally and irrevocably guarantees the due and faithful
repayment on time of the aforesaid installment of the Advance Payment under and in
accordance with the Agreement, and agrees and undertakes to pay to the Authority ,
upon its mere first written demand, and without any demur, reservation, recourse, contest
or protest, and without any reference to the Contractor, such sum or sums up to an ag-
gregate sum of the guarantee amount as the Authority shall claim, without the Authority
being required to prove or to show grounds or reasons for its demand and/or for the sum
specified therein.

2. A letter from the Authority, under the hand of an officer not below the rank of
[……………………of Authority], that the Contractor has committed default in the
due and faithful performance of all or any of its obligations for the repayment of the
installment of the Advance Payment under and in accordance with the Agreement shall
be conclusive, final and binding on the Bank. The Bank further agrees that the Authority
shall be the sole judge as to whether the Contractor is in default in due and faithful per-
formance of its obligations during and under the Agreement and its decision that the
Contractor is in default shall be final, and binding on the Bank, notwithstanding any
difference between the Authority and the Contractor, or any Dispute between them
pending before any court, tribunal, arbitrators or any other authority or body, or by the
discharge of the Contractor for any reason whatsoever.

3. In order to give effect to this Guarantee, the Authority shall be entitled to act as if the
Bank were the principal debtor and any change in the constitution of the Contractor
and/or the Bank, whether by their absorption with any other body or corporation or
otherwise, shall not in any way or manner affect the liability or obligation of the Bank
under this Guarantee.

4. It shall not be necessary, and the Bank hereby waives any necessity, for the Authority to
proceed against the Contractor before presenting to the Bank its demand under this Guar-
antee.

5. The Authority shall have the liberty, without affecting in any manner the liability of
the Bank under this Guarantee, to vary at any time, the terms and conditions of the
Advance Payment or to extend the time or period of its repayment or to postpone for any
time, and from time to time, any of the rights and powers exercisable by the Authority
against the Contractor, and either to enforce or forbear from enforcing any of the terms
and conditions contained in the Agreement and/or the securities available to the Authority
, and the Bank shall not be released from its liability and obligation under these presents
by any exercise by the Authority of the liberty with reference to the matters aforesaid
or by reason of time being given to the Contractor or any other forbearance, indulgence,
act or omission on the part of the Authority or of any other matter or thing whatsoever
which under any law relating to sureties and guarantors would but for this provision have

1059
Amaravati Development Corporation Limited

the effect of releasing the Bank from its liability and obligation under this Guarantee and
the Bank hereby waives all of its rights under any such law.

6. This Guarantee is in addition to and not in substitution of any other guarantee or security
now or which may hereafter be held by the Authority in respect of or relating to the
Advance Payment.
7. Notwithstanding anything contained hereinbefore, the liability of the Bank under this
Guarantee is restricted to the Guarantee amount and this Guarantee will remain in force
for the period specified in paragraph 8 below and unless a demand or claim in writing is
made by the Authority on the Bank under this Guarantee all rights of the Authority under
this Guarantee shall be forfeited and the Bank shall be relieved from its liabilities here-
under.
8. The guarantee shall cease to be in force and effect 90 (ninety) days after the end of
the one year from the date of payment of the installment of the Advance Payment, as set
forth in Clause 19.2 of the Agreement.
9. The Bank undertakes not to revoke this Guarantee during its currency, except with
the previous express consent of the Authority in writing, and declares and warrants that
it has the power to issue this Guarantee and the undersigned has full powers to do so on
behalf of the Bank.
10. Any notice by way of request, demand or otherwise hereunder may be sent by post
addressed to the Bank at its above referred branch, which shall be deemed to have been
duly authorized to receive such notice and to effect payment thereof forthwith, and if sent
by post it shall be deemed to have been given at the time when it ought to have been
delivered in due course of post and in proving such notice, when given by post, it shall
be sufficient to prove that the envelope containing the notice was posted and a certificate
signed by an officer of the Authority that the envelope was so posted shall be
conclusive.
11. This Guarantee shall come into force with immediate effect and shall remain in force and
effect for up to the end **** month in the year ***** or until it is released earlier by the
Authority pursuant to the provisions of the Agreement.

Signed and Sealed this……. Day of ………. 20………….. at………….

SIGNED, SEALED AND DELIVERED

For and on behalf of the bank

By:(Signature)

Name Designation:

Code Number:

1060
Amaravati Development Corporation Limited

Address NOTES:

(i) The Bank guarantee should contain the name, designation and code number of the
officer(s) signing the guarantee.

(ii) The address, telephone number and other details of the head office of the Bank as well as
of issuing branch should be mentioned on the covering letter of issuing branch.

1061
 Amaravati Development Corporation Limited

Schedule H (Contract Price Weightages)

(See Clause 10.1.4 and 19.3)

Contents

1.0 The Contract Price for this Agreement is Rs……………….

2.0 Proportions of the Contract Price for different stages of Construction of the
Road and Utilities/Services shall be as specified below;

Table 1
Weightage in
percentage Percentage
S No Item Stage for Payment
to the Con- weightage
tract Price
Investigation & Sur-
vey, Design, Ap-
proval of detailed
1 0.5%
engineering draw-
ings, Preparation of
BoQs.
(a) Earthworks upto Subgrade in Main
Carriageway (MCW), BRT
(b) Sub Base and Granular Base
Courses for MCW, BRT
(c) Bituminous works for MCW &
BRT
Road Works includ-
ing Main Carriage- (d) Cycle Track
way, BRT, Cycle (e) Side walk
Track, Footpath, (f) Junctions
2 Cross Drainage 11.31%
(g) Culverts
Structures, Junc-
tions etc., but ex- (h) Bridges
cluding Storm Wa- (i) Foundation
ter Drainage (ii) Substructure
(iii) Superstructure including
miscellaneous works
(i) Traffic signs, markings and appurte-
nances, Street Lighting, Plantation and
all road furniture’s & Facilities

Storm Water Drain- (a) Longitudinal Trunk Drains

3 8.29%
age (b) Median Drains of size 0.6m x 0.6m

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 Amaravati Development Corporation Limited

Table 1
Weightage in
percentage Percentage
S No Item Stage for Payment
to the Con- weightage
tract Price
(c) Collecting chambers of 0.6m x
0.6m
(d) Man Holes
(e) Miscellaneous

Intake well cum raw water pumping

station along with Electro-mechanical
items
Raw water raising main with surge pro-
tection system
Water Treatment Plant (190 MLD)
Semi Underground reservoir at WTP
with pump house
Electro-mechanical items &surge pro-
tection system at WTP
Clear water pumping mains (MS & DI-
K9) and additional pipelines for WTP
& WDC connectivity.

Potable Water with Ring main isolation system(TCMS)

4 65.87%
Head works 7 no. of Cushion tanks (ELSRs)
8 No. of SUGRs & pump houses along
with Electro-mechanical items
RMS, BMS for WDCs, SUGRs &
Cushion tanks & Electrical supply to
Isolation valve electrical actuators in
the entire network
WDC Ancillary Works
SCADA and Control system
Laying of the Trunk mains with DI K9
pipes with specials including excava-
tion, dewatering if required, filling, dis-
posal of the surplus earth and provision
for bedding or encasing if required
complete as per the approved drawing

1063
 Amaravati Development Corporation Limited

Table 1
Weightage in
percentage Percentage
S No Item Stage for Payment
to the Con- weightage
tract Price
Laying of the Trunk mains with MS
pipes with specials including excava-
tion, dewatering if required, filling, dis-
posal of the surplus earth and provision
for bedding or encasing if required
complete as per the approved drawing
Laying of the Distribution mains with
DI K7 pipes with specials including ex-
cavation, dewatering if required, fill-
ing, disposal of the surplus earth and
also provision for bedding or encasing
if required complete as per the ap-
proved drawing
All types of valves including valve ac-
tuators and valve chambers and Thrust
blocks.
Laying of the 40mm dia. lubricated
HDPE pipes along with specials com-
plete as per the approved drawing
along the Main Trunk
Miscellaneous

a) Laying of the Trunk lines (DI K7,

HDPE) with specials including excava-
tion, dewatering if required, filling, dis-
posal of the surplus earth and provision
for bedding or encasing if required
complete as per the approved drawing

b) Laying of the Distribution lines (DI

K7, HDPE) with specials including ex-
5 Recycled water cavation, dewatering if required, fill- 0.98%
ing, disposal of the surplus earth and
provision for bedding or encasing if re-
quired complete as per the approved
drawing

c) Laying of the MDPE pipes for tap-

ping from distribution with specials /
saddles, complete as per the approved
drawing

1064
 Amaravati Development Corporation Limited

Table 1
Weightage in
percentage Percentage
S No Item Stage for Payment
to the Con- weightage
tract Price
d) Laying of the laterals (Drip pipes) in
3 rows, in each green zone, complete as
per the approved drawing
e) All types of valves including valve
actuators and valve chambers and
Thrust blocks.
f) Miscellaneous

a) Laying of the pipelines (DWC

HDPE) including excavation, dewater-
ing if required, filling, disposal of the
surplus earth and provision for bedding
or encasing if required complete as per
the approved drawing

b) Laying of the pipelines (Inner HAC

lined DI K7 & K9) including excava-
tion, dewatering if required, filling, dis-
posal of the surplus earth and provision
for bedding or encasing if required
complete as per the approved drawing

c) Laying of the pipelines (RCC NP4)

including excavation, dewatering if re-
quired, filling, disposal of the surplus
6 Sewerage earth and provision for bedding or en- 3.89%
casing if required complete as per the
approved drawing
d) Laying of the pipelines (Inner HAC
lined DI K9) including excavation, de-
watering if required, filling, disposal of
the surplus earth and provision for bed-
ding or encasing if required complete
as per the approved drawing
e) Manholes including excavation, de-
watering if required, filling, disposal of
the surplus earth and provision for bed-
ding complete as per the approved
drawing

f) Miscellaneous

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 Amaravati Development Corporation Limited

Table 1
Weightage in
percentage Percentage
S No Item Stage for Payment
to the Con- weightage
tract Price

a) RCC Power duct of size 4.28m x

4.40m including excavation, dewater-
ing if required, filling, disposal of the
surplus earth including all accessories
complete as per drawing
b) RCC Power duct of size 4.28m x
4.0m including excavation, dewatering
if required, filling, disposal of the sur-
plus earth including all accessories
complete as per drawing
c) RCC Power duct of size 4.28m x
3.15m including excavation, dewater-
ing if required, filling, disposal of the
surplus earth including all accessories
complete as per drawing
d) RCC Power duct of size 3.40m x
3.15m including excavation, dewater-
ing if required, filling, disposal of the
7 Power surplus earth including all accessories 4.89%
complete as per drawing

e) RCC Power duct of size 2.50m x

2.80m including excavation, dewater-
ing if required, filling, disposal of the
surplus earth including all accessories
complete as per drawing

f) RCC Power duct of size 2.00m x

2.50m including excavation, dewater-
ing if required, filling, disposal of the
surplus earth including all accessories
complete as per drawing

g) RCC Power duct of size 1.50m x

2.50m including excavation, dewater-
ing if required, filling, disposal of the
surplus earth including all accessories
complete as per drawing

1066
 Amaravati Development Corporation Limited

Table 1
Weightage in
percentage Percentage
S No Item Stage for Payment
to the Con- weightage
tract Price
h) Laying of 225mm dia. HDPE Sili-
core Power ducts of given configura-
tion including excavation, dewatering
if required, filling, disposal of the sur-
plus earth, placing of spacers, warning
tapes, tiles including all complete as
per drawing
i) Laying of the RCC NP4 pipes at the
crossings including excavation, de-
watering if required, filling, disposal of
the surplus earth and provision for bed-
ding complete as per the approved
drawing
j) RCC Man holes including excava-
tion, dewatering if required, filling, dis-
posal of the surplus earth, cover includ-
ing all accessories complete as per
drawing
k) Miscellaneous

a) Laying of 7-way 40mm multi ducts

& 160mm HDPE pipes including exca-
vation, dewatering if required, filling,
disposal of the surplus earth, placing of
spacers, warning tapes, tiles including
all complete as per drawing
b) Laying of the RCC NP4 pipes at the
crossings including excavation, de-
watering if required, filling, disposal of
8 ICT (Pipe Conduits) 3.86%
the surplus earth and provision for bed-
ding complete as per the approved
drawing
c) Manholes including excavation, de-
watering if required, filling, disposal of
the surplus earth, cover including all
accessories complete as per drawing
d) Miscellaneous

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 Amaravati Development Corporation Limited

Table 1
Weightage in
percentage Percentage
S No Item Stage for Payment
to the Con- weightage
tract Price

a) Laying of the RCC NP4 pipes at the

crossings including excavation, de-
watering if required, filling, disposal of
9 Gas the surplus earth, closing the pipe ends 0.41%
with brick work and provision for bed-
ding complete as per the approved
drawing

Submission of Com-
pletion drawings (as
built drawings),
Preparation of
-
10 O&M Manuals,
Training the staff in
batches, Trial run &
Commissioning of
the Utilities

3.0 Procedure of Estimating the Value of Work Done

3.1 Road Works (MCW & BRT), Cycle Track, Footpath, Cross Drainage Structures,
Junctions etc., but excluding Storm Water Drainage.

Procedure for estimating the value of Road work done shall be as follows in Table 2

Table 2: Road Works

% of
Stage for Payment Payment procedure
weightage
(a) Earthworks upto Subgrade in Main Car-
riageway (MCW), BRT
(b) Sub Base and granular base courses for
Unit of measurement is linear
MCW, BRT
length. Payment of each stage shall
be made on pro rata basis on com-
(c) Bituminous works for MCW & BRT 11.31%
pletion of a stage in a length of not
less than Ten percent of the total
(d) Cycle Track: Including Earthworks, Sub- length.
grade, Sub Base, Base & Premix Carpet
(e) Side walk: Including Earthworks, GSB,
Concrete bed & Tiles

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Amaravati Development Corporation Limited

Table 2: Road Works

% of
Stage for Payment Payment procedure
weightage
Cost of Two Completed Junctions
shall be determined on pro rata
(f) Junctions: Including Earthworks, Subgrade, with respect to the total number of
Sub Base, Base & Bituminous Works Junctions. Payment shall be made
on the completion of Two Junc-
tions.
Cost of Two Completed Culvert
shall be determined on pro rata
(g) Culverts: Pipe Culverts & Box Culverts with respect to the total number of
Culverts. Payment shall be made
on the completion of Two Culverts.
(h) Bridges

(i) Foundation: On completion of the founda-

tion work including foundations for wing and
return walls Cost of each Bridge shall be deter-
mined on pro rata basis with re-
spect to the total linear length (m)
(ii) Substructure: On completion of abut-
of the Bridges. Payment shall be
ments, piers up to the abutment/pier cap, wing
made on completion of each stage
walls, return walls, guide bunds, if any.
of a Bridge as per the weightage
(iii) Superstructure: On completion of the su- given in this table.
per structure in all respects including hand
rails/crash barriers, tests on completion etc.,
complete in all respects.
Unit of measurement is linear
(i) Traffic signs, markings and appurtenances, length. Payment shall be made on
Street Lighting, Plantation, and all road furni- pro rata basis on completion of a
ture’s & Facilities stage in a length of not less than
Ten percent of the total length.

3.2 Storm Water Drainage

Procedure for estimating the value of Storm Water work done shall be as follows in Table 3;

Table 3: Storm Water Drainage

% of
Stage for Payment Payment procedure
weightage
(a) Longitudinal Trunk Drains - including Ex-
cavation, dewatering if required, refilling with Unit of measurement is linear length.
Payment shall be made on pro rata
Sand, disposal of surplus material, PCC bed-
ding, Weep holes etc. complete as per the ap- 8.29% basis on completion of a stage in a
proved drawing length of not less than Ten percent of
the total length.
(b) Median Drains of size 0.6m x 0.6m

1069
Amaravati Development Corporation Limited

Table 3: Storm Water Drainage

% of
Stage for Payment Payment procedure
weightage
(c) Collecting Chambers: Laying of PVC
pipes, Kerb inlets, Collecting chambers of
0.6m x 0.6m under grated inlets
(d) Man Holes including Covers

3.3 EMP
Procedure for estimating the value of EMP work done shall be as follows in Table 4;

Table 4: EMP
% of
Stage for Payment Payment procedure
weightage
Unit of measurement is linear
length. Payment shall be made on
Environmental Protection measures as per En-
pro rata basis on completion of a
vironmental Mitigation Plan
stage in a length of not less than
Twenty percent of the total length.

3.4 Potable Water with Headworks

Procedure for estimating the value of Potable Water work done shall be as follows in Table 5;

Table 5: Potable Water with Headworks

% of
Stage for Payment Payment procedure
weightage
Intake well cum raw water pumping station
4.07%
along with Electro-mechanical items
Raw water raising main with surge protection
0.78%
system
Water Treatment Plant (190 MLD) 19.14%
Semi Underground reservoir at WTP with
5.41%
Pump house
Electromechanical items & Surge protection
5.58%
system at WTP
Clear water pumping mains (MS & DI-K9) and
additional pipelines for WTP & WDC connec- 1.06%
tivity.
Ring main isolation system (TCMS) 0.43%

7 no. of Cushion tanks (ELSRs) 2.34%

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Table 5: Potable Water with Headworks

% of
Stage for Payment Payment procedure
weightage
8 No. of SUGRs & pump houses along with
3.01%
Electro-mechanical items
RMS, BMS for WDcs, SUGRs & Cushion
tanks & Electrical supply to Isolation valve 2.26%
electrical actuators in the entire network.
WDC Ancillary works 5.62%
SCADA and Control system 1.61%

Laying of the Trunk mains with DI K9 pipes Unit of measurement is linear length.
with specials including excavation, dewatering Payment shall be made on pro rata
if required, filling, disposal of the surplus earth basis on completion of a stage in a
and provision for bedding or encasing if re- length of not less than Ten percent of
quired complete as per the approved drawing the total length.

Laying of the Trunk mains with MS pipes with Unit of measurement is linear length.
specials including excavation, dewatering if Payment shall be made on pro rata
required, filling, disposal of the surplus earth basis on completion of a stage in a
and provision for bedding or encasing if re- length of not less than Five percent of
quired complete as per the approved drawing the total length.

Laying of the Distribution mains with DI K7

pipes with specials including excavation, de-
watering if required, filling, disposal of the sur- 14.54%
plus earth and provision for bedding or encas-
ing if required complete as per the approved
drawing
Unit of measurement is linear length.
Payment shall be made on pro rata
All types of valves including valve actuators basis on completion of a stage in a
and valve chambers and Thrust blocks. length of not less than Ten percent of
the total length.

Laying of the 40mm dia. lubricated HDPE

pipes along with specials complete as per the
approved drawing along the Main Trunk

Miscellaneous

3.5 Recycled Water

Procedure for estimating the value of Recycled Water work done shall be as follows in Table 6;

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Table 6: Recycled Water

% of
Stage for Payment Payment procedure
weightage
a) Laying of the Trunk lines (DI K7, HDPE)
with specials including excavation, dewatering
if required, filling, disposal of the surplus earth
and provision for bedding or encasing if re-
quired complete as per the approved drawing
b) Laying of the Distribution lines (DI K7, Unit of measurement is linear length.
HDPE) with specials including excavation, de- Payment shall be made on pro rata
watering if required, filling, disposal of the sur- basis on completion of a stage in a
plus earth and provision for bedding or encas- length of not less than Ten percent of
ing if required complete as per the approved the total length.
drawing

c) Laying of the MDPE pipes for tapping from

distribution with specials / saddles, complete 0.98%
as per the approved drawing

Unit of measurement is linear length.

d) Laying of the PVC laterals in 3 rows, in each Payment shall be made on pro rata
green zone, complete as per the approved basis on completion of a stage in a
drawing length of not less than Twenty per-
cent of the total length.
Unit of measurement is linear length.
Payment shall be made on pro rata
e) All types of valves including valve actuators
basis on completion of a stage in a
and valve chambers and Thrust blocks.
length of not less than Ten percent of
the total length.
f) Miscellaneous

3.6 Sewerage
Procedure for estimating the value of Sewerage work done shall be as follows in Table 7;

Table 7: Sewerage
% of
Stage for Payment Payment procedure
weightage
a) Laying of the pipelines (DWC) including Unit of measurement is linear length.
excavation, dewatering if required, filling, dis- Payment shall be made on pro rata ba-
posal of the surplus earth and provision for 3.89% sis on completion of a stage in a
bedding or encasing if required complete as per length of not less than Twenty percent
the approved drawing of the total length.

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Table 7: Sewerage
% of
Stage for Payment Payment procedure
weightage
b) Laying of the pipelines (RCC NP4) includ- Unit of measurement is linear length.
ing excavation, dewatering if required, filling, Payment shall be made on pro rata ba-
disposal of the surplus earth and provision for sis on completion of a stage in a
bedding or encasing if required complete as per length of not less than Ten percent of
the approved drawing the total length.
Cost of Five completed manholes
(c) Manholes including excavation, dewater-
shall be determined on pro rata with
ing if required, filling, disposal of the surplus
respect to the total number of Man-
earth and provision for bedding complete as
holes. Payment shall be made on the
per the approved drawing
completion of Five Manholes.

3.7 Power
Procedure for estimating the value of Power work done shall be as follows in Table 8;

Table 8: Power
% of
Stage for Payment Payment procedure
weightage
a) RCC Power duct of size 4.28m x 3.15m in-
cluding excavation, dewatering if required,
filling, disposal of the surplus earth including
all accessories complete as per drawing
Unit of measurement is linear length.
b) RCC Power duct of size 4.28m x 4.0m in-
Payment shall be made on pro rata ba-
cluding excavation, dewatering if required,
sis on completion of a stage in a length
filling, disposal of the surplus earth including
of not less than Five percent of the to-
all accessories complete as per drawing
tal length.
c) RCC Power duct of size 4.28m x 4.40m in-
cluding excavation, dewatering if required,
filling, disposal of the surplus earth including
all accessories complete as per drawing
d) Laying of 225mm dia HDPE Silicore Power
ducts of given configuration including excava- 4.89%
tion, dewatering if required, filling, disposal of
the surplus earth, placing of spacers, warning Unit of measurement is linear length.
tapes, tiles including all complete as per draw- Payment shall be made on pro rata ba-
ing sis on completion of a stage in a length
e) Laying of the RCC NP4 pipes at the cross- of not less than Ten percent of the total
ings including excavation, dewatering if re- length.
quired, filling, disposal of the surplus earth and
provision for bedding complete as per the ap-
proved drawing
f) RCC Man holes including excavation, de-
watering if required, filling, disposal of the sur- Cost of Five completed manholes
plus earth, cover including all accessories com- shall be determined on pro rata with
plete as per drawing
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Table 8: Power
% of
Stage for Payment Payment procedure
weightage
respect to the total number of Man-
holes. Payment shall be made on the
completion of Five Manholes.
g) Miscellaneous

3.8 ICT
Procedure for estimating the value of ICT work done shall be as follows in Table 9;

Table 9: ICT
% of
Stage for Payment Payment procedure
weightage
a) Laying of 7way 40mm multi ducts 160mm
HDPE pipes including excavation, dewatering
if required, filling, disposal of the surplus
earth, placing of spacers, warning tapes, tiles
including all complete as per drawing
b) Laying of 7way 40mm multi ducts & Unit of measurement is linear length.
160mm HDPE pipes including excavation, de- Payment shall be made on pro rata ba-
watering if required, filling, disposal of the sur- sis on completion of a stage in a length
plus earth, placing of spacers, warning tapes, of not less than Ten percent of the total
tiles including all complete as per drawing length.
c) Laying of the RCC NP4 pipes at the cross- 3.86%
ings including excavation, dewatering if re-
quired, filling, disposal of the surplus earth and
provision for bedding complete as per the ap-
proved drawing
Cost of Five completed manholes
d) Manholes including excavation, dewatering
shall be determined on pro rata with
if required, filling, disposal of the surplus
respect to the total number of Man-
earth, cover including all accessories complete
holes. Payment shall be made on the
as per drawing
completion of Five Manholes.
e) Miscellaneous

3.9 Gas
Procedure for estimating the value of Gas work done shall be as follows in Table 10;

Table 10: Gas

% of
Stage for Payment Payment procedure
weightage
a) Laying of the RCC NP4 pipes at the cross- Unit of measurement is linear length.
ings including excavation, dewatering if re- 0.41% Payment shall be made on pro rata basis
quired, filling, disposal of the surplus earth, on completion of a stage in a length of

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closing the pipe ends with brick work and pro- not less than Ten percent of the total
vision for bedding complete as per the ap- length.
proved drawing

4.0 Procedure for payment for Maintenance

4.1 The cost for maintenance shall be as stated in Clause 14.1.1.
4.2 Payment for Maintenance shall be made in quarterly instalments in accordance
with the provisions of Clause 19.7.

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Schedule I – Drawings

Contents

1.0 - Drawings...............................................................................................................

2.0 - Additional Drawings. ...........................................................................................

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1.0 Drawings

In compliance of the obligations set forth in Clause 10.2 of this Agreement, the
Contractor shall furnish to the Authority’s Engineer, free of cost, all Drawings listed
in Appendix I-I of this Schedule-I.

2.0 Additional Drawings

If the Authority’s Engineer determines that for discharging its duties and functions
under this Agreement, it requires any Drawings other than those listed in Appendix
I, it may by notice require the Contractor to prepare and furnish such Drawings
forthwith. Upon receiving a requisition to this effect, the Contractor shall promptly
prepare and furnish such Drawings to the Authority’s Engineer, as if such Drawings
formed part of Appendix I of this Schedule-I.

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Appendix I

(Schedule - I)

LIST OF DRAWINGS

All the Drawings that the Contractor is required to furnish under Clause 10.2 for the Survey,
Investigation, Design, Construction, Testing, Commissioning of smart infrastructure works of
Additional lanes of Roads, Storm water Drains, Culverts, minor/major Bridges ,Water Supply
including Headworks (Intake well, Raw water pumping main, Water treatment Plant, Cushion
tanks , semi underground reservoirs, Integration with entire water supply and other Ancillary
works), Sewerage Network, Power & ICT conduits, RCC duct for Power cables, Reuse water
network ,Gas lines crossings, Cycle track, Street furniture and Avenue Plantation & 10 years
O&M for Water supply including Headworks for Road E3 on EPC basis under Package-XV in
Amaravati, the new Capital City of Andhra Pradesh state, India are given in table below;

Table 1: List of Drawings

S. No. Description
1 Road Works
i Drawings of horizontal alignment, vertical profile and cross sections
ii Drawings for all Minor Bridges
ii Drawings of cross drainage Works
iii Drawings of major junctions & minor junctions
iv Drawings of road furniture items including traffic signage, markings, safety
barriers, etc.
Other civil structures

2 Utility Drawings
i LS, CS and Layout plans of water supply network with valves, fittings, specials
and accessories.
ii Detail Structural drawing of all structures like valve chambers, thrust blocks etc.
ii LS, CS and Layout plans of recycled water supply network with valves, fittings,
specials and accessories.
iii LS, CS and Layout plans of sewerage network with all appurtenance.
iv Detail Structural drawing of all structures like valve chambers, thrust blocks
manholes and other civil structures etc.
3 Standard Drawings
i Valve chambers
ii Thrust blocks
iii Trench Excavation details

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S. No. Description
Other civil structures
4 Domestic and Industrial sewer
i RCC Man hole and Drop hole
ii House connection chambers
iii Pipe bedding details
iv Typical section of sewer trench
v Residential /Industrial network Drawing
Other civil structures
5 Storm water drainage network
i Storm water drainage layout plan
ii LS, CS and Layout plans of storm water network with all appurtenance
iii Primary Drainage network
iv Collection chamber
vii RCC storm water channels
viii Outfall structures
ix Other civil structures
6 Power and ICT network
i LS, CS and Layout plans of Pipe Conduit sections of power and ICT network
with all appurtenance.
ii LS, CS and Layout plans for the power RCC ducts along with ventilation shafts,
entry and exit etc.
iii All GAD and Structural Drawings for all civil structures.
iv Other civil structures
7 Street Lighting
i Schematic diagram for complete lighting system
ii SLD for complete lighting system
8 Potable Water Supply – Headworks
i. Structural drawings for Intake well cum pump house, approach bridge and ap-
proach road along with architectural view.
ii. Structural drawings for WTP, SUGR at WTP, Clear water pump house at WTP
along with architectural view.
iii Layout drawings of Intake well cum pump house, WTP, WDC with SUGRs &
WDC with Cushion tanks
iv Process flow diagram & hydraulic flow diagram of WTP

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S. No. Description
v Structural drawings of WDCs with SUGRs cum pump houses & Cushion tanks
along with architectural view.
vi System Architecture drawings and P&ID drawings for Water supply SCADA
system.
vii. Structural drawings for Indoor substation and SCADA control room at all loca-
tions
viii SLDs for Electrical components
ix Structural drawings for Chief Engineer bungalow, Plant Superintendent, Staff
quarters, office buildings, Command Control Centre (C3), Guest house etc.
x Structural drawings for other civil structures

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Schedule J – Project Completion Schedule

(See Clauses 10.3.2)

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1 Project Completion Schedule

During Construction period, the Contractor shall comply with the requirements set forth
in this Schedule-J for each of the Project Milestones and the Scheduled Completion
Date. Within 15 (fifteen) days of the date of each Project Milestone, the Contractor
shall notify the Authority of such compliance along with necessary particulars thereof.

Sr No Milestone Schedule
To be completed within 6 months from the date of concluding agree-
1 Milestone 1
ment.
Upon successful completion of milestone 1 whichever occurs later
2 Milestone 2 and shall be completed in 6 Months (i.e. 8 months from the date of
concluding agreement)
Upon successful completion of milestone 2 whichever occurs later
3 Milestone 3 and shall be completed in 6 Months. (i.e. 10 months from the date of
concluding agreement)

Total Duration 18 Months from the date of concluding agreement.

2 Project Milestone-I

2.1 Project Milestone-I shall occur on the date falling on the 1st day from the Appointed
Date (the “Project Milestone-I”).

2.2 Prior to the occurrence of Project Milestone-I, the Contractor shall have commenced
construction of the Project Roads and Utilities and submitted to the Authority duly and
validly prepared Stage Payment Statements for an amount not less than 55% (Fifty-five
per cent) of the Contract Price.

3 Project Milestone-II

3.1 Project Milestone-II shall occur on the date falling on the 241th day from the Appointed
Date (the “Project Milestone-II”).

3.2 Prior to the occurrence of Project Milestone-II, the Contractor shall have continued with
construction of the Project Roads and Utilities and submitted to the Authority duly and
validly prepared Stage Payment Statements for an amount not less than 70% (Seventy
per cent) of the Contract Price.

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4 Project Milestone-III

4.1 Project Milestone-III shall occur on the date falling on the 301th day from the Ap-
pointed Date (the “Project Milestone-III”).

4.2 Prior to the occurrence of Project Milestone-III, the Contractor shall have continued
with construction of the Project Roads and Utilities and submitted to the Authority duly
and validly prepared Stage Payment Statements for an amount not less than 80%
(Eighty per cent) of the Contract Price.

5 Scheduled Completion Date

5.1 The Scheduled Completion Date shall occur on the 360th day from the Appointed Date.

5.2 On or before the Scheduled Completion Date, the Contractor shall have completed con-
struction in accordance with this Agreement.

6 Extension of time

Upon extension of any or all of the aforesaid Project Milestones or the Scheduled Com-
pletion Date, as the case may be, under and in accordance with the provisions of this
Agreement, the Project Completion Schedule shall be deemed to have been amended
accordingly.

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Schedule K - Tests on Completion

(See Clause 12.1.2)

Contents

1.0 Schedule for Tests.....................................................................

2.0 Tests..........................................................................................

3.0 Testing.......................................................................................

4.0 Completion Certificate.............................................................

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1.0 Schedule for Tests

1.1 The Contractor shall, no later than 30 (thirty) days prior to the likely completion of
Construction, notify the Authority’s Engineer and the Authority of its intent to subject
the Project components (roads and utilities / services and water supply head works) to
Tests, and no later than 10 (ten) days prior to the actual date of Tests, furnish to the
Authority’s Engineer and the Authority detailed inventory and particulars of all Works
and equipment forming part of Works at his own cost in presence of Authority engineer
or his representative.

1.2 The Contractor shall notify the Authority’s Engineer of its readiness to subject the
Project components (roads and utilities / services) to Tests at any time after 10 (ten)
days from the date of such notice, and upon receipt of such notice, the Authority’s
Engineer shall, in consultation with the Contractor, determine the date and time for
each Test and notify the same to the Authority who may designate its representative
to witness the Tests. The Authority’s Engineer shall thereupon conduct the Tests itself
or cause any of the Tests to be conducted in accordance with Article 12 and this
Schedule-K and Schedule-D.

2.0 Tests

2.1 Visual and physical test: The Authority’s Engineer shall conduct a visual and physi-
cal check of Construction to determine that all Works and equipment forming part
thereof conform to the provisions of this Agreement.

2.2 Riding quality test: Riding quality of each lane of the carriageway shall be checked
with the help of a calibrated bump integrator and the maximum permissible roughness
for purposes of this Test shall be 1800 (Eighteen Hundred) mm for each kilometer.

2.3 Tests for bridges: All major and minor bridges shall be subjected to the rebound
hammer and ultrasonic pulse velocity Tests, to be conducted in accordance with the
procedure described in Special Report No. 17: 1996 of the IRC Highway Research
Board on Non-destructive Testing Techniques, at two spots in every span, to be
chosen at random by the Authority’s Engineer. Bridges with a span of 15 (fifteen)
meters or more shall also be subjected to load testing.

2.4 Water Tightness test: All hydraulic structures, such as sewer lines network, industrial
network, joints, manholes etc. or any other liquid containers shall have to be tested for
water tightness. The water tightness test shall be conducted as specified in IS: 4127-
Latest revision.

2.5 Water Tightness test: Tests to be conducted for all civil structures (WTP, SUGRs,
ELSRs etc.,) as per the latest revision of IS: 3370 (Part - 1)

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2.6 Water Tightness test for Manhole: The entire height of the manhole shall be tested
for water tightness as per CPHEEO Manual, by closing both the incoming and outgoing
ends of the sewer and filling the manhole with water and the drop-in water level not
more than 50 mm per 24 hours shall be permitted.

2.7 Hydraulic Test: Fill the pipeline with water after it has been laid; bleed off any
trapped air. Subject the lowest element in the system to a test pressure that is 1.5 times
the design pressure should be maintained for a period (As per code) and check for any
leakage. When, in the opinion of the engineer, local conditions require that the trenches
be backfilled immediately after the pipe has been laid, apply the pressure test after
backfilling has been completed but not sooner than a time which will allow sufficient
curing of any concrete that may have been used. Typical minimum concrete curing
times are 36 hours for early strengths and 7 days for normal strengths.
2.8 Other Tests: The Authority’s Engineer may require the Contractor to carry out
or cause to be carried additional Tests, in accordance with Good Industry Practice, for
determining the compliance of the Project components (roads and utilities / services)
with Standards and Specifications.

2.9 Environmental audit: The Authority’s Engineer shall carry out a check to determine
conformity of the Project components (roads and utilities / services) with the environ-
mental requirements set forth in Applicable Laws and Applicable Permits.

2.10 Safety Audit: The Authority’s Engineer shall carry out, or cause to be carried out, a
safety audit to determine conformity of the Project components (roads and utilities/ser-
vices) with the safety requirements and Good Industry Practice.

2.11 Visual and physical test for Street lighting covering pole, luminaire, power supply,
grounding, communication between luminaire to control panel and central control sys-
tem.

2.12 Installation testing including lighting performance verification.

2.13 All of the electrical equipment covered by this report shall be tested in accordance
with all relevant design and installation standards and codes of practices. Routine and
Type test reports shall be required as minimum. The contractor shall notify the engi-
neer, in writing, when each Section of work is complete and whole of the work is
completed. Each Section of the work and whole of the work shall be tested in accord-
ance with all relevant design and installation standards and codes of practices.

3.0 Testing

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3.1. This Sub-Clause shall apply to all tests on Plant, Materials and workmanship specified
in the Contract.

The Contractor shall provide all apparatus, assistance, documents and other infor-
mation, electricity, equipment, fuel, consumables, instruments, labor, materials, and
suitably qualified and experienced staff, as are necessary to carry out the specified tests
efficiently. The Contractor shall agree, with the Authority’s Representative, the time
and place for the specified testing of any Plant, Materials and other parts of the Works.

The Authority’s Representative may vary the location or details of specified tests, or
instruct the Contractor to carry out additional tests. If these varied or additional tests
show that the tested Plant, Materials or workmanship is not in accordance with the
Contract, the cost of carrying out this Variation shall be borne by the Contractor, not-
withstanding other provisions of the Contract.

The Authority’s Representative shall give Notice to the Contractor not less than 24
hours prior to the tests, of the Authority’s Representative’s intention to attend the tests.
If the Authority’s Representative does not attend at the time and place agreed the Con-
tractor may proceed with the tests, unless otherwise instructed by the Authority’s Rep-
resentative, and the tests shall then be deemed to have been made in the Authority’s
Representative’s presence.

The Contractor shall promptly forward to the Authority’s Representative duly certified
reports of the tests. When the specified tests have been passed, the Authority’s Repre-
sentative shall endorse the Contractor’s test certificate, or Issue a certificate to him, to
that effect. If the Authority’s Representative has not attended the tests, he shall be
deemed to have accepted the readings as accurate.

The Contractor shall carry out the Tests on Completion of Design-Build in accordance
with this Clause.

The Contractor shall give Notice to the Authority’s Representative not less than 21 days
prior to the date after which the Contractor will be ready to carry out each of the Tests
on Completion of Design-Build. Unless otherwise agreed, Tests on Completion of De-
sign-Build shall be carried out within 14 days after this date, on such day or days as the
Authority’s Representative shall instruct.

Unless otherwise stated, the Tests on Completion of Design-Build shall be carried out
in the following sequence and are further detailed in the Authority’s Requirements:

Pre-commissioning tests, which shall include the appropriate inspections and (“dry” or
“cold”) functional tests to demonstrate that each item of Plant can safely undertake the
next stage, (b); commissioning tests, which shall include the specified operational tests

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to demonstrate that the Works or Section can be operated safely and as specified, under
all available operating conditions; and trial operation, which shall demonstrate that the
Works or Section perform reliably and in accordance with the Contract.

The Authority shall be the sole beneficiary of any revenue or benefit resulting from the
Tests on Completion of Design-Build.

During trial operation, when the Works are operating under stable conditions, the Con-
tractor shall give Notice to the Authority’s Representative that the Works are ready for
any other Tests on Completion of Design-Build, including performance tests to demon-
strate whether the Works conform with criteria specified in the Authority’s Require-
ments and with the Schedule of Guarantees.

Trial operation shall not constitute a commencement of the Operation Service. The
O&M shall only start after issue of Completion Certificate.

In considering the results of the Tests on Completion of Design-Build, the Authority’s

Representative shall make allowances for the effect of any use of the Works by the
Authority on the performance or other characteristics of the Works. As soon as the
Works, or a Section, have passed each of the Tests on Completion of Design-Build de-
scribed in above sub-paragraph, the Contractor shall submit a report certified by the
Contractor of the results of these Tests to the Authority’s Engineer.

If the Tests on Completion of Design-Build are being unduly delayed by the Contractor,
the Authority’s Engineer may by Notice require the Contractor to carry out such Tests
within 21 days after receiving the Notice. The Contractor shall carry out such Tests on
the day or days within that period as the Contractor may fix and of which he shall give
Notice to the Authority’s Engineer.

If the Contractor fails to carry out the Tests on Completion of Design-Build within the
period of 21 days, the Authority’s Personnel may proceed with the Tests at the risk and
cost of the Contractor. The Tests on Completion shall then be deemed to have been
carried out in the presence of the Contractor and the results of the Tests shall be accepted
as accurate.

If the Tests on Completion of Design-Build are being unduly delayed by the Authority,
an extension of time shall be provided by the Authority for such delay, if the completion
is or will be delayed.
\
Retesting of the Works

If the Works, or a Section, fail to pass the Tests on Completion of Design-Build, and
the Authority’s Engineer or the Contractor may require the failed Tests, and Tests on

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Completion of Design-Build on any related work, to be repeated under the same terms
and conditions.

Failure to Pass Tests on Completion of Design-Build

If the Works, or a Section, fail to pass the Tests on Completion of Design-Build repeated
under above Sub-Clause [Retesting of the Works] the Authoritys Engineer shall be en-
titled to: order further repetition of tests on Completion of Design-Build under Sub-
Clause (Retesting of the Works]; or If the Contractor fails to carry out any obligation
under the Contract, the Authority’s Engineer shall by Notice require the Contractor to
make good the failure and to remedy it within the time specified in the said Notice.

4.0 Completion Certificate

4.1 Upon successful completion of Tests, the Authority’s Engineer shall issue the Com-
pletion Certificate in accordance with the provisions of Article 12.

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Schedule L – Provisional Certificate and Completion Certificate

Contents

Provisional Certificate...................................................................................................

Completion Certificate...................................................................................................

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Provisional Certificate

(See Clause 12.2)

 I, … ………….. (Name of the Authority’s Engineer), acting as Authority’s Engineer,

under and in accordance with the Agreement dated …………... (the “Agreement”), for
“Survey, Investigation, Design, Construction, Testing, Commissioning of smart
infrastructure works of Additional lanes of Roads, Storm water Drains, Culverts,
minor/major Bridges ,Water Supply including Headworks (Intake well, Raw water
pumping main, Water treatment Plant, Cushion tanks , semi underground reservoirs,
Integration with entire water supply and other Ancillary works), Sewerage Network,
Power & ICT conduits, RCC duct for Power cables, Reuse water network ,Gas lines
crossings, Cycle track, Street furniture and Avenue Plantation & 10 years O&M for
Water supply including Headworks for Road E3 on EPC basis under Package-XV in
Amaravati, the new Capital City of Andhra Pradesh state,
India.through…………………. (Name of Contractor), hereby certify that the Tests in
accordance with Article 12 of the Agreement have been undertaken to determine
compliance of the Project.............................. with the provisions of the Agreement.

1. Construction Works that are incomplete on account of Time Extension have been
specified in the Punch List appended hereto, and the Contractor has agreed and accepted
that it shall complete all such Works in the time and manner set forth in the Agreement.
In addition, certain minor Works are incomplete and these are not likely to cause Material
inconvenience to the users of the Project .............................. or other their safety. The
contractor has agreed and accepted that as a condition of this Provisional Certificate, it
shall complete such minor Works within 30 (thirty) days hereof. These minor Works have
also been specified in the aforesaid Punch List.

2. In view of the foregoing, I am satisfied that that Project .............................................

can be safely and reliably placed in service of the users thereof, and in terms of
the Agreement, the Project .............................. is hereby provisionally declared fit for
entry into operation on this the ………day of ……….20 …..

ACCEPTED, SIGNED, SEALED SIGNED, SEALED AND DELIVERED

AND DELIVERED

For and on behalf of For and on behalf of

CONTRACTOR by

Authority’s Engineer by:

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(Signature) (Signature)
Completion Certificate

(See Clause 12.4)

 I, … ………….. (Name o f the Authority’s Engineer), acting as Authority’s Engineer,

under and in accordance with the Agreement dated ………….. (the “Agreement”), for
“Survey, Investigation, Design, Construction, Testing, Commissioning of smart
infrastructure works of Additional lanes of Roads, Storm water Drains, Culverts,
minor/major Bridges ,Water Supply including Headworks (Intake well, Raw
water pumping main, Water treatment Plant, Cushion tanks , semi underground
reservoirs, Integration with entire water supply and other Ancillary works),
Sewerage Network, Power & ICT conduits, RCC duct for Power cables, Reuse
water network ,Gas lines crossings, Cycle track, Street furniture and Avenue
Plantation & 10 years O&M for Water supply including Headworks for Road E3
on EPC basis under Package-XV in Amaravati, the new Capital City of Andhra
Pradesh state, India.
through …………………. (Name of Contractor), hereby certify that the Tests in accord-
ance with Article 12 of the Agreement have been successfully undertaken to determine
compliance of the Project ............................................. with the provisions of the Agree-
ment, and I am satisfied that the Project ............................................. can be safely and
reliably placed in service of the Users thereof.

1. It is certified that, in terms of the aforesaid Agreement, all Works forming part of Project
Works have been completed, and the Project Works is hereby declared fit for entry into
operation on this the ………..day of ……..20 …..

Authority’s Engineer by: SIGNED, SEALED AND DELIVERED

For and on behalf of

(Signature) (Name)

(Designation) (Address)

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Schedule M – Payment Reduction for Non-Compliance (Not used)

(See Clauses 17.2 &17.4)

Contents

1.0 Payment reduction for non-compliance with the Maintenance Require-

ments........................................................................................................................

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Payment reduction for non-compliance with the Maintenance Requirements

1.1 Monthly lump sum payments for Maintenance shall be reduced in the case of
non- compliance with the Maintenance Requirements set forth in Schedule-D and
Schedule-E.

1.2 Any deduction made on account of non-compliance with the Maintenance Require-
ments shall not be paid even after compliance subsequently. The deduction shall con-
tinue to be made every month until compliance is done.

1.3 The Employer’s Engineer shall calculate the amount of payment reduction on
the basis of weightage in percentage or cost assigned to non-conforming items as
defined in the Schedule-D

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Schedule N - Selection of Employer’s Engineer / Authority Engineer

(See Clause 18.1.1)

Contents

1 - Selection of EMPLOYER’s Engineer..............................................................................

2 - Terms of Reference..........................................................................................................

3 - Appointment of Government entity as EMPLOYER’s Engineer......................................

Annex-I - Terms of Reference for Employer’s Engineer.......................................................

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1. Selection of EMPLOYER’s Engineer

1.1 The provisions of the Model Request for Proposal for Selection of Technical Consult-
ants, issued by the Ministry of Finance in May 2009, or any substitute thereof shall
apply for selection of an experienced firm to discharge the functions and duties of
an EMPLOYER’s Engineer.

1.2 In the event of termination of the Technical Consultants appointed in accordance with
the provisions of Paragraph 1.1, the EMPLOYER shall appoint another firm of Tech-
nical Consultants forthwith and may engage a government-owned entity in accord-
ance with the provisions of Paragraph 3 of this Schedule-N.

2. Terms of Reference
The Terms of Reference for the EMPLOYER’s Engineer (the “TOR”) shall substan-
tially conform with Annex 1 to this Schedule N.

3. Appointment of Government entity as EMPLOYER’s Engineer

Notwithstanding anything to the contrary contained in this Schedule, the EMPLOYER
may in its discretion appoint a government-owned entity as the EMPLOYER’s Engi-
neer; provided that such entity shall be a body corporate having as one of its primary
functions the provision of consulting, advisory and supervisory services for engineer-
ing projects; provided further that a government-owned entity which is owned or con-
trolled by the EMPLOYER shall not be eligible for appointment as EMPLOYER’s
Engineer.

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Annex – I
(Schedule - N)

Terms of Reference for Employer’s Engineer

1.0 Scope
1.1 These Terms of Reference (the “TOR”) for the EMPLOYER’s Engineer are being
specified pursuant to the EPC Agreement dated........... (the “Agreement), which has
been entered into between the …………. Name of EMPLOYER (the “EMPLOYER”)
and .......... (the “Contractor”) for
“…………………………………………………………………………………………
…………………………………………………………………………………state on
Engineering, Procurement & Construction (EPC)” Basis, and a copy of which is
annexed hereto and marked as Annex-A to form part of this TOR.

1.2 The TOR shall apply to design, construction and maintenance of the Project Roads
and Services

2.0 Definitions and interpretation

2.1 The words and expressions beginning with or in capital letters and not defined herein
but defined in the Agreement shall have, unless repugnant to the context, the meaning
respectively assigned to them in the Agreement.
2.2 References to Articles, Clauses and Schedules in this TOR shall, except where the
context otherwise requires, be deemed to be references to the Articles, Clauses and
Schedules of the Agreement, and references to Paragraphs shall be deemed to be
references to Paragraphs of this TOR.
2.3 The rules of interpretation stated in Clauses 1.2, 1.3 and 1.4 of the Agreement shall
apply, mutatis mutandis, to this TOR.

3.0 General
3.1 The EMPLOYER’s Engineer shall discharge its duties in a fair, impartial and effi-
cient manner, consistent with the highest standards of professional integrity and Good
Industry Practice.

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3.2 The EMPLOYER’s Engineer shall perform the duties and exercise the authority
in accordance with the provisions of this Agreement, but subject to obtaining
prior written approval of the EMPLOYER before determining:

(a) any Time extension;

(b) any additional cost to be paid by the EMPLOYER to the Contractor;
(c) the Termination Payment; or
(d) any other matter which is not specified in (a), (b) or (c) above and which
creates an obligation or liability on either Party for a sum exceeding
Rs.5,000,000 (Rs. fifty lakh).
3.3 The EMPLOYER’s Engineer shall submit regular periodic reports, at least once every
month, to the EMPLOYER in respect of its duties and functions under this Agree-
ment. Such reports shall be submitted by the EMPLOYER’s Engineer within 10 (ten)
days of the beginning of every month.
3.4 The EMPLOYER’s Engineer shall inform the Contractor of any delegation of
its duties and responsibilities to its suitably qualified and experienced personnel pro-
vided, however, that it shall not delegate the authority to refer any matter for the
EMPLOYER’s prior approval in accordance with the provisions of Clause 18.2.
3.5 The EMPLOYER’s Engineer shall aid and advise the EMPLOYER on any proposal
for Change of Scope under Article 13.
3.6 In the event of any disagreement between the Parties regarding the meaning, scope
and nature of Good Industry Practice, as set forth in any provision of the Agreement,
the EMPLOYER’s Engineer shall specify such meaning, scope and nature by issuing
a reasoned written statement relying on good industry practice and authentic literature.

4 .0 Construction Period
4.1 During the Construction Period, the EMPLOYER’s Engineer shall review the Re-
ports, Designs and Drawings furnished by the Contractor along with supporting data,
including the geo-technical and hydrological investigations, characteristics of materi-
als from borrow areas and quarry sites, topographical surveys, and the recommenda-
tions of the Safety Consultant in accordance with the provisions of Clause 10.1.6.
The EMPLOYER’s Engineer shall complete such review and send its observations
to the EMPLOYER and the Contractor within 15 (fifteen) days of receipt of such
Reports, Designs and Drawings; provided, however that in case of a Structure, the
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aforesaid period of 15 (fifteen) days may be extended up to 30 (thirty) days. In par-

ticular, such comments shall specify the conformity or otherwise of such Drawings
with the Scope of the Project and Specifications and Standards.
4.2 The EMPLOYER’s Engineer shall review any revised Reports, Designs and Draw-
ings sent to it by the Contractor and furnish its comments within 10 (ten) days of
receiving such Reports, Designs and Drawings.
4.3 The EMPLOYER’s Engineer shall review the (a) Quality Assurance Plan (b) Health,
Safety and Environmental Management Plan submitted by the Contractor and shall
convey its comments to the Contractor within a period of 21 (twenty-one) days stating
the modifications, if any, required thereto. The Employer’s Engineer shall ensure the
Contractor’s Project Management requirements, BIM and CAD requirements regu-
larly on a monthly basis to the Employer.
4.4 The EMPLOYER’s Engineer shall complete the review of the methodology proposed
to be adopted by the Contractor for executing the Works, and convey its comments
to the Contractor within a period of 10 (ten) days from the date of receipt of the
proposed methodology from the Contractor.
4.5 Deleted.
4.6 The EMPLOYER’s Engineer shall review the monthly progress report furnished
by the Contractor and send its comments thereon to the EMPLOYER and the Con-
tractor within 7 (seven) days of receipt of such report.
4.7 The EMPLOYER’s Engineer shall inspect the Construction Works and the Project
Roads and shall submit a monthly Inspection Report bringing out the results of in-
spections and the remedial action taken by the Contractor in respect of Defects or
deficiencies. In particular, the EMPLOYER’s Engineer shall include in its Inspection
Report, the compliance of the recommendations made by the Safety Consultant.
4.8 The EMPLOYER’s Engineer shall conduct the pre-construction review of manufac-
turer's test reports and standard samples of manufactured Materials, and such other
Materials as the EMPLOYER’s Engineer may require.
4.9 For determining that the Works conform to Specifications and Standards, the EM-
PLOYER’s Engineer shall require the Contractor to carry out, or cause to be carried out,
tests at such time and frequency and in such manner as specified in the Agreement and in
accordance with Good Industry Practice for quality assurance. For purposes of this Para-
graph 4.9, the tests specified in the relevant Codes or any modification/substitution

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thereof and standards for shall be deemed to be tests conforming to Good Industry
Practice for quality assurance.
4.10 The EMPLOYER’s Engineer shall test check at least 20 (twenty) percent of the
quantity or number of tests prescribed for each category or type of test for quality
control by the Contractor.
4.11 The timing of tests referred to in Paragraph 4.9, and the criteria for acceptance/
rejection of their results shall be determined by the EMPLOYER’s Engineer in ac-
cordance with the Quality Control Manuals and/or the relevant Codes and Standards.
The tests shall be undertaken on a random sample basis and shall be in addition to,
and independent of, the tests that may be carried out by the Contractor for its own
quality assurance in accordance with Good Industry Practice.
4.12 In the event that results of any tests conducted under Clause 11.10 establish any
Defects or deficiencies in the Works, the EMPLOYER’s Engineer shall require the
Contractor to carry out remedial measures.
4.13 The EMPLOYER’s Engineer may instruct the Contractor to execute any work which
is urgently required for the safety of the Project Works, whether because of an
accident, unforeseeable event or otherwise; provided that incase of any work required
on account of a Force Majeure Event, the provisions of Clause 21.6 shall apply.
4.14 In the event that the Contractor fails to achieve any of the Project Milestones, the
EMPLOYER’s Engineer shall undertake a review of the progress of construction and
identify potential delays, if any. If the EMPLOYER’s Engineer shall determine that
completion of the Project Works is not feasible within the time specified in the
Agreement, it shall require the Contractor to indicate within 15 (fifteen) days the steps
proposed to be taken to expedite progress, and the period within which the Project
Completion Date shall be achieved. Upon receipt of a report from the Contractor, the
EMPLOYER’s Engineer shall review the same and send its comments to the EM-
PLOYER and the Contractor forthwith.

4.15 The EMPLOYER’s Engineer shall obtain from the Contractor two copies of all the
Contractor’s quality control records and documents before the Completion Certificate
is issued pursuant to Clause 12.4.

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4.16 EMPLOYER’s Engineer may recommend to the EMPLOYER suspension of the

whole or part of the Works if the work threatens the safety of the Users and pedes-
trians. After the Contractor has carried out remedial measure, the EMPLOYER’s En-
gineer shall inspect such remedial measures forthwith and make a report to the EM-
PLOYER recommending whether or not the suspension hereunder may be revoked.

4.17 In the event that the Contractor carries out any remedial measures to secure the safety
of suspended works and Users, and requires the EMPLOYER’s Engineer to inspect
such works, the EMPLOYER’s Engineer shall inspect the suspended works within 3
(three) days of receiving such notice, and make a report to the EMPLOYER forthwith,
recommending whether or not such suspension may be revoked by the EMPLOYER.

4.18 The EMPLOYER’s Engineer shall carry out, or cause to be carried out, all the Tests
specified in Schedule-K and issue a Completion Certificate or Provisional Certificate,
as the case may be. For carrying out its functions under this Paragraph 4.18 and all
matters incidental thereto, the EMPLOYER’s Engineer shall act under and in accord-
ance with the provisions of Article 12 and Schedule-K.

5.0 Maintenance Period

5.1 The EMPLOYER’s Engineer shall aid and advise the Contractor in the preparation
of its monthly Maintenance Programme and for this purpose carry out a joint monthly
inspection with the Contractor.

5.2 The EMPLOYER’s Engineer shall undertake regular inspections, at least once every
month, to evaluate compliance with the Maintenance Requirements and submit a
Maintenance Inspection Report to the EMPLOYER and the Contractor.

5.3 The EMPLOYER’s Engineer shall specify the tests, if any, that the Contractor shall
carry out, or cause to be carried out, for the purpose of determining that the Project
Works is in conformity with the Maintenance Requirements. It shall monitor and
review the results of such tests and the remedial measures, if any, taken by the
Contractor in this behalf.
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5.4 In respect of any defect or deficiency referred to in Paragraph 3 of Schedule-E, the

EMPLOYER’s Engineer shall, in conformity with Good Industry Practice, specify the
permissible limit of deviation or deterioration with reference to the Specifications and
Standards and shall also specify the time limit for repair or rectification of any
deviation or deterioration beyond the permissible limit.

5.5 The EMPLOYER’s Engineer shall examine the request of the Contractor for closure
of any lane(s)/utilities lines of the Project Roads and/or Services for undertaking
maintenance/repair thereof, and shall grant permission with such modifications, as it
may deem necessary, within 5 (five) days of receiving a request from the Contractor.
Upon expiry of the permitted period of closure, the EMPLOYER’s Engineer shall
monitor the reopening of such lane(s), and in case of delay, determine the Damages
payable by the Contractor to the EMPLOYER under Clause 14.5.

6.0 Determination of costs and time

6.1 The EMPLOYER’s Engineer shall determine the costs, and/or their reasonableness,
that are required to be determined by it under the Agreement.

6.2 The EMPLOYER’s Engineer shall determine the period of Time Extension that is
required to be determined by it under the Agreement.

6.3 The EMPLOYER’s Engineer shall consult each Party in every case of determination
in accordance with the provisions of Clause 18.5.

7.0 Payments

7.1 The EMPLOYER’s Engineer shall withhold payments for the affected works for
which the Contractor fails to revise and resubmit the Drawings to the EMPLOYER’s
Engineer in accordance with the provisions of Clause 10.2.4 (d).

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7.2 EMPLOYER’s Engineer shall -

(a) within 10 (ten) days of receipt of the Stage Payment Statement from the Con-
tractor pursuant to Clause 19.4, determine the amount due to the Contractor
and recommend the release of 90 (ninety) percent of the amount so determined
as part payment, pending issue of the Interim Payment Certificate; and

(b) within 15 (fifteen) days of the receipt of the Stage Payment Statement referred
to in Clause 19.4, deliver to the EMPLOYER and the Contractor an Interim
Payment Certificate certifying the amount due and payable to the Contractor,
after adjustments in accordance with the provisions of Clause19.10.

7.3 The EMPLOYER’s Engineer shall, within 15 (fifteen) days of receipt of the Monthly
Maintenance Statement from the Contractor pursuant to Clause19.6, verify the Con-
tractor’s monthly statement and certify the amount to be paid to the Contractor in
accordance with the provisions of the Agreement.

7.4 The EMPLOYER’s Engineer shall certify final payment within 30 (thirty) days of
the receipt of the final payment statement of Maintenance in accordance with the
provisions of Clause 19.16.

8.0 Other duties and functions

The EMPLOYER’s Engineer shall perform all other duties and functions as specified
in the Agreement.

9. 0 Miscellaneous

9.1 A copy of all communications, comments, instructions, Drawings or Documents sent

by the EMPLOYER's Engineer to the Contractor pursuant to this TOR, and a copy of
all the test results with comments of the EMPLOYER's Engineer thereon, shall be
furnished by the EMPLOYER's Engineer to the EMPLOYER forthwith.

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9.2 The EMPLOYER's Engineer shall retain at least one copy each of all Drawings and
Documents received by it, including 'as-built' Drawings, and keep them in its safe
custody.

9.3 Within 90 (ninety) days of the Project Completion Date, the EMPLOYER's Engineer
shall obtain a complete set of as-built Drawings, in 2 (two) hard copies and in micro
film form or in such other medium as may be acceptable to the EMPLOYER, reflect-
ing the Project ............................................. as actually designed, engineered and
constructed, including an as-built survey illustrating the layout of the Project Works
and setback lines, if any, of the buildings and structures forming part of Project Facil-
ities; and shall hand them over to the EMPLOYER against receipt thereof.

9.4 The EMPLOYER's Engineer, if called upon by the EMPLOYER or the Contractor or
both, shall mediate and assist the Parties in arriving at an amicable settlement of any
Dispute between the Parties.

9.5 The EMPLOYER's Engineer shall inform the EMPLOYER and the Contractor of any
event of Contractor's Default within one week of its occurrence.

9.6 The Employer’s Engineer, if called upon by the Employer, shall attend the meetings
on Project reviews, discussions to be held at Employer office with required reports
and presentations.

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Schedule O – Insurance

Contents

1 Insurance during Construction Period.............................................

2 Insurance for Contractor’s Defects Liability......................................

3 Insurance against Injury to Persons and Damage to Property.........

4 Insurance to be in Joint Names........................................................

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1. Insurance during Construction Period

1.1. The Contractor shall effect and maintain at its own cost, from the Appointed Date
till the date of issue of the last Completion Certificate, the following insurances for
any loss or damage occurring on account of Non Political Event of Force
Majeure, malicious act, accidental damage, explosion, fire and terrorism:

(a) Insurance of Works, Plant and Materials and an additional sum of [15 (fifteen)]
per cent of such replacement cost to cover any additional costs of and incidental to
the rectification of loss or damage including professional fees and the cost of demol-
ishing and removing any part of the Works and of removing debris of whatsoever
nature; and

(b) Insurance for the Contractor’s equipment brought onto the Site by the Contractor,
for a sum sufficient to provide for their replacement at the Site.

(c) The Contractor shall effect and maintain at its own cost, from the Appointed Date
till the date of issue of the last Completion Certificate, the following insurances
for any loss or damage occurring on account of Non Political Event of Force
Majeure, malicious act, accidental damage, explosion, fire, terrorism and War and
Riots Protection Insurance

1.2 The insurance under paragraph 1.1 (a) and (b) above shall cover the Authority and the
Contractor against all loss or damage from whatsoever cause arising under paragraph
1.1 other than risks which are not insurable at commercial terms.

1.3. “All risks of loss including theft of or damage to physical property and of personal
injury and death which arise during and in consequence of the performance of
the Contract other than the Exceptional Risks are the responsibility of the
Contractor. Any loss not insured or not recovered (including policy excesses etc.)
from insurers shall be borne by the Contractor. All insurances shall be in the joint
name of contractor and the Authority. The contract shall maintain a Contractors All
Risk Policy (CAR) for the entire duration of the contract including O&M period for
the entire facility” The Contractor shall also take additional covers (Add-On covers)
insurance like Third Party Liability, Surrounding properties, Clearance and Removal
of debris, Cross liability, Express Freight, Extended Maintenance Cover up to Final
Takeover, etc. The sum insured for such Add-On covers shall be decided by the CON-
TRACTOR based on his assessment and risk involved in the contract. Risks to be
covered by insurance shall not be limited merely to the items mentioned above. The
CONTRACTOR shall arrange for insurance of any other risks he may deem prudent,
but the expenses thereof shall be to the account of the contractor only full plant. If

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necessary, Transit and storage (all risks) insurance coverage for additional transit in-
volved for sending equipment/material to Sub-Contractor/Fabricator’s shop for fabri-
cation/ reprocessing and receiving back at site shall be taken.

2. Insurance for Contractor’s Defects Liability

The Contractor shall effect and maintain Insurance Cover for the Works from the date of
issue of the Completion Certificate until the end of the Defects Liability Period for any
loss or damage for which the Contractor is liable and arises from a cause occurring
prior to the issue of Completion Certificate. The Contractor shall also maintain other
insurances for maximum sums as may be required under the Applicable Laws and
in accordance with Good Industry Practice.

3. Insurance against injury to persons and damage to property

3.1 The Contractor shall insure against each Party’s liability for any loss, damage, death
or bodily injury which may occur to any physical property (except things insured
under Paragraph l and 2 of this Schedule or to any person (except persons insured
under Clause 20.9), which may arise out of the Contractor’s performance of this
Agreement and occurring before the issue of the Performance Certificate. This insur-
ance shall be for a limit per occurrence of not less than the amount stated below with
no limit on the number of occurrences. The Insurance Cover shall be not less than: Rs.
20 Lakhs.

3.2 The insurance shall be extended to cover liability for all loss and damage to the
Authority’s property arising out of the Contractor’s performance of this Agreement
excluding:

(a) the Authority’s right to have the Construction Works executed on, over, under, in
or through any land, and to occupy this land for the Works; and
(b) Damage which is and unavoidable result of the Contractor’s obligations to exe-
cute the Works.

4. Workmen Compensation Policy

5. Insurance to be in joint names

The insurance under paragraphs 1 to 3 above shall be in the joint names of the
Contractor and the Authority.

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Schedule P- CAD Requirement

(See Clause 3.1.7 K)

Annex - I - CAD Guideline..............................................................

Appendix - A - AutoCAD Layer Definitions.....................................

Appendix - B - Useful Tables for AutoCAD......................................

Appendix - C - Drawing Type and Drawing Number Series..........

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Annex – I

(Schedule - O)

CAD Guideline
1 OVERVIEW

Purpose

The primary goal of standardizing the use CAD is to create an environment for seam-
less integration/collaboration between all disciplines & business lines of all consult-
ants/contractors regarding the use of CAD for production of any Drawing. The docu-
ment will achieve this through setting out the Guideline for Drawing data production.
This will then enable Drawing data to be incorporated into the ADCL GIS.

1.2 Application

This CAD standard shall be applied to all disciplines in all offices and design houses
working in this Project. The scope of this document is to provide guidelines and pro-
cedures for adopting AutoCAD layering standards in preparing design and as-built
Drawings for automated transference to ADCL GIS. This Guideline will address the
following:

i. Layer assignments

ii. Standard symbols

iii. Layers and layer names

iv. Attributes to each future

v. Templates

vi. Color usage associated with line widths for all Highways and
Utility Drawings.

The Guideline are to be applied for all Drawings from Concept through to As Built
handover stage.

2 Filing and Storage of Drawings

2.1 Filing and Storage of Drawings

In order that the Project information is readily accessible it is essential that all Draw-
ing data is filed and stored in a consistent and logical manner.

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2.2 Electronic Copies

All electronic Drawing and sketch files associated with a particular Project shall be
filed within the Project folder.

2.3 Folder Structure

The standard folder structure for CAD data is as shown in Figure 1 below, it adopts
the Code of Practice BS1192:2007 on Common Data Environment for collaborative
working.

Figure 1:

2.4 Folder Name: Project Number and Title

This can be under the main office or discipline folder, or, if the number of files would
render lists unwieldy, then further sub-folder are permissible. Folder names are not to
include any symbols.

2.5 Sub Folder Name: CAD

Contains Drawings and digital information organized as shown in

Figure 1.
In a multi-disciplinary office, the main sub-folders defined below may be sub-
divided as necessary into the relevant disciplines:

2.5.1 Sub Folder Name: WIP (Work in Progress)

Contains the current working Project Drawings and sketches. This is where all
files currently in the iterative process of design have not yet been approved to
be shared.

This folder shall contain further sub-folders which can be amended to suit Pro-
ject requirements.

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2.5.2 Sub Folder Name: Shared

Contains verified, checked and approved CAD data for use by others for ref-
erence. This folder will hold the Project specific Drawings such as title frames,
references, images, etc.

This folder shall contain further sub-folders which can be amended to suit Project
requirements

2.5.3 Sub Folder Name: Published

Contains all final published sheet files, figures or sketches. This folder must contain
the last issued Models/Xrefs. Data filed in this area shall never be deleted or over-
written, but will remain until archived.

2.5.4 Sub Folder Name: Archive

Contains all previous issues and superseded data. This folder is to allow re-
trieval of previously issued Drawings at certain stages of design decisions.
This folder will provide an audit trail of Documentation and changes through
the life of the Project.

2.5.5 Sub Folder Name: Received

Contains read only copies of design data which have been received from Third
Party sources or Stakeholders and will contain further sub-folders to identify
the source and date of receipt.

The Received folder can be directly under the main Project folder structure,
under CAD or wherever the Authority find it suitable. The vital concern is
that a folder must be dedicated for incoming issues, where a full archive of all
received information is stored with an audit trail that is related to the sending
company and the date received and the current copy is easily identifiable
throughout the Project.

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2.6 Collaborative Working

Figure-2 Application of code of practice BS 1192:2007 on Common Data Envi-
ronment (CDE)

i. Within WIP folder each discipline can create a folder structure to suit its
needs.

ii. Common resource files such as title sheets, mapping, surveys, imagery and
other shared CAD data must be available to all disciplines in the Shared area.

iii. Once data has been checked, verified and approved, it must be copied to
the Shared area and other disciplines notified.

iv. When models are revised, or updated; other disciplines referencing the model
will be affected, so effective communication between disciplines is essential.

v. When data files have been authorized and verified for issue, it is copied to
the Published area, to maintain a local copy within the design organization’s
server.

vi. The previous version of the data in the Published area shall be moved to the
Archive area as a historical record and to maintain an audit trail.

2.7 Hard Copies

The print containing the original stamped, checked and approved signatures
becomes the hard-copy 'master plot' for the Drawing. See Section 3.3.13.

2.7.1 Drawings

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The Project Implementation Plan (PIP) will define the area where the hard-copies
for Projects are to be filed.
The electronic version of the master plot of the Drawing shall be known as the
‘reference master’. The reference master, if required, shall be utilized for the electronic
issue of the file.
Superseded master plots shall be retained and endorsed "superseded".

2.7.2 Check Prints

All completed and signed check prints shall be filed within the Drawing office by the
drafting checker in an area in accordance with the Project Implementation Plan (PIP).

All check prints are to be retained at least for the term of the Project unless otherwise
agreed with the AUTHORITY. No check prints are to be disposed of without the
consent of the Project Manager.

3 DRAWING DEVELOPMENT

3.1 Drawing Numbering System

The Drawing numbers are to be entered into the Drawing register during crea-
tion of the Drawings so as to eliminate duplicate Drawing numbers being as-
signed. The Drawing number shall be unique for each Drawing and will nor-
mally be in the form:

Table 1

Discipline /
Originator Project Drawing Document Drawing Sheet
Name - - code Number - No
code Type code

Example ADCL - SIIMP - SWD - DWG 1001 - 001

See
Reference 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5

Fields will be separated by a hyphen (-)

3.1.1 Originator Code

A three-letter code to identify who prepared the Drawing. Refer to Appendix- C.

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3.1.2 Project Name

Refer to Appendix C

3.1.3 Drawing Type/ Discipline code

Two letter codes to assist in identifying a discipline or type of Drawing (i.e. HW for
Highways, ST for Structures, SK for Sketch, etc.). Refer to Appendix C.

3.1.4 Document Code

Two letter code to assist in identifying type of document. Refer to Appendix C.

3.1.5 Drawing Number Code

Four digits’ sequential number for a specific Drawing type series. Refer to Appendix
C. Subsequent issue of a Drawing shall have the revision coding incremented by the
next sequential number or letter.

Note #3: Working Drawings shall not have the Drawing status and revision in the file
name.

3.2 Model File (Xref) Naming

Model Files shall be named in accordance with the convention described below

Table 3
Model
Originator Project Discipline Short
type - -
code Name code Description
Identifier
Proposed _Cen-
Example D2 CRDA SIIMP HW tre_
- - -
line
See
Reference 3.2.1 3.1.2 3.1.3 3.1.4 3.2.5

Example – CRDA – SIIMP-WS - Proposed_Centre_Line

3.2.1 Model Identifier Code

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This code identifies the model file if it is in 2D or 3D Drawing as defined

below:

Table 4

Description Model Type Identifier

2D Model D2

3D Model D3

3.2.2 Originator Code

A three-letter code to identify the designer who prepared the Drawing. Refer
to Appendix C.

3.2.3 Project Name

Refer to Appendix C

3.2.4 Drawing Type/ Discipline code

Two letter code to assist in identifying a discipline or type of Drawing (i.e. HW

for Highways, ST for Structures, SK for Sketch, etc.). Refer to Appendix C.

3.2.5 Short Description Field

A short description of the model/X ref file. An underscore is to be used in place

of any spaces in the description field.

Working models shall not have the Drawing status and revision in the file name .

3.3 Drawing Title Blocks and Signatures

A standard Drawing arrangement (Drawing border and title block) shall be
adopted for all Drawings and shall be consistent across all Drawings within
the Project. Title block entries shall be concise and informative to indicate fully
the content of the Drawing.

3.3.1 Drawing Title

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i) The top line shall identify the specific area or Section within the contract, i.e.
“HIGHWAYS”, or it may be left blank where no such area or Section exists.

ii) The second third and fourth lines shall identify the content or purpose of the
Drawing, i.e. “TRAFFIC SIGNS AND ROAD MARKINGS”

iii) Where several Drawings depict similar detail and no other qualifications are
available for distinguishing between them, the distinction shall be made by
labelling each Drawing consecutively with sheet numbers, such as “SHEET
1 OF 10”, “SHEET 2 OF 10”, etc.

Figure 3

3.3.2 Drawing Status

The issue DRAWING

STATUS box shown below (Figure 4) shall be completed to describe the
current status of the Drawing. Refer to Table 5 for the list of Drawing sta-
tus/stages:

Figure 4

Table 5
Drawing Status
Concept Design
Preliminary Design
Detailed Design

Tender

Contract

As Built

3.3.3 Project Name Field

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For Project Name refer to Baseline Assessment Report on detailed list of Pro-
jects.

Figure 5

3.3.4 Project Code Field

For AUTHORITY-specific Project codes refer to Baseline Assessment Report

on detailed list of prioritized Projects.
Figure 6

3.3.5 Drawing Creation Date Field

The Drawing creation date shall be in the whole word format for Month and
Year as highlighted below (Figure 7):

Figure 7

3.3.6 Revision History Table

A concise description of each approved and issued revision shall be entered into the
revision description column. The revision columns indicate the history and devel-
opment of the Drawing; therefore, the description shall be as informative as is prac-
tical.

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Drawings that are issued under specific Submissions or Milestones sets shall have
clear, consistent revision description that states the purpose of the submission. e.g.
ISSUED FOR APPROVAL, etc.

Figure 8

The date shown in the revision history table shall be in the format
DDMMMYY as highlighted in Figure 9 below.

Figure 9

The months shall be abbreviated as shown in table 6 below:

Table 6

Abbreviation Month Abbreviation Month

JAN January JUL July
FEB February AUG August
MAR March SEP September
APR April OCT October
MAY May NOV November

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JUN June DEC December

The date of completion of the revision and the initials of the person effecting
the revision shall be stated.

The earliest revision descriptions shall be deleted when there is no space to

include the current revision within the revision column.

3.3.7 Drawing Number Field

Drawing number field shall be completed as highlighted box below:

Figure 10

Refer to Section 3.1 for Drawing numbering convention.

3.3.8 Revision Field Box

Revision field box shall be completed as highlighted below: Refer to 3.10.3

Figure 11

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3.3.9 Name Fields

The ‘Drawn’, ‘Designed’, ‘Checked’ and ‘Approved’ field boxes on the title block,
as highlighted below, shall include the first name initial and the full last name of the
person who performed or is responsible for the major portion of the work.

3.3.10 Drawing Scale Field

Figure 12
For completing the Drawing scale field box in the title frame, refer to Section 3.6.
A scale bar for presenting the scale of the Drawing should be used in the Drawing
layout.

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3.3.11 Signatures
Figure 13
The revision history table shall contain the current issue revision number, date
of issue, Drafter/Author, Checker, Approver signatures or initials and description
of current revision.
Table 7

TITLE BLOCK CAD HARD COPY PDF COPY

DRAWN BY See 3.3.12 See 3.3.13 See 3.3.14

CHECKED BY See 3.3.12 See 3.3.13 See 3.3.14

APPROVER BY See 3.3.12 See 3.3.13 See 3.3.14

3.3.12 CAD Files

When issued, Drawing files shall bear the typed CAD initials of the author,
checker and approver on the revision history box.

3.3.13 Hard Copy

Figure 14

The original hard copy set to be submitted shall be signed by hand and
stamped. This set will become the control set for reference. The Drawing shall
bear hand signature of the Drawing Approver beside his/her name in the

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Approved field box on the title frame as shown in Figure 15. Each Drawing
shall be stamped with the issuing company’s official stamp.

Figure 15: Signed hard copy by Approver

Original hand-signed copy is required for all ‘Final’ Drawings submitted for:
Concept design, Preliminary design, Detailed design, Tender set, Contract set,
GFC Drawings (during Construction) and As Built.

Subsequent hard copies of the submitted original do not have to be hand

signed. Scanned copies of the hand signed Drawing are permitted as long as
the clarity of the Drawing is not compromised. Alternatively, copies may be
printed directly from CAD. It is acceptable for these not to contain a copy of
the hand signature, but to bear typed initials instead.

3.3.14 PDF Copy

When Issued, PDF copy can be generated electronically from the cad file
bearing the typed initials of the author, checker and approver.

3.4 Units
All general Drawing work (e.g. Xrefs) are to be in model space and be pro-
duced in meters to three decimal places. Drawing borders to be in paper space
and in millimeters.

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e.g. 54.000
78.720
0.325
Dimensions in meters and using whole numbers, can be expressed using the
‘m’ (meter) suffix as in the following

45.000m

The position of the decimal point shall be the same as a full stop and no space
shall be left between the number and its units, to ensure clarity, as in the fol-
lowing example:

5.800m

All other non-linear measurements, e.g. areas and volumes, shall be followed
by the unit symbol. The most common non-linear measurements are as follows

2
Square meter - m
3
Cubic meter - m

All detail Drawing work (e.g. standard details) is to be in model space and be
produced in millimeters in whole numbers (i.e. no decimal places).
e.g. 10000
787

Dimensions in millimeters using whole numbers, can be expressed using

the ‘mm’ (millimeter) suffix as in the following

250mm

Chainages shall be in meters and written as shown

0+100 (Chainages in whole numbers can be written without the decimal ac-
curacy)

15+255.345

Chainages are plan measurements taken along a setting out line, and provide a
horizontal distance not taking into account slope lengths.

3.5 Drawing Sizes

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Drawing sizes shall conform to the International Standards Organization

(ISO). Sizes (in mm) are as follows: -

A0 – 1189 x 841
A1 – 841 x 594
A2 – 594 x 420
A3 – 420 x 297
A4 – 297 x 210

In general, all Drawings shall be produced at the preferred A1 original size.

The use of A0 size Drawings shall be avoided wherever possible.

Each group or set of Drawings shall use only one Drawing size unless situa-
tions make this impractical.

3.6 Scales

Scales used on Drawings shall be selected as indicated in the table below.

Only standard metric scales shall be used. In all cases, the selected scale shall
be large enough to permit easy and clear interpretation of the information de-
picted.

Specific scale requirements of particular Drawings such as layouts will be as

stated as per RFP.

Table 8
Permitted scales
1:1 1:2 1:5 2:1
1:10 1:20 1:25 1:50 5:1
1:100 1:200 1:250 1:500 10:1
1:1000 1:2000 1:2500 1:5000 20:1
1:10,000 1:20,000 1:25,000 1:50,000 50:1

In exceptional cases where for functional reasons the recommended scale can-
not be applied, intermediate scales may be chosen, provided that the required
scale is of a whole number, such as 1:125, 1:150, etc.

The following scale notes shall be considered:

i. Number of scales on any one Drawing shall be kept to a minimum.

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ii. CAD entities shall be drawn at full scale (1 Drawing unit = 1

Measurement unit). Final plotted scale shall be established during
composition of the Drawing layout for plotting.

iii. Originators using AutoCAD shall employ the PAPER

SPACE/MODEL SPACE facility to establish Drawing layout and
scales. All Drawing entities shall reside in MODEL SPACE with the
exception of view ports, general notes, revision clouding and its labels,
title block and border.

iv. Where different scales exist, each scale shall be specified under the
title of the area of the Drawing to which it applies and noted in the
Title Block field as shown below.

Figure 16

v. Where a single scale is used on a Drawing, it shall be specified within

the title block only. (See the object area and shall be large enough to
below). The scales selected shall depend on the object area and shall be
large enough to permit easy and clear interpretation of information and
ensure clarity of prints on the original as well as reduced copies i.e. A3
versions of A1 Drawings.

Figure 17

vi. Where different scales are used for horizontal and vertical dimensions,
such as in profiles, each scale shall be clearly indicated on the
Drawing as shown below:

Figure 18

vii. When the Drawing is not drawn to any scale, ‘NTS’ (Not to Scale)
shall be placed in the title block as shown below:

Figure 19

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Scale bars shall be shown on all Drawings containing plans.

3.7 Key Plan
Where layout plans are produced on a number of Drawings to cover the extent
or Section of the Project, a Key Plan shall be included on each sheet, clearly
indicating the Section of the Works under consideration. A dedicated box in
the title frame is provided for the Key Plan as shown below.

Figure 20

3.8 Drawing Notes

Notes are to be numbered and positioned appropriately and shall include the follow-
ing notes:

i. All Dimensions are in meters unless otherwise stated. (Only on Draw-

ings drawn in meters)

ii. All levels are in meters (Only on Drawings where this note is applicable)

iii. All dimensions are in millimeters unless otherwise stated. (Only on Draw-
ings drawn in millimeters)

3.9 General Notes

Where notes are, extensive and apply on several Drawings, a General Notes
Drawing shall be provided which consolidates all notes. Deviation from these notes
on a particular Drawing may be permitted, provided this amendment is shown in
the Notes section of the Drawing.
Where a General Notes Drawing is used, the first note on each applicable Drawing
shall contain the following statement: -

“1. FOR GENERAL NOTES, REFER TO DRAWING”

3.10 Drawing Revision

3.10.1 Revision Clouds and Triangles

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Each area where changes/revisions made since the last issue / submission shall be
ringed with a cloud and marked with an equilateral triangle containing the current
revision letter. Revision clouds and its triangle label shall be placed on the paper
space. Arc length of cloud shall be 15 as a general rule to maintain consistency.
Revision clouds shall be 1.0mm thick (gray or colour 252) and triangles shall
be placed on layer REV.
Clouding and revision triangles denoting the previous revision shall be removed
from the CAD file.

Figure 21

3.10.2 Revision Description

The date and description of the revision / issue shall be given in the revision history
table on the title frame.

3.10.3 Drawing Revision Code

This code identifies the Drawing revision and shall be as defined in Table 11
below. Subsequent issue of a Drawing shall have the revision coding incre-
mented by the next sequential number or letter.
Table 9

Revision / Issue Code

R01, R02, R03…. etc.

Note:
As Drawings move from one stage to another all historical revision history under
that stage is to be removed from the revision history on the title block.

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3.11 Drawing Register and Transmittal Record

The issue of Drawings shall be recorded on the Drawing register and a trans-
mittal provided by Drawing originators containing like information. The
Drawing register shall be a concise and continuous record of Drawing revi-
sions and issue history.

The current revision indicator shall be recorded for each issue.

3.12 Checking and Approval of Drawings

During Drawing production, a system of continuous checking shall be em-

ployed by the AUTHORITY to confirm that all CAD information fully com-
plies with the conditions set out in this document.

It is imperative that all Drawings are subjected to a Quality Assurance and

Quality Control (QA/QC) check and are duly signed and authorised prior to
issue. Any Drawing leaving the Drawing office shall have been properly
checked for presentation, clarity, accuracy, technical correctness and compli-
ance with the relevant CAD Standard. Refer to the flow chart overleaf in Fig-
ure 22 for an overview of the checking procedure.

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Figure 22: Flow diagram showing overview of CAD Drawing checking procedure

3.12.1 Self Check

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After preparation, the Drawing shall be checked by the Drawing originator and
any required amendment to the Drawing is to be carried out prior to
handing over the check print for checking.

3.12.2 Drafting Check

Generally, the Drafting Check must precede the Engineering Check.

The Drafting Check will normally be carried out by a person designated by
the CAD Office representative/Manager.

The Drafting Check shall verify adherence to the Project Brief in conjunc-
tion with any applicable supplied criteria. The checker shall also make an as-
sessment with respect to presentation, standard of workmanship and adherence
to the CAD Standard Manual.

The Drafting Check shall, where deemed necessary, include an electronic

check of the CAD File to ensure compliance with applicable standards and/or
client requirements.

The check print shall be clearly marked by the checker with any required mod-
ifications.

Upon completion of the Drafting Check the checker shall then sign, date and
highlight the required action to be taken.

Any amendment to the Drawing requirements may, if required, be carried out

prior to the Engineering Check and a new print raised, duly stamped and signed.

3.12.3 Engineering Check

The Engineering check will normally be carried out by a competent and rele-
vant experienced Senior Engineer within the AUTHORITY’s organization.

The Engineering check shall verify adherence to the design calculations, de-
sign standards and associated Construction issues.

Upon completion of the Engineering Check, the checker shall then sign, date
and highlight the required action to be taken.

3.12.4 Further Drawing amendments

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Upon completion of the Drafting Check and Engineering Check the completed
check print shall be returned to the originator of the Drawing for amendment
of the Drawing. Where required, further check prints shall be raised and the
checks repeated.

3.12.5 Approval
Upon completion of the checking process, a clean print of the Drawing
shall be submitted to the relevant checkers for signature and to the designated
authority for approval. This then becomes the controlled Drawing for refer-
ence. The checker’s and approver’s initials together with the relevant dates
shall be entered in the appropriate areas of the CAD file.

4.1 Drawing set up

i. All AutoCAD Drawings should be produced & saved in AutoCAD

version not lowers than 2009.

ii. Pre-defined Project Drawing templates will be used for setting the
layers of identifiable Drawings (e.g. drainage, roads).

iii. Units in AutoCAD shall be set to meters for Infrastructure layouts

and profiles and millimeters for detail Drawings such as standard
details.

iv. The CAD files provided will be in the current version of

AutoCAD file format used on the Project.

v. Fonts and line types are to be followed as provided in this manual.

vi. Files shall be purged before issue only.

vii. Drawing features/entities must be in model space. Title frames must

be in paper space.

viii. The colour and line type of each entity is drawn on BY LAYER.

ix. All polygons shall be closed polylines.

x. Do not place entities on layer 0. This layer is for the creation of

blocks only.

4.2 Line Work

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4.2.1 Line Types

i. The following guidelines shall apply to the use of line types:

ii. LINETYPE to be set BYLAYER. (Deviation: Standard AutoCAD

Blocks)

iii. All layers shall have their entities set to ‘BYLAYER’

iv. All colours of AutoCAD objects to be BYLAYER. (Deviation:

Standard AutoCAD Blocks)

v. The plotted appearance of line types shall be consistent across all

Drawings.

vi. Modification of AutoCAD default source file is not permitted.

vii. Lines on a Drawing that cannot be represented by those in the

default AutoCAD source file may be loaded from the approved
Custom line types provided.

4.2.2 Line Weights

Table 10

Plotted Line
Display
Colour No. Weight Plotted Colour
Screen Color
(mm)
ADCL_COL_ ADCL_BW
A1.CT _A1.CT
1 RED 0.18 BLACK BLACK
2 Yellow 0.25 BLACK BLACK
3 Green 0.35 BLACK BLACK
4 Cyan 0.50 BLACK BLACK
5 Blue 0.70 BLACK BLACK
6 Magenta 0.35 BLACK BLACK
7 White 0.25 BLACK BLACK
8 Dark Grey 0.20 Object Colour Object
9 Light Grey 0.15 Object Colour Colour
10 Object Colour 0.6 Object Colour BLACK
11-79 & 81-249 Object Colour 0.35 Object Colour BLACK
80 Object Colour 0.6 Object Colour BLACK
Object
250-255 (Greys) Object Colour 0.15 Object Colour
Colour

4.3 Text

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4.3.1 General

i. The AutoCAD Styles shall have a default height setting = 0.

ii. Sloping, italic, and elaborate fonts are not permitted.

iii. The objective shall be to make all lettering highly legible so that
information can be communicated with the minimal possibility of
error in reading. Lettering sizes shall be chosen such that it shall
remain legible when Drawings are reduced to A3 size.

iv. Lettering shall be consistent, both in size and placement.

Lettering sizes for specific applications, such as notes or titles,
shall not vary within the same Drawing.
v. Lettering shall be uniform, clear, sharp and distinct. The mixing
of lettering styles, sloping, italic, and elaborate fonts shall not be
permitted.
vi. All text shall be regularly spaced, upright and uppercase and not
be underlined. Deviation: Titles under plans, details etc. are to be
underlined.

vii. All text shall be left justified. Deviation: Titles shall be centre
justified and underlined.
viii. Specific notations shall be carefully placed so they relate to the
portion of the Drawing or detail to which they apply.
ix. The placing of notes through Drawing lines is to be avoided.
x. Leader arrows relating to specific text or annotation shall be
placed in model space with the detail it is referencing on the same
layer as the text to which it relates.

4.3.2 Fonts

Permitted text fonts are as shown below:

Table 11

Auto CAD Style Auto CAD Font CAD

Name File Usage
Technical/Engineering
ISOCP ISOCP.SHX
Drawings

ARIAL ARIAL.TTF Presentation Drawings

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4.3.3 Text Assignments

The table below indicates approved texts with their appropriate colour/ap-
plication assignments:
Table 12

Plotted Text Plotted

Width Fac-
Height Line Usage
tor
(mm) weight
General text, Dimensions, Notes
– used on A3 & A4 only where
1
1.8 0.18 Drawing is not plotted at a re-
duced scale.
General text annotations, Dimen-
2.5 1 0.25 sions, Notes Special Notes
For more prominent notes or la-
3.5 1 0.35 bels requiring special emphasis.
Normal Titles, Drawing Num-
5.0 1 0.5 bers, Section titles, Detail Titles
7.0 1 0.7 Major Titles

i. The preferred text height for general text and notes is 2.5mm.

ii. The text height adopted for a Project shall be consistent across
all Drawings unless situations make this impractical.

4.4 Dimensioning
Automated dimensioning commands within CAD software programs shall be used
for creation and editing of dimensions, as shown in table 16 below. The editing of
dimension values via basic text editing commands is not permitted. Dimensions
shall be associative and placed on their own unique layer.

Table 13
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Dimension Extension
Extension Stack Off-
Text Line Arrow Size Centre Mark
Line Offset set
Height Extension

2.5mm Dimexo = 2 Dimexe = 2 Dimdli=6.25 Dimasz= 2.5 Dimcen = 1

4.5 Standard Symbols and Blocks

In order to promote consistency, standard symbols shall be utilized. All blocks are to be
inserted into the Drawing on its appropriate Drawing layer. Where a symbol required is
not available from the blocks provided with this manual, symbols compliant to Interna-
tional standards shall be used. These new blocks shall be submitted to AUTHORITY to
update the list of standard symbols library for the programme.

All symbols shall be consistent within a Drawing or set of Drawings.

All blocks that need to be created as new blocks shall have all their elements saved
on layer 0.

All symbols used within a Drawing must be defined using a legend.

4.6 Hatching

Wherever possible, all hatching created shall be associative and placed on its own
unique layer. Exploding of hatches must be avoided.

4.7 Colours

In AutoCAD, entity colour shall be assigned “By Layer”. Deviation can be on

standard blocks, i.e. are Road signs blocks where specific standard colours are assigned
for each.

4.8 Layering

CAD Layering shall be in accordance with AUTHORITY AutoCAD Layering Stand-

ards as included in Appendix A of this document. Additional layers may be required

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and the naming of such layers must be in the same format in accordance with AU-
THORITY AutoCAD Layering Standards as shown in Section 4.8.1.

4.8.1 Layer Name Layout

Where new layers are to be created the AutoCAD layer naming convention is as
follows:

1 2 3
RD_EX_CNRL

Where:
1 = Department Designator
2 = Status / Section Designator
3 = Feature / Entity Designator

Department Designator (Field 1)

This code identifies the AUTHORITY Department (i.e. B = Building Affairs,

D = Drainage
Affairs and RD = Roads Affairs.)
Status / Section Designator (Field 2)

This code identifies the main classification of the type of element within a
discipline. For example
‘’EX_SEW” describes as existing sewer.

Feature / Entity Designator (Field 3)

This code further identifies the entity description feature name. For example, ‘’ABD”
describes as the abandoned sewerage network.

4.8.2 List of AUTHORITY Standard Layers

See Appendix A.

4.9 Models/Reference Files (Drefs)

i. Where CAD data is to be shared between Drawings the use of reference

files is to be adopted.
ii. All reference files are to be inserted in model space with the UCS set to
‘world’. All files are to be inserted at 0,0,0.
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iii. Unused reference files shall be detached upon completion of Drawings.

iv. The number of reference files on a Project shall be kept to a minimum.
v. The preferred method of attaching Drefs shall be Overlay option.
vi. Reference files shall be inserted on unique layer that does not conflict
with the general content of the Drawing. (i.e. layer Z_DREF in AutoCAD).
vii. Reference files shall be “CLIPPED” within the Active Drawing sheet file
to ensure that only the design data relevant to the Drawing is displayed.
viii. Reference files issued externally or shared between departments shall
indicate revised areas with a revision cloud and triangle. A revision history
shall be maintained within the reference file. In AutoCAD, the revision
history log shall be placed in paper space, see Figure 29 below.
ix. For Model File Naming refer to Section 3.2

4.10 Plotting

The following standard colour source files shall be used:

Figure 23

Table 14

Colour Black and White

Aarvee-CRDA--COL_A1.CTB Aarvee-CRDA-BW_A1.CTB

This standard colour source file shall be flexible and can be adjusted to suit user’s
need during plotting. When Drawing, files are required, CTB file used for the plotting
of the Drawing must also be submitted.

4.10.1 Date and File location update

These are field entities contained within the Drawing border and are used to print the
date and time of print, file location, file name, etc.

4.11 Data Submission Standards

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All Drawing files must conform to the AutoCAD layering standards set forth in this
document.

4.11.1 Submission

Refer to Programme Management Information System (PMIS) and Document.

Management procedures on submission of Drawing.

4.11.2 File Format

Digital submittals shall be in PDF format & CAD format. DWG files must be in ZIP
format when submitted in soft copy in CD. Also, refer to Document Management Pro-
cedures for submission of document.

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Appendix A – AUTOCAD LAYERS DEFINITIONS

A.1 General Layers

CORE LAYERS NON-DISCIPLINE

Layer Name Screen Line type Plotted Description

Colour Line weight

Z_18TEXT red Continuous 0.18 TEXT AT RESPECTIVE HEIGHT

Z_25TEXT wh ite Continuous 0.25 TEXT AT RESPECTIVE HEIGHT

Z_35TEXT green Continuous 0.35 TEXT AT RESPECTIVE HEIGHT

Z_50TEXT cyan Continuous 0.50 TEXT AT RESPECTIVE HEIGHT

Z_70TEXT blue Continuous 0.70 TEXT AT RESPECTIVE HEIGHT

Z_DIMS red Continuous 0.18 ALL DIMENSIONS

Z_DWG_GRID 251 Continuous 0.15 DESIGN ROAD FEATURE: GRID

Z_DWG_SHT wh ite Continuous 0.25 DRAWING SHEET & TITLE

BLOCK
Z_NORTH green Continuous 0.35 NORTH POINT

Z_REV yellow Continuous 0.25 REVISION CLOUD SAND TRIAN-

GLE
Z_SECMK green Continuous 0.35 SECTION AND DETAIL MARKS

Z_XREF wh ite Continuous 0.25 EXTERNAL REFERENCE (XREF)

GIS LAYERS

Layer Name Screen Line type Plotted Line Description

Colour weight

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ACAD_ISO13W100
GIS_ACQ_BDRY 20 0.25 LAND AQUISITION
BOUNDARY

GIS_CADAS- red Continuous 0.18 CADASTRAL PLOT

TRAL

GIS LAYERS

Layer Name Screen Line type Plotted Line Description

Colour weight

GIS_CNTRS 9 Continuous 0.15 CONTOURS

GIS_CNTRS_TE red Continuous 0.18 CONTOURS TEXT

XT

GIS_CSTL 90 Continuous 0.35 COASTLINE

GIS_FLOWLINE 8 Continuous 0.20 FLOWLINES

GIS_PPLN 252 Continuous 0.15 POLICY PLAN

GIS_RD01 121 Continuous 0.35 MAJOR ROAD

GIS_RD02 151 Continuous 0.35 MINOR ROAD

GIS_RD03 181 Continuous 0.35 STREETS

PROPOSED RIGHT OF
GIS_ROW_BDRY 170 PHANTOM2 0.35 WAY BOUNDARY

GIS_ZONE 13 Continuous 0.35 ZONE

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A.2 Drainage layers

A.2.1 Surface Ground Water

PROPOSED SURFACE GROUND WATER (SGW)

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

PROPOSED SURFACE GROUND

D_PR_SGW 80 SGW_PR 0.6 WATER LINES

PROPOSED SGW ATTRIBUTES

Continuous (ID, Diameter, Length, Material etc.)
D_PR_SGW_ATT white 0.25

PROPOSED SURFACE GROUND WATER (SGW)

Plotted
Screen
Layer Name Line type Line Description
Colour
weight
PROPOSED SGW DISCHARGE
D_PR_SGW_DCH 90 Continuous 0.35
CHAMBER
PROPOSED SGW DRAIN
D_PR_SGW_DT yellow Continuous 0.25
TRENCH
PROPOSED SGW FLUSHING
D_PR_SGW_FCH 90 Continuous 0.35
CHAMBER

D_PR_SGW_FLOW white Continuous 0.25 ROPOSED SGW FLOW ARROW

PROPOSED SGW FLOWMETER

D_PR_SGW_FMC 90 Continuous 0.35
CHAMBER
PROPOSED SGW GULLY CON-
D_PR_SGW_GC 90 Continuous 0.35
NECTION

D_PR_SGW_GL 90 Continuous 0.35 PROPOSED SGW GULLY

PROPOSED SGW INSPECTION

D_PR_SGW_ICH 90 Continuous 0.35
CHAMBER
PROPOSED SGW INTAKE
D_PR_SGW_ITCH 90 Continuous 0.35
CHAMBER

D_PR_SGW_MH 90 Continuous 0.35 PROPOSED SGW MANHOLE

1141
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PROPOSED SGW MANHOLE

D_PR_SGW_MH_A Continuous ATTRIBUTES
white 0.25
TT (ID, Depth, Cov. Lvl, Inv. Lvl, etc )
PROPOSED SGW OUTFALL
D_PR_SGW_OFCH 90 Continuous 0.35
CHAMBER
PROPOSED SGW PUMP STA-
D_PR_SGW_PS 90 Continuous 0.35
TION

D_PR_SGW_RM 90 RM_PR 0.35 PROPOSED SGW RISING MAIN

D_PR_SGW_VALV 90 Continuous 0.35 PROPOSED SGW VALVE

PROPOSED SGW VALVE

D_PR_SGW_VC 90 Continuous 0.35
CHAMBER
PROPOSED SGW WASHOUT
D_PR_SGW_WCH 90 Continuous 0.35
CHAMBER

EXISTING SURFACE GROUND WATER (SGW)

Plotted
Screen Line
Layer Name Line type Description
Colour weight

EXISTING SURFACE
D_EX_SGW 96 SGW_EX 0.35 GROUND WATER LINES
EXISTING SGW ATTRIBUTES
Continuous (ID, Diameter, Length, Material
D_EX_SGW_ATT white 0.25
etc.)
EXISTING SGW DISCHARGE
D_EX_SGW_DCH 96 Continuous 0.35
CHAMBER
EXISTING SGW DRAIN
D_EX_SGW_DT yellow Continuous 0.25
TRENCH
EXISTING SGW FLUSHING
D_EX_SGW_FCH 96 Continuous 0.35
CHAMBER

D_EX_SGW_FLOW white Continuous 0.25 ROPOSED SGW FLOW ARROW

EXISTING SGW FLOWMETER

D_EX_SGW_FMC 96 Continuous 0.35
CHAMBER
EXISTING SGW GULLY CON-
D_EX_SGW_GC 96 HIDDEN2 0.35
NECTION

D_EX_SGW_GL 96 Continuous 0.35 EXISTING SGW GULLY

1142
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EXISTING SGW INSPECTION

D_EX_SGW_ICH 96 Continuous 0.35
CHAMBER
EXISTING SGW INTAKE
D_EX_SGW_ITCH 96 Continuous 0.35
CHAMBER

D_EX_SGW_MH 96 Continuous 0.35 EXISTING SGW MANHOLE

EXISTING SGW MANHOLE

D_EX_SGW_MH_A Continuous 0.35 ATTRIBUTES (ID, Depth, Cov.
96
TT Lvl, Inv. Lvl, etc.)
EXISTING SGW OUTFALL
D_EX_SGW_OFCH 96 DASHED2 0.25
CHAMBER

D_EX_SGW_PS 96 Continuous 0.35 EXISTINGSGW PUMP STATION

D_EX_SGW_RM 96 RM_EX 0.35 EXISTING SGW RISING MAIN

D_EX_SGW_VALV 96 Continuous 0.35 EXISTING SGW VALVE

EXISTING SURFACE GROUND WATER (SGW)

Plotted
Screen Line
Layer Name Line type Description
Colour weight
EXISTING SGW VALVE
D_EX_SGW_VC 96 Continuous 0.25
CHAMBER
EXISTING SGW WASHOUT
D_EX_SGW_WCH 96 Continuous 0.25
CHAMBER

1143
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A.2.2 Domestic Sewage Water

PROPOSED DOMESTIC SEWAGE LINE

Screen Plotted
Layer Name Line type Description
Colour Line
DESIGN SEWER FEATURE:
SEW_DE_PSWR 242 SEW_PR 0.35 PROPOSED SEWER LINES

DESIGN SEWER FEATURE:

SEW_DE_MH 242 Continuous 0.25
MANHOLE
DESIGN SEWER FEATURE:
SEW_DE_SWPS 242 Continuous 0.25 SEWAGE PUMPING
STATION
DESIGN SEWER FEATURE:
SEW_DE_VSHFT 242 Continuous 0.25
VENT SHAFT

DESIGN SEWER FEATURE:

SEW_DE_SCONN 242 Continuous 0.25
SEWER CONNECTION

DESIGN SEWER FEATURE:

SEW_DE_MHFC 242 Continuous 0.25
MANHOLEFRAME & COVER

DESIGN S EW ER FEATURE:
SEW_DE_STP 242 Continuous 0.25 SEWAGE TREATMENT
PLANT
DESIGN SEWER FEATURE:
SEW_DE_PM 242 Continuous 0.25
SEWAGE PUMPING MAIN

1144
Amaravati Development Corporation Limited

A.2.3 Industrial Effluent Design Layers

PROPOSED INDUSTRIAL EFFLUENT

Plotted
Screen
Layer Name Line type Line Description
Colour
weight
DESIGN INDUSTRIAL EF-
FLUENT FEATURE: PRO-
INEFF_DE_PINEF white Continuous 0.35
POSED INDUSTRIAL EFFLU-
ENT
DESIGN INDUSTRIAL EF-
INEFF_DE_VSHFT white Continuous 0.25 FLUENT FEATURE: VENT
SHAFT
DESIGN INDUSTRIAL EF-
FLUENT FEATURE: INDUS-
INEFF_DE_IEPS white Continuous 0.25
TRIAL EFFLUENT
PUMPING STATION
DESIGN INDUSTRIAL
EFFLUENT FEATURE: SEC-
INEFF_DE_SINLET wh ite Continuous 0.25
TONDARY TREATMENT
PLANT INLET S
INEFF_DE_TER-
DESIGN INDUSTRIAL EF-
TIARY
white Continuous 0.25 FLUENT FEATURE: TER-
TREATMETN
TIARY TREATMENT PLANT
PLANT

A.2.4 Potable Water

PROPOSED POTABLE WATER LINE

Layer Name Screen Line type Plotted Description

Colour Line
weight

DESIGN POTABLE WATER

PW_DE_PWTM Blue Continuous 0.35 FEATURE: POTABLE
WATER TRANSMISSION
MAIN
DESIGNPOTABLE WATER
PW_DE_PWDIST Blue Continuous 0.25 FEATURE: POTABLE WATER
DISTRIBUTION

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PROPOSED POTABLE WATER LINE

Layer Name Screen Line type Plotted Description

Colour Line
weight

DESIGN POTABLE WATER

PW_DE_PWPS Blue Continuous 0.25 FEATURE: POTABLE
WATER PUMPING STATION
DESIGN POTABLE WAT E R
PW_DE_VCH Blue Continuous 0.25 FEATURE: VALVECHAMBER
DESIGN POTABLE WATER
PW_DE_FH Blue Continuous 0.25 FEATURE: FIRE HYDRANT
DESIGN POTABLE WATER
PW_DE_POTRES Blue Continuous 0.25 FEATURE: POTABLE WATER
RESERVOIR
DESIGN POTABLEWATER
PW_DE_PWM Blue Continuous 0.25 FEATURE: POTABLE WATER
METER
DESIGN POTABLE WATER
PW_DE_PWFIT Blue Continuous 0.25 FEATURE:
POTABLE WATER FITTINGS

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Amaravati Development Corporation Limited

A.2.5 Recycled Water

PROPOSED RECYCLED WATER

Layer Name Screen Line type Plotted Description
Colour Line
weight
DESIGN RECYCLED WATER
RW_DE_RWPM Green Continuous 0.35 FEATURE: RECYCLED WATER
PUMPING MAIN
DESIGN RECYCLED WATER
RW_DE_RWDIST Green Continuous 0.025 FEATURE: RECYCLED WATER
DISTRIBUTION
DESIGN RECYCLED WATER
RW_DE_RWPS Green Continuous 0.025 FEATURE: RECYCLED WATER
PUMPING STATION
DESIGN RECYCLED WATER
RW_DE_RWRES Green Continuous 0.025 FEATURE: RECYCLED WATER
RESERVOIR
DESIGN RECYCLED WATER
RW_DE_RWVCH Green Continuous 0.025 FEATURE: RECYCLED WATER
VALVE CHAMBER
DESIGN RECYCLED WATER
RW_DE_RWFIT Green Continuous 0.025 FEATURE: RECYCLED WATER
FITTINGS

A.3 ROAD LAYERS

A.3.1 Road Design Layers

PROPOSED ROAD

Plotted
Screen
Layer Name Line type Line Description
Colour
weight
DESIGN ROAD FEATURE: ANI-
RD_DE_AFNCE 22 FENCELINE1 0.35
MAL FENCE
RD_DE_BICYL green Continuous 0.35 BICYCLE LANE

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PROPOSED ROAD

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

DESIGN ROAD FEATURE:

RD_DE_BRDG yellow Continuous 0.25 BRIDGE FLYOVER

DESIGN ROAD FEATURE:

RD_DE_CHNL red HIDDEN2 0.18
CHANNEL
DESIGN ROAD FEATURE:
ENTRAL/ROUNDABOUT IS-
RD_DE_CILND green Continuous 0.35
LAND
DESIGN ROAD FEATURE:
RD_DE_CLMN red Continuous 0.18
COLUMN
DESIGN ROAD FEATURE:
RD_DE_CLVT white Continuous 0.25
CULVERT
DESIGN ROAD FEATURE:
RD_DE_CNRL red CENTER2 0.18
CENTERLINE
DESIGN ROAD FEATURE:
CONCRETE SLOPE PROTEC-
RD_DE_CSLPE magenta Continuous 0.35
TION
DESIGN ROAD FEATURE:
RD_DE_ECWAY cyan Continuous 0.5 EDGE OF CARRIAGEWAY
FENCELINE DESIGN ROAD FEATURE:
RD_DE_FNCE green 0.35
2 FENCE
DESIGN ROAD FEATURE:
RD_DE_FTPH 11 Continuous 0.35
FOOTPATH
DESIGN ROAD FEATURE:
RD_DE_GRAIL white Continuous 0.25
GUARD RAIL
DESIGN ROAD FEATURE: IS-
RD_DE_ILND green HIDDEN2 0.35
LAND
DESIGN ROAD FEATURE:
RD_DE_JILND green Continuous 0.35 JUNCTION ISLAND
DESIGN ROAD FEATURE:
RD_DE_KBDD green HIDDEN2 0.35
DROPPED KERB
DESIGN ROAD FEATURE:
RD_DE_KBED white Continuous 0.25
EDGE KERB
DESIGN ROAD FEATURE:
RD_DE_KBFL yellow DASHED2 0.25
FLUSH KERB
DESIGN ROAD FEATURE:
RD_DE_KBRD cyan Continuous 0.5
RAISED KERB

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PROPOSED ROAD

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

RD_DE_LOW blue DASHDOT2 0.7 LIMIT OF WORKS

DESIGN ROAD FEATURE:
RD_DE_EMBK yellow Continuous 0.25
EMBANKMENT
DESIGN ROAD FEATURE:
RD_DE_MEDIAN green Continuous 0.35
MEDIAN
DESIGN ROAD DATA:
RD_DE_OTHR red Continuous 0.18 OTHER INFORMATION

DESIGN ROAD FEATURE:

RD_DE_PBAY green Continuous 0.35
PARKING BAY
DESIGN ROAD FEATURE:
RD_DE_PDCR 8 Continuous 0.2 PEDESTRIAN CROSSING

DESIGN ROAD FEATURE:

RD_DE_PRAMP green Continuous 0.35 PEDESTRIAN RAMP
DESIGN ROAD FEATURE:
RD_DE_PRKG white Continuous 0.25
PARKING
DESIGN ROAD DATA: IPS,
RD_DE_PTS yellow Continuous 0.25 CURVE POINTS ETC
DESIGN ROAD FEATURE:
PAVEMENT (BITUMINOUS,
RD_DE_PVMT 8 Continuous 0.2
CONCRETE ETC.)
RD_DE_RAILWAY white TRACKS 0.25 DESIGN ROAD FEATURE:
RAILWAY
RD_DE_RAMP yellow Continuous 0.25 DESIGN ROAD FEATURE:
RAMP
RD_DE_RLVL white Continuous 0.25 DESIGN ROAD FEATURE:
ROAD LEVEL
RD_DE_RNDA white Continuous 0.25 DESIGN ROAD FEATURE:
ROUND ABOUT
DESIGN ROAD FEATURE:
RD_DE_RSTL white Continuous 0.25 ROAD SPEED TABLE

RD_DE_SHLDR green Continuous 0.35 DESIGN ROAD FEATURE:

SHOULDER

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PROPOSED ROAD

Plotted
Screen
Layer Name Line type Line Description
Colour
weight
DESIGN ROAD FEATURE:
RD_DE_SPTR 20 Continuous 0.35
ROAD
SEPARATOR

PROPOSED ROAD

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

DESIGN ROAD FEATURE:

RD_DE_UPSS yellow Continuous 0.25 UNDERPASS TUNNEL

DESIGN ROAD FEATURE:

RD_DE_URARE
40 DASHED2 0.35 UTILITY RESERVE AREA
A
DESIGN ROAD FEATURE:
RD_DE_VBAR magenta Continuous 0.35 VEHICLE BARRIER
DESIGN ROAD FEATURE:
RD_DE_VERGE yellow Continuous 0.25
VERGE

EXISTING ROAD

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

EXISTING ROAD FEATURE:

RD_EX_AFNCE 22 FENCELINE1 0.35 ANIMAL FENCE

RD_EX_BICYL green Continuous 0.35 BICYCLE LANE

EXISTING ROAD FEA-

RD_EX_BRDG yellow Continuous 0.25
TURE: BRIDGE FLYOVER
EXISTING ROAD FEATURE:
RD_EX_CHNL red HIDDEN2 0.18
CHANNEL

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EXISTING ROAD FEATURE:

ENTRAL/ROUNDABOUT IS-
RD_EX_CILND green Continuous 0.35
LAND
EXISTING ROAD FEATURE:
RD_EX_CLMN red Continuous 0.18
COLUMN
EXISTING ROAD FEATURE:
RD_EX_CLVT white Continuous 0.25
CULVERT
EXISTING ROAD FEATURE:
RD_EX_CNRL red CENTER2 0.18
CENTERLINE

EXISTING ROAD

Plotted
Screen
Layer Name Line type Line Description
Colour
weight
EXISTING ROAD FEATURE:
CONCRETE SLOPE PROTEC-
RD_EX_CSLPE magenta Continuous 0.35
TION
EXISTING ROAD FEATURE:
RD_EX_ECWAY cyan Continuous 0.5 EDGE OF CARRIAGEWAY
EXISTING ROAD FEATURE:
RD_EX_FNCE green FENCELINE2 0.35
FENCE
EXISTING ROAD FEATURE:
RD_EX_FTPH 11 Continuous 0.35
FOOTPATH
EXISTING ROAD FEATURE:
RD_EX_GRAIL wh ite Continuous 0.25
GUARD RAIL
EXISTING ROAD FEATURE:
RD_EX_ILND green HIDDEN2 0.35
ISLAND
EXISTING ROAD FEATURE:
RD_EX_JILND green Continuous 0.35 JUNCTION ISLAND

EXISTING ROAD FEATURE:

RD_EX_KBDD green HIDDEN2 0.35 DROPPED KERB
EXISTING ROAD FEATURE:
RD_EX_KBED white Continuous 0.25
EDGE KERB
EXISTING ROAD FEATURE:
RD_EX_KBFL yellow DASHED2 0.25
FLUSH KERB
EXISTING ROAD FEATURE:
RD_EX_KBRD cyan Continuous 0.5
RAISED KERB
RD_EX_LOW blue DASHDOT2 0.7 LIMIT OF WORKS

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EXISTING ROAD

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

EXISTING ROAD FEATURE:

RD_EX_EMBK yellow Continuous 0.25 EMBANKMENT
EXISTING ROAD FEATURE:
RD_EX_MEDIAN green Continuous 0.35
MEDIAN
EXISTING ROAD DATA:
RD_EX_OTHR red Continuous 0.18 OTHER INFORMATION
EXISTING ROAD FEATURE:
RD_EX_PBAY green Continuous 0.35
PARKING BAY
RD_EX_PDCR 8 Continuous 0.2 EXISTING ROADFEATURE:
PEDESTRIAN CROSSING

EXISTING ROAD

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

EXISTING ROAD FEATURE:

RD_EX_PRAMP green Continuous 0.35 PEDESTRIAN RAMP
EXISTING ROAD FEATURE:
RD_EX_PRKG white Continuous 0.25
PARKING
EXISTING ROAD DATA: IPS,
RD_EX_PTS yellow Continuous 0.25 CURVE POINTS ETC
EXISTING ROAD FEATURE:
PAVEMENT (BITUMINOUS,
RD_EX_PVMT 8 Continuous 0.2
CONCRETE ETC.)
RD_EX_RAIL- EXISTING ROAD FEATURE:
white TRACKS 0.25
WAY RAILWAY
EXISTING ROAD FEATURE:
RD_EX_RAMP yellow Continuous 0.25
RAMP
EXISTING ROAD FEATURE:
RD_EX_RLVL white Continuous 0.25
ROAD LEVEL
EXISTING ROAD FEATURE:
RD_EX_RNDA white Continuous 0.25 ROUND ABOUT

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EXISTING ROAD

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

EXISTING ROAD FEATURE:

RD_EX_RSTL white Continuous 0.25 ROAD SPEED TABLE

RD_EX_SHLDR green Continuous 0.35 EXISTING ROAD FEATURE:

SHOULDER
EXISTING ROAD FEATURE:
RD_EX_SPTR 20 Continuous 0.35 ROAD SEPARATOR

EXISTING ROAD FEATURE:

RD_EX_UPSS yellow Continuous 0.25 UNDERPASS TUNNEL

EXISTING ROAD FEATURE:

RD_EX_URARE
40 DASHED2 0.35 UTILITY RESERVE AREA
A
EXISTING ROAD FEATURE:
RD_EX_VBAR magenta Continuous 0.35 VEHICLE BARRIER

RD_EX_VERGE yellow Continuous 0.25 EXISTING ROAD FEATURE:

VERGE

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A.3.2 Traffic and Safety

TRAFFIC & SAFETY - DESIGN

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

TRAFFIC: BARRIERS,
RD_DE_TS_BARL green Continuous 0.35 RAILS & BOLLARDS

TRAFFIC: CONTROL BOX

RD_DE_TS_CTRL- Continuous OR SERVICE BOX
red 0.18
BOX
RD_DE_TS_DET-
8 Continuous 0.2 TRAFFIC: DETECTOR LOOP
LOOP

RD_DE_TS_DUCT 30 Continuous 0.35 TRAFFIC: DUCT

RD_DE_TS_HMPL 8 Continuous 0.2 TRAFFIC: SPEED HUMP

Continuous TRAFFIC: INSPECTION

RD_DE_TS_INCH 12 0.35
CHAMBER

RD_DE_TS_MNHL yellow Continuous 0.25 TRAFFIC: MANHOLE

RD_DE_TS_OHLL white Continuous 0.25 TRAFFIC: OVERHEAD CA-

BLE/LINE
RD_DE_TS_OTHR yellow Continuous 0.25 TRAFFIC: OTHER

RD_DE_TS_PBDG 31 Continuous 0.35 TRAFFIC: PEDESTRIAN

BRIDGE
RD_DE_TS_PGR 40 Continuous 0.35 TRAFFIC: PEDESTRIAN
GUARDRAIL
RD_DE_TS_PUP 13 Continuous 0.35 TRAFFIC: PEDESTRIAN UN-
DERPASS
TRAFFIC: ROAD DIREC-
TIONAL SIGNS (EX: DIREC-
RD_DE_TS_RDSN yellow Continuous 0.25
TIONS, LIMITS ETC.)
TRAFFIC: SIGNS
(EX: WARNINGS, SPEED
RD_DE_TS_SIGN white Continuous 0.25
LIMITS ETC.)
RD_DE_TS_SIGN-
white Continuous 0.25 TRAFFIC: SIGN POST
POST

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TRAFFIC & SAFETY - DESIGN

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

RD_DE_TS_SIGNAL white Continuous 0.25 TRAFFIC SIGNAL

RD_DE_TS_SIGNAL- TRAFFIC SIGNAL

POST white Continuous 0.25 POST/POLE

RD_DE_TS_STNM green Continuous 0.35 TRAFFIC: STREET NAME

POST/SIGN
RD_DE_TS_STUDS 8 Continuous 0.2 TRAFFIC: STUDS

TRAFFIC: ANNOTATIONS /
RD_DE_TS_TEXT white Continuous 0.25 DESCRIPTIVE TEXT
TRAFFIC: POLICE PLAT-
RD_DE_TS_TPP 8 Continuous 0.2
FORM

RD_DE_TS_UGLL yellow Continuous 0.25 TRAFFIC: UNDERGROUND

CABLE/LINE

TRAFFIC & SAFETY - EXISTING

Plotted
Screen
Layer Name Line type Line Description
Colour
weight
TRAFFIC: BARRIERS, RAILS
RD_DE_TS_BARL green Continuous 0.35 & BOLLARDS
TRAFFIC: CONTROL BOX OR
RD_EX_TS_CTRL- red Continu- 0.18 S E RV IC E BOX
BOX
RD_EX_TS_DET- ous
8 Continuous 0.2 TRAFFIC: DETECTOR LOOP
LOOP
RD_EX_TS_DUCT 30 Continuous 0.35 TRAFFIC: DUCT

RD_EX_TS_HMPL 8 Continuous 0.2 TRAFFIC: SPEED HUMP

TRAFFIC: INSPECTION CHAM-

RD_EX_TS_INCH 12 Continuous 0.35
BER
RD_EX_TS_MNHL yellow Continuous 0.25 TRAFFIC: MANHOLE

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TRAFFIC & SAFETY - EXISTING

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

RD_EX_TS_OHLL white Continuous 0.25 TRAFFIC: OVERHEAD CA-

BLE/LINE
RD_EX_TS_OTHR yellow Continuous 0.25 TRAFFIC: OTHER

RD_EX_TS_PBDG 31 Continuous 0.35 TRAFFIC: PEDESTRIAN

BRIDGE
RD_EX_TS_PGR 40 Continuous 0.35 TRAFFIC: PEDESTRIAN
GUARDRAIL

TRAFFIC & SAFETY - EXISTING

Plotted
Screen
Layer Name Line type Line Description
Colour
weight
TRAFFIC: PEDESTRIAN UN-
RD_EX_TS_PUP 13 Con tinuous 0.35
DERPASS
TRAFFIC: ROAD
DIRECTIONAL SIGNS
RD_EX_TS_RDSN yellow Continuous 0.25
(EX: DIRECTIONS, LIMITS
ETC.)
TRAFFIC: SIGNS
(EX: WARNINGS, SPEED LIM-
RD_EX_TS_SIGN white Continuous 0.25
ITS ETC.)
RD_EX_TS_SIGN-
white Continuous 0.25 TRAFFIC: SIGN POST
POST
RD_EX_TS_SIGNAL white Continuous 0.25 TRAFFIC SIGNAL

RD_EX_TS_SIGNAL-
white Continuous 0.25 TRAFFIC SIGNAL POST/POLE
POST
TRAFFIC: STREET NAME
RD_EX_TS_STNM green Continuous 0.35
POST/SIGN
RD_EX_TS_STUDS 8 Continuous 0.2 TRAFFIC: STUDS

TRAFFIC: ANNOTATIONS
RD_EX_TS_TEXT white Continuous 0.25
/DESCRIPTIVE TEXT

RD_EX_TS_TPP 8 Continuous 0.2 TRAFFIC: POLICE PLATFORM

TRAFFIC: UNDERGROUND
RD_EX_TS_UGLL yellow Continuous 0.25
CABLE/LINE

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A.3.3 Street Lighting Layers

STREET LIGHTING - PROPOSED

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

RD_DE_ST_CBLE cyan Continuous 0.5 STREET LIGHTING CABLE

STREET LIGHTING - PROPOSED

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

RD_DE_ST_DUCT 20 Continuous 0.35 STREET LIGHTING DUCT

STREET LIGHTING FEEDER
RD_DE_ST_FDPL magenta Continuous 0.35
PILLAR
RD_DE_ST_POLE yellow Continuous 0.25 STREET LIGHTING POLE
STREET LIGHTING SUBSTA-
RD_DE_ST_SUBSTN cyan Continuous 0.5
TION
STREET LIGHTING ANNOTA-
RD_DE_ST_TEXT white Continuous 0.25
TION/TEXT

STREET LIGHTING - EXISTING

Plotted
Screen
Layer Name Line type Line Description
Color
weight

RD_EX_ST_CBLE cyan DASHED2 0.5 STREET LIGHTING CABLE

RD_EX_ST_DUCT 20 HIDDEN2 0.35 STREET LIGHTING DUCT

STREET LIGHTING FEEDER
RD_EX_ST_FDPL magenta Continuous 0.35
PILLAR
RD_EX_ST_POLE 8 Continuous 0.25 STREET LIGHTING POLE
STREET LIGHTING SUBSTA-
RD_EX_ST_SUBSTN cyan Continuous 0.5
TION
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STREET LIGHTING - EXISTING

Plotted
Screen
Layer Name Line type Line Description
Color
weight
STREET LIGHTING ANNOTA-
RD_EX_ST_TEXT white Continuous 0.25
TION/TEXT

A.3.4 Road Furniture Layers

ROAD FURNITURE LAYERS

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

ROAD/STREET FURNITURE:
RD_F_BNCH yellow Continuous 0.25
BENCH/SEAT
ROAD/STREET FURNITURE:
RD_F_LGHT white Continuous 0.25
LIGHTING
ROAD/STREET FURNITURE:
RD_F_OTHR white Continuous 0.25
OTHERS
ROAD/STREET FURNITURE:
RD_F_POLE yellow Continuous 0.25
POLE
ROAD/STREET FURNITURE:
RD_F_TEXT white Continuous 0.25
ANNOTATION/TEXT

A.3.5 Roads – Common Layers

(ROADS) - COMMON LAYERS

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

RD_C_25DASH white DASHED2 0.25 HIDDEN DETAILS

RD_C_25HID white HIDDEN2 0.25 HIDDEN DETAILS

ALL CONCRETE OUTLINES IN
RD_C_50OUT cyan Continuous 0.5
SECTION

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(ROADS) - COMMON LAYERS

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

RD_C_50REBARS cyan Continuous 0.5 REINFORCEMENTDETAILS

RD_C_CHAIN_TEXT wh ite Continuous 0.25 CHAINAGE TEXT

RD_C_CHAIN_TICK yellow Continuous 0.25 CHAINAGE TICK MARK

RD_C_CONT_MAJR 8 Continuous 0.2 MAJOR CONTOUR

(ROADS) - COMMON LAYERS

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

RD_C_CONT_MINR 9 Continuous 0.15 MINOR CONTOUR

RD_C_COORD_GRID 252 Continuous 0.15 COORDINATE GRID

RD_C_CTRLINE red CENTER2 0.18 CENTRE LINE

RD_C_HATCH red Continuous 0.18 HATCH

PHAN- SHEET CONTINUATION
RD_C_MATCH_LINE blue 0.7
TOM MATCH LINE
RD_C_PROF cyan DASHED2 0.5 PROFILES

RD_C_PROF-LINE green Continuous 0.35 PROFILE LINES

RD_C_PROF_GRID_ PROFILE GRIDLINE @ MAJOR

8 Continuous 0.2
MAJR STATIONS

RD_C_PROF_GRID_ PROFILE GRIDLINE @ MINOR

9 Continuous 0.15
MINOR STATIONS

SURVEYROAD FEATURE: SPOT

RD_C_SPT_HGT yellow Continuous 0.25
HEIGHT MARKER && TEXT

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(ROADS) - COMMON LAYERS

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

SURVEY ROAD FEATURE:

RD_C_SPT_NUM yellow Continuous 0.25
SURVEY POINT NUMBER

RD_C_TABLE white Continuous 0.25 TABLES

RD_C_TEXT white Continuous 0.25 COMMON TEXT

A.3.6 Structures – Common Layers

STRUCTURES
Plotted
Screen Descrip-
Layer Name Line type Line
Colour tion
weight
BR_ABT RED Continuous 0.3 ABUTMENT

BR_BEARING GREEN Continuous 0.25 BEARING

BR_BH 11 Continuous 0.10 HATCH

BR_BR 160 Continuous 0.6 BOUNDARY

BR_CB 9 Continuous 0.25 CRASH BARRIER

BR_CEN WHITE Center 0.18 CENTER LINE

MA-
BR_DIM Continuous 0.18 DIMENSION
GENTA

BR_DS 200 Continuous 0.18 DRAINAGE SPOUT

BR_GEN YELLOW Continuous 0.30 STRUCTURE

BR_HIDDEN 8 HIDDEN 0.15 DOTTED / HIDDEN LINES

BR_MAIN RED Continuous 0.35 HEADING TEXT

BR_MARK CYAN Continuous 0.15 HAUNCH LINES

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STRUCTURES
Plotted
Screen Descrip-
Layer Name Line type Line
Colour tion
weight
BR_PIER RED Continuous 0.25 PIER

BR_REINF BLUE Continuous 0.35 REINFORCEMENT

TEXT IN NOTES & DIMEN-

BR_TEXT GREEN Continuous 0.3
SIONS

BR_TITLE WHITE Continuous 0.35 TITLE BLOCK

A.4 UTILITIES LAYERS

A.4.1 Electricity

(ELECTRICITY)

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

ACAD_ISO04W SERVICES FIXTURES (ELEC-

SVE_11KV 240 100 0.35 TRICITY): 11KV

ACAD_ISO04W SERVICES FIXTURES (ELEC-

SVE_132K 240 100 0.35 TRICITY): 132KV

ACAD_ISO04W SERVICES FIXTURES

SVE_66KV 240 100 0.35 (ELECTRICITY): 66KV
SERVICES FIXTURES
Continuous (ELECTRICITY): ABANDONED
SVE_ABDL 13 0.35
LINE
SERVICES FIXTURES
Continuous (ELECTRICITY): ELECTRI CITY
SVE_DUCT 10 0.35
DUCT
SERVICES FIXTURES
SVE_ERTH_PI 8 Continuous
0.2 (ELECTRICITY): EARTH PIT
T

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(ELECTRICITY)

Plotted
Screen
Layer Name Line type Line Description
Colour
weight
SERVICES FIXTURES
SVE_FT_TEE 30 Continuous (ELECTRICITY): ELECTRICAL
0.35
FITTING TEE

Continuous SERVICES FIXTURES (ELEC-

SVE_LOWV 220 0.35 TRICITY): LOW VOLTAGE
SERVICES FIXTURES
Continuous (ELECTRICITY): MEDIUM
SVE_MEDV 150 0.35
VOLTAGE
SERVICES FIXTURES
SVE_MHLL White Continuous 0.25 (ELECTRICITY): UTILITY/
MANHOLE
SERVICES FIXTURES
SVE_MNHL White Continuous 0.25
(ELECTRICITY): MANHOLE

SERVICES FIXTURES
SVE_MRKR White Continuous 0.25
(ELECTRICITY): MARKER

ELECTRICITY

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

SERVICES FIXTURES
SVE_OHLL white Continuous 0.25 (ELECTRICITY): OVERHEAD
LINE
SERVICES FIXTURES
SVE_OTHR white Continuous 0.25
(ELECTRICITY): OTHER

SERVICES FIXTURES
SVE_POLE white Continuous 0.25
(ELECTRICITY): POST /POLE

SERVICES FIXTURES
SVE_PYLN white Continuous 0.25
(ELECTRICITY): PYLON

SVE_SBOX white Continuous 0.25 SERVICES FIXTURES

(ELECTRICITY): SERVICE BOX

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ELECTRICITY

Plotted
Screen
Layer Name Line type Line Description
Colour
weight

SERVICES FIXTURES
SVE_SJNT green Continuous 0.35 (ELECTRICITY): ELECTRICAL
STRAIGHT JOINT

SVE_SSTL yellow Continuous 0.25 SERVICES FIXTURES

(ELECTRICITY): SUBSTATION

SERVICES FIXTURES
SVE_TEXT white Continuous 0.25 (ELECTRICITY): ANNOTATION /
TEXT
SERVICES FIXTURES
SVE_TRANSF Cyan Continuous 0.5 (ELECTRICITY): TRANS-
FORMER
SERVICES FIXTURES
SVE_UGLL white Continuous 0.25 (ELECTRICITY): UNDER-
GROUND LINE

A.4.2 Water

WATER

Plotted
Screen Line Description
Layer Name Line type
Colour weight

SERVICES FIXTURES (WATER):

SVW_ABDL 13 Continuous 0.35
ABANDONED WATER LINE
SERVICES FIXTURES (WATER):
SVW_BNDL 130 Continuous 0.35
BUND
SERVICES FIXTURES (WATER):
200 Continuous 0.35
SVW_CLR_PT CHLORINATION POINT

SERVICES FIXTURES (WATER):

SVW_CPRT 200 Continuous 0.35
CASING PROTECTION

SERVICES FIXTURES (WATER):

SVW_DRKL 130 Continuous 0.35
DRINKING AREA

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WATER

Plotted
Screen Line
Layer Name Line type Description
Colour weight

SVW_DUCT 30 Continuous 0.35 SERVICES FIXTURES (WA-

TER): DUCT

150 Continuous 0.35 SERVICES FIXTURES (WA-

SVW_FT_ADPTR TER): FITTING ADAPTER

SVW_FT_BEND 150 Continuous 0.35 SERVICES FIXTURES (WA-

TER): FITTING BEND

SVW_FT_ENDCAP 150 Continuous 0.35 SERVICES FIXTURES (WA-

TER): FITTING ENDCAP

SVW_FT_RDCR 150 Continuous 0.35 SERVICES FIXTURES

(WATER): FITTING REDUCER

SVW_FT_TEE 150 Continuous 0.35 SERVICES FIXTURES (WA-

TER): FITTING TEE

SVW_GCHNL 200 Continuous 0.35 SERVICES FIXTURES (WA-

TER): GRAVITY CHANNEL

SVW_GPIPE 200 Continuous 0.35 SERVICES FIXTURES (WA-

TER): GRAVITY PIPE
SERVICES FIXTURES (WA-
SVW_HYDR 200 Continuous 0.35
TER): HYDRANT
SVW_METER 200 Continuous 0.35 SERVICES FIXTURES (WA-
TER): METER
SVW_MNHL 170 Continuous 0.35 SERVICES FIXTURES (WA-
TER): MANHOLE
SVW_MRKR 130 Continuous 0.35 SERVICES FIXTURES (WA-
TER): MARKER

170 Continuous 0.35 SERVICES FIXTURES (WA-

SVW_PIPE TER): WATER PIPE LINE

SVW_PUMP 200 Continuous 0.35 SERVICES FIXTURES (WA-

TER): PUMP
SVW_SCSR 200 Continuous 0.35 SERVICES FIXTURES (WA-
TER): SCADA SENSOR
SERVICES FIXTURES (WA-
SVW_SPIPE 200 Continuous 0.35
TER): SERVICE PIPE

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WATER

Plotted
Layer Name Screen Line type Line Description
Colour weight

SVW_STRG_PT 200 Continuous 0.35 SERVICES FIXTURES (WATER):

STORAGE POINT
SERVICES FIXTURES (WATER):
SVW_TANK 230 Continuous 0.35
TANK
SVW_TANK_FI SERVICES FIXTURES (WATER):
200 Continuous 0.35
L_PT TANKER FILLING POINT

SVW_TEXT white Continuous 0.25 SERVICES FIXTURES (WATER):

ANNOTATION /TEXT
SERVICES FIXTURES (WATER):
WATER SLUICE VALVE, AIR
SVW_VALV 160 Continuous 0.35 VALVE, FLOW CONTROL VALVE,
SERVICE VALVE, SYSTEM
VALVEVALVE
SERVICES FIXTURES (WATER):
SVW_WELL 200 Continuous 0.35
WELL

SVW_WFAC 200 Continuous 0.35 SERVICES FIXTURES (WATER):

WATER FACILITY
DASH- SERVICES FIXTURES (WATER):
SVW_WMAIN 170 0.35
DOT2 WATER MAIN

SVW_WSCON 200 Continuous 0.35 SERVICES FIXTURES (WATER):

WATER SERVICE CONENCTION

A.4.3 Commercial

COMMERCIAL

Plotted
Layer Screen
Line type Line Description
Name Colour
weight

SERVICE FIXTURES (COMMERCIAL):

SVC_TEXT white Continuous 0.25 ANNOTATION / TEXT

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SERVICE FIXTURES (COMMERCIAL):

SVC_SBDL white Continuous 0.25
SIGNBOARD
COMMERCIAL

Plotted
Layer Screen
Line type Line Description
Name Colour
weight

SVC_POLE white Continuous 0.25 SERVICE FIXTURES (COMMERCIAL):

POST / POLE

0.25 SERVICE FIXTURES (COMMERCIAL):

SVC_OTHR white Continuous OTHER FEATURES

SVC_BBDL 30 Continuous 0.25 SERVICE FIXTURES (COMMERCIAL):

BILLBOARD

0.25 SERVICE FIXTURES (COMMERCIAL):

SVC_BANK white Continuous ATM AND SIMILAR FEATURES

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Appendix B – USEFUL TABLES FOR AUTOCAD

Table-1 Model Space Zoom XP Factors (Meters)

Scale of Drawing Zoom XP Scale

1: 1000 1
1: 1250 0.8
1: 2500 0.4
1: 5000 0.2
1: 10000 0.1
1: 25000 0.04
1: 50000 0.02
1: 500 2
1: 200 5
1: 100 10
1: 50 20
1: 20 50
1: 10 100
1: 5 200
1: 2 500
1: 1 1000

Table-2 Model Space Zoom XP Factors (Millimeters)

Scale of Drawing Zoom XP Scale

1: 500 0.002

1: 200 0.005

1: 100 0.01

1: 50 0.02

1: 20 0.05

1: 10 0.1

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Scale of Drawing Zoom XP Scale

1: 5 0.2

1: 2 0.5

1: 1 1

Table-3 Text Heights for use in Model Space (Meters)

Scale of Factor
Drawing (Multiply) Text Height

0.25 Pen 0.35 Pen 0.5 Pen

1: 1000 1.00 2.5 3.5 5

1: 1250 1.25 3.125 4.375 6.25

1: 2500 2.50 6.25 8.75 12.5

1: 5000 5 12.5 17.5 25

1: 10000 10 25 35 50

1: 25000 25 62.5 87.5 125

Scale of Factor Text Height

Drawing (Multiply)

0.25 Pen 0.35 Pen 0.5 Pen

1: 50000 50 125 175 250

1: 500 0.5 1.25 1.75 2.5

1: 200 0.2 0.5 0.7 1

1: 100 0.1 0.25 0.35 0.5

1: 50 0.05 0.125 0.175 0.25

1: 20 0.02 0.05 0.07 0.1

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Scale of Factor Text Height

Drawing (Multiply)

1: 10 0.01 0.025 0.035 0.05

1: 5 0.005 0.0125 0.0175 0.025

1: 2 0.002 0.005 0.007 0.01

1: 1 0.001 0.0025 0.0035 0.005

Table-4 Text Heights for use in Model Space (Millimeters)

Scale of Factor Text Height

0.25 Pen 0.35 Pen 0.5 Pen
1: 500 500 500 1250 1750
1: 200 200 200 500 700
1: 100 100 100 250 350
1: 50 50 50 125 175
1: 20 20 20 50 70
1: 10 10 10 25 35
1: 5 5 5 12.5 17.5
1: 2 2 2 5 7
1: 1 1 1 2.5 3.5

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Appendix C – DRAWING TYPE AND DRAWING NUMBER SERIES

Appendix C - Project Number

Zone-1 Project Codes

Amaravati Capital City ACC

Appendix C Originator Code

Originator Code Name

APCRDA Andhra Pradesh Capital Region Development Authority

ADC Amaravati Development Corporation

CH2MHILL CH2MHill

AARVEE Aarvee Associates

Appendix C Drawing Type Code

Document Code Description

DWG DRAWING

DL DRAWING LIST

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Appendix C Drawing Type and Drawing Number Series

Discipline/ Drawing Title Series Drawing No.

Type
General Layouts and miscellaneous Drawings 0000 - 0249
Geotechnical 0250 - 0499
Highways 0500 - 0999
Site Clearance 1000 -1499
Traffic 1500 - 1999
Street Lighting 2000 - 2499
SK – Sketch Draw- Fencing 2500 - 2999
ings Grading 3000 - 3999
Structures 4000 - 4999
Utility Services Corridors 5000 - 5499
Surface Water 5500 - 5999

Discipline/ Drawing Title Series Drawing No.

Type
Foul Sewer 6000 - 6499
Treated Sewerage Effluent 6500 - 6999
Potable Water 7000 - 7499
Fire Water 7500 - 7999
Electricity 8000 - 8499

GE - General Drawing Lists 0001 - 0999

---
General Notes, Abbreviations & Legends, Location 0001 - 0999
Plan, General Key Plan, etc.
----
GT - Geotechnical Standard & Miscellaneous Details 7000 - 7999

General Notes, Abbreviations & Legends, Location 0001 - 0999

Plan, General Key Plan, District, Zone & Munici-
pality
Boundaries,
Cross Road(Detailed
Sections Corridor and
etc.. Typical), Pavement 1000 - 1999
Proposed Road Layout & Key Plan 2000 - 2999
Setting Out Plan (Horizontal Alignment Plan) 3000 - 3999
Road Profiles 4000 - 4999
Junction Layout Plan and Levels 5000 - 5999
HW - Highways Swept Path Analysis For Junctions 6000 - 6999
Standard & Miscellaneous Details 7000 - 7999
Detail Road Signs & Markings 8000 - 8999
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Discipline/ Drawing Title Series Drawing No.

Type

General Notes, Abbreviations & Legends, Location 0001 - 0999

Plan, General Key Plan, etc.
Site Clearance Layout & Key plan 2000 - 2999
SC – Site Clearance ---
Standard & Miscellaneous Details 7000 - 7999
---
General Notes, Abbreviations & Legends, Location 0001 - 0999
Plan, General Key Plan, etc.
Traffic Flow 1000 - 1999
Bus Route 2000 - 2999
Traffic Signal 3000 - 3999
Traffic Management Plan 4000 - 4999
TR-Traffic/ Traffic Diversion Plan 5000 - 5999
Transport ---
Standard & Miscellaneous Details 7000 - 7999
---
General Notes, Abbreviations & Legends, Location 0001 - 0999
SL - Street Lighting Plan, General Key Plan, etc.
Street Lighting Typical Cross Sections
Discipline/ Drawing Title Series Drawing No.
Type
Street Lighting Layout & Key plan 2000 - 2999
Electrical Work for Road Lighting and Traffic 3000 - 3999
Signs

Standard & Miscellaneous Details 7000 - 7999

General Notes, Abbreviations & Legends, Location 0001 - 0999

plan, General Key Plan, etc.
Fencing Layout & Key plan 2000 - 2999
FE – Fencing
Standard & Miscellaneous Details 7000 - 7999
---
General Notes, Abbreviations & Legends, Location 0001 - 0999
Plan, General Key Plan, etc.
Existing Grading and Topographic Survey Layout 1000 - 1999
Plan
Proposed Grading Layout & Key plan 2000 - 2999
GR - Grading ---
Standard & Miscellaneous Details 7000 - 7999

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Discipline/ Drawing Title Series Drawing No.

Type
---
General Notes, Abbreviations & Legends, Location 0001 - 0999
Plan, General Key Plan, etc.
GAD of Structures 1000 - 1999
ST - Structures ---
Standard & Miscellaneous Details 7000 - 7999
---
General Notes, Abbreviations & Legends, Location 0001 - 0999
Plan, General Key Plan, etc.
Utility Cross Sections 1000 - 1999
UC-Utility Services Combined Utilities Plan Layout 2000 - 2999
Corridor ---
Standard & Miscellaneous Details 7000 - 7999
---

General Notes, Abbreviations & Legends, Location 0001 - 0999

Plan, General Key Plan, etc.
Potable Water Network Plan
Proposed Potable Water Layout & Key plan 2000 - 2999
Longitudinal Sections (Profiles) 3000 - 3999
GAD of MBR and Pump Houses, SLD for the 4000 - 4999
pumping arrangement from MBR, GAD of ESRs
PW - Potable Water
---
Standard & Miscellaneous Details 7000 - 7999
SCADA system for Potable water distribution 8000 - 8999
network

General Notes, Abbreviations & Legends, Location 0001 - 0999

Plan, General Key Plan, etc.
RW - Recycle Water Recycle Water Network Plan 1000 - 1999
Proposed TSE Layout & Key plan 2000 - 2999

Discipline/ Drawing Title Series Drawing No.

Type
Longitudinal Sections (Profiles) 3000 - 3999
---
Standard & Miscellaneous Details 7000 - 7999
----

General Notes, Abbreviations & Legends, Loca- 0001 - 0999

tion
Sewer Collection Network 1000 - 1999

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Discipline/ Drawing Title Series Drawing No.

Type
Sewer Layout & Key plan 2000 - 2999
FS - Foul Sewer/ Longitudinal Sections (Profiles) 3000 - 3999
Sewerage ---
Standard & Miscellaneous Detail 7000 - 7999

General Notes, Abbreviations & Legends, Loca- 0001 - 0999

tion
Industrial Effluent Network Plan 1000 - 1999
Proposed Industrial Effluent Layout & Key plan 2000 - 2999
Longitudinal Sections (Profiles) 3000 - 3999
IE- Industrial Efflu- ---
ent Standard & Miscellaneous Details 7000 - 7999
----

General Notes, Abbreviations & Legends, Loca- 0001 - 0999

tion
Surface Water Network Plan 1000 - 1999
Proposed Surface Water Layout & Key plan 2000 - 2999
Longitudinal Sections (Profiles) 3000 - 3999
SW - Surface Water ---
Standard & Miscellaneous Details 7000 - 7999

Discipline/ Drawing Title Series Drawing No.

Type
General Notes, Abbreviations & Legends, Loca- 0001 - 0999
tion Plan, General Key Plan, Cluster layout, zoning
etc.
Sub-station & network Layout, Single line dia- 1000 - 1999
gram, General Arrangement etc.
Extra High Voltage Electricity Supply Layout & 2000 - 2999
Key plan
EL - Electricity
High Voltage Electricity Supply Layout & Key 3000 - 3999
plan
Medium Voltage Electricity Supply Layout & Key 4000 - 4999
plan
Low Voltage Electricity Supply Layout & 5000 - 5999
Key plan
Standard & Miscellaneous Details 7000 - 7999
--

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Discipline/ Drawing Title Series Drawing No.

Type
General Notes, Abbreviations & Legends, Loca- 0001 - 0999
tion Plan, General Key Plan, etc.
Existing Site Features 1000 - 1999
Sensitive Receptors 2000 - 2999
Surveys & Investigations 3000 - 3999
EN - Environmental
Monitoring Locations 4000 - 4999
Standard & Miscellaneous Details 7000 - 7999
--
-

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Schedule Q- Guideline for Health, Safety and Environment Plan

The Contractor shall provide a General and Administrative HSE Procedures that will engage
the welfare of labor, staff and others abiding by the rules and regulations and provide for
records to the Authority.

The Contractor shall prepare specific HSE plans based on the specific construction proce-
dures to be adopted specifically for this project to address complexity, safety and welfare of
labor/staff/equipment as per the details given below.

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Contents
1. HSE Standards
2. Legislation
3. HSE Management System
4. HSE Risk Management
5. Hazard identification and control
6. Environmental Management
7. HSE PERSONNEL
8. Competence and Training
9. HSE Orientation Training
10. ID card & Booklet
11. Intervention
12. Medical fitness to work
13. HSE Communications and Meetings
14. HSE Performance Reporting
15. Target and Objective setting
16. HSE Incident Management
17. Emergency Preparedness and Response
18. HSE Audits, Reviews and Inspections
19. HSE Records
20. Sub-Contractor Management
21. Project HSE plan
22. Substance abuse

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1. HSE Standards

The Contractor shall ensure that all personnel engaged (including sub-contractors) with the
project shall be conversant with and at all times comply with the HSE standards for the project.
The HSE standards shall include the relevant India HSE legislation, relevant IS (Bureau of
Indian Standards) & Project HSE documents. (documents prepared by the AUTHORITY with
regards to HSE). See Annexure-I

i. LEGISLATION
For the purposes of the project relevant Indian HSE legislations shall apply to the
project as dictated by the various Ministries including but not at the least – Ministry of
Labor & Employment; Department of Labor – Government of Maharashtra; Ministry
of Environment, Forest and Climate Change.

ii. HSE MANAGEMENT SYSTEM

The Contractor shall ensure that they will have an HSE policy and an HSE Management
system (including safe work procedures) that is documented, visibly endorsed by the
company’s top management and implemented & maintained at the project.

The scope of the contractors HSE Management system (including safe work
procedures) shall cover all areas of work on the project and shall include any work to
be performed by the contractor personnel or any of their sub-contractor, interfaces with
the Authority/Authority Engineer.

iii. HSE RISK MANAGEMENT

The Contractor shall ensure that they employ best practice methods and meet all legal
requirements in identifying, assessing and controlling HSE hazards. They shall
document these methods and the outcomes.

iv. HAZARD IDENTIFICATION AND CONTROL

The Contractor shall identify hazards and their control measures through a formal
hazard identification process. The Contractor shall also ensure that they have a written
safe work procedure for all the works to be undertaken on the project.

HSE ENFORCEMENT

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The Authority shall have the right at any time to audit or inspect Contractor facilities, pro-
cedures, and safety management systems. The Contractor shall fully co-operate in such re-
views and shall implement recommendations at its own cost where Project HSE Standards
or statutory rules and regulations are contravened. Contractor shall ensure the timely closing
out of issues raised via these HSE assessments.

The Authority will bring to the attention of Contractor any situation where the Authority
observes, or is informed of, a contravention of the HSE rules and procedures or unsafe acts;
or a situation where those contraventions or unsafe acts identified are not considered likely
to present an immediate risk, but are likely to lead to injury, ill health or damage to the
environment.

If the Authority observes, or is informed of, a contravention of the safety rules and proce-
dures or unsafe acts, and if those contraventions or unsafe acts identified are considered
likely to present an immediate risk to personnel, then they shall have the authority to stop
such work until remedial actions have been addressed to prevent such unsafe acts from re-
curring.

If contraventions or unsafe acts persist or present an imminent risk of serious injury or ill
health to the persons involved, Authority will have the right to stop work being performed
and to order a suspension of the execution of any new work in that part or parts of the Works
affected by Contractor’s HSE violation or negligence. Contractor shall have no right to claim
for any extension of time or to claim for compensation for the suspension of the work or for
the waiving of the liquidated damages.

Contractor shall not resume provision of the Works affected until the Authority is satisfied
that the non-compliance has been rectified.

all not be employed again on the project or any of the sites without the written approval of
the AUTHORITY. The Contractor shall be responsible for enforcing the Site HSE Rules and
Regulations upon its Subcontractors and all other persons entitled to be on any work sites.

1. ENVIRONMENTAL MANAGEMENT

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The Contractor shall specify in their HSE plan measures applied to avoid harm to the
environment.

2. HSE PERSONNEL
The Contractor shall ensure that adequate HSE personnel are appointed on the project.
The Contractor shall ensure that all HSE personnel meet the requirements as dictated
by the project HSE standards.

3. COMPETENCE AND TRAINING

The Contractor shall ensure that that all personnel are competent, capable and qualified
to a level that allows them to work without creating unnecessary risk for themselves
and others. All personnel shall have and maintain the necessary HSE competencies to
perform work on the project to the required HSE standards.
The Contractor shall ensure that all supervisory personnel have formal training in su-
pervisory activities and specialist HSE training to conduct their duties.

4. HSE ORIENTATION TRAINING

The Contractor shall ensure that all personnel working at the project receive an induc-
tion HSE training explaining the nature of the work, the hazards that may be encoun-
tered during the site work and the particular hazards attached to their own function
within the operation on the first day of work on the project. The training shall cover the
contents as detailed within the Project HSE standards.

The contractor shall ensure that any new personnel are informed in an equal manner.

5. INTERVENTION
The Contractor shall have implemented a system that assures competence (including
HSE) of personnel...

The Contractor shall establish and agree with the Authority a key list of personnel un-
dertakings taking HSE critical roles. The list shall identify these key individuals by
name and by (key) role. For every role on this list, the contractor shall define minimum
requirements for HSE competences and qualifications relevant to the work.

The Contractor shall have implemented a system that records the training of personnel.
The Contractor shall keep training records up-to-date and shall furnish information
about the system and/or records of training upon request by AUTHORITY.

1. MEDICAL FITNESS TO WORK

The contractor shall ensure that all personnel engaged on the project are medically fit
for the job to be undertaken. Where required, the Contractor shall be able to demon-
strate that personnel, selected for key positions are evaluated for their fitness to work
on the project.

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2. HSE COMMUNICATIONS AND MEETINGS

The Contractor shall ensure efficient and effective HSE communication and consulta-
tion with all personnel involved on the project. This includes but is not limited to
toolbox meetings prior to the start of work, regular worksite HSE meetings with all
parties involved (including subcontractors).

3. HSE PERFORMANCE REPORTING

The Contractor shall submit on a monthly basis an HSE performance report to the Au-
thority. This report shall contain as a minimum the following data, as related to the
project:

 A list, including a brief description, of all incidents (including near misses and
potential incidents);

 Number of Fatalities (FAT);

 Number of Lost Workday Cases (LWC);

 Number of First Aid Cases (FAC);

 Number of Environmental Non-conformances;

The format & content for the HSE performance report shall be agreed with the Authority
prior to the commencement of the project.

4. TARGET AND OBJECTIVE SETTING

The Contractors HSE goal shall be "Target Zero" to reflect the projects commitment to
an accident free workplace. The Contractor’s targets and objectives shall be focused
on leading indicators and pro-active efforts to reduce the likelihood and severity of in-
cidents.

5. HSE INCIDENT MANAGEMENT

The Contractor shall report any HSE incident and/or accident, related to contractor ac-
tivities or personnel, to the Authority & National or Local authorities as required by
relevant legislation.

The Contractor shall also notify the Authority immediately of any HSE incident, in-
cluding near misses and significant potential incidents, arising from the contractors or
sub-contractor’s activities associated with the project, related to:

 Harm to contractor and or Sub Contractor personnel or Third Party;

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 Harm to the environment,

 Damage to, or loss of, contractor or sub-contractor /Third party assets;

 Harm to Authority reputation.

The Contractor shall fully investigate any incidents on the project and cooperate with
the AUTHORITY and participate as necessary in any investigation of HSE incidents as
required by the project HSE standards.

6. EMERGENCY PREPAREDNESS AND RESPONSE

The Contractor shall maintain a documented, robust fit-for-purpose Emergency Re-
sponse Plan for the project. The Contractor shall also provide fit-for-purpose survival
equipment, first-aid equipment, life-saving equipment, fire-fighting equipment and
oil/chemical spill equipment. The contractor shall ensure that involved personnel are
trained and competent in its use.

The Contractor shall develop and maintain a programme of training and exercises to
ensure competency of all individuals and teams involved in the emergency response
teams in accordance with the project HSE standards.

7. HSE AUDITS, REVIEWS AND INSPECTIONS

The Contractor shall perform audits, reviews and inspections on the project as required
by project HSE standards. During these audits, reviews and inspections, the Contractor
shall verify that they have fulfilled any and all legal obligations, including conditions
and stipulations in all relevant licenses, consents and permits and that the work on the
project is performed in accordance.

The Contractor shall develop a detailed HSE inspection & audit schedule for the project
and submit copies of the reports to the Authority.

8. HSE RECORDS
The Contractor shall retain all relevant HSE records resulting from work on the project
in line with relevant legislation & project HSE standards.

9. SUB-CONTRACTOR MANAGEMENT
The Contractor shall ensure that all sub-contractors comply with all the HSE standards
relevant to the project (including these conditions).

The Contractor shall be accountable for the sub-contractors HSE performance.

10. PROJECT HSE PLAN

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The Contractor shall prepare and submit to the Authority a project HSE plan which
covers all work under the project. This project HSE plan shall be reviewed by the
Contractor at regular intervals of not less than 6 months.

11. SUBSTANCE ABUSE

The Contractor shall ensure that that all personnel working on the project do not at any
time partake of, be under the influence of drugs, alcohol, sedatives or other similar
intoxicating substances, other than for bona fide medical reasons.

Any personnel found contravening with the above will be removed from the project
with immediate effect and handed over to the authorities.

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Contractor HSE Plan Template

Contents
Section 1 - Project Details
Section 2 - Information and Training for People on Site
Section 3 - Contractor Management Selection of Plant
Section 4 - Emergency Procedures
Section 5 - Arrangements for Controlling Significant site Risks
Section 6 - Environmental Management

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Template for Contractor HSE Plan

This plan is provided as a guidance template for the Contractor to include in their HSE plan.
The sections mentioned in this HSE plan template will be the minimum standards that the Con-
tractors HSE plan will be assessed against.
Table-1

Section Titles of sec-

Details of what is required in each section
No tions

Contractor must ensure that these sections are included in their Construction HSE plan.
The details in the sections are provided as guidance.

SECTION 1 - PROJECT DETAILS

Contractor to provide contact information for Key Contractor
personnel. Contact information to include Name, Mobile num-
ber, email id. Key personnel include:
 Contractor Project Director
Project Specific
1.1  Contractor Project manager
Details
 Contractor Construction manager
 Contractor HSE Manager
 Contractor General Foremen.

Details of other Details as above of any consultants that the contractor may em-
1.2
Consultants ploy on the project.

Contractor to detail the site security arrangements that will be

in place on the project. Suggestions as below:
 Site entrance control points
 Identity card system

1.3 Project Security  Vehicle barrier types

 Visitors to site procedures
 Delivery vehicle procedures
 Vehicle parking restrictions
 Need for 24hr cover etc.

Contractor to detail what arrangements will be made on site to

Welfare Ar- ensure that appropriate welfare facilities are provided and main-
1.4
rangements tained according to the size of the workforce and nature of the
work.

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As a minimum, an assessment must be carried out to determine

specific welfare requirements and arrangements throughout the
project, from day one to the last day persons are on site. Consid-
eration must be given to any requirements for male / female
changing, showers or disabled facilities, etc. Details to be in-
cluded:
 What type and size of facilities are required,
 When they will be operational,
 State what the initial set up is and what the
subsequent set up will be
 Where they are located. Produce clear layout drawing
 Who provides and maintains each facility.
 Expected standards and monitoring requirements.

Project Organi- Contractor to include a detailed organization chart with names,

1.5
zation Chart designations & contact numbers for the project.

Contractor to detail how they plan to communicate HSE with

the different parties on the project. For example, what kinds of
HSE meetings will be held on the project, how often, who will
Arrangements attend etc. Suggestions HSE Communication include:
1.6 for communica-
tion  Regular team meeting.
 Tool box talks
 Trainings

1.7 Project Goals Contractor to detail what are the project HSE goals.

HSE Compli- Contractor to detail how HSE compliance monitoring will be

1.8
ance monitoring conducted, who will conduct, how often this will be conducted.

Senior Manage- Contractor to detail how Senior management on the project will
1.9 ment HSE mon- be involved in HSE monitoring, How often will they be in-
itoring volved, what is the process.

SECTION 2 - INFORMATION AND TRAINING FOR PEOPLE ON SITE

Contractor to detail the methods by which they will check that
people on site have been satisfactorily inducted & trained. Sug-
gestions include: -
Inductions &
2.1  Arrangements for delivery – i.e. who does the in-
Trainings
duction? Who does the training?
 Arrangements by which management are informed
of new starters;

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 Arrangements for recording of inductions/trainings?

 Any passes, or other identification issued after in-
duction
 Arrangements for re-induction or safety updating as
the contract enters a new phase or persons are trans-
ferred to a different section.
 What are the training arrangements for the project?

Site Safety Contractor to detail what site safety rules will be developed or is
2.2
Rules available for the project.

SECTION 3 - CONTRACTOR MANAGEMENT

Contractor to detail how they will select sub-contractors on the
project.
 How will they ensure that only competent HSE contrac-
Selection of
tors are on site
3.1 Contractors
 How do they plan to communicate HSE issues with the
sub-contractors
 How do they plan to coordinate the works with the sub-
contractors

Contractor to detail how they will ensure that only safe plant &
equipment is bought to the project.
Selection of  How will they check the plant & equipment
3.2
Plant
 How often
 Who will check

SECTION 4 - EMERGENCY PROCEDURES

 Contractor to detail what are the first aid arrangements
that will be made on site. For example:
 Locations of first aid boxes
4.1 First Aid  Names of First aid personnel and their locations
 Location of First Aid room
 Numbers of First Aider’s required
 Location of accident book

Fire and Emer- Contractor to detail what are the fire safety arrangements that
4.2 gency Proce- will be available on site. For example:
dures  Fire points – How many, where will they be located

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 What kind of extinguishers will be available

 What kind of training will be available
 What will the emergency actions be for the project

Contractor to detail what are the accident & incident reporting

procedures for the project. For example:
 How will accidents be reported?
Accident & In-
4.3
cident reporting  To whom?
 Who will coordinate?
 How will they be recorded?

SECTION 5 - ARRANGEMENTS FOR CONTROLLING SIGNIFICANT SITE RISKS

Production of
Method Contractor to detail how method statements will be checked for
5.1 Statements HSE hazards & risks?

Contractor to detail how risk assessments will be produced?

 Who will produce these?
 How will they be reviewed?
Risk Assess-
5.2
ments  Methods of communicating to the workforce on the
content of the risk assessments?
 How will sub-contractor risk assessments be checked
for the above?

SECTION 6 - ENVIRONMENTAL MANAGEMENT

The contractor to detail how they plan to manage the environ-
mental aspects of the project. Suggestions include:
Environmental
6.1 Management  Environmental management plan.
Strategy  Project specific Environmental processes
 Environmental aspects & impact register

Contractor to detail how they plan to manage waste (construc-

tion, hazardous & non-hazardous). Suggestion include:
Waste
6.2 Management  How will waste be collected on site?
Planning  How do they plan to dispose the waste?
 Who will dispose it, where?

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Contractor to detail what are the environmental emergency

plans for the project. Suggestion include:
Environmental
6.3 Emergency  Who will initiate action?
plans  Who will report? To whom?
 What are the foreseen emergencies?

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Annexure- I: Construction HSE Management procedures

(Schedule – P)
SECTION 1: INTRODUCTION
This document describes how Health, Safety & Environment (HSE) will be managed on
the Project. This document is provided to ensure that the appointed Contractor, under-
stand the HSE standards on the programme. This document should be read along with
the ADCL ‘Health Safety Environment Execution Plan’ (PMC-657466-HSE-S01-PRC-
015).

 The standards laid down by this document is mandatory for all on the Project.
 The Contractor must familiarize themselves with these standards and also ensure
that these standards are adhered to by any subcontractors/suppliers and any self-
employed persons working within their workforce.
 These standards will assist the contractor in their planning and provision of satis-
factory HSE resources on projects.
 These standards will be audited in accordance with set performance measurement
procedures as per specific audit schedule completed for every project.
 Poor or non-compliance with these standards may result in the contractor being re-
moved from the project.

1.1 PURPOSE

The purpose of this document is to provide a systematic framework to:

 Implement & Manage HSE on the Project.

 Achieve the overall HSE objectives of the Project.
 Ensure open and transparent communication of HSE on Project.

1.2 LEGAL AND OTHER REQUIREMENTS

The Contractor shall comply with all local legislations, and HSE requirements. Where
legal requirements conflict with those set out in any other HSE document, the more strin-
gent requirement will apply.

All works will be carried out in compliance with the HSE rules, acts & regulations set out
by the following:

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 The Government of India, Ministry of Labour & Employment (http://labour.gov.in/)

 Department of Labour – Government of Maharashtra (https://mahakamgar.maha-
rashtra.gov.in/index.htm)
 Ministry of Environment, Forest and Climate Change (http://www.moef.nic.in/)
 Bureau of Indian Standards (http://www.bis.gov.in/index.asp)
 Contractually specified international standards and codes of practice
 Relevant industry standards and guidelines
 Contractual standards, procedures, and work instructions

2. MANAGEMENT STRUCTURE, APPOINTMENTS AND RESPONSIBILITIES

2.1 MANAGEMENT RESPONSIBILITIES

2.1.1 CONTRACTOR SENIOR MANAGEMENT RESPONSIBILITIES
 Ensure and maintain the HSE of all those who are affected by the Project.
 Ensure that the arrangements and resources on the Project are adequate and re-
viewed as necessary.
 Maintain a reporting structure for HSE matters and ensure that reporting lines and
responsibilities of line management are clearly defined.
 Attend or support appropriate HSE management or steering groups as necessary.
 Ensure that HSE is the first agenda point of all meetings
 Ensure that resources are available to maintain an effective HSE performance, in-
cluding budgetary, suitably trained staff and competent staff with clear lines of com-
mand and responsibility.
 Carry out HSE tours on a regularly defined basis.
 Be aware of the principles of the current HSE legislation and developments and
ensure that their staffs are aware of their accountability for HSE.
 Ensure that all accidents and incidents reported on the Project are fully investigated
and actions closed out.
 Ensure that appropriate support has been offered to those affected by incidents.
 All Contractor Senior Management will lead by example.

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2.1.2 CONTRACTOR LINE MANAGEMENT RESPONSIBILITIES

 Be aware of the HSE requirements of applicable to the Project.
 Ensure that during planning, construction and production, maintenance and repair,
sufficient allowance is made for safe systems of work, adequate welfare facilities &
supervision.
 Ensure that the management team is adequately staffed with suitably trained and ex-
perienced personnel with clearly understood and defined responsibilities that allow
for close and effective supervision of operations.
 Ensure that a competent staff member will be present at all times when work is being
undertaken under their control.
 Liaise with their HSE team on Project HSE requirements.
 Ensure that they understand the requirements of the Project HSE Plans & Procedures
and that the plan is communicated and implemented effectively on site.
 Ensure that safety critical appointments are made in writing and persons appointed are
suitable for the role.
 Arrange/chair/attend the site HSE meetings.
 Ensure that overall and specific risk assessments & method statements are produced,
submitted and communicated to relevant parties on time.
 Implement HSE systems to remove confusion over areas of responsibilities.
 Ensure that work is carried out as planned, relevant legislation is complied with and
that high standards of professionalism, site tidiness and access are maintained at all
times.
 Ensure inspection and monitoring under their areas of control are carried out and any
action points raised are closed out.
 Commend those who maintain high standards of HSE and discipline those who con-
sistently fail to achieve the required standard.
 Ensure that legal requirements relating to the involvement of the workforce are im-
plemented to promote HSE compliance.
 Review reporting and investigation of all accidents, dangerous occurrence and envi-
ronmental incidents in conjunction with HSE staff and ensure that appropriate reme-
dial actions are taken to prevent recurrence

All Contractor Line Management must set and lead by example

2.1.3 RESPONSIBILITIES OF CONTRACTOR SUPERVISORS

 Be familiar with legal principles, safe working practices, method statements, risk as-
sessments applicable to their work and ensure they are enforced.
 Incorporate HSE instruction in their routine orders and see that they are carried out.
 Suitably brief men under their control so that work is carried out in a safe & controlled
manner without undue risks.
 Avoid improvisation or deviation from method statements & risk assessments for tasks
being undertaken.
 Ensure that all operatives are trained for the task in which they are engaged.
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 Ensure that new employees are inducted and made aware of the hazards and controls
in their workplace.
 Ensure that project employees not under their direct control are protected from the
consequences of the work under them.
 Check plant & equipment and ensure that they are in good working order.
 Ensure that all operatives are provided with appropriate PPE for the tasks they are
undertaking.
 Ensure that workplaces are safe, tidy & organised at all times.
 Ensure that plant & equipment is switched off when not in use and kept in a safe
condition
 Ensure that welfare facilities are maintained in a clean condition.
 Prevent horseplay and discipline those who consistently fail to consider their own
wellbeing and that of others around them.
 Report all accidents/incidents/near- misses to the site HSE department.
All Contractor supervisors must set a personal example
2.1.4 RESPONSIBILITIES OF WORKFORCE
 Take all reasonable care to ensure your own safety and that of any others who may be
affected by your work.
 Attend the site induction, tool box talks and other HSE communications as required
by the project.
 Avoid improvisations or deviations from approved method statements & risk assess-
ments.
 Use the specified tools and equipment for the job.
 Take personal responsibility for your actions.

3. PLANNING
3.1 RESPONSIBILITY FOR HSE
Contractors shall be responsible for the HSE of all its employees and Subcontractors’ em-
ployees and the environmental impact of their assigned work. The Contractor shall at all
times comply with and ensure that its employees, Subcontractors comply with all HSE
rules, regulations and standards (as mentioned in section 1.3).

The e Contractor shall take, or cause to be taken, any additional measures, which the Gov-
ernmental/Authority may direct to protect against injury or death of any person or damage
to or loss of any property or to the environment during/after the Contractor’s performance
of the works.

Submittal of any documentation to the Authority does not relinquish the Contractor of its
direct responsibility for the HSE of persons and the protection of the environment.

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3.2 PROJECT HSE RISK ASSESSMENT

Before commencement of an onsite project work, the Contractor shall ensure that a robust
‘Project HSE Risk Assessment’ of the works to be undertaken is conducted. The Project
HSE Risk Assessment shall be a systematic assessment of the HSE hazards & risks that
the Contractor could encounter and shall also detail the means to control these.

The Contractor will be expected to recognize HSE hazards, evaluate them with the help of
competent people, and to communicate to workers on how to control these hazards during
the execution of the works.

The Contractor will be expected to use different types of hazard analyses to ensure that
work progresses in a manner that does not endanger persons, property, process and the
environment. Examples of these include:

 Hazard Analysis;
 Emergency Procedures;
 Job/Task Hazard Analysis;
 Field Level / Daily Risk Assessment;

The Contractor shall review the Project HSE Risk Assessment upon any change in the
scope of work and/or at predetermined intervals during the execution of works.

4. ARRANGEMENT FOR CONTROLLING SIGNIFICANT RISKS

4.1 METHOD STATEMENTS

The P Contractor shall ensure that suitable ‘Method Statements’ are produced for all sig-
nificant works. These method statements shall detail the sequence or steps involved in
executing the works and also the methodologies...
The Package Contractor shall ensure that no work is started on site without an approved
& agreed Method Statement.
4.2 PERMIT TO WORK

Where the risks are high and the use of a method statement and risk assessment alone
does not necessarily ensure that a safe system of work is followed, the Contractor shall
ensure that a permit to work is implemented. As a minimum, Contractors shall ensure
that the following works are controlled by a permit to work:

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Demolition Permit
Permit-to-Dig
Confined Space Permit
Hot Works Permit
General permit to work
Electrical and Mechanical Permit/LOTO

The need for a permit to work system will be identified in the risk assessment for the
activity. Examples of jobs that are typically covered under a permit shall include but
not be limited to hot works (cutting, grinding, welding etc.), elevated works (anything
above 4 meters), confined space entry, work on electrical systems, non-routine lifts.

Contractors shall ensure that they nominate a person as the permit coordinator who shall
have the responsibility to oversee the permit to work procedure. All permits shall be
valid for a single shift only. Records of any permits issued shall be kept in the permit
coordinators office for further inspection.

4.3 PERSONAL PROTECTIVE EQUIPMENT

The P Contractor shall ensure that Personal Protective Equipment (PPE) is provided
as identified in the Method Statements & Risk Assessments. Notwithstanding the PPE
described in the Method Statements & Risk Assessments, the Contractor shall ensure
that as a minimum standard Safety Helmet, Hi-Viz Jackets, Safety Goggles, and Safety
Shoes (with penetration protection) is available to all undertaking works on the pro-
ject.

All PPE supplied on the project shall meet or exceed the specifications as dictated
by Indian Standards Institute or the Contract documents. Where there is a conflict
the more stringent standard shall apply.
5. TRAINING, AWARENESS & COMPETENCE
All project employees must receive appropriate HSE training upon engagement.
These trainings shall be delivered by the individual Contractors to their personnel and
to any subcontractor/third party engaged by them. HSE trainings will include - Induc-
tion Training, Tool Box Talks (TBT’s), Work/Topic specific training, which will be
determined by the Programme/Project HSE Training Matrix, and will be dependent
on the tasks scheduled to be performed.

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5.1 MINIMUM REQUIREMENTS

The Contractor shall ensure that all their personnel (including sub-contractors & any third
party contracted to them) complete the following fundamental trainings:

 New Project HSE Induction – this module will orient employees in the basic HSE
Policies and Procedures relevant at the project.
 Position specific HSE training – this will include training that depends upon the posi-
tion the individual holds on the project. For example, if the person is designated as a
rigger, he will have to attend rigger training and a slinging & lifting training. These
trainings can be conducted either in-house by the individual Contractors or by an Ap-
proved Third Party. The Contractor shall also be aware that Project employees may be
required to complete additional specialized HSE training, provided by commercial
training specialists. Such training shall be identified in the project training matrix.
 Tool Box Talks – These will be conducted on daily/weekly basis as dictated by the
activities/tasks that groups of people are undertaking.

The Contractor shall ensure that all HSE training conducted on the Project is documented
and tracked.

5.2 PROJECT HSE INDUCTION

The Contractor shall conduct an HSE Induction for all project employees (this shall include
all personnel employed by the contractor, their sub-contractors, Third Party, Visitors etc.)
so that they remain aware of appropriate precautions that apply to them whilst on the work
site. This HSE induction shall be conducted prior to being authorization to enter the site
and/or commencing work. As a minimum, this training shall include a presentation of the
site hazards, safety and security rules and emergency procedures. Depending on the appre-
ciation of the level of risk for the contracted work, other relevant HSE subjects will be
presented.

The site HSE induction shall be conducted by the Contractor HSE Manager and shall be
conducted in a language understood by the site personnel. All e Contractors shall ensure
that their ‘Project HSE Induction’ training is submitted to the AUTHORITY for review
and approval.

As the project progresses, the Project HSE induction shall be reviewed by the Contractor
HSE Manager at regular intervals to reflect site conditions.

5.3 TOOL BOX TALKS & DAILY BRIEFINGS

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The e Contractor shall ensure that daily/weekly toolbox meetings and other daily briefings
are conducted on a regular basis. These where possible shall be conducted by the foreman
and site in-charge.

5.4 EMERGENCY RESPONSE PLAN TRAINING

The Contractor shall ensure that all project employees are aware of the Project Emergency
Response Plan. The Contractor shall ensure that training to familiarize project employees
on the Project emergency response plans is conducted at regular intervals of not less than
6 months. The Project emergency response plan training will include the procedures for
reporting to external emergency response organizations (e.g., police, fire department, am-
bulance services, hospitals, rescue services, and hazardous material response services),
building or site evacuation, designated evacuation assembly areas, and methods of ac-
counting for staff upon evacuation. Emergency drills will be performed periodically, but
at least twice per year.

5.5 TRAINING DOCUMENTATION

The Contractor shall ensure that all HSE training shall be documented. Documentation and
certificates verifying completion will be maintained by the Package Contractor on site.

6. HSE COMMUNICATIONS
6.1 HSE COMMUNICATION PROGRAM

The Contractor shall establish an effective communication network to disseminate HSE

information to all Project Personnel, to ensure support to the HSE program.

The table below gives an overview of the HSE communication methods that the Package
Contractor shall adopt on the project.

Method Frequency
Pre-start meetings Minimum once prior to commencement of works
Progress meetings As required by the project or as a minimum once a month.
HSE Meetings As required by the project or as a minimum once a month.
Daily briefings Daily
HSE Inductions As required by the project.
Tool Box Talks As required by the project or as a minimum Weekly.
Safety Alerts As required.

6.2 HSE MEETING PROGRAM

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Safety meetings provide a method for maintaining safety awareness and providing safety-
related information and training to employees. The Contractor’s shall plan and include/in-
dicate in their HSE Plan the types and frequency of HSE meetings that it will conducted
during the Project, including but not limited to:

 Daily Toolbox Meetings;

 Weekly Safety Meetings;
 HSE Committee Meetings.

The P Contractor shall keep records of all matters discussed and decisions made at each
meeting, records of Site inspections performed, register of work permits issued, records
of attendance of participants, etc.

The Contractors HSE meeting program shall:

 Review and discuss all Site HSE matters of the employees;

 Review safe work practices;
 Co-ordinate jobs so that the work does not pose as a hazard to others;
 Co-ordinate movement and storage of hazardous materials;
 Inform Personnel of potentially dangerous Works operations on the Site;
 Review progress of Works and work permit control;
 Review training requirements;
 Review work procedures and method statements;
 Review incidents and near misses.

The Contractor shall ensure that all major decisions and actions proposed by the meetings
are effectively communicated for implementation.

6.3 HSE PROMOTION AND AWARENESS

The Contractor will actively promote HSE awareness amongst the project employees by
implementing a HSE awareness programme. HSE awareness will be promoted both gen-
erally and specifically as relevant to particular areas or activities. A key feature of the
awareness programme will be generating communication on HSE matters across organi-
zational boundaries. These will be achieved through various means including, as a mini-
mum:

 HSE notice boards: HSE specific, regularly serviced and updated;

 HSE incentive scheme: performance acknowledged and rewards communicated;

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 Regular bulletins: HSE specific information on any task item, including updates on
new hazards, changes to any activity or condition, alteration to procedures, etc.;
 Posting of minutes of meetings on HSE issues: update on action items, current per-
formance, new information, items of general awareness for communication;
 Regular HSE workplace walkabouts by both Senior and Line Management: will be
performed on both an informal and formal recorded basis. These will be high profile
will include constructive discussion with all personnel as necessary.
7. MONITORING
7.1 HSE INSPECTIONS

The P Contractor shall carry out HSE inspections at regular intervals, covering not only its
works on the project but also other areas under their control such as camps/mess facilities.
These HSE inspections shall be led by the Contractor HSE team but shall also be attended
by the Package Contractor Construction team. The Contractor shall ensure that Project
HSE Inspections are carried out at least once a week. Inspections of other areas such as
campsites/mess areas shall be carried out at a suitable frequency and agreed with the AU-
THORITY. Where necessary, the Authority representatives will join these inspections. The
Contractor shall ensure that inspections of temporary works such as shoring of form work,
excavation, trenches, cranes and scaffolds shall be carried out after inclement weather.
Copies of such inspections reports shall be submitted to the Authority for review & com-
ments.

7.2 SENIOR MANAGEMENT HSE SITE WALKS

The Authority shall conduct a Senior Management HSE site walk once a month with each
individual Contractor. The Contractor shall ensure that Senior Members from its Project
team are available for these site walks.

7.3 HSE AUDITS

The Contractor shall establish and maintain an HSE audit program to be carried out on its
operations to evaluate the efficiency of its HSE management systems in place. The results
of audits, identified corrective actions and determined root causes shall be submitted to the
Authority for review and comments.

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7.4 HSE OBSERVATION PROGRAM

The Contractor will encourage and educate the project staff to observe and identify safe
and at-risk conditions and behaviors. Staff are also encouraged to report near misses in
order to look for trends and tackle issues before accidents and incidents occur.

7.5 REPORTING UNSAFE CONDITIONS

The following reporting procedures will be followed by Contractor/Project Personnel. Upon

detection of any unsafe condition or practice, the responsible worker will bring the unsafe
condition or practice to the attention of the worker’s direct supervisor, unless the unsafe
condition or practice involves the worker’s direct supervisor. If so, the e Contractor’s HSE
Manager needs to be notified at once by the responsible worker.

8. INCIDENT REPORTING & INVESTIGATION

8.1 GENERAL
The Contractor shall in his HSE plan establish procedures to identify, record, investigate and
analyze all accidents/incidents, dangerous occurrences, near misses, which occur on the Pro-
ject. The investigation and analysis shall identify the root cause and contributory causes of
these events and formulate measures accordingly to prevent future recurrence of similar in-
cidents. The Package Contractor shall ensure that copies of all such reports are submitted to
the AUTHORITY for review and comments.
8.2 REPORTING OF INCIDENTS

Contractors shall ensure that all incidents are reported to the Authority at the earliest. The
initial notification time in any case shall not be more than one (1) hour from the time of the
incident. Following the initial notification, the Contractor shall (within 24hrs) ensure that a
written notification is sent to the Authority. Contractors shall ensure that all accident/inci-
dent reports are submitted to the Authority within an agreed timeframe. For the purpose of
reporting, on the Project the following definitions shall be adopted by all Package Contrac-
tors:
 Lost Time Injury: Any accident/incident that results in an employee not being able
to work on the day following the accident.
 Medical Treatment Case: Any work-related accident/incident where the employee
has to receive medical treatment in a facility outside project first aid. This can be a
clinic or hospital.

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 First Aid Case: A minor work-related injury that requires the person to seek medical
attention at the project first aid clinic.
 Near Miss: An unplanned event or condition that occurred in the project which alt-
hough didn’t not result in an injury or damage property but had the potential to do so.
 Major Accident/Incident/Near-Miss: Categorized / defined as one which meets or
exceeds the following consequences: -
 Harm to People: Major injury or health effects (including permanent disability) -
Affecting work performance; on longer term, e.g. prolonged absence from work. -
Irreversible health damages without loss of life, e.g. noise induced hearing loss,
chronic back injuries.
 Property Damage: Damage to any Project property in excess of INR 50000.00 or
will take more than 2 days of to rectify.
 Environmental Effect: Any damage to the environment which costs an upwards of
INR 50000.00 to clean up.
 Work Related: Any injury (however small) that has happened to a personnel whilst
he was working on the project site.
8.3 REPORT DOCUMENTATION

The Contractor shall ensure that the accident/incident report that is submitted to the Au-
thority as a minimum will have the following described details/sections.

 Details of the investigation Team: List of investigation team members

 Background of the Incident: The environment of the accident before the accident
occurred
 The Incident: Detailed description of what happened in detail, the actions taken by
the Package Contractor.
 Immediate Cause: Direct and indirect causes of the incident.
 Root Cause: Complete root cause analysis of what caused the incident/accident.
 Investigation Findings: Sketch of the incident scene, photographs, diagrams and
physical evidence, persons with information and statements
 Statements of accident victims
 Recommendations: Immediate and long-term corrective actions, risk mitigation
measures and target completion dates
 Lessons learned
 Supporting documents such as any medical records, clean up records.

9. EMERGENCY RESPONSE

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9.1 GENERAL

Contractors shall as a part of their HSE Plan have a written Emergency Response Plan
(ERP). The Contractor’s ERP will consider potential emergencies that may arise during
the performance of the Works and develop procedures to deal with the emergencies. The
Contractor shall consider the following emergency scenarios for development in the ERP.

 Fatalities or serious injuries

 Major construction incidents not involving injury (e.g. structural collapse, collapse
of excavations, tower crane failure, vehicle collision)
 Fire and explosion
 Bomb alert
 Environmental incidents, including chemical spillage / toxic release
 Security violations
 Property damage
 Extreme weather.
Emergency procedures developed by the Contractor shall ensure that Contractor’s Site
Manager or most senior supervisor present takes charge and directs the handling of the
emergency. Package Contractor shall conduct weekly inspections of escape routes, fire
brigade access, firefighting facilities and work areas to ensure that the requirements stipu-
lated in the Emergency Response Plan are complied with.

9.2 EMERGENCY RESPONSE PLAN (ERP)

Prior to commencing work on site, the contractor shall prepare an ERP. The objectives of
the plan shall be to:

 Provide a framework for planning for, responding to and recovering from emer-
gency situations that may occur within the Package Contractor’s area of responsi-
bility;
 Allocate sufficient resources and facilities to manage and mitigate emergency sit-
uations;

When planning ERP’s, the Contractor shall ensure that the following shall be taken into
account:

 Site size, characteristics of the site and the work being undertaken;

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 Means of raising the alarm under those conditions;

 Plant and equipment to be used in the event of an emergency;
 Location of nearest emergency services and their capabilities;
 Access to the site for emergency services.
The ERP’s developed by the Contractor shall be specific to the Contractor’s Work. Topics
to be addressed in the plan shall include, but are not necessarily limited to the following:

 A list of all key emergency response personnel on site showing responsibilities and
contact details, including all-hours telephone numbers;
 Details of emergency services (police, fire, ambulance, spill clean-up etc.);
 Communications strategy, including liaison with emergency services and the Au-
thority’s representative;
 Emergency provisions on site, including fire prevention, detection and fighting sys-
tems, spill prevention and response equipment and first aid facilities;
 Protocols and procedures to be implemented in the event of specific emergency sit-
uations;
 Emergency response training;
9.3 EMERGENCY COMMUNICATION

The Contractor shall ensure that the ERP is reviewed at regular not less than every six
months. The Contractor shall also bring the contents of the ERP to the attention of the
Project personnel during Project Inductions, Tool Box Talks, Safety talks etc. These brief-
ings shall as a minimum include:

 Emergency procedures for different scenarios;

 Location of emergency equipment and supplies;
 Local emergency contacts, hospital routes, evacuation routes, and assembly points;
 Communication methods;
 Names of personnel trained in first-aid and CPR;
 Procedures for contacting Package Contractor and AUTHORITY key personnel.

9.4 REPORTING OF AN EMERGENCY

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The Contractor shall ensure that all emergencies are reported to the Authority as soon as
reasonably practicable. In any state this time frame shall not exceed 1 hour from the time
of the incident.

9.5 EMERGENCY PREPAREDNESS

The Contractor will ensure that an ERP drill is carried out at regular intervals, these inter-
vals shall not be greater than six months. The Contractor shall ensure that emergency drills
are conducted for all the scenarios that have been identified in the ERP. The Contractor
shall also ensure that emergency staff including first aid and emergency responders are
available and that they participate in the emergency drills. Upon completion of each drill,
an evaluation shall be made of the ERP to determine its effectiveness. Any problems or
concerns identified during the evaluation will be corrected.

9.6 EMERGENCY RESPONSE TEAM

The Contractor shall maintain a nominated team for managing and responding to emer-
gencies throughout the lifecycle of the project. The Emergency Response Team shall con-
sist of project employees who are trained (by a competent third party where required) to
respond in emergencies. The Contractor shall also ensure that the Emergency Response
Team is available on the project on all shifts and that they have ready access to the emer-
gency equipment at all times. Contact details of key personnel within the response team
are to be posted on the project to facilitate communication flow in the event of an emer-
gency.

9.7 EMERGENCY RESOURCES

The Contractor shall ensure that emergency resources including equipment, materials,
transport and personnel, for managing potential emergencies on site are available on the
project at all times. This shall include an appropriate number of first aid personnel along
with a fully equipped first aid room and/or clinic as well as industry standard firefighting
equipment, fire/smoke detection systems, alarms and any other emergency equipment as
identified by the ERP.

All incident response resources shall be suitable for the site and activity under considera-
tion. Equipment, including emergency response PPE, spill kits and firefighting systems,
are to be installed at all locations where high-risk activities are being carried out and must

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be inspected, tested and maintained regularly by the Contractor. If any equipment is miss-
ing or damaged, it shall be replaced.

10. SITE WELFARE FACILITIES

The Contractor shall ensure that adequate and appropriate arrangements exist for welfare
facilities such as first aid, canteen/mess, rest areas, drinking water and toilets. These facil-
ities shall be provided and maintained by Contractors. Welfare facilities onsite must be as
close as practical to the working locations. Large sites may require multiple facilities to
avoid long distance travel. The Contractor is required to develop a specific temporary fa-
cilities and welfare plan detailing specific arrangements.

10.1 FIRST AID ROOM

The Contractor shall make adequate arrangements for a first aid room, equipped and
staffed to the extent required. The first aid room as a minimum meets the requirements
below but in any case, will meet any requirements as laid down by local regulations.

 Designated first aid room shall not be used for any other purpose other than for first
aid or medical purposes;
 The room shall be identified clearly through first aid signage;
 It shall be located in a way to allow easy access and egress during emergency;
 Shall be spacious enough to accommodate a wheel chair or a stretcher;
 Shall be equipped with adequate facilities and equipment, well illuminated, venti-
lated, sufficient air conditioning and made up of a surface that is easy to clean;
 Arrangements exist for the disposal of refuse;
 Shall be clearly identified in the emergency plan / layout;
 Shall be equipped with a phone or other means of communication to contact ambu-
lance /hospital/ doctor on call/Company representatives.
10.2 FIRST AID BOX

The Contractor shall be depending upon the size and location of the site, ensure that first
aid boxes are provided at strategic locations & shall be suitably identifiable, and access to
them shall be ensured throughout the working hours. The Contractor shall also regularly
inspect these first aid boxes to ensure that it is fully stocked and items inside are not ex-
pired. Records of such inspections shall be maintained and produced to the Authority dur-
ing HSE inspections (as required).

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10.3 FIRST AIDER’S

The Contractor shall ensure that adequate personnel trained on first aid through an ap-
proved agency are available on the programme. A copy of the qualification certificate shall
be maintained by the Contractor for records and this certificate made available upon re-
quest from the AUTHORITY (during HSE inspections as required). Names of the qualified
first aid personnel shall be exhibited near the first aid box and other prominent locations
on the project and site offices with immediate contact details.

10.4 NURSE /DOCTOR ON CALL

The Package Contractor shall make appropriate arrangements to attend to the emergency
medical situations through the appointment of a male/female nurse/Doctor onsite (as re-
quired contractually). Alternatively, the Contractor shall ensure that provision is made to
ensure that medical assistance is given to any injured person as quickly as possible through
a contractual arrangement that may be made with a clinic / approved hospital. The
name/information about the hospital shall be exhibited at prominent locations within the
project/ site offices and shall be bought to the attention of the project personnel at the time
of the induction.

10.5 FIRST AID TREATMENT RECORDS

Records of the first aid containing the details of the treatment given, name of the treated
person, date and time of accident, place and circumstances, details of injury and treatment
given and name of person rendering treatment shall be maintained by the Contractor and
provided to the Authority (during HSE inspections as required).

10.6 CANTEEN/MESS

The Contractor shall make adequate arrangements to ensure that project personnel can
consume food in a clean & hygienic environment. Canteen/mess facilities shall be estab-
lished at the site for providing food and beverages to the project personnel. Food may be
prepared at the site or pre-prepared food may be made available.

The Contractor shall ensure that eating areas are suitable for the project personnel using
them. For example, if the local culture is to consume food whilst sitting on the floor, then
the canteen/mess facility shall ensure that there is provision for project personnel to sit on

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the floor. The canteen/mess facility shall be adequate for the number of personnel and
shall accommodate all users.

The Contractor shall consider the following when setting up a canteen:

Food preparation area Sinks – for washing up / hand washing

Drinking water supplies as appropriate Cold / Hot running water
Washing up liquid Easy cleaning access
Cutlery & Crockery Shade
Food storage Fire extinguisher matched to risk and
associated training
Means of escape Rubbish collection
Rubbish bins with liners Electrical items tested / certificated

10.7 DRINKING WATER

Adequate drinking water shall be provided to the project employees by the Contractor.
The Package Contractor shall take into consideration the requirement of drinking water
points to be available around the Project site. The drinking water points around the site
shall be easily accessible by the project employees. Adequate signage shall be put up to
differentiate drinking water from non-drinking water.

10.8 TOILETS

The Contractor shall ensure that toilets are provided to for the project employees. Consid-
eration shall be given to male & female toilets (where required).

Water Tanks

The Contractor shall ensure that all water storage tanks are cleaned on a regular basis. The
Package Contractor shall ensure that all portable water tanks are cleaned once every three
(3) months as a minimum and that the water quality is tested and deemed fit for consump-
tion.

11. SECTION 0: HSE ENFORCEMENT

The Contractor is fully responsible to ensure that they comply with all the HSE legislations
& contractual HSE requirements. However, the Authority have the right at any time to

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audit/inspect the Package Contractors facilities, procedures and safety management sys-
tems. The Contractor shall fully co-operate in such reviews and shall implement recom-
mendations at its own cost where the Authority or statutory rules and regulations are con-
travened. The Contractor shall ensure the timely closing out of issues raised via these HSE
assessments.

12. HSE STAFF

12.1 HSE PERSONNEL

The Contractor shall appoint only qualified and suitable HSE personnel to the project. The
Package Contractor shall ensure that the Curriculum Vitae (CV) and HSE certifications of
the HSE Personnel is submitted to the Authority prior to mobilizing the individual to the
project.

12.2 CONDUCT AND COMPETENCY

The Contractor shall ensure that all such personnel are competent to perform the job as-
signed to them...

12.3 PROHIBITION OF PERFORMANCE OF OTHER DUTIES

The Contractor shall ensure that no HSE personnel shall be required or permitted to do any
work that is unrelated to, inconsistent with, or detrimental to the performance of the HSE
duties.

12.4 FACILITIES TO BE PROVIDED TO HSE PERSONNEL

The Contractor shall provide all HSE personnel with the facilities, equipment, and infor-
mation that are necessary to allow the HSE personnel to carry out his duties effectively.
The Contractor shall ensure that as facilities and equipment as mentioned below is pro-
vided to the HSE department as a minimum.

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Schedule R - Project Management Requirements

Project Management Requirements…………………………………...…

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Project Management Requirements:

The Contractor shall perform all the Project Management activities necessary for proper
planning, management and control of the work. Below are the Project management re-
quirements which Contractors needs to comply at different stage of the Projects:

1. Participate in the Project kick-off Workshop with Project stakeholders designated by

Authority. The kick-off Workshop shall accomplish the following objectives:
 Common understanding of the Project goals and objectives

 Define respective roles and responsibilities and

 Agree on the methods of communication and reporting throughout the Project

duration.

2. Participate in monthly Project status review meetings and present the Project progress
update in the meeting. The frequency of Project status review meetings may change
based on actual requirements.

3. Schedule: The Contractor shall submit detailed schedule in Prima Vera/ MS project
with narration in soft and hard copies that cover’s the full scope of Contractor’s work
within 30 calendar days of date of appointment. This will be reviewed within 15 calendar
days by Authority. The Contractor shall incorporate the comments and resubmit the
schedule no later than 15 calendar days after receiving the comments from Authority.
Upon approval, the above schedule will become the baseline schedule for all the future
monitoring and tracking.

The Contractor should keep to the following guidelines

i) Develop and incorporate a detailed Work Breakdown Structure

(WBS) for all Project schedules that are submitted.

ii) All schedules shall be created, maintained and submitted to

Authority in Oracle Primavera P6 or higher version of Primavera
P6 in an electronic format.

iii) All schedules shall follow the Critical Path Method (CPM) of
scheduling and shall have meaningful and realistic logical ties and
relationships between activities.

iv) The use of negative lags is not permitted in the baseline and all
other versions of the schedule.

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v) The schedule must contain all the long lead procurement items
identified.

vi) Shall exercise reasonableness while assigning constraints in schedule

and milestones

vii) The Contractor shall allocate the Contract amount in detail to all the
activities. It shall be used as guide for progress (S-Curve) monitoring
only. Progress S-Curve to be updated each month and Progress
Measurement will be on the basis of Earned Value Management.

viii) The Contractor shall provide narration with all the calculations,
reports, forecast, supporting documents and detailed list of
assumptions made on the development of the project schedule.

ix) Activities shall comprise of specific and measurable elements of work.

Durations for each activity shall be calculated using productivity
rates.

x) All schedules shall be resource loaded and Resource Histogram shall

be submitted along with schedule.

xi) Upon approval, the copy of the Baseline schedule will become the
first Current Schedule. The Contractor shall not change the approved
schedule unless instructed in writing by the Authority. It shall be used
as basis for measuring progress performance.

xii) The Current schedule shall be actively updated and maintained by the
Contractor every month.

xiii) The updated Primavera P6 schedule file should be submitted every

month along with Monthly progress report in electronic format. A
pdf copy of the updated schedule with all activities also needs to be
submitted

xiv) A schedule narrative document shall accompany the updated

electronic schedule describing the work performed in the reporting
period.

xv) Two month look ahead schedule should be submitted along with the
Monthly Progress Report.

4. Cash Flow: Cash Flow shall be extracted from Baseline Schedule and Updated
Schedule every month. Cash Flow shall be submitted along with Monthly Progress
Report to show the actual versus plan and updated on monthly basis

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5. Lessons Learned Database: The Contractor shall develop and actively maintain a “les-
sons learned” database on a monthly basis (to be included in the monthly Project re-
port) and submit it to Authority at the end of the Project during closeout.

6. Risk Register: Maintain an active risk register addressing the risks and mitigation
measures (could be in excel format) that lists the Project risks related to their Scope of
Work. Risk Register shall be updated every month and to be submitted every month
along with Monthly Progress Report.

7. Inter-Project Links: Identify potential inter-Project links, inter-dependencies or con-

flicts/ interference to work or work areas and narrate them in the monthly progress re-
port.

8. Monthly Progress Report: Prepare and submit a monthly progress report no later than 7
days of each month (standard format and template will be provided by Authority at a
later date). Items 3 to 7 mentioned above shall be the minimum information that will
need to be included in the monthly progress report.
9. Monthly payments are subject to timely submission of monthly progress report
and the monthly updated electronic schedule file in the required and acceptable format.

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Schedule S - Quality Assurance

(See Clause 3.1.7 (o))

1.1 GENERAL:

The Contractor shall implement a Project Quality Management Plan in accordance with
ISO-9001 “Quality System – Model for Quality Assurance in Design/Development,
Production, Installation and Servicing” or any other system as approved by Engineer to
ensure that all materials, workmanship, plant and equipment supplied and work done under
the contract meets the requirements of the contract. This plan shall apply to all activities
related to the quality of items, including designing, purchasing, inspecting, handling,
assembling, testing, storing, and shipping of materials and equipment and different
elements of construction work and installations of system components.

The Quality Plan to be prepared by the Contractor and submitted to the Engineer shall
follow the requirements of ISO 9001 and address each element therein. This Quality Plan
/ QA manual, specific to this work must be submitted within one month of award of
contract.

Running on account payment will be released after the following milestones are achieved
and Engineer has issued a ‘Notice of No Objection’ or a Notice of No Objection subject
to……(specifying the condition).

(a) Release of on-account payment after two months of signing the contract agreement
– On submittal of QA Manual duly approved by Engineer (ER). Otherwise 10% of
the running bill be withheld till compliance.
(b) Closure of Non-conformance Report – Action taken on non-compliance and its
closure to be ensured within 15 days of issue of non-conformance report. In case of
non-closure of report, running on-account bill will be withheld @ 1 % of amount for
every non-closure, till the same are closed satisfactorily.
(c) Release of on-account payment after four months and thereafter every 3 months from
the date of start of work – On submittal of Internal Quality Audit Report duly
reviewed by Engineer and Action Taken Report. Otherwise 10% of the running bill
be withheld till compliance.
(d) Release of Final bill –

(i) Closure of all non-conformance reports

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(ii) Submittal of all quality documented record pertaining to monitoring and

accountability including QA Manual &Procedures Registration of the
Contractor’s organization, or subcontractors or sub-consultants is not required
for this Project but the Project Quality Management Plan as submitted shall
meet the intent of the ISO 9001 requirement in that there is a comprehensive
and documented approach to achieving the project quality requirements.

1.2 Quality Assurance Management Plan

The Project Quality Management Plan (PQMP) shall as a minimum address the quality
system elements as required by ISO 9001, generally noting the applicability to the
Contractor’s Works Programme for the Project. Procedures or Quality Plans to be prepared
by others (Suppliers, Subcontractors, Sub-consultants) and their incorporation in the
overall PQMP shall be identified.
The Contractor shall provide and maintain a Quality Assurance Plan (QA) to regulate
methods, procedures, and processes to ensure compliance with the Contract requirements.
The QA Plan, including QA written procedures, shall be submitted to the Engineer for his
review.
Adequate records shall be maintained in a readily retrievable manner to provide
documented evidence of quality monitoring and accountability. These records shall be
available to Authority at all times during the term of the Contract and during the Defects
Liability Period and for a five-year period thereafter.

The Plan shall identify:

(a) Design Process: that control, check and verify the accuracy, completeness and
integration of the design shall be performed by certified personnel and in accordance
with documented procedure that have the written consent of the Engineer.
(b) Special Processes: that control or verify quality shall be performed by certified
personnel and in accordance with documented procedures that have the written
consent of the Engineer;
(c) Inspection and Test: Inspection and testing instructions shall provide for reporting
non-conformances or questionable conditions to the Engineer; Inspection shall occur
at appropriate points in the installation sequence to ensure compliance with
drawings, test specifications, process specifications, and quality standards. The
Engineer shall designate, if necessary, inspection hold points into installation or
inspection planning procedures;
(d) Receiving Inspection: These procedures shall be used to preclude the use of
nonconforming materials and to ensure that only correct and accepted items are used

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and installed; Identification and Inspection Status: a system for identifying the
progressive
(e) inspection status of equipment, materials, components, sub-assemblies, and
assemblies as to their acceptance, rejection, or non-inspection shall be maintained;
(f) Identification and Control of Items: an item identification and tractability control
shall be provided;
(g) Handling, Storage, and Delivery: provide for adequate work, surveillance and
inspection instructions.
The Plan shall ensure that conditions adverse to quality such as failures, malfunctions,
deficiencies, deviations, and defects in materials and equipment shall be promptly
identified and corrected.
The Plan shall provide for establishing, and maintaining an effective and positive system
for controlling non-conforming material including procedures for the identification,
segregation, and disposal of all non-conforming material. Dispositions for the use or repair
of nonconforming materials shall require the Engineers consent.

1.3 Plan Implementation and Verification

The Plan shall clearly define the QA Organization. Management responsibility for the QA
shall be set forth on the Contractor’s policy and organization chart. The Plan shall define
the requirements for QA personnel, their skills and training. Records of personnel
certifications shall be maintained and monitored by the QA personnel. These records shall
be made available to the Engineer for review, upon request.
The QA operations shall be subject to the Engineers, Authority or Authority’s authorized
representative’s verification at any time, including: surveillance of the operations to
determine that practices, methods and procedures of the plan are being properly applied;
inspection to measure quality of items to be offered for acceptance; and audits to ensure
compliance with the Contract documents.
The contractor’s Quality Audit Schedule shall be submitted to the Engineer for consent
every three months or more frequently as required.
The results of Quality Audits shall be summarized in the Contractor’s Monthly progress
reports. The Contractor shall provide all necessary access, assistance and facilities to
enable the Engineer to carry out on-site and off-site surveillance of Quality Assurance
Audits to verify that the quality system which has the consent of the Engineer is being
implemented fully and properly.

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Schedule T – Reports

INDEX

DISCLAIMER:

1. Reference Geotechnical Investigation Report

2. Map showing HFL’s of Vaagu’s

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