JABATAN BEKALAN

AIR LUAR BANDAR

SARAWAK

TECHNICAL
GUIDELINES
WATER SUPPLY SYSTEMS

Edition
2024
 JBALB Technical Guidelines for Water Supply System in Sarawak

Abbreviation

AC Alternating Current
API Application Programming Interface
BOMBA Fire and Rescue Department of Malaysia
BPS Booster Pump Station
BRC British Reinforcement Company
BS British Standard
CCTV Closed-Circuit Television
CI Cast Iron
CO2 Carbon dioxide
DMA/DMZ District Metering Area / District Metering Zone
DI Ductile Iron
EC Electrolytic Chlorination
H2S Hydrogen Sulfide
HDPE High Density Polyethylene Pipe
ICT Information and Communications Technology
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronics Engineers
JBALB Rural Water Supply Department (Jabatan Bekalan Air Luar Bandar)
FIFO First-in-First-Out
FRP Fiberglass Reinforced Plastic
GI Galvanized Iron
HLT High Level Tank
HT High Tension
kVA Kilo-volt-amperes
kW Kilowatt
LT Low Tension
MCC Motor Control Centre
MCMC Malaysian Communications and Multimedia Commission
ML Mega Liter
MLD Mega Liter per Day
MoH Ministry of Health
MSB Main Switch Board
MSCL Mild Steel Cement Lining
NB-IoT Narrowband Internet of things
NDWQS National Drinking Water Quality Standard
NPSH Net Positive Suction Head
NREB Natural Resources and Environment Board
NRW Non Revenue Water
O2 Oxygen
OSHA Occupational Safety and Health Act
PLC Programmable Logic Controller
RC Reinforced Concrete
RCPM Remote Cathodic Protection Management
RF Radio Frequency
Rpm Rotational speed per minute
SCADA Supervisory Control and Data Acquisition
SESCO/SEB Sarawak Energy Berhad
 JBALB Technical Guidelines for Water Supply System in Sarawak

SEMI Voltage Sag Immunity Standards

SRB Sarawak River Board
SWSS Smart Water Supply System
uPVC Unplasticized Polyvinyl Chloride
WTP Water Treatment Plant
 JBALB Technical Guidelines for Water Supply System in Sarawak

Contents
1 WATER DEMAND AND CONSUMPTION 1
1.1 Scope of Work Supply 1
1.2 Per Capita Consumption 1
1.3 Demand Fluctuations Factors 1
1.4 Allowance in excess 1
1.5 Fire Fighting Demand 2
1.6 Design Period for Water Supply Components 2
1.7 Population and Water Demand Estimates 2
1.7.1 Population Projection 2
1.7.2 Water Demand Estimation and Projection 3
2 Pipeline 4
2.1 Types of Distribution Systems 4
2.2 Maximum system design working pressure (MSDWP) 4
2.3 Distribution and Reticulation Layout 5
2.4 Selection of Type of Pipe Material 5
2.5 Principal advantages and limitation of selected water supply pipe materials 6
2.6 Selection and Installation of Air Valve 7
3 Service Reservoir 9
3.1 Basic Components 9
3.2 Type of Reservoir 9
3.3 Design requirement for treated water reservoir 10
3.4 Installation of Altitude Valve 11
4 Raw Water Resource 12
4.1 Assessment of Raw Water Sources 12
4.1.1 Surface Water Source 12
4.1.2 Ground Water Source 12
4.2 Selection of Raw Water Intake Location 13
4.3 Raw Water Intake Structure 13
4.3.1 Pontoon Intake 14
4.3.2 Jetty Intake 14
5 Water Treatment Plant Process 15
5.1 Raw Water Quality 15
5.2 Treated Water Quality 16
5.3 Treatment Plant Location 19
5.3.1 Planning 19
5.3.2 Plant design 19
5.4 Environmental factors 20
5.5 Treatment Process 20
5.5.1 Typical Process of Treatment 21
5.5.2 Selection of Treatment Process 21
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5.6 Pre-Sedimentation 22
5.7 Chemical Dosing System 23
5.8 Chemical Storage 24
5.9 Filtration 25
5.10 Operation and Maintenance Requirement 25
5.11 Layout 25
5.12 Operation Building 27
5.12.1 The Laboratory 27
5.12.2 Filter Operating Gallery 28
6 Quarters 30
7 Sludge and Wastewater Disposal 31
8 Mechanical Works 32
8.1 Parameters for Pumps Selection 32
8.1.1 Raw water pump head design 34
8.1.2 Treated Water Pump Selection 34
8.2 Pump Installation Layout 34
8.3 Mechanical Seal vs Gland Packings (Surface Pump) 35
8.4 Motor Starter Requirement 35
8.5 Variable Speed Drive (VSD) 35
8.6 Surge Suppression System 36
8.7 Cranes 37
8.8 Forklift 38
8.9 Fire Fighting Services 38
8.10 Cathodic Protection 38
8.11 Pressure Gauge 38
9 Electrical Works 39
9.1 Power Supply 39
9.2 Sizing of Motor 39
9.3 Control Panel 39
9.4 Generator 39
9.5 General Lighting and Power 41
9.6 Earthing system 41
9.7 Lightning Protection System (LPS) 41
9.8 Main Switch Board 42
9.9 Electrical Wiring 42
10 Digitalization 43
10.1 Production Digitalization 45
10.2 Distribution Digitalization 55
10.3 Consumption Digitalization 58
10.4 System Integration 61
10.5 Last Mile Internet Connection (LMIC) 63
11 Safety and Security 64

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11.1 Security Fencing and Gates 64

11.2 Other Security Consideration 64
11.3 Safety Requirement 64
12 Testing and Commissioning for Water Treatment Plant / Booster Pump Station 68
13 Color Code 68
14 Reference 69
15 Attachment 71
15.1 Checklist on design report for Watermain, Booster Station and Reservoir 71
15.2 Check list on tender drawing for Watermain, Booster Station and Reservoir 71
15.3 Checklist on design report for Water Treatment Facilities 71
15.4 Testing and Commissioning Document for Booster Station 71
15.5 Testing and Commissioning Document for Water Treatment Plant 71

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 JBALB Technical Guidelines For Water Supply System In Sarawak

1 WATER DEMAND AND CONSUMPTION

1.1 Scope of Work Supply

Public potable water supply systems in JBALB Sarawak jurisdiction.

1.2 Per Capita Consumption

Category Consumption
Domestic Urban 250 litres/capita/day
Rural 180 litres/capita/day
Commercial Hotels/resorts 450 litres/room/day
Complexes/Office buildings 10 litres/m2/day
Shop houses 2000 litres/floor/day
Institutions Schools (day) 45 litres/pupil/session/day
Schools (Boarding) 250 litres/pupil/session/day
Hospitals 400 litres/bed/day
Government clinics 45 litres/patient/day
Armed Forces/Polices 350 litres/person/day
Places of worship 10 litres/person/day
Industrial* Light 22,000 litres/hectare/day
Medium 35,000 litres/hectare/day
Heavy 45,000 litres/hectare/day

Note: -
* As classified under the Piawaian Perancangan Kawasan Perindustrian issued by the Jabatan
Perancangan Bandar dan Desa or Land & Survey Department Sarawak.
- Urban means communities with population exceeding 10,000 persons for design purpose.

1.3 Demand Fluctuations Factors

Peak demand is obtained by multiplying the average demand by the peak factor in the
design of pipelines:

Maximum hourly or peak consumption 2.2

Average daily consumption 1.0

1.4 Allowance in excess

Allowance in excess of the consumption demand based on average daily consumption should
be made to provide for the following: -
a. 20% reserve margin for treatment plant usage
b. 25% for non-revenue water (distribution loss)
Note: -
For design with the existing supply, it is required to study the actual demand pattern and
subsequently derive the appropriate factors and figures for non-revenue water.

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 JBALB Technical Guidelines for Water Supply System in Sarawak

1.5 Fire Fighting Demand

Risk Category Average Total Spanning Maximum No. Of
Flow (Metres) hydrant Outlets
(Litres Per Used
Minute) Simultaneously
Class A Risk 4100 90 3@ 1370 litre
Large buildings, shopping complexes, per minute
high rise buildings, large industrial
estate, Warehouse and ports
Class B Risk 2700 90 2@ 1370 litre
Congested areas with buildings up to 5 per minute
storeys
Class C Risk 1370 90 1
Shophouse up to 3 storeys, light
industry
Class D Risk 1140 120-terrace 1
Residential terrace house, detached, 150-detached/
semi detached semi - detached
Class E Risk 680 180 1
Others

Note: -
1. To comply with the Fire and Rescue Department of Malaysia requirement.
2. For Fire flow plus peak demand, the minimum residual pressure should be 10m head.
3. The system should be designed to provide minimum residual pressure at 20m head
for urban and 10m head for rural during the peak demand at end of the pipeline.

1.6 Design Period for Water Supply Components

Demand projection provided based on 5 yearly intervals up to maximum design period.
• Civil works and Reticulation work - maximum of 30 years.
• Pumps, mechanical, electrical and electronic items - minimum of 5 years.

1.7 Population and Water Demand Estimates

The predicted population growth should be based on the latest figures from the Department
of Statistics Malaysia which should be projected using appropriate growth rate and/or from
other sources, e.g. District Health Office, District Office & Education Department. Population
density figures and predicted density changes should be derived and used.

1.7.1 Population Projection

The basic formula for population projection for water supply planning purposes: -
Pn = P (1 + r) n
Where Pn = Projected population
P = Population at census
r = Annual growth rate
n = Number of years

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 JBALB Technical Guidelines for Water Supply System in Sarawak

1.7.2 Water Demand Estimation and Projection

The basic formula for water demand estimation to be used is as follows: -
Wdn = (Pn x C x DF) + Dn
Where,
Wdn = Water demand at the end of year “n”
Pn = Projected population at the end of year “n”
C = Per capita consumption
DF = Demand fluctuation factor
Dn = Additional demand for new developments and Allowance
in excess of the consumption at the end of year “n”
n = Number of years

Water Demand estimation and projection provided based on 5 yearly intervals up to

maximum design period.

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 JBALB Technical Guidelines for Water Supply System in Sarawak

2 Pipeline
The water distribution system consists of transmission, distribution and reticulation pipelines,
balancing and service reservoirs and treated water pumping stations. The objective of a water
transmissions and distribution system is to convey water at a suitable pressure and the required
quantity to the consumers.

Definitions are as follows:

1. Transmission pipelines – gravity or pumping mains that carry water from WTP/pumping
stations to reservoirs or reservoirs to reservoirs.
2. Distribution pipelines – gravity mains that connect water from service reservoirs to
reticulation mains.
3. Reticulation pipelines – pipes of smaller sizes that carry water from distribution pipes to
water demand centres such as housing areas or factories.
4. Balancing / Service reservoirs – storage tanks that hold water for certain period of time.
5. Treated water pumping stations – pumping facilities that pump water to a higher elevation
such as reservoirs.

2.1 Types of Distribution Systems

System Advantages Disadvantages
Gravity • Most reliable • Higher capital cost for
• Low operational costs construction of elevated
water tanks
• No regulation of flow and
pressure
Pumping and gravity • Least cost option under • Problems associated with
combination certain topographical operation and
conditions maintenance of pumping
systems
Direct pumping • Pressure and flow can be • Too dependent on power
easily regulated supply
• Remedial action can be
speedily taken

2.2 Maximum system design working pressure (MSDWP)

1. For a pumping system, the MSDWP is the maximum pumping pressure under the closed
valve condition during the design period of the system. This valve shall be located at the
end of the pipeline of the pumping system.
2. For a gravity system, the MSDWP is the maximum pressure that the system will be
subjected to when the service reservoir is full during the design period of the system.
3. For a combined system comprising of a pumping system and a gravity system, the section
tests and system test for each system shall be carried out separately.

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2.3 Distribution and Reticulation Layout

1. The service reservoir shall be as close as possible to the water demand area, so as to
provide the least capital and operating costs.
2. Where the service reservoir cannot be sited close to demand area, a twin pipeline layout
shall be considered.
3. The reticulation pipes shall be laid so as to form a loop system and dead ends shall be
discouraged.
4. Where extreme topographical conditions prevail in demand areas, such as greater than
40 meter difference in elevation, pressure zoning of service according to ground
elevations may be necessary. This can be achieved by using pressure reducing valve.
5. Pipelines shall be preferably be laid adjacent to roads so as to provide easy access for
maintenance. Wayleave approval must be applied to relevant authorities / parties before
proceeding with the works.
6. The system should be designed to provide minimum residual pressure at 10m head for
rural during the peak demand at end of the pipeline.
7. In all reticulation pipes, the maximum residual pressure in the system shall not exceed
60m head as far as possible. Where necessary, pressure reducing valves should be
installed to reduce NRW. Booster station in sequence or in-line BPS may be considered.
8. Watermains should be usually laid in front of shoplots and houses.
9. Gate/sluice valves should be located to minimize water supply interruption during pipe
breakages. The valves interval should be at least 1.5km internal or at every tee-off
junction.
10. Valves should not be located under pavements whenever possible.
11. Position of fire hydrants to be approved by the Fire and Rescue Department of Malaysia.
12. All the pipes, fittings, valves, specials shall conform with the latest approval from the State
Water Authority.
13. Pumping mains should preferably be of ductile iron or steel pipes unless otherwise
approved.

2.4 Selection of Type of Pipe Material

The followings considerations shall apply for the selection of type of pipe material for water
supply: -

1. Size and maximum working and test pressure, including surge pressure.
2. Strength of pipe to withstand designed internal and external loads.
3. Durability of pipe.
4. Suitability and workability for laying and operating requirements.
5. Capital, operation and maintenance cost.
6. Extent of possible leakage.
7. Pipe material availability
8. Evaluation against environmental factors.
9. Evaluation against conveyed water quality.
10. Evaluation against soil/groundwater properties and characteristics.

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2.5 Principal advantages and limitation of selected water supply pipe materials
Pipe Material Advantages Disadvantages
Ductile Iron (DI) ▪ High mechanical strength and ▪ Heavy
toughness ▪ Susceptible to corrosion if internal
▪ High fatigue resistance or external protection systems
▪ Ease of jointing damaged
▪ Flexible joint tolerates some ▪ Potential high pH problems when
defection conveying soft waters
▪ Pipe impermeable to gas and ▪ Retrospective installation of
organic contaminants fittings may be complicated on
▪ Easy to trace for detection and ungauged pipes (dia > 350mm)
location of leaks
▪ Well established methods of repair
High Density ▪ Corrosion resistant ▪ Fusion jointing requires skilled
Polyethylene ▪ Relatively light-weight installers and special equipment
(HDPE) ▪ Flexible ▪ Reliant on stable support from soil
▪ Out-of-trench jointing possible ▪ Susceptible to permeation or
degradation on prolonged
exposure to direct sunlight
▪ Pipe location difficult making
leakage detection complicated
▪ Retrospective installation of
fittings or repair complicated in
large diameters (nominal size >
335mm)
Steel ▪ High mechanical strength and ▪ Welded joints require skilled
toughness installers and special equipment
▪ High fatigue resistance ▪ Susceptible to corrosion if
▪ Flexible protection systems damaged
▪ Available in long lengths ▪ Welded joints normally required
▪ Can be welded to form a leak-free reinstatement of protection
system that will resist end load systems on site
▪ Easy to trace ▪ Cathodic protection requires
▪ Pipe impermeable to gas and regular monitoring or
organic contaminants maintenance
▪ Easy for detection and location of ▪ Potential high pH problems when
leaks conveying soft waters
▪ Reliant on stable support from soil
▪ Retrospective installations of
fittings or repair may be
problematical if non-standard pipe
size are used
Unplasticized ▪ Corrosion resistant ▪ Susceptible to impact damage
Polyvinyl Chloride ▪ Relative light-weight ▪ Susceptible to poor installation
(uPVC) ▪ Ease of jointing ▪ Reliant on stable support from soil
▪ Ultraviolet degradation on
prolonged exposure to direct
sunlight

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 JBALB Technical Guidelines for Water Supply System in Sarawak

Pipe Material Advantages Disadvantages

▪ Susceptible to permeation or
degradation by certain organic
contamination
▪ Pipe location difficult making
leakage detection complicated
Acrylonitrile ▪ Corrosion resistant ▪ Susceptible to impact damage
Butadiene Styrene ▪ Relative light-weight ▪ Susceptible to poor installation
(ABS) ▪ Ease of jointing ▪ Reliant on stable support from soil
▪ Ultraviolet degradation on
prolonged exposure to direct
sunlight
▪ Susceptible to permeation or
degradation by certain organic
contamination
▪ Pipe location difficult making
leakage detection complicated

Pipe Material Usage DI Steel HDPE uPVC ABS

With pumping stations, WTP, reservoir sites ** ** √ X X
Built into water retaining structures ** X X X X
Under crossing, road crossing ** ** √ X √
Over crossing, overhead bridge, culvert crossing √ ** X X X
Transmission pipe lines √ ** √ X X
Distribution pipelines √ √ ** √ √
Reticulation pipelines √ √ ** ** **
Submarine pipelines X √ ** X X
Corrosive environment, coastal areas √ X ** √ **
Peat soil √* √* X X X
Swamp √* √* √ √ √
Contaminated soil (petroleum & acid based) √ √ X X X
Nominal diameter 150mm – 500mm ** ** ** ** **
Nominal diameter above 500mm √ ** X X X

Legend:
** Highly recommended
√ Recommended
X Not recommended
√* For steel, cathodic protection may required.
For DI, polyethylene sleeve is required.

2.6 Selection and Installation of Air Valve

Excess air in a pipe can cause slower flow, pipe churning damage, cause turbulence, and
increased corrosion rate.

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Air valves allow excess air to escape from the pipeline while containing pipeline fluids within
the pipeline during operation. They also allow air to escape from the pipes during filling.

The valves can inject air into the pipes while they are being emptied, preventing a vacuum,
which would cause the pipe to collapse.

Kinetic type air valve so named combination air valves, triple acting air valves etc. The kinetic
air valve provides excellent protection against vacuum formation with its advanced
aerodynamics design and kinetic orifice. The design of air valve shall enable the following
functions: -

• Large air release during water filling pipeline;

• Small air release under pressurized pipeline;
• Large air intake during draining or burst of the pipeline.
i. The valve shall be of float type, either single or double chamber, having a cast iron / ductile
iron full bore body and bolted cover, designed with bottom inlet, float guide mechanism
and the cylindrical float. The float and all parts of the valve and operating mechanism
shall be made of non-corrodible materials. The float shall be of the type of cylindrical
shape, made of solid material, preferably stainless-steel float or hard plastic-based
material to avoid deformation and ensure smooth sliding movement.
ii. The valve shall be able to sustain high water hammer (or anti water hammer) and allow
quick closure without failure.
iii. The air valve shall have no arm or no lever to prevent vibrating, bending, direct closure of
the float.
iv. The valve cover shall be able to prevent the entrance of insects and foreign particles.
v. The maintenance of the valve shall be performed from the top without the need to
remove the valve from the pipe.
vi. The valve shall be fusion epoxy coated inside and outside of valve body for long term
services.

The Installation of Air Valve

Air valves shall be provided at all peak points along a pipeline profile and where there are
significant negative changes in pipeline gradient.

Correct Position and Installation 90° of Air Incorrect Installation (less than 90°)
Valve

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3 Service Reservoir
➢ To provide a reserve of water due to breakdown
➢ To provide a reserve to meet fluctuating demand
➢ To act as a break pressure tank
➢ To provide a reserve of water for fire fighting

3.1 Basic Components

a. Inlet pipe for the entry of water
b. Outlet pipe connected to the distribution mains
c. Overflow pipe discharging into drain and maintaining level
d. An indicator for indicating the depth of water which can be read from outside or SCADA
system
e. Scour pipe for cleaning the reservoir
f. Automatic devices or altitude valve to stop pumping when the tank in full.

3.2 Type of Reservoir

RC Elevated Reservoirs

Pressed Steel Tank

FRP Elevated Tank

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HDPE Elevated Tank Bolted Steel Tank

Other Types of Tank

3.3 Design requirement for treated water reservoir

a. All reservoirs should be designed so as to be fully protected from all possible
contamination without internal tank liner.
b. All elevated storage tank and tower should be of Reinforced Concrete unless otherwise
approved.
c. Reservoir with capacity more than 1 ML should have partition for maintenance and
cleaning of the interior and shall not allow stratification of water quality. Standby outlet
pipe shall be allowed.
d. All storage reservoirs are to be provided with scour pipe of sufficient size that bigger than
inlet pipe.
e. The minimum storage requirement for service reservoirs and suction tanks should be
designed to allow for one (1) day storage and meet fluctuating demand and firefighting
requirement.
f. The treated water suction tank should have a minimum capacity equivalent to eight (8)
hours pumping rate.

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g. All appurtenances and regulating services should be standard water supply practices.
These include pressure regulating valves, flow measurement recorders, air and reflux
valves, altitudes valves, level indicator etc.
h. Preferable inlet pipe is located at top of the tank and outlet pipe at bottom of the tank.
i. Bypass system between inlet and outlet shall be provided.
j. Proper safety access and staircase from the ground level to tank shall be provided.

3.4 Installation of Altitude Valve

The altitude valves (AV) are used to control the level of water in elevated reservoirs. They may
also be installed at ground reservoir inlet pipes greater than 450mm diameter. Altitude valves
shall be installed in chambers above ground and shall be provided with bypass pipe
arrangement so that distribution to the supply of water is minimized when the valve is being
maintained.

➢ Pilot is installed at higher ground to prevent flooding so

that it can "breathe" normally and the whole AV will
function normally.
➢ Pilot of the AV is connected with 3 lines:-
a) Copper lines for pressure adjustment.
b) HDPE line - pressure sensing line, connection from
HLT / Reservoir to pilot.
➢ Technically, pilot of the AV is having similar design as the
AV body, equipped with the small diaphragm, and
magnify the pressure difference to AV body to open or
close the diaphragm. It shall be operational normally
under atmosphere pressure. When pilot is submerged
in the water, it’s lost its sensitivity and always result
overflow of the HLT.

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4 Raw Water Resource

4.1 Assessment of Raw Water Sources

The assessment of raw water sources should include the following: -

a) River Yield - safe yield based 7-day low flow for a return period of 50 years vs. estimated
future demand.
b) Raw water quality – present & future status with emphasis on existing and potential
contamination/pollution by chemical and bacteriological agents.
c) Land use and heavy impact activities surrounding raw water source.
d) Requirements for storage - location, volume, capacity of catchment areas & yields,
duration of drought & water quality due to storage and fluctuation. The capacity of the
storage will be determined by duration of drought.
e) Source protection & alarming system & raw water (quality & quantity) monitoring system.
f) Catchment details and special requirement for catchment control measures.
g) Various possible options of water sources (surface water/groundwater)
h) Environmental flow & other legal users of the source
i) Cost/Benefit analysis

4.1.1 Surface Water Source

a) Various possible options for the surface water source have been consider.
b) Comparison of the various options for the raw water source has been carried out (should
include costs advantages & disadvantages, etc.)
c) The safe yield of the recommended raw water source satisfied the following conditions:
❖ Adequate to meet the maximum projected water demand while not significantly
affecting the ecology of the water course downstream of the intake.
❖ Provide a reasonable surplus for anticipated growth.
❖ Adequate to compensate for all losses such as sitting, evaporation, seepage, etc.
❖ Adequate to provide ample water for other legal users of the source.
d) Where run of river safe yield is insufficient, adequate impounded storage for raw water is
provided.

4.1.2 Ground Water Source

The following information on the proposed ground water source have been provided:

a) Sites considered and reasons for selection.

b) Elevations with respect to surrounding and flood plain(s).
c) Character of formations through which the source is to be developed.
d) Geologic conditions affecting the site such as test holes, abandoned wells or
anticipated interference between proposed and existing wells.
e) Summary of source exploration (test well depths, location, pumping rates and
duration, water levels, specific yield, capture area and pumping radius of influence for
production wells, etc.
f) Raw water quality report

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g) Sources of possible contamination such as sewers and sewerage facilities, highways,

landfills, chemical facilities, etc.
h) Preserve of existing wells and their effects on proposed wells.
i) Depths of any known water bearing aquifers that will reduce well yield if penetrated.
j) Total depths of all known water bearing aquifers in the area concerned.
k) Wellhead protection measures considered.
l) Aquifer protection and management issues.

4.2 Selection of Raw Water Intake Location

The design should take into consideration, the selection of site of Intake based on:

a) Raw water quality & quantity & environmental considerations (geological, biological,
floodplain, debris/logs issue, riverbank conditions, erosion and deposition,
seismic/wave, safety, river navigation, etc.);
b) Silt loading, debris/log, provision for desilting, screening and isolation of intake, facility
and protection against damage, flow distribution, ease of operation and maintenance;

4.3 Raw Water Intake Structure

(a) The design should take into consideration riverbank conditions, soil investigation,
maximum & minimum water levels, presence of erosion and deposition, silt loading,
debris, provision for desilting, screening & isolation of intake, dual facility & protection
against damage.
(b) All intake structures to be on stable ground and stable stretches of the rivers.
(c) The design shall have sufficient factor of safety against external forces such as strong
currents, floating and submerged materials, etc.
(d) Site shall be of easy access and have proper access (asphaltic concrete tar sealed road).
(e) Intake structure is located at sufficient water depth so as to be able to keep the raw water
pumps low flow.
(f) Intake structure does not obstruct passage of vessels in navigable rivers. Warning signages
and lightings as per requirement by SRB are to be provided.
(g) Is designed to supply evenly distributed flow to the pump suction to prevent formation of
surface/submerged vortices, introduction of air into the pump, etc.
(h) Is designed to cater for future upgrading or addition of pumps to cater for increase in
water demand.
(i) Intake structure is designed to allow the pumps to achieve optimum hydraulic
performance for all operating conditions.
(j) Is equipped with a coarse screen and a fine screen, both removable and are readily
accessible for cleaning (preferably self-cleaning).
(k) Fenders/log booms are provided to protect the intake from floating logs, debris, etc.
(l) Lifting hoist is provided for installation and maintenance of the pumps, pipes, fittings,
valves, etc. ‘A’ frame can be used only if submersible pump is less than 0.5 tonne
otherwise monorail/gantry cranes have to be provided.
(m) Waterproof shed is provided for switchgear, lifting hoist & other electrical equipment.
Switchgear & terminal box are cited above highest flood level possible.
(n) Provisions of instruments for measuring water levels (e.g., ultrasonic level sensor) and
quantities and for monitoring water quality are required.

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(o) Protection from the entry of stray animals and trespassers by the provision of fencing and
lighting.
(p) Provision of oil boom kit or other products to contain oil spillage or contamination at raw
water intake.

4.3.1 Pontoon Intake

(a) Pontoon structure is properly designed using durable material.
(b) The pumpsets can be securely mounted on the pontoon.
(c) The pontoon is securely anchored without risk of overturning during changes in water
level’
(d) Where mooring ropes are used, they are long enough and well secured to allow for
changes in water level.
(e) The pump’s discharge pipe is long enough and well secured to allow for changes in water
level.
(f) Heavy duty flexible discharge pipe of suitable material is used.
(g) A housing is provided over the pump(s) and motors where centrifugal pumps are used.\
(h) Coarse screens are incorporated in the design of the pontoon to protect the pumps or
footvalves from debris, etc.
(i) Electrical cables of sufficient length are designed to allow for highest water level pontoon
position.
(j) Pontoon structure is properly linked with jetty accessible for operation & maintenance,
including hand operated cart.

4.3.2 Jetty Intake

(a) The jetty is designed to meet the requirements of the appropriate design codes and
standards, to sound engineering principles and is fit for the intended purposes.
(b) The intake jetty is sited on stable ground which is not subjected to siltation and erosion.
(c) The jetty is of reinforced concrete construction.
(d) The deck of the jetty is above the maximum water level.
(e) The jetty is designed with platform for inspection, mounting & dismantling of raw water
pumps, valves, etc.
(f) Rigid pump base should be provided for installation of pumps.
(g) Pump base should be sited at minimum low water level.
(h) The jetty width is designed for vehicle access for transporting pumps, valves, pipes, etc.,
during maintenance.

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 JBALB Technical Guidelines for Water Supply System in Sarawak

5 Water Treatment Plant Process

Purpose of water treatment:

➢ To remove colour, dissolved gases and turbidity

➢ To remove taste and odour
➢ To remove disease causing microorganisms so that the water is safe to drink.
➢ To remove hardness of water (for industrial use)

5.1 Raw Water Quality

The physico-chemical and bacteriological characteristics and constituents in the raw water shall
comply fully with the latest National Drinking Water Quality Standards (Table 1, Column I,
NDWQS). It lists the recommended physical, chemical, radiochemical and microbiological levels
of raw water which is suitable for conventional treatment as a potable water supply.

Table 1, Column I, National Drinking Water Quality Standards, Ministry of Health Malaysia
RECOMMENDED RAW WATER QUALITY
No Parameters Column I
Acceptable Value
mg/l (unless otherwise stated
GROUP I
1 TOTAL COLIFORM 5,000 MPN/100ml or cfu/100ml
2 TURBIDITY 1000 NTU
3 COLOUR 300 TCU
4 pH 5.5 – 9.0
GROUP II
1 TOTAL DISSOLVED SOLIDS 1500
2 BIOLOGICAL OXYGEN DEMAND 6
3 CHEMICAL OXYGEN DEMAND 10
4 CHLORIDE 250
5 ANIONIC DETERGENT MBAS 1.0
6 AMMONIA (as N) 1.5
7 NITRATE (as N) 10
8 IRON (as Fe) 1.0
9 FLUORIDE 1.5

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10 HARDNESS 500
11 MANGANESE 0.2
GROUP III
1 MERCURY 0.001
2 CADMIUM 0.003
3 SELENIUM 0.01
4 ARSENIC 0.01
5 CYANIDE 0.07
6 LEAD 0.05
7 CHROMIUM 0.05
8 SILVER 0.05
9 COPPER 1.0
10 MAGNESIUM 150
11 SODIUM 200
12 ZINC 3
13 SULPHATE 250
14 MINERAL OIL 0.3
15 PHENOL 0.002
GROUP IV
ORGANOCHLORINE PESTICIDES:
1 ALDRIN/DIELDRIN 0.00003
2 DDT 0.002
3 HEPTACHLOR & HEPTACHLOR EPOXIDE 0.00003
4 METHOXYCHLOR 0.02
NON-ORGANOCHLORINE PESTICIDES:
5 HEXACHLOROBENZENE 0.001
6 LINDANE 0.002
7 CHLORDANE 0.0002

HEBRICINES:
8 2,4-D (DICHLOROPHENOXYACETIC ACID) 0.03
GROUP V
RADIOACTIVITY:
1 GROSS α 0.1Bq/l
2 GROSS β 1.0Bq/l
TOTAL 40 PARAMETERS

5.2 Treated Water Quality

The physico-chemical and bacteriological characteristics and constituents in the treated water
shall comply fully with the latest National Drinking Water Quality Standards (Table 2, Column I,
NDWQS). It lists the recommended physical, chemical, radiochemical and microbiological levels
of treated water which is suitable after undergoing conventional treatment for potable water
supply and shall not be exceeded for maximum protection of the consumer.

Table 2, Column 1, National Drinking Water Quality Standards, Ministry of Health Malaysia
DRINKING WATER QUALITY STANDARDS
No Parameters Column I
Maximum Acceptable Value
mg/l (unless otherwise stated)
GROUP I
MICROBIOLOGICAL:
1 TOTAL COLIFORM MPN METHOD/ MEMBRANE FILTRATION
METHOD: MUST NOT BE DETECTED IN ANY 100ml
SAMPLE
2 E.coli OR THERMOTOLERANT ABSENT IN 100ml SAMPLE
3 COLIFORM BACTERIA
4 FAECAL STREPTOCOCCI MEMBRANCE FILTER METHOD: ABSENT IN 100ml
SAMPLE

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MON METHOD: <1 IN 100ml SAMPLE

5 CLOSTRIDIUM PERFRINGENS ABSENT
6 VIRUSES ABSENT IN 100ml
7 PROTOZOA ABSENT IN 100ml
8 HELMINTHS ABSENT IN 100ml
PHYSICAL:
9 TURBIDITY 5 NTU
10 COLOUR 15 TCU
11 pH 6.5 – 9.0
12 FREE RESIDUAL CHLORINE 0.2 – 5.0
13 COMBINED RESIDUAL CHLORINE NOT LESS THAN 1.0
14 MONOCHLORAMINE 3
GROUP II
INORANIC:
1 TOTAL DISSOLVED SOLIDS 1000
2 CHLORIDE 250
3 AMMONIA (as N) 1.5
4 NITRATE (as N) 10
5 IRON (as Fe) 0.3
6 FLUORIDE 0.4 – 0.6
7 HARDNESS 500
8 ALUMINIUM 0.2
9 MANGANESE 0.1
GROUP III
1 MERCURY 0.001
2 CADMIUM 0.003
3 ARSENIC 0.01
4 CYANIDE 0.07
5 LEAD 0.01
6 CHROMIUM 0.05
7 COPPER 1
8 ZINC 3
9 SODIUM 200
10 SULPHATE 250
TRIHALOMETHANE:
The sum of the ratio of the concentration to each
of the guideline value should not exceed 1.
11 CHLOROFORM 0.2
12 BROMOFORM 0.1
13 DIBROMOCHLOROMETHANE 0.1
14 BROMODICHLOROMETHANE 0.06
15 SELENIUM 0.01
16 SILVER 0.05
17 MAGNESIUM 150
18 ANTIMONY 0.005
19 BARIUM 0.7
20 BORON 0.5
21 MOLYBDENUM 0.07
22 NICKEL 0.02
23 URANIUM 0.002
24 HYDROGEN SULFIDE 0.05
25 MINERAL OIL 0.3
26 PHENOL 0.002
27 BROMATE 0.025
28 CHLORITE 0.2
29 2-CHLOROPHENOL 0.0001
30 2,4-DICHLOROPHENOL 0.0003
31 2,4,6-TRICHLOROPHENOL 0.2
32 FORMALDEHYDE 0.9
33 DICHLOROACETIC ACID 0.05
34 TRICHLOROACETIC ACID 0.1
35 CHLORAL HYDRATE (TRICHLOROACETALDEHYDE) 0.01
36 DICHLOROACETO-NITRILE 0.09

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37 DIBROMOACETO-NITRILE 0.1
38 TRICHLOROACETO-NITRILE 0.001
39 CYANOGEN CHLORIDE (as CN) 0.07
GROUP IV
1 ALDRIN/DIELDRIN 0.00003
2 DDT 0.002
3 HEPTACHLOR & HEPTACHLOR EPOXIDE 0.00003
4 METHOXYCHLOR 0.02
5 LINDANE (BHC) 0.002
6 ENDOSULFAN 0.03
7 CHLORDANE 0.0002
8 1,2-DICHLOROPROPANE 0.04
9 1,3-DICHLOROPROPENE 0.02
10 HEXACHLOROBENZENE 0.001
11 PENTACHLOROPHENOL 0.009
12 ALACHLOR 0.02
13 ALDICARB 0.01
14 AMETRYN 0.05
15 ATRAZINE 0.002
16 BENTAZONE 0.3
17 CARBOFURAN 0.007
18 CHLOROTOLURON 0.03
19 CYANAZINE 0.0006
20 2,4-DICHLOROPHENOXYACETIC ACID (2,4D) 0.03
21 DIQUAT 0.01
22 1,2-DIBROMO-3-CHLOROPROPANE 0.001
23 1,2-DIBROMOETHANE 0.0004
24 ISOPROTURON 0.009
25 MCPA 0.002
26 METOLACHLOR 0.01
27 MOLINATE 0.006
28 PENDIMETHALIN 0.02
29 PERMETHRIN 0.02
30 PROPANIL 0.02
31 PYRIDATE 0.1
32 SIMAZINE 0.002
33 TRIFURALIN 0.02
34 2,4 DB 0.09
35 DICHLORPROP 0.1
36 FENOPROP 0.009
37 MECOPROP 0.01
38 2,4,5-T 0.009
39 TERBUTHYLAZINE 0.007
ORGRANIC SUBSTANCES:
40 CARBON TETRACHLORIDE 0.002
41 DICHLOROMETHANE 0.02
42 1,2-DICHLOROETHANE 0.03
43 1,1,1-TRICHLOROETHANE 2
44 VINYL CHLORIDE 0.005
45 1,1-DICHLOROETHENE 0.03
46 1,2-DICHLOROETHENE 0.05
47 TRICHLOROETHENE 0.07
48 TETRACHLOROETHENE 0.04
49 BENZENE 0.01
50 TOULENE 0.7
51 XYLENE 0.5
52 ETYLBENZENE 0.3
53 STYRENE 0.02
54 BENZO (A) PYRENE 0.0007
55 MONOCHLOROBENZENE 0.3
56 1,2-DICHLOROBENZENE 1
57 1,4-DICHLOROBENZENE 0.3
58 TRICHLOROBENZENE (TOTAL) 0.02

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59 DI (2-ETHYLHEXYL) ADIPATE 0.08

60 DI (2-ETHYLHEXYL) PHTHALATE 0.008
61 EDETIC ACID (EDTA) 0.6
62 ACRYLAMIDE 0.0005
63 EPICHLOROHYDRIN 0.0004
64 HEXACHLOROBUTADIENE 0.0006
65 MICROCYSTIN-LR 0.001
66 NITRILOTRIACETIC ACID (NTA) 0.2
67 TRIBUTYLIN OXIDE 0.002
GROUP V
RADIOACTIVITY:
1 GROSS α 0.1Bq/l
2 GROSS β 1.0Bq/l
TOTAL 131 PARAMETERS

Notes: Any toxic substances not listed shall be deemed as not allowable in drinking water

5.3 Treatment Plant Location

Principal factors to be considered when selecting a WTP site: -

5.3.1 Planning
➢ Present and future demands, direction and rate of growth of service area and potential
deterioration of source quality in future so that the site selected is flexible enough to
accommodate these changing factors.
➢ Plant site can be designed to be compatible with its surroundings which normally involve
studying the master plan for area concerned (if available) and discussions with local
authorities and principal groups who may be affected.

5.3.2 Plant design

➢ Various space needs of a plant and to carefully consider the construction, operation and
environmental needs, initially and in the future (extensions of at least two more bays).
➢ Site topography, constraints imposed by existing facilities, environmental aspects, etc.
(a) Relation to intake site and service area

The site is optimally located in relation to the source of water and the area to be
served. It shall be located at strategic location and preferably with easy access. Raw
water intake shall be located as near as possible to the WTP.

(b) Elevation and pumping

Assessment towards the conservation of power costs having regards to the various
variable on pump sizes, sizes of transmission lines, service area elevations including
future service area limits to determine the optimum configuration.

(c) Site topography

Topography of site shall suit the hydraulic profile of the WTP process components
and surface drainage. A gentle and moderate slope is required, and the process
units shall be aligned down the slope rather than across, to achieve gravity flow
through the plant to avoid excessive earthworks and the need for elevated
structures.

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(d) Geotechnical

Assessment and evaluation of potential sites by reference to geological map and

also site inspection and reconnaissance, together with local knowledge of site
conditions. In general, sites with high groundwater levels, swampy or with poor
soil conditions, involve excessive rock excavation, cut and fill, extensive storm
drainage facilities shall be avoided as this would involve extra costs for design and
construction.

(e) Flooding

Shall always be sited above the 1 in 100-year design flood level or maximum flood
levels experienced if records are insufficient for flood analysis.

(f) Access

Preferable to be (a) in proximity of existing main roads (to enable delivery of

chemicals & equipment & facilitate construction) having no restriction on type of
traffic and (b) Alignment and gradient of access road shall be so planned that trucks
and tankers laden with chemical load can run on it without load shedding.

(g) Power Supply and telecommunications

Shall be located where power supply and telecommunication facilities are readily
available. Backup on site diesel generator shall be provided to increase in reliability
of power supply.

(h) Land availability

Shall has the least land acquisition problems and costs.

5.4 Environmental factors

An environmental study complying the Natural Resources & Environment Ordinance shall be
carried out to assess the effects which the WTP may have on its surrounding areas or vice versa.
Other factors such as noise and dust during construction, discharge of wastewater into
surrounding areas (during T&C of plant including from pipelines and reservoirs), noise during
operation (pumps, generators and chemical trucks), danger from chlorine leakages (both in
plant and during delivery), dust and odours from chemicals, residuals, etc, residuals and
wastewater disposal effect on water courses/lakes and overflow discharge and its effect on
water courses.

5.5 Treatment Process

Main factors in selection of treatment process systems:

➢ Source water quality

➢ Treated water quality standard.
➢ Reliability of process systems and equipment
➢ Operational requirements and personnel capacities
➢ Flexibility in dealing with changing water quality and equipment malfunctions

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➢ Available space for construction

➢ Plant residuals disposal constraints
➢ Capital and operating cost

5.5.1 Typical Process of Treatment

(a) Raw water extraction – pump from rivers, streams, ponds, storage dams or underground
wells.
(b) Pre-sedimentation tank – as primary settling to remove small particulars such as sand and
silt from the raw water, where necessary.
(c) Screening – to remove large solids from the raw water.
(d) Aeration - in some WTPs
• To liberate dissolved gases like CO2, H2S etc.
• To provide O2 for oxidization of dissolved iron and manganese to their insoluble
form.
• To remove objectionable taste and odour.
(e) Chemical treatment for conventional treatment process:
• Coagulation – physical & chemical process that converts suspended & colloidal
particles and dissolved solids to form microfloc using coagulant.
• Flocculation – process to promote interaction of particles & form aggregates that
can be efficiently removed in subsequent processes.
• Sedimentation – gravitational separation to remove settleable suspended solids.
• Filtration – separation of un-sedimented substances that are carried over from
sedimentation tank.
(f) Disinfection – destruction of pathogen (bacteria, viruses, etc.) using disinfectant.
(g) Fluoridation – for prevention of dental caries in children.
(h) Storage – gravitate or pump to consumers.

5.5.2 Selection of Treatment Process

➢ Quality of the raw water at the proposed intake should be studied over an extended
period so that seasonal and yearly variations in the quality would be revealed and
accounted for.

➢ The treatment shall be a suitable combination of processes as dictated by the quality of

raw water. The latest Recommended Raw Water Quality Criteria (Table 1, NDWQS)
provides a guide for raw waters that are amenable to conventional treatment.

➢ When the characteristics and constituents of raw water do not comply to the
recommended criteria set in Table 1 of NDWQS, special treatment is required. Special
treatment includes additional process such as algae control, pre-chlorination, ozonation,
activated carbon absorption, sludge treatment etc. depending on what is needed to
achieve treated water that complies to Table 2 of NDWQS.

➢ Samples of raw water must be collected at different times to cover the range of quality
and fluctuation for physical and chemical analyses. The studies of the raw water should
be subjected to, preferably at two weeks intervals and on all days/periods of abnormal
weather, are:

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a. Physical, chemical and bacteriological analysis of samples of the raw water must be
carried out. Tentative treatment process for the raw water is selected based on
preliminary results.
b. These processes are then tested out on samples of raw water using the Jar Tests to
determine the type and approximate range of chemical dosages required for pre-
chlorination (if necessary), adsorption, coagulation, disinfection and conditioning.
c. Marble or Calcium carbonate stability test must be carried out to determine the
alkalinity and pH which prevail at calcium carbonate equilibrium and thereby select
the lime/soda ash dosage required.
d. Samples of the treated water resulting from the jar and marble tests must be tested
physically, chemically and biologically for compliance to the requirements of
treated water in NDWQS Table 2.
e. The analysis in (d) above should be carried on not only on the treated water from
the jar test which appears clearest and with most rapid settling time but on the
treated water from the next three or four best tests especially during the beginning
stages of investigations to ease in the final decision making.
f. Jar test must also be used as a basis of selection of the most economical method of
treatment that will produce treated water comply to NDWQS Table 2.
g. Salinity test shall be conducted as well.

➢ The use of polymer in treatment process is to be avoided in view of the risk of filter
choking.

➢ Inclined plates or tube settlers is not preferred in the design of new WTP. They may only
be considered/recommended for upgrading works of existing plant.

5.6 Pre-Sedimentation
For raw water with high content of suspended solid, pre-sedimentation is provided.

a) Design calculations are provided to show that the proposed pre-sedimentation basins are
sized according to the treatment plant capacity and suspended solids content.
b) The pre-sedimentation basins have hopper bottom or be equipped with mechanical
moving sludge removal apparatus.
c) Have a means of dewatering the settled sediments.
d) Are designed such that the incoming water is dispersed evenly across the tank width to
prevent short circuiting.
e) There is a by-pass around each pre-sedimentation unit.
f) The pre-sedimentation basins are designed with a minimum of three (3) hours detention
time (actual detention time is to be determined through sedimentation tests).
g) Duplicate pre-sedimentation basins are provided to allow 1 unit to shut down for
maintenance.

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h) Isolating valves are provided for shut down for maintenance.

5.7 Chemical Dosing System

1. All chemical feed piping and equipment (chemical resistance type) and batching tanks (2
nos. with stainless steel mixers) shall be constructed or lined with materials suitable for
use with wide range of chemicals to allow maximum flexibility and to be provided with
insect-proof netting.
2. All chemical dosing system must be carried out in solution for powdered chemicals and
preferably liquid chemicals where necessary, depending on WTP location and logistics
needs, using metering pumps (1 duty and 2 standby) for plant of 1 MLD and above.
3. For plant below 1 MLD capacity, all chemical feed system shall in general be by gravity and
be manually operated, with 1 duty and 1 standby.
4. The dosing system shall include duty and standby line c/w with y-strainer, PRV, back
pressure valves, pulsation dampers, calibration/measuring cylinders, local control panel,
cabling works and other necessary items.
5. The dosing system shall be designed based on suitable solution strength that will not
cause pump blockage and tank size for optimal and ease of operation. The system shall
cater for at least 8 hours continuous operation.
6. Pre-soda dosing, if required, shall be dosed before the coagulant.
7. Post soda dosing, if required, shall be after chlorination.
8. Chlorination system for plant < 5 MLD, use calcium hypochlorite and plant ≥ 5 MLD, use
liquid chlorine gas system.
9. Electro-chlorination system (100 % standby for electrolyser & hydrogen ventilation) shall
consist of electrolyser, chillers, brine tanks, softeners, rectifier, brine dosing system,
service water, duty & standby dosing lines, dosing pumps (1 duty, 1 standby), local control
panels, hydrogen gas detector, cabling works & necessary items, if used. Standby calcium
hypochlorite tanks (2 nos.) c/w dosing system (1 duty, 1 standby) with storage lasting at
least 24 hours or liquid chlorine gas dosing systems in case EC system encounter problem.
10. All mixing tanks are provided with waist height loading platforms to facilitate discharging
of chemicals by hand.
11. The mixing tanks & dosing area are provided with adequate drainage & washing facilities
for easy cleaning.
12. Duplicate fluoridator equipment are to be provided if fluoridation is required. It is
required to check with Medical Department on the requirement for fluoride dosing.
13. Duplicate chlorinators with auto-change over are provided.
14. The dosing system shall be designed to provide the following levels of constituents in
finished water: -
a. free residual chlorine < 0.2 mg/L at any points of the distribution system.
b. pH value: 6.5-9, depending on disinfection regime and corrosiveness of the water.
c. Fluoride residual: 0.4 - 0.6 mg/L.
d. Residual aluminium > 0.2 mg/L.
e. And all other standard requirements in Table 2 of NDWQS.

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 JBALB Technical Guidelines for Water Supply System in Sarawak

WTP < 1 MLD WTP ≥ 1 MLD

Gravity dosers Metering pumps

5.8 Chemical Storage

1. There is provision of chemical storage for 3 months operation (for powdered coagulant)
and 1 month operation (for liquid coagulant).
2. WTP of 5 MLD & above, adequate aisle space shall be provided for easy access using
forklift.
3. The chemicals shall be easily moved into storage, out of storage and to the mixing tanks
on a first-in-first-out basis.
4. The entrance to the chemical store shall be large enough to allow the supply truck to
reverse into the building to facilitate unloading of chemicals. A ramp must be provided at
the entrance for movement of the supply truck.
5. Automatic steel roller shutter door shall be provided.
6. All plant shall be equipped with forklift or suitable equipment.
7. All plant shall be equipped with hand powered trolley for transfer chemical cylinders, bags,
equipment up to 300 kg.
8. Adequate natural ventilation shall be provided by using fixed louvres clear glass windows
at the top. Openings of the louvre windows are covered with insect-proof netting to
prevent entry of insects. Bird netting shall also be provided to prevent entry of birds.
9. For safety precautions, PPE, emergency eyewash and shower and all relevant safety and
hazards warning signs must be provided/displayed at the potentially hazardous location.
10. For chlorine storage and facilities:
a. The chlorine dosing facilities & the chlorine store shall be isolated from the rest of the
facilities.
b. For plant of 5 MLD & above, a separate building shall be provided for dosing & storage
of chlorine.
c. Corrosion resistant materials such as plastics, fibreglass or stainless steel shall be used
as construction material in the chlorine room.
d. Hoist & other mechanical equipment must be protected against corrosion.
e. They are of fireproof construction, remote from fire risk & must be located on ground
floor.
f. There is a minimum of two access door opening outwards.
g. Adequate corrosion resistant extractor fans are provided with switches installed
outside the room.

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h. All chlorine stores and dosing rooms are provided with chlorine leaks detectors with
audible alarms located outside.
i. For plants 5MLD and above capacity, a chlorine neutralization gas scrubbing system is
provided.
j. For plants below 5MLD capacity, auto-shut down valve system must be provided.
k. Ammonia solution shall be provided for detection of chlorine leakage.

11. Fluoride dosing facilities and store shall be isolated from the rest of the facilities. Fluoride
dosing shall be carried out in solution form.

5.9 Filtration
General requirement for design of filter such as filtration rate, length and breadth ratio, size
filter, tank depth, free board, water depth, head loss, media depth, pipes sizing and
recommended flow velocity of the pipe and channel, backwash system, air bower capacity shall
be provided.

5.10 Operation and Maintenance Requirement

3 months (for powdered chemicals),

1 month (for liquid chemicals)

WTP ≤ 1 MLD, 24 hrs/day;

> 1 MLD, ≤ 22 hrs/day.

5.11 Layout
(a) Layout of all treatment units, control house, chemical stores, pumping stations and other
appurtenances should be compact and to allow optimum efficiency in operation and
maintenance of the system with a minimum number of operators.
(b) A minimum of two (2) treatment trains is provided, operating in parallel.

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(c) Hydraulics profile of the WTP should be such as to prevent excessive head loss and
excessive velocities and to enable gravity flow from one process unit to another wherever
possible. All connections between the various treatment units are direct and as short as
possible.

(d) A schematic diagram of the proposed system must be provided in all cases of design,
showing all levels, pipe type, sizes and lengths, hydraulics gradient, reservoirs levels and
capacities, pumping heads and capacities, the highest and lowest points of consumers
service, including all chemical feed systems.
(e) Full consideration is given to easy inspection, operation & maintenance of entire
treatment facility by locating the process units which require more attention than others
close to one another and next to operations building.
(f) Covered walkways shall be provided to connect the individual treatment units.
(g) Provision should be made for adequate isolation of individual treatment units and
adequate working area for purpose of maintenance and repairs.
(h) Access & lifting devices for removal of all major equipment are provided.
(i) Adequate walkways with safety handrail along the filters, sedimentation tanks &
flocculation basin are provided. Safety handrails are provided at all structures high above
ground.
(j) Adequate air scour and wash-water rates should be provided for thorough and effective
backwashing of filter media. Wash water lines should be provided with a rate control valve.
(k) In all cases, provisions for future expansion and augmentation of the treatment plant and
facilities shall be provided for.
(l) Due consideration should be given to the architectural design and layout of the buildings
so as to project an image of cleanliness, efficiency and reliability.
(m) Sanitary and sludge handling facilities and drains should be sited so as not to cause
contaminations.
(n) Every WTP shall install 5 units of water meters at: -
a. Raw Water Pump
b. WTP Outlet
c. For Filters Backwash use at WTP with backwash tank or supply main before
entering WTP (without backwash tank)
d. For Headworks use at service pipe
e. Discharge pipe to sludge facilities
(o) Operation units such treated water pumping station & generator house are located
separately from the main operations building to reduce noise problems.

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(p) Premix access roads and service roads of adequate width and adequate parking space for
cars and motorcycles are provided.
(q) Adequate drainage facilities are provided for discharge of surface water, overflows from
the treatment facilities, wastewater flows & scour flows.
(r) Security fencing, gates, adequate external lightings and fire protection are to be provided.
(s) Signboard is to be provided at WTP and booster pump station as well as at the junction of
the access road to the plant or booster pump station. Separate signboard is to be provided
for raw water intake and reservoir, if located outside of WTP’s compound.

5.12 Operation Building

(a) Building is large enough to accommodate the plant staff for regular inspection and
maintenance.
(b) Office & meeting room (if provided) have adequate furniture and are air-conditioned for
larger treatment plant.
(c) M&E spares and tools store is furnished with proper steel racks.
(d) A water pond for monitoring water quality is to be provided. If there is no provision for
water pond, the lobby should have clarity bowl, main instrumentation panel and
aquarium for monitoring water quality.
(e) Schematic drawing and general layout of WTP with the relevant data are provided in the
lobby or control room.
(f) 3D model shall be provided for WTP ≥ 10 MLD.
(g) Control room shall be air-conditioned.
(h) Adequate separate toilet & bath facilities for men and ladies (for staff and visitors) and
sufficient locker facilities provided in the rest room or pantry.

5.12.1 The Laboratory

(i) The laboratory is provided with the following:
• Purpose-built wooden cabinets for storage of chemicals & water testing equipment.
• Sufficient work benches with colour formica finish table-top complete with sinks.
• Fridge.
• Proper water supply & drainage facilities.
• Direct sampling facilities for raw water, settled water, filtered water and treated
water.
• Air-conditioning and with adequate furniture.
• All laboratory equipment and apparatus necessary based on latest JBALB requirement
as Appendix A.
• All testing reagents and tablets, standard solutions and other necessary laboratory
chemicals for testing instrument calibration/maintenance purpose.
• Online water quality monitor/ analyzer - residual chlorine analyzer, pH analyzer (raw,
settled, filtered & treated), turbidity meter (raw, settled filtered & treated), residual
alum analyzer (raw, settled, filtered & treated), fluoride analyzer for WTP ≧ 5 MLD.
• Sampling pump must be installed at the appropriate location. For example, filtered
water sampling pump must be located at the outlet pipe of the filter.

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• Sampling pumps must be installed at places which are easy to be accessed by the plant
operator.
• Sampling pump must be installed at one duty and one standby, if there are different
treatment packages/module for the plant, sampling must be done for every
treatment module.
• Stream current detector/monitoring (with standby unit) complete with PID controller
for monitoring of raw water and automating dosing control of alum/PAC/ACH for
plant with high fluctuation in raw water quality.
• All WTPs are to be equipped with local charge analyzer (LCA).

5.12.2 Filter Operating Gallery

The filter operating gallery is provided with the following:
a) Large clear glass aluminum casement windows & panels preferably from ceiling to floor
on the side facing the filters, for easy viewing of filter operations.
b) Separate operating console for each filter.
c) Common dial indicators for wash water flow rate, air scour, etc. of at least 300 mm dia. or
digital indicators.
d) Direct access door between the filter operating gallery and the filters.
e) Filter operating consoles arranged neatly and in such a manner that the operator can
watch the filters washing operation easily while operating the filter consoles.
f) The filter pipework gallery is provided with adequate ventilation & lighting, access stairs,
drainage facilities, minimum floor gradient of 1 in 500 sloping towards the drain pipe, neat
arrangement of pipework with adequate space for easy access, installation, valves
operation, inspection, maintenance or repair and pipework are painted according to the
required colour code.
g) The filtered water outlet chamber has chamber lined with white glazed tiles on the inside,
inspection opening with clear Perspex covers and vent openings to prevent water vapour
collection on underside of the Perspex covers.

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 JBALB Technical Guidelines For Water Supply System In Sarawak

Appendix A
No Parameter Analysis Equipment Glasswares Accessories: Reagents Remarks
1 Free Chlorine Portable Photometer and Comparator Sample cells Plastic stirring rod, test discs for Tablet DPD 1 Reagents/tablets for
comparator, standard verification kit and minimum 3 months stock
2 Total Chlorine delicate task wipers Tablet DPD 4
Test Disc Chlorine DPD Test
3 pH (4.4-6.3) Test Disc PH (4.4-6.3) Methyl Red

4 pH (5.2-6.8) Test Disc PH (5.2-6.8) Bromocresol purple

5 pH (6.0-7.6) Test Disc PH (6.0-7.6) Bromothymol Blue

6 pH (6.5-8.4) Test Disc PH (6.5-8.4) Phenol Red

7 Iron Test Disc Iron (0.1-1 mg/L) Iron Low Range Tablets

8 Manganese Test Disc Manganese (0.2-4 mg/L) Manganese Low Range Tablet 1
Manganese Low Rage Tablet 2
9 Aluminium Test Disc Aluminium (0.01-0.3 mg/L) Aluminium Tablet 1
Aluminium Tablet 2
10 Turbidity Benchtop Turbidimeter and Portable Turbidimeter Sample cells Delicate task wipers

11 Colour Nessleriser (For Colour) Pair of Nessler tubes for Colour test HAZEN/APHA Disc (0-250 mg pt/l)
Delicate task wipers
12 Fluoride (if Nessleriser (For Fluoride) Pair of Nessler tubes for Fluoride test NOM DISC, Fluoride; 0-1.6mg/l Fluoride A-Z tablets Reagents/tablets for
applicable) Delicate task wipers Fluoride excess AL tablets minimum 3 months stock
13 Jar Test Jar Tester (6 Paddle) 500 ml glass beakers (6 unit) Cellulose filter paper (0.45 micron)
Adjustable Volume Micropipette (1 mL) (2 unit) 500 mL glass graduated cylinder (1 unit) Pipette tips (1ml)
Adjustable Volume Micropipette (5 mL) (2 unit) 100 mL glass graduated cylinder (1 unit) Pipette tips (5ml)
Adjustable Volume Micropipette (10 ml) (2 unit) 100 mL glass beaker (8 unit) Pipette tips (10ml)
Syringe (1ml) (2 unit) Filter funnel
Syringe (10mL) (2 unit) Funnel Holder
Laboratory Scale (Analytical Balance) Magnetic Stirrer (7mm x 30mm)
Magnetic Stirrer Plate
14 Specific Gravity Hydrometer (for Liquid polyaluminium chloride TYPE 1) (1.13-1.23 g/ml) Depend on chemicals to be
Hydrometer (for Liquid polyaluminium chloride TYPE 2) (1.18-1.35 g/ml) used.
Hydrometer (for Liquid polyaluminium chloride TYPE 3) (1.32-1.38 g/ml)
Hydrometer (for Liquid Aluminium Sulphate) (min. 1.31 g/ml)
Hydrometer (for Soda Ash Solution) (1.0-1.2 g.ml)
Hydrometer (for Aluminium Sulphate Solution) (1.0-1.2 g.ml)
Hydrometer (for Chlorine Solution) (1.0-1.2 g.ml)
15 Salinity TDS Meter (with temperature measurement) TDS calibration solution If expect saline intrusion.

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 JBALB Technical Guidelines For Water Supply System In Sarawak

6 Quarters
(a) Usually for accommodation of WTP operators working in shifts.
(b) If WTP is located near an existing community/town, the quarters may be located at/near
the community/town for social reasons.
(c) If WTP is at a remote area, quarters may have to be in the vicinity of, but outside the
compound of the WTP, with gate and fencing. Sufficient street lighting should be provided
leading from the quarters to the WTP.
(d) Quarters to be provided with electricity, lighting, water supply and internal plumbing.
Those facilities shall be separate installation from WTP. (Occupant must apply their
individual electricity connection meter with SEB/SESCO)
(e) Quarters to be designed to follow the State Pre-Approved Plant (SPAP) standard with
minimum three (3) bedrooms and floor area.
(f) Quarters to be provided with furniture as per standard furniture list.

TABLE I
Class F Quarters
Item Article Quantity
1. Easy Chairs 4
2. Occasional table 1
3. Dining table 1
4. Chairs standard 6
5. Kitchen table 1
6. Kitchen cupboard 1
7. Kitchen sink with tap 1
8. Ceiling fan 1
9. Refuse bin 1
Bedrooms No. 1 No. 2 & 3
10. Bedsteads 1 double 2 single
11. Foam rubber mattresses 1 2
12. Mosquito frames 1 2
13. Dressing table with mirror 1 2
14. Wardrobes 1 2
15. Ceiling fan 1 2
16. Washstand with tap 1
17. Toilet bowl 1
18. Shower head 1

30
 JBALB Technical Guidelines for Water Supply System in Sarawak

7 Sludge and Wastewater Disposal

The treatment and ultimate disposal of sludge and wastewater are rapidly becoming an integral
part of the design and operation of water treatment plant facilities.

(a) Environmental Quality Act 1974: Environmental Quality (Industrial Effluent) Regulations 2009
- shall apply to any premises which discharge or release industrial effluent or mixed effluent
other than premises as specified in First Schedule.
(b) Industrial effluent: any waste in the form of liquid or wastewater generated from
manufacturing process including the treatment of water for water supply or any activity
occurring at any industrial premises.
(c) Sludge: any deposit of particulate matter settled from any liquid, including deposit resulting
from physical, chemical, biological or other treatment of water or industrial effluent or mixed
effluent.
(d) Restriction on discharge or disposal of sludge - Clause 23. (1) No person shall discharge, or
cause or permit the discharge or disposal of any sludge generated from any production or
manufacturing process, any industrial effluent treatment system or water treatment plant
onto or into any soil, or surface of any land, or into any inland waters or Malaysian waters
without the prior written permission of the Director General.
(e) Consultant to check and comply with NREB’s requirement on sludge treatment facilities and
disposal.
(f) The options for ultimate disposal of sludge and wastewater include: -
a. To dedicated landfill
b. To municipal sanitary landfill
c. To sanitary sewer
(g) With high land costs and more restrictive measures for discharge into sanitary severs utilities
throughout the world are looking into other beneficial use programs for sludge and
wastewater, not only as a cost-effective alternative but also as a publicly acceptable
management practice. Some of the possible options for reuse of sludge/wastewater are as
follows: -
a. Commercial products
b. Co-use with biosolids
c. Land application
 JBALB Technical Guidelines for Water Supply System in Sarawak

8 Mechanical Works

8.1 Parameters for Pumps Selection

(a) Capacity of the pump to be provided shall consider extra allowance of minimum 10% of
plant design capacity.
(b) Design of pump operation configuration shall consider 200% standby.
(c) Capacity (Flow Rate) →Refer Pump Performance Curve
(d) Total Head →Total Static Head + Friction Loss (Pipe) + Minor Loss (Fittings)
(e) Pump Type → Surface Pump Vs Submersible Pump
(f) Speed → Operation Note: Preferably 1500 Rpm and below For Raw Water Pump
(g) Suction/NPSH → For Pumps, Suction Lift Must Not Exceed 5 Meters be including all losses.
(h) Prime Mover (Motor/Engine) Output →Refer to Rated Power in Pump Catalogue
(i) Driving motor power to be not less than 110% of the maximum power requirement of the
driven element.
(j) Raw Water / Treated Water Condition (I.E. Ph Value, Turbidity, etc.)
(k) The output of the pump shall be obtained with cut down impeller. Full size impeller should
not be used to achieve the specified duty point.
(l) The impellers shall be designed for high efficiency. The pump offered shall operates and
remain in the stable region of the pump characteristic curve ranging 70% to 120% of Best
Efficient Point (BEP) of the pump’s rated or design flow rate.
(m) The pump shall be fitted with impeller/casing wear rings.
(n) Common head, e.g., 10m, 20m, 35m, 55m etc. and Common rated power, e.g., 11kW,
22kW, 45kW, 75kW. Applicable to Dosing pump also.
(o) Pre-tender marketing research (Consultant or In house design) to avoid future argument
of pump selection during implementation stage. (Pump selector online for multiple brands)
(p) Suction and discharge piping shall be sized so that velocities are not excessive. The
velocities of 2.4 m/s in discharge piping and 1.5 m/s in suction piping are reasonable
maximum. Economic efficiency should be considered when selecting the discharge-side
velocities in the case of long piping and extended periods of operation.
(q) Direct connection of elbows to the suction port of the pump shall be avoided and a short
straight pipe shall be installed if the elbows is necessary to be installed.
(r) For negative suction, and independent suction pipe shall be independent for each pump.

E.g., Power Required for Pump: P = C X Shaft Power

where, P = Power required for the prime mover

C = Excess Power Safety Factor (Motor: 1.10 – 1.30 / Engine: 1.15 – 1.30)
 JBALB Technical Guidelines for Water Supply System in Sarawak

(s) Eccentric reducers in pump suction piping (Tapered at bottom) to prevent air-pocket.
i. Pump nozzles are smaller than inlet / outlet piping. That is why we need to use
reducers and expanders at the pump suction and discharge piping. Horizontal
surface allows hydraulic transportation of air.

(t) Separate suction lines are to be provided when pumps are operating under negative
suction heads. (Same size of pump)
 JBALB Technical Guidelines for Water Supply System in Sarawak

8.1.1 Raw water pump head design

To consider Lowest River Water level, i.e., low water level

i. The intake is located at a place from where it can draw water even during the 1 in 50-year
7-day low flow.
ii. The intake structure is located at sufficient water depth so as to be able to keep the raw
water pumps low flow (7-day Q50).
iii. Pump base should be sited at minimum low water level at Pontoon or Jetty Intake (Fixed
& Flexible Pump Mounting).

8.1.2 Treated Water Pump Selection

a) Preferably Horizontal Split Casing (Single stage double entry volute centrifugal pump)
compared to End suction. Design is mechanically balanced, more long lasting.
b) Preferably constant speed pump (auto trans) to fill storage reservoir, variable speed (VSD)
to serve direct pumping to consumer.

8.2 Pump Installation Layout

Design of pump installation layout shall consider to use fittings that produce minimum losses.

Typical Pump Layout

 JBALB Technical Guidelines for Water Supply System in Sarawak

8.3 Mechanical Seal vs Gland Packings (Surface Pump)

a) Raw water: the pump to be fitted with packed stuffing boxes incorporating lantern rings
which include internal flashing by the water being pumped. PTFE type materials.
b) Treated water: Mechanical Seal (tungsten carbide vs tungsten carbide or silicon carbide
vs silicon carbide surfaces.
c) The submersible pump shall be fitted with double mechanical rotating shaft seal system
running in an oil chamber.

8.4 Motor Starter Requirement

General Conditions of Electrical Supply and Electric Motors and Motor Starters Specification
Ref: PWD/E1/05, year 1979.

a) Supply Conditions
Alternating Current, 50 cycles (Hz), 230 volts single phase and 400 volts three phase 4
wire. (Voltage variation allowed - plus or minus 5%).

b) Up to and Including 1 HP
Single phase 230-volt motors may be used with direct-on-line starting. Starters must be
used for motors over 1/2 H.P.

c) Up to and Including 3 HP
May be three phase squirrel cage type with direct-on-line starters.

d) Over 3 HP Up to but not Including 10 HP

May be of the squirrel cage type but must be fitted with star/delta or Auto transformer
type starters.

e) HP and Above
i. May be of the Auto Trans or VSD fitted with mechanical devices to prevent quick
movement of the starter switch and starting without all resistance or reactance in
circuit.
ii. In clarification of the requirements for motors of 10 HP above, motors other than
wound rotor type may be used providing the associated starting equipment limits the
starting current to not more than 200% of full load current.

f) All motors and electrical equipment to have a Power Factor of at least 0.85 but 0.9 is
preferred.

8.5 Variable Speed Drive (VSD)

a) VSD installed at enclosed area with higher heat dissipation rate than operating
temperature as stated in the VSD catalogue shall be provided with proper air conditioning
system.
b) The air-conditioning shall run at alternate twelve (12) hours duration and provided with
automatically change configuration.
 JBALB Technical Guidelines for Water Supply System in Sarawak

c) Complying Sarawak Electricity Ordinance The Electricity (State Grid Code) Rules, 2003 -
PC4.3 Harmonics

d) Standard Guidelines:
i. IEEE 519 1992 Harmonic Control in Electrical Power Systems
ii. Output Peak Voltage and rise time to be compatible with motors complying with
IEC 60034-17 (General purpose motors), as measured at motor terminals with
motor cable type and length specified in the tender documents.
iii. IEC Quality Assessment System for Electronic Components
iv. IEC 60146: Semiconductor converters
v. IEC 60391: Marking of insulated conductors.
vi. IEC 60529: Degree of protection provided by enclosures (IP Code)
vii. IEC 60801-2: Electronic compatibility for industrial process measurement and
control equipment. Part 2: Electrostatic discharge requirements.
viii. IEC60721-3-3: Class 3C3 High Grade conformal coated PCBs

e) Requirement of VSD features: -

– With or Without Low Harmonics Drives
i. Total harmonic distortion (THDi) 5% - 7% or lower <2% - 4%. Normal drive THDi>20%
ii. Harmonics filters go a long way in making electrical usage more efficient and
effective.

– Active vs Passive Harmonics Filters

i. Passive harmonics filters are the more common devices used in a variety of
capacities and voltages. These filters utilize components like inductors, capacitors,
and resistors. Passive filters generally filter noise on a single variable speed drive.
They eliminate harmonics before the electrical current reaches’ equipment.
ii. Active harmonics filters can work with many variable speed drives and actively
reduce noise by constantly monitoring electricity and injecting currents to
mitigate harmonics. Active filters are ideal for a system with many non-linear
loads.
iii. While these filters can handle a great deal active harmonics filter generally cost a
lot more than a passive filter. Active filters also do not require a pre-study of the
current’s harmonics prior to installation.
iv. One harmonic filter to be associated with One unit of pumpset.

– Build-in or standalone harmonics filters → Concern on Space Constraints

i. Brake chopper (IGBT) option (Limits the load on the intermediate circuit in the
case the motor acts as a generator)

8.6 Surge Suppression System

a) Prevention of transient pressure or surges shall be one of the first considerations in the
design of the pumping system.
 JBALB Technical Guidelines for Water Supply System in Sarawak

b) Surge suppression systems with adequate air valves and vacuum relief valves along the
pipeline shall be provided to protect against surge or water hammer which may cause
damages to the pumps and pipeworks.
c) Selection of appropriate type of surge suppression system shall be done after a
comprehensive study conducted during the design stage.
d) Surge Vessel: 2 nos. of air compressors (1 duty, 1 standby) complete with air receiving
tank, control panel.
e) Surge analysis report required to be submitted.
f) Surge Anticipator Valves: combined air and vacuum relief valve

8.7 Cranes
a) All heavy equipment, including pipework shall be provided with means for installation and
removal of the equipment by appropriate lifting devices.
b) Cranes are preferably to be electrically-operated unless specified.
c) Criteria and standards as follow shall be used in determining the application of cranes: -
i. Monorail cranes are used when a single degree of movement is required and the
centre line of the equipment is in line with the entry or exit of the building
ii. The beam can be either “U’ type or “I” type.
iii. Gantry cranes are preferably to be used when two degrees of movement is required.
iv. The electrical lifting and travel for gantry cranes shall be used when the load is more
than two (2) tonnes.
d) Cranes shall be sized to withstand SPAN 1.25 times its Safe Working Load (SWL).
e) Overhead travelling cranes
i. Capacity of the crane is the maximum weight of the component to be lifted in the
pumphouse.
ii. Safe working load (SWL) shall be at least 20% greater than the individual weight of
the single pump or motor or other major equipment to be lifted.
f) For SWL less than 10 tonnes, transverse crane bridge shall be a single box girder mounted
on top of double channel end carriages.
g) For SWL of 10 tonnes and above, transverse crane bridge shall be a double box girder with
double rail crab.
 JBALB Technical Guidelines for Water Supply System in Sarawak

h) Height of a plant area or the building shall be sufficient such that the largest equipment
may be lifted over or around.

8.8 Forklift
a) Forklifts shall be provided for the purposes of chemical loading and unloading within
enclosed reception areas.
b) Forklifts provided shall be battery-operated type unless specified.
c) Sufficient areas for the movement of forklift within the areas shall be considered during the
design stage.

8.9 Fire Fighting Services

a) Designs for firefighting services provided shall comply to Uniform Building By-Laws (UBBL)
1984 and requirements by Jabatan Bomba dan Penyelamat Malaysia (BOMBA).
b) Equipment provided for firefighting services shall comply to Malaysian Standards for Fire
Safety and Protection.

8.10 Cathodic Protection

a) The design of all main pipelines shall take into consideration of corrosion control when
necessary.
b) Testing for soil corrosivity should be required and cathodic protection systems shall be
provided where there may be risk of corrosion of the iron pipes.
c) The report for soil resistivity measurement survey and corrective survey shall be provided.
d) Design of cathodic protection systems provided shall follow the code of practice for
cathodic protection.
e) The design of the cathodic protection system shall be for a period of thirty (30) years and
comply to BS 7631-1: 1991 and National Association of Corrosion Engineers (NACE SP0169-
2007).

8.11 Pressure Gauge

Oil-based dial of pressure gauge is preferred. Quick-type push fit design is preferred / equipped
with stopcock to prevent the gauge under pressure all the time.

Install before the discharge valve

 JBALB Technical Guidelines for Water Supply System in Sarawak

9 Electrical Works

9.1 Power Supply

(a) Tapping off from SESCO/SEB power supply i.e., Existing SESCO Substation, High Tension
Line, Low Tension Line.
(b) Provide standby generator for backup power supply.
(c) In cases of SESCO power supply is not available, generators shall be provided to supply
electric power to the whole plant / booster station.
(d) If power supply to the treatment plant site is available, provision shall be made for
separate electricity supply substation building in an area within the treatment plant
compound.
(e) SESCO capital contribution for substation, transformers, switchgear, ring main unit (RMU),
HT/LT Overhead Line, distribution pillar, submain cable, HT/kwh meter connection.
(f) Design and application to SEB shall comply to the requirement of latest Handbook on
Application for Electricity Supply, SEB Distribution Services Circular and Approved List of
Materials.
(g) Access to substation shall be separate from the access to WTP and booster station.

9.2 Sizing of Motor

(a) Motor specification:
i. High efficiency, Class EFF 1 or better
ii. Preferably Squirrel cage type motor
iii. Variable speed motor
iv. Class F insulation
(b) Motors starters Direct-On-Line, Star-Delta, Auto-Trans, Soft starter, Variable Speed Drive
(c) Power supply: 415V; 50 Hz; 3Phase
(d) Motor power ranges 3.7 kW – 450 kW
(e) Protection system: overloading, high temperature, under voltage, single phasing etc.
(f) Thermistors (for motors >100kw)
(g) Anti-condensation heater (for motors >100kw, for surface pump)
(h) Motor rated power not less than 10% in excess of driven equipment bhp.

9.3 Control Panel

(a) MCC Panel for water pump shall be in the pumphouse or control room.
(b) Control panel for raw water pump at Raw Water Intake shall be outdoor waterproof type.
(c) Pump control panel shall be starting and control by Variable Speed Drive (VSD)

9.4 Generator
(a) Design capacity of the generator set shall be designed for 100% standby for full
operational of plant and systems.
(b) Standby generator set shall be designed and sized to meet the calculated standby load
requirement. The standby load shall include all equipment required for full normal
operations during power failure.
(c) The generator set rating to be selected shall be the highest calculated KVA which covering
the Maximum Demand.
(d) Generator minimum running load shall not be less than 30% of the generating rating.
 JBALB Technical Guidelines for Water Supply System in Sarawak

(e) Generator house shall be provided with Acoustic Treatment (acoustic door, air intake
silencer, air discharge silencer).
(f) Generator set installation shall be completed with AMF (Auto Main Failure) Board, Control
Panel, Lead Acid Battery c/w battery charger.
(g) Genset shall be provided with safety devices such as low lub oil pressure switch, high
water temperature switch, overspeed and failure to start.
(h) Genset panel shall be provided with Auto/Manual Change Over Switch.
(i) Daily service fuel tank shall be provided for each generator set. The tank shall be
accommodated for 8 hours operation.
(j) Physical size of tank must allow for 10 - 20 % spare capacity.
(k) Diesel fuel tank shall be provided adjacent to the genset house/room. The tank shall be
sized for at least 7 days’ supply for easy access areas and 21 days for remote areas, based
on 8 hours operation.
(l) Diesel fuel tank shall be provided with mild steel tank, skid mounted c/w filling connection,
outlet connection, sight-glass level indicator, vent pipe, isolating valve, flowmeter, level
sensor etc.
(m) The tank shall be provided with easy access to facilitate loading of fuel from a fuel tanker.
(n) Where possible, the tank shall be sited on higher ground to enable the fuel to be supplied
by gravity to the engine of the generator.
(o) Preferably an electrically operated fuel transfer pump shall be provided unless specified.
(p) Genset installation shall comply with DOE requirement.
(q) Firefighting system shall be provided at Genset House/Room and comply with BOMBA
requirement.
(r) All cables and fuel lines shall be neatly arranged in trenches with galvanized chequered
plate covers and the trenches shall be well drained.
Bomba Requirement
 JBALB Technical Guidelines for Water Supply System in Sarawak

9.5 General Lighting and Power

(a) Fluorescent lamp with metal reflector at pump room, generator room, MSB room.
(b) Anti-corrosive fitting lamps shall be provided in the Chlorine room.
(c) Emergency lighting shall be provided in the pump room, generator room, MSB room and
other buildings.
(d) Power socket installed at generator room and MSB room shall be metalclad type.
(e) Compound lighting shall be provided at WTP, Booster Station and Reservoir areas.
(f) Spotlight shall be provided at High Level Tank.

9.6 Earthing system

(a) Complete earthing system shall be provided for generator, main switch board, sub switch
board, MCC panel.
(b) Earth electrode for neutral earth genset shall be connected to the genset main earthing
busbar using 25mm x 3mm copper tape.
(c) Earthing conductor from main earthing bar to earth chamber shall be 2 sets of copper
tape (based on 50kVA breaker rating).

9.7 Lightning Protection System (LPS)

(a) Methods and materials used for the construction and installation of the Lightning
Protection System (LPS) shall comply to MS IEC 62305:2007 and IEC 62561.
(b) Lightning protection systems shall be provided at high level tank, reservoir, pump house,
chemical house.
(c) Complete lightning protection system shall include air termination, down conductors and
earth termination.
(d) Unless otherwise specified, down conductor system shall be 25mm X 3mm annealed
copper tapes installed in concealed of the structure.
(e) Down conductors covered by insulated material shall not be installed in gutters or down-
spouts.
(f) The down conductor shall be installed in such a way that its path is as direct as possible
between air termination system and earth termination system.
(g) The number of down conductors shall not be less than two and should be distributed
around the parameter of the structure to be protected subject to architectural and
practical constraint.
(h) If specified in the drawing and/or Bill of Quantities that natural conductors such as
reinforcing bars and structural steelwork may be used as a down conductor system
provided that they are electrically continuous and adequately earthed.
(i) Proper care shall be taken into consideration in the route to earth when using a particular
rod of the reinforcement steel as the down conductor. This is to ensure that the rod that
is located on the same position will be used all the way down, thereby providing direct
electrical continuity.
(j) Steelwork within reinforced concrete structures is considered to be electrically
continuous provided that the major part of interconnections of vertical and horizontal
bars are welded or otherwise securely connected.
(k) Connections of vertical bars shall be welded over a length not less than 30mm or properly
clamped.
 JBALB Technical Guidelines for Water Supply System in Sarawak

(l) Electrical continuity of the reinforcing bars shall be determined by electrical testing
between the uppermost part and ground level.
(m) An additional conductor may be used to enhance the natural down conductor system if
the overall electrical resistance is greater than 0.2 Ohms.
(n) Additional conductor shall be bonded to the reinforcement bars by means of purpose
made clamps conforming to IEC 62561 at 1-meter intervals.

9.8 Main Switch Board

(a) Main Switch Board shall be installed at MSB room and comply with SESCO requirement.
The Switchboard room shall not be used as a store or for any purpose.
(b) Separate feeder pillar/distribution board for compound lighting
(c) Separate Distribution Board (DB) in pump house and switchboard room for general
lighting and power
(d) Fire protection system shall be provided at MSB room and comply with BOMBA
requirement.
(e) A rubber mat of minimum thickness 5mm and width 600mm shall be provided in front of
the switchboard for its entire length.
(f) Cable trench covers in MSB room shall using wood or concrete material.
(g) Power Capacitor Bank shall be provided if there is motor load or MSB size 150Amps.
(h) Nominal voltage:
➢ 240 VAC for single phase system
➢ 415 VAC for three phase 4-wire system
➢ Variation: -10% / +5% (216V/375.5V - 252V/436V)
(i) Frequency: 50 Hz +/-1%
(j) The form of separation for Main Switch Board (MSB) and Sub Switch Board (SSB) shall be
according to the requirement specified as below;
i) Rating below 150A – Form 2B
ii) Rating 200A to 500A – Form 3B
iii) Rating above 500A – Form 4B
(k) The form of separation for Main Control Centre Panel (MCC) shall be according to the
requirement specified as below;
i) Rating below 500A – minimum Form 3B
ii) Rating above 500A – Form 4B

9.9 Electrical Wiring

(a) The wiring system shall be surface galvanised iron (G.I) conduit with PVC cables. At
corrosive area, either use concealed conduit or surface PVC conduit.
(b) Underground cable shall be laid in cable trench at MSB room, genset house and pump
room.
(c) Fire resistant cable shall be used for: from genset to AMF board & from AMF board to
essential main switch board.
(d) HDPE pipe (Class D) shall be provided for cable entry to building i.e., pump house, MSB
room, generator room etc.
(e) G.I pipe sleeve (Class B) shall be provided for road crossing, drainage.
 JBALB Technical Guidelines for Water Supply System in Sarawak

10 Digitalization
SCADA (or Supervisory Control and Data Acquisition) is a control system architecture comprising
computers, networked data communications and graphical user interfaces (GUI) for high-level
process supervisory management, while also comprising other peripheral devices like
programmable logic controllers (PLC) and discrete proportional-integral-derivative (PID)
controllers to interface with water treatment plant processes. This is an important control system
architecture for digitalization of water treatment plant production processes and become an
industry standard for water supply industries in the world.

SCADA monitoring is the essential part in water supply production digitalization. The main
components of monitoring are as follows:
a) Raw water intake – monitor raw water level, raw water pump condition, raw water pressure
main flow and pressure;
b) Chemical – chemical dosing pump condition and chemical dosing rate for each chemical used
for treatment processes;
c) Water quality – monitor water quality for raw water, settled water, clarified water, filtered
water and treated water;
d) Treated water – monitor treated water pump condition, treated water pumping main flow
and pressure;
e) High level tank – monitor HLT level sensor;
f) Energy monitoring – current monitoring module, load and energy consumption etc.

The monitoring components are as follows:

a) Sensing devices or sensors – for monitoring of water level, flow, pressure and water quality
(including flowmeter and sensing devices in analyzer rack);
b) PLC – an industrial microprocessor–based controller which can range from small modular
devices with several inputs and outputs (I/O), in a housing integral with the processor, and
which are networked to other PLC and SCADA systems. Its function in SCADA is as the
controller located at each process area which act as the data concentrator for each process
areas;
c) Sampling pumps – to sample the selected water for water quality analysis which will be
pumped to analyzer rack;
d) Analyzer rack – a water quality monitoring rack which is normally placed in the WTP’s
laboratory;
e) Human-Machine Interface (HMI) – to visualize the condition and data analytics of the
collected data at the treatment plant. It is normally placed at strategic areas in WTPs for easy
viewing by the operators;
f) WTP SCADA – a central data processing and analytic hub for the WTP. It is placed at the WTP
admin building;
g) Gateway – act as a data transmission device from the WTP SCADA to the JBALB HQ Central
SCADA.

Other supporting components are:

a) Cabling works – due to excessive vibration in the treatment house, cabling works are required
to transmit data from the sensing devices to the PLC and WTP SCADA;
 JBALB Technical Guidelines for Water Supply System in Sarawak

b) Pedestal panel – a housing unit for the transmitter, surge protection and accessories required
for level sensors;
c) MCC (Motor control centre) panel – installed for monitoring of pumps, mixers and energy
monitoring.

The process can be simplified as follows:

The data from WTP SCADA will then be transmitted to Central SCADA platform which is hosted
at SAINS Data Centre. It is part of the entire Smart Water Supply System architecture which is
also monitoring distribution pipelines and also digitization of drawings.

Why integration is crucial?

a) To ensure continuity of JBALB water supply operation which leverages on digitalization
features to be functional;
b) To avoid wastages of digitalization development initiatives due to improper system and
equipment maintenance;
c) To ensure digitalization initiatives are up-to-date, properly maintained and serviced;
d) To ensure continuous improvement to water quality services;
e) To fully integrate other digitalization initiatives under Federal and State projects which
needs to be incorporated into JBALB central water supply monitoring system;
f) To ensure only qualified contractor with the required expertise is appointed to maintain
the systems and equipment;
g) To avoid inconsistencies on level of service and maintenance throughout divisions;
h) To ensure no white elephant (no projects being abandoned after completion);
i) To ensure digitalization initiatives are following to Sarawak government’s IT policy and
guidelines; and
j) To ensure digitalization initiatives implemented in JBALB are continuous, competent and
relevant to the water industry standard and practices.
 JBALB Technical Guidelines for Water Supply System in Sarawak

10.1 Production Digitalization

Consultant which was tasked to carry out design for projects involving construction or
upgrading of any water supply facilities, must ensure that SCADA system works are provisioned
in the tender document before the contract is being tendered. The system deployment can be
procured through any procurement procedures required; however, the tender document must
ensure that system integration is explicitly mentioned in the specification and requirements.
The cost to carry out SCADA implementation works including the required system integration
must be borne by the contract and budgeted prior to implementation of the project.

Before Contractor carried out installation of SCADA or any production monitoring system at
JBALB WTP, a proposal with system architecture diagram must be produced first. Say, the
SCADA system is different from JBALB Central SCADA system, the system architecture between
JBALB HQ SCADA and WTP SCADA can be visualized in the following examples:

The scope of works for other WTP SCADA can range from installing PLC for Raw Water Intake,
Treated Water Pumps, Chemical Plant and Admin Building (for Water Quality). Normally, the
information will be read by the onsite SCADA workstation. The setup of JBALB Smart Water
Supply System is as follows:

SAINS DATA CENTER

Smart Water
Supply System
Setup JBALB SWSS
Portal Web Portal
- A portal consist of
WaterGEM S different modules such as
- Hydraulic modelling for leak detection, NRW, etc.
Predictive water supply network - Using Sarawak Gov
M odule Intelli domain for easy access
Data ETL M obile
(Aquasuite) Softw are Process
- Predict/ - Data analytics for
- Extract data
forecast and leak detection and
on level,
emulate NRW i2O
flow and
water - Consolidated Application
pressure
demand water network - Data collection
monitoring and Central and analytics for
GIS SCADA HLT and EFM.
Reservoir and EFM

DIGITIZATION OF JBALB HQ JBALB WTP SITE

DRAWINGS COM M AND CENTRE

GIS Data

Office JBALB HQ SCADA JBALB HQ WTP

Workstation Workstation Workstation
- Visualization of location - Visualization of WTP
- Backup data
in the event and area data; SCADA data
- Alarm management - Alarm management
of internet
- Alarm notification - Alarm notification
or electricity
blackout. - Simple data analytics on - Simple data analytics on
Digitization of Existing Digital
level, pressure, valves, level, pressure, valves,
Drawings Drawing Data
battery status battery status
 JBALB Technical Guidelines for Water Supply System in Sarawak

The detailed requirement of the proposed SCADA (production digitalization) are as follows:
No. Particulars Requirement
1 SCADA ➢ SCADA architecture shall not be a proprietary ecosystem whereby all
Architecture end-to-end solution consists of only single proprietary provider. It
must consist of hardware, PLC and OPC software (OLE Process Control)
which is SCADA;
➢ SCADA system architecture and the required documents must be
provided:
• Submitted in form of A3 drawing, signed by certified professional
engineer;
• Configuration shall show essential SCADA equipment to be
provided for the entire plant;
• Typical connection between outstations (O/S) and the master
station;
• Overall concept must be distributed control system – each
individual section of the works responds automatically to local
requirements and overall work requirements;
• Provide list of equipment provided and network architecture;
• Provide HMI interface screenshot (for every page);
• Flowmeter and HLT within WTP shall form part of the SCADA;
• Each PLCs IP address and port no;
• ModBUS mapping addressing for the signal;
• Each DPM communication setting, and a set of ModBUS
addressing document;
• Substation electrical single line diagram;
• Proposed SCADA signals;
• Proposed telco for network connectivity; and
• Overall WTP process diagram
• Can be remote monitoring or automated. If automated, shall
provide sequence control functions for particular process areas at
local control panels;
• Loss of host computers and connection shall not impair process
controls;
• Any automation shall be functionally demonstrated before
implementation. Range of automation shall be made clear with
allowable customization to suit WTP operation.
• Full operational data must be communicated and available at the
Master Station;
• Master station must be located at main control room of the WTP
building;
• O/S must be PLC-based, and connected to Master Station;
• Must be fail-safe, designed for continuous 24 hours operation,
with minimum maintenance. Failure of any part of the system
 JBALB Technical Guidelines for Water Supply System in Sarawak

No. Particulars Requirement

shall be localized to that part only and shall not cause damage to
the other parts of the system;
• Non-critical component failures (such as HMI), shall not cause data
corruption or loss of on-line functions;
➢ For smaller WTPs (less than 5 MLD), SCADA architecture may not be
needed. However, it must be designed to accommodate with at least
a workstation (to connect to Sarawaknet’s system) and data server.
Application shall be made to SSMU to install modem router for
internet connection to connect to WORMS;
➢ After T&C, contractor is required to hand over the SCADA software
installation CD, manual, network subscription (if applicable), together
with the required documents to JBALB.
2 Master Station ➢ Should the ICT equipment be provided by the project (such as Federal-
SCADA Software funded and alternative funding projects), it shall be Windows based
and Equipment client/server system to operate between PLC based O/S and master
station with specification as follows:
• SCADA software
• Must use OPC client software.
• Workstation
• Min. one workstation;
• Min. Windows 10 or latest;
• Min. 4-core processor (Cache 2.50 GHz) or higher;
• Min. 64GB DDR RAM;
• Min. 5TB hybrid of SSD and HDD storage;
• Graphic card with min. 8GB GDDR6 RAM;
• Ethernet LAN 10/100/1000 Mbps;
• Dual display monitor supports min. HD (1920x1080).
• Local data server
• Min. two data server – one as a backup;
• Min. Microsoft SQL Server standard or equivalent.
Must be latest update;
• Min. 8-core processor (Cache 2.20 Ghz) or higher,
or CPU utilization not exceeding 50% at peak load;
• Min. 64GB RAM;
• Min. 8 x 600 GB storage, or accommodate all
current and future requirements plus 30% spare
capacity;
• Come with antivirus software.
• HCI Switch
• Min. 16 ports, 10GB uplink. Shall depend on number of O/S
connections installed.
• Servers and switches must be placed in a server rack at least 18U;
• Specification shall be revised from time to time to suit for latest
technology update;
 JBALB Technical Guidelines for Water Supply System in Sarawak

No. Particulars Requirement

• Power fail-safe feature and save critical operation data in the event of
shutdown or power outage;
• Uninterruptible Power Supply (UPS)
• Total load hours of min. 4 hours
• Human Machine Interface (HMI)
• Must have HMI main screen with overall SCADA architecture;
• Include data for O/S – routine and historical data;
• HMI must be touch screen, interactive and located at easily access
area;
• Master page of HMI consist of the following layout:
• Sarawak Government and JBALB logo;
• Name of WTP;
• Title line – page title, number, time and date;
• Banner area – for posting of alarms for operator’s immediate
attention;
• Dialogue line – for operator’s entry or action, typically at the
bottom side;
• Display area – remainder, largest portion of the screen for displays
presentation;
• Overall plant diagram showing the basic process groups;
• Schematic of each processes;
• Diagram of each grouping of major equipment;
• An animated diagram for each process control/sequential loop;
• Links to other pages;
• No contractor’s/consultant’s/project’s names are allowed at HMI
interface. Contractor should not link the system with any outside
system without JBALB's approval.
• Other pages can contain the following:
• Process details and configuration c/w graphic display;
• Animated display graphic;
• Machines/equipment status – running, stopped, tripped, failed,
available and not available;
• Valves – open, closed, failed and available/not available;
• Circuit breakers – open, closed and tripped.
• Alarm lists and event lists;
• Historical data or data analysis.
• Alarm Management
• Complete and comprehensive displaying, logging and storing
alarms;
• Shall be chronological order;
• No action/acknowledgement shall be flashing;
• Alarm cannot be disabled unless allowed;
• Alarm history stored for up to 3 months.
• Event Management
 JBALB Technical Guidelines for Water Supply System in Sarawak

No. Particulars Requirement

• Capture and log events or status changes in the system including
operator’s actions.
• Event shall be stored for up to 3 months.
• Trending data
• Management reports
3 Outstation • Must be PLC-based;
Equipment • Must be as close as possible to the equipment to be monitored;
• Shall be able to be calibrated locally or remotely;
• Instrument Panel
• Height from the floor between 0.9 – 1.7 meter;
• Self-draining steel plinth;
• Come with hinged doors with lockable handles and removable
access covers;
• Cover must be dust-proof, vermin-proof, water-proof at least IP54
for indoor, IP65 for outdoor;
• Doesn’t allow for condensation.
• Panel Wiring
• Shall be PVC insulated cable. Conform to electrical wiring standards
• External Cabling and Wiring
• Cables must run on walls, ceiling or other building structures,
secured on cable trays or enclosed in wall or GI conduit
appropriately;
• Power cables and control cables must be segregated and installed
on separate trays, secured on the walls and/or floor of the trenches,
without hindering walking space. All cables must be segregated
from other pipework, chemical lines and other services;
• Conduit shall be of Class B hot dipped galvanized and screwed
stainless steel type;
• Other specifications to conform to electrical wiring standards;
• After installation, must be tested, calibrated before being
commissioned for use.
4 Program-mable • Normally consist of CPUs, power supply, programming software,
Logic Controller Ethernet and I/O interface system;
(PLC) • Can be remote monitoring or automation. For automated system, to
perform control and data acquisition function for the automation
processes of the plant;
• Must be rugged, designed to operate reliably in conditions that expose
to vibration, environmental challenges and electrical noise;
• Sufficient to process the 140% required number of input and output
(I/O) - 20% active spares + 20% for future I/O;
• Below specification shall apply:
• Instrument Panel and Wiring
• Same as O/S conditions.
• Uninterruptible Power Supply (UPS)
 JBALB Technical Guidelines for Water Supply System in Sarawak

No. Particulars Requirement

• Total load hours of min. 4 hours;
• Come with main fail and battery low contacts relayed to the PLC;
• Shall be provided from a sensing circuit – adjustable to between
18-23 V with 0.5V hystesysis.
• Outdoor Transmitter Panel
• Shall be of stainless steel, with plate thickness > 2mm;
• Panel with AC supply shall be equipped with 15A main switch,
HRC fuses, earth leakage circuit breaker and lightning surge
protector.
• Networking
• Shall be duplicated networking system;
• Shall be connected to fibre optic backbone via an integrated
TCP/IP network port using 100/1000 MBps ethernet switches;
• Networking cable must be at least CAT5 and concealed in
suitable conduits;
• Networking cable conduit must be separated from power cable
conduits;
• Communication between O/S must be a set of LAN or WAN
which is using ModBUS and TCP/IP protocol. No proprietary
network ecosystem e.g LoRA, Sigfox etc is allowed;
• In the event switches to be installed outside of master station, it
must be installed in a switch rack;
• No wireless connection is allowed between O/S PLC to master
station with pumping equipment and other mechanical
interference;
• Wireless connection priority is using Wi-Fi or with booster. If
VSAT/FWB is needed due to distance, SCSDU needs to be
informed for application to install VSAT/FWB;
• Wireless connection using radio links are highly discouraged.
Application of wireless radio shall be registered with the MCMC
and conform to MCMC guidelines and national legislation.
Detailed cost for fees such as apparatus assignment fees must
be provided.
• I/O Modules
• Each module shall have on-board diagnostics and able to
perform hot-swapping functionalities. In the event of
replacement, it shall not disrupt data transfer from the
subsequent modules after the affected modules are removed;
• Digital module – accept switch contacts, solid-state switches and
high level logic, shall provide DC power to dry-field contacts or
transistor switches, contact inputs shall be optically isolated to
protect input circuits from transients and surges up to 200V
RMS;
 JBALB Technical Guidelines for Water Supply System in Sarawak

No. Particulars Requirement

• Analogue module – accept 4-20 mA DC, 1-5 V DC, thermocouple,
RTD, 0-10 volts AC and pulse energy single ended and differential
inputs from field mounted transmitors;
• Analogue output modules shall convert data words into
proportional, isolated 4 20mA DC analogue output signal to
adjust set points of local process controllers, pump speeds, dose
rates, valve positions, etc.
5 Water Quality • Water quality analyzer shall form part of the SCADA monitoring setup
Analyzer for water treatment plant construction or upgrading;
• Parameters to be monitored shall comply with NDWQSP (Group I –
Physical is compulsory, Group II – TDS, Chloride & Aluminium are
compulsory, Fluoride is compulsory for WTP with fluoride monitoring,
while Manganese, Iron and Ammonia are encouraged);
• Mandatory monitoring is raw, settled, filtered and treated water.
Clarified water and sludge are encouraged;
• Analyzer rack shall be formed part of the laboratory equipment in the
laboratory room for the WTP;
• It must be calibrated against the actual result during testing and
commissioning;
• Sampling pump must be installed at the appropriate location. For
example, filtered water sampling pump must be located at the outlet
pipe of the filter;
• Sampling pumps must be installed at one duty and two standby. If they
are different treatment packages/module for the plant, sampling must
be done for every treatment module;
• Sampling pumps must be installed at places which are easy to be
accessed by the plant operator.
• Sensor shall measure in the range of below:
• All parameters must be time-stamped;
• pH range -2 to 14.00 with sensitivity of +/- 0.01;
• Turbidity range for raw water: 0-2000 NTU with sensitivity of +/- 0.1
NTU or +/-5% whichever is greater;
• Turbidity range for settled, clarified, filtered and treated water: 0-
50 NTU with accuracy of +/- 2% of reading, +/- 0.01 NTU (from 0-40
NTU), +/- 10% of reading (from 40-2000 NTU);
• Res. Chlorine range for treated water: 0 – 20 mg/l with accuracy of
0.01 mg/l or +/- 1% of range, whichever is greater;
• Res. Fluoride range for treated water: 0 – 10 mg/l with accuracy of
0.1 mg/l or +/- 10% of range, whichever is greater;
• Color range shall be 0-100 with accuracy of 1 unit or +/- 10% of
range, whichever is greater;
• Res. Alum shall be 0-1 ppm with accuracy of 0.001 ppm or +/- 10%
of range, whichever is greater;
 JBALB Technical Guidelines for Water Supply System in Sarawak

No. Particulars Requirement

• Iron shall be 0-1ppm with accuracy of 0.001 ppm or +/- 10% of
range, whichever is greater;
• Manganese shall be 0-0.5 ppm with accuracy of 0.001 ppm or +/-
10% of range, whichever is greater;
• Ammonia shall be 0-0.2 ppm with accuracy of 0.01 ppm or +/- 10%
of range, whichever is greater;
• TDS range for raw water: 0 – 1500 ppm with sensitivity of +/- 0.1
ppm or +/-5% whichever is greater;
• Conductivity for raw and treated water: 0 – 1500 µs/cm with
sensitivity of +10 µs/cm (must come with temperature sensor range
15-50ºC);
• Built-in electronics of the sensor shall be encapsulated with chemical
resistance and mechanical strength rated IP66 for protection from
moisture, humidity, dust and chemical intrusion. It must be wall-
mounted on sturdy and secured stainless steel rack;
• Must incorporate LCA – local charge analyzer;
• To incorporate VSD type sampling pumps (if possible);
6 Water Resource • Water resource monitoring shall be installed at appropriate location.
Monitoring To minimize development capital costs and maintenance, data loggers
must be battery-powered with solar charging capabilities with
specification as below:
• Low power consumption: Min. 3.6 V lithium lasts min. 2 years;
• Data memory of min. 8 MB flash EPROM;
• Able to record min. 100,000 events at 1 second resolution;
• Communication using RS232 port/USB/ethernet and Wi-Fi;
• Environment range: -40 to +70ºC;
• Other requirements to follow DID HP 32 standard;
• Must connect to central SCADA. Data must be easily captured for
use by central SCADA through API with the data logger’s network.
• The locality shall not duplicate location of existing DID and NREB
loggers. In the event existing loggers are available, need to liaise with
DID and NREB for data integration;
• Water quality for water resource must comply to the MoH standard
• Mandatory monitoring is salinity, conductivity, turbidity, pH, weather
condition, water condition and water appearance;
• Sensor shall measure in the range of below (some are not mandatory
monitoring, but must follow the range specified below.
• All parameters must be time-stamped;
• Salinity range: 0 – 30 ppt with sensitivity of +/- 0.1 ppt;
• Conductivity for raw and treated water: 0 – 1500 µs/cm with
sensitivity of +10 µs/cm (must come with temperature sensor
range 15-50ºC);
• Turbidity range: : 0-2000 NTU with sensitivity of +/- 0.1 NTU or +/-
5% whichever is greater;
 JBALB Technical Guidelines for Water Supply System in Sarawak

No. Particulars Requirement

• pH range: -2 to 14.00 with sensitivity of +/- 0.01;
• DO range: 0 to 10.00 mg/L with sensitivity of +/-0.01 mg/L;
• DO % range: 0 to 100% with sensitivity of 0.1%;
• Weather condition to be captured e.g. rainy;
• Water condition to be captured: low tide, slow flow, high tide;
• Water appearance to be captured: turbid, clear, normal;
• BOD range: 0 – 100 mg/L with sensitivity of 0.1 mg/L;
• COD range: 0 – 100 mg/L with sensitivity of 0.1 mg/L;
• TSS range: 0 – 300 mg/L with sensitivity of 0.1 mg/L;
• Ammoniacal Nitrogen range: 0 – 5 mg/L with sensitivity of 0.01
mg/L;
• Nitrate range: 0 – 7 mg/L with sensitivity of 0.01 mg/L;
• Phosphate range: 0 – 0.5 mg/L with sensitivity of 0.01 mg/L.
• Must allow for manual sampling to carry out manual and laboratory
tests such as for FCC and TCC.
7 Signals • Signals must follow the following standards:
Location Signal Signal Type
Raw Water Intake River Water Level AI
Raw Water Pump Running Status DI
Raw Water Pump Tripped Status DI
Raw Water Flowrate AI
Raw Water Totalizer AI (Double Word)
Raw Water Delivery Pressure AI
Chemical Plant Chemical Dosing Pump Running (All) DI
(Dosing) Chemical Dosing Pump Tripped (All) DI
Treated Water Pumping Treated Water Pump Running Status DI
Treated Water Pump Tripped Status DI
Clear Water Tank Water Level AI
Backwash Tank Water Level AI
Treated Water Flowrate AI
Treated Water Totalizer AI (Double Word)
Treated Water Delivery Pressure AI
Admin Building/Lab Raw Water Turbidity AI
(Water Quality)
Raw Water pH AI
Raw Water Colour AI
Settled Water Turbidity AI
Settled Water pH AI
Filtered Water Turbidity AI
Filtered Water pH AI
Clarifier Water Colour AI
Treated Water Turbidity AI
Treated Water pH AI
Treated Water Residual Fluoride AI
Treated Water Residual Chlorine AI
Treated Water Residual Alum AI
Treated Water Colour AI
High Level Tank Water Level (if any) AI
LV Substation Incoming Total Power D
Incoming Energy P
D
Incoming Voltage M
P
D
Incoming Current Co
M
P
D
Incoming pF m
Co
M
P
D
Incoming Reactive Power m
Co
M
D
P
Incoming Apparent Power m
Co
M
P
D
m
Co
M
P
Co
m
M
 JBALB Technical Guidelines for Water Supply System in Sarawak

No. Particulars Requirement

Location Signal Signal Type
Treated Water Pumping Pump Running Status DI
Pump Tripped Status DI
Suction Tank Water Level AI
Reservoir Tank Water Level AI
Reservoir Tank Outlet Flowrate AI
Reservoir Tank Outlet Totalizer AI (Double Word)
Treated Water Pumping Flowrate AI
Treated Water Pumping Totalizer AI (Double Word)
Treated Water Delivery Pressure (Outgoing Pumping AI
Pressure)
VSD Speed (if applicable) AI

8 Chemical Dosing • Dosing pumps must be formed as part of the SCADA system;
• Dosing pumps must be installed at the designated dosing tank, for both
pre-treatment and treatment stages, except for chlorine at clear water
well and booster station’s suction tank (if applicable);
• Dosing pumps must be installed at one duty and two standby. If they
are different treatment packages/module for the plant, dosing must be
monitored for every treatment module;
• Dosing pumps must be installed at places which are easy to be
accessed by the plant operator;
• Must monitor status for start, stop, tripped, failed, or not available;
• Usage of auto dosing modules such as stream current monitoring
(SCM) is mandatory for raw water with highly fluctuating quality and
volume, encouraged for others. However, it must have ease of
maintenance, and effective.
9 Flowmeter • Shall be battery-powered type. For flowmeters to measure raw and
treated within WTP, must be connected to power cable. Battery must
be lithium battery, last not less than 6 years, come with warranty of at
least 2 years and designed to withstand up to 60ºC;
• Can be either electromagnetic or ultrasonic;
• Accuracy must be equal or better than 0.40% of actual lamina flow
from full scale flow rate to 50% flow rate increasing progressively to
maximum of 5% of the actual flow at 10% flow rate;
• Flowmeter to measure raw and treated water within WTP must form
part of the SCADA system.
10 Transmitter/ • Signal cable must be originally manufactured for type of O/S to be
Signal Converter installed, and not through third party contractor/supplier;
(For Flowmeter) • Signal cable must be able to withstand under water.
• Transmitter/signal converter for flowmeter shall be microprocessor-
based type with function for adjustment, self-diagnostic and error
reporting. It shall incorporate hardware and software protection;
• Shall enable add on for future communication module;
• Shall be equipped with comprehensive display minimum of the
following:
• Flow rate;
• Velocity;
 JBALB Technical Guidelines for Water Supply System in Sarawak

No. Particulars Requirement

• Totalizer (all forward flow, reverse flow, and net flow);
• Volume delivered based on time of day or flow rates or a
combination;
• Date & time;
• Selectable volume and flow rate unit (MLD, M3/h, GPM etc.).
• Must have built-in data logger or data backup system to ensure no loss
of historical data and parameters.
11 Energy • Shall provide to monitor total plant energy usage, where it can link
Monitoring back to IOT gateway and forward the information to master station at
real time;
• Monitor incoming MSB for WTP, capture hourly energy consumption,
energy parameters such as 3-phase real power, power factor, current,
voltage, etc.;
• Modular form provided for flexible installation and configuration. It
must form part of the proposed MSB;
• User can interact through LCD display and buttons. LCD display must
be high resolution;
• Communication protocol must be ModBUS RTU;
• Connectors between sensors to the sensing module should be flexible
connector such as RJ12;
• Modules must be lockable, IP68 rated and able to be close/open by
users;
• Cables within and between modules shall be managed properly
through cable management system and labelling;
• System shall be able to monitor several circuits via a single current
measurement module, a single voltage measurement point for few
outgoing circuits and outgoing current module or as user required.
12 CCTV • In the event of installation of CCTV, it is required to obtain approval
Monitoring from Unit Keselamatan dan Penguatkuasaan Sarawak (UKPS) before
implementation;
• Due to heavy utilization of bandwidth by CCTV, intranet and internet
connection must be standalone and not shared with SCADA or IOTs
installed at WTPs or BPSs;
• In the event of offsite monitoring, LMIC must be utilizing unlimited
data high fibre broadband or FWB. Usage of LMIC with capped data are
not allowed. For areas with only VSAT available, CCTV should not be
implemented to minimize heavy bandwidth usage.

10.2 Distribution Digitalization

Consultant which was tasked to carry out design for projects involving construction or
upgrading of any water supply facilities for distribution, must ensure that all telemetry installed
must come with telemetry backend systems, and are provisioned in the tender document
before the contract is being tendered. The system deployment can be procured through any
 JBALB Technical Guidelines for Water Supply System in Sarawak

procurement procedures required; however, the tender document must ensure that system
integration is explicitly mentioned in the specification and requirements. The cost to carry out
telemetry implementation works including the required system integration must be borne by
the contract and budgeted prior to implementation of the project.

Telemetries integration should follow the following architecture.

SAINS DATA CENTER
Reservoir Level
Distribution
Digitalization GSM/
GPRS
i2O HLT
Application Transmitter Sensor
- Visualization of
location and area - Level data
data; - Sensor
- Alarm GSM/ condition data
Predictive management GPRS - Battery health
M odule Intelli - Alarm notification Battery
Data ETL
(Aquasuite) Softw are - Simple data
Process
analytics on flow
- Predict/ - Data analytics - Extract data EFM , TPP & Export M eters
and pressure
forecast and for leak on level,
emulate detection and flow and
NRW Flowmeter
water pressure
- Consolidated Transmitter Sensor
demand
water network Central - Flow
monitoring SCADA - Pressure
and GIS - Sensor
DIGITIZATION OF JBALB HQ condition data
DRAWINGS COM M AND CENTRE - Battery health Battery

HLT
GIS Data 3G/GSM
/GPRS
Backup Server JBALB HQ HLT
SCADA Transmitter Sensor
- Backup data Workstation
in the event - Level data
- Visualization of location and - Sensor
of internet
area data;
or electricity condition data
- Alarm management
blackout. - Battery health
Digitization of Existing - Alarm notification Battery Solar Panel
Drawings Digital - Simple data analytics on level,
Drawing Data pressure, valves, battery status

The detailed requirement for telemetries (distribution digitalization) are as follows:

No. Particulars Requirement

1 Data • Shall be battery-powered type. Battery must be lithium battery, last not less
Loggers than 6 years, come with warranty of at least 2 years and designed to
withstand up to 60ºC;
• Data logger shall come with the following components: data logger,
connection cables, software interface and SIM card;
• Must be compact, robust, reliable and light weight;
• Minimum memory of 4MB for non-volatile data storage up to a year. Must
ensure no data loss can occur from power interruption;
• Support GSM/GPRS quadband data, SMS network or any equivalent network.
No proprietary network protocol is allowed;
• Data transmission shall be 15 mins, 30 mins, 1 hour, 1 day, 1 week or 1 month
at programmable date and time;
• Shall have alarm dial out setting for each channel;
• Shall come with internal or external antenna with 5m or 10m cable;
• Must be IP68 certified and installed in an underground chamber;
• Subscription during project of at least 36 months with GPS/GPRS/3G/4G or
compatible network connection;
 JBALB Technical Guidelines for Water Supply System in Sarawak

No. Particulars Requirement

• Scope for system integration between IOTs and SWSS shall be included as
part of the project implementation for the HLT IOTs.
2 Chamber • Chamber shall be built of brick wall or concrete wall according to JBALB
standard drawing as per drawings attached.

JBALB Standard Drawing for Electromagnetic Flowmeter Installation in the

Chamber
(JBALB/HQ/STRD/FM/001)

JBALB Standard Drawing for Flow Transmitter Pedestal

(JBALB/HQ/STRD/FTP/001)
3 Flowmeter • Can be either electromagnetic or ultrasonic;
• Must have SWA approval prior to installation;
• Accuracy must be equal or better than 0.40% of actual lamina flow from full
scale flow rate to 50% flow rate increasing progressively to maximum of 5%
of the actual flow at 10% flow rate;
 JBALB Technical Guidelines for Water Supply System in Sarawak

No. Particulars Requirement

• Must be located appropriately to measure flow of the intended area to be
monitored;
• Shall be remote type (detachable from converter) and can be connected to
converter via IP68 cable and connectors with maximum length of 30m;
• Shall be rated IP68;
• Shall be free from external influences which can affect accuracy such as
magnetic fields, electromagnetic fields etc.;
• Designed full or contoured bore with range of diameters from 25mm to
1500mm;
• Shall be flanged design and be rated to handle pressure of up to 16 Bar;
• Body shall be made of carbon steel and electrodes are from stainless steel
(AISI 316);
• Lining should be suitable for potable water such as polypropylene and
ebonite;
• Ground termination must be provided;
• Accuracy shall be 0.25% or better;
• Able to measure forward flow, reverse flow and empty flow.
4 Level • Level can be measured either using level detector or hydrostatic;
Sensors/ • For level detector, level electrodes shall be made of stainless steel (Grade
Detectors 316) encapsulated in heat shrinkable tubing down to 75mm from end of the
electrode. Electrode heads shall be manufactured from reinforced glass fibre
or similar corrosion proof insulated material and IP65-rated;
• For hydrostatic, it must be built by means of gauge pressure transmitter
which consist of 1-inch diameter direct tapping complete with GI pipe or
copper tubing and isolating corks. Pressure transmitter must be installed at
the outlet pipe and ground base of the HLT/reservoir. Level can be measured
from deducting pressure in meter with the height of HLT/reservoir from the
outlet at ground base;
• The following signal must be able to be monitored:
• Water level;
• Pressure;
• Flow rate (if any);
• Suction valves;
• Deliver valves;
• Battery status;
• Solar system health.
• It is highly encouraged to incorporate inlet and outlet pressure and flow
monitoring, which the system can be combined within the level sensing
equipment panel.

10.3 Consumption Digitalization

As for consumption digitalization, installed smart water meters (SWM) must be borne by the
contract including system integration and network configuration/study. Diagram below shows
 JBALB Technical Guidelines for Water Supply System in Sarawak

architecture of SWMs which needs to be complied by the contract either using radio frequency
(RF) or NB-IOT.

Below are the details of requirements for the SWMs:

No. Particulars Requirement
1 Smart Water Meters & • Must be approved by SWA prior to implementation;
Data Concentrator • Shall be battery-powered type. Battery must be lithium battery
or equivalent, last not less than 5 years, come with warranty of
at least 2 years and designed to withstand up to 60ºC;
• It must come with a local mechanical meter for counter
checking/calibration or with equivalent mechanism;
 JBALB Technical Guidelines for Water Supply System in Sarawak

No. Particulars Requirement

• Must be able to withstand physical and environmental
resistance;
• Must be compact, robust, reliable and light weight;
• Minimum memory of 4MB for non-volatile data storage up to a
year. Must ensure no data loss can occur from power
interruption;
• Support NB-IOT, RF or any equivalent network. No free band
(such as infrared signals) and proprietary ecosystem is allowed;
• For RF, network frequency must be dedicated licensed signals
with MCMC. JBALB shall not be tasked to borne any payment of
licensing and assignment fees to MCMC, as it shall be fully borne
by the suppliers;
• Data transmission shall be 15 mins, 30 mins, 1 hour, 1 day, 1
week or 1 month at programmable date and time;
• Must be IP68 certified and installed at a meter stand (refer JBALB
standard drawing);
• Installation shall not cause existing meter stand or
communication pipes to be realigned;
• For RF, must come with handheld meter reading device using a
certified, waived of any MCMC annual fees and reliable radio
frequency;
• Subscription during project of at least 36 months with NB-IOT,
RF or compatible network connection.
• Data concentrator must not allow storage of data for more than
1 month. All data must only be temporarily stored in the data
concentrator and should be protected from risk of hacking.
2 Software for SWMs • Smart meter must be able to transfer data through API with
JBALB Advanced Meter Infrastructure (AMI) platform. JBALB
CCD to liaise with SAINS on the device integration;
• Web-based development for consumption and monitoring
billing are not allowed;
• Installation of servers and other hardware for data acquisition
are not allowed (except federal-funded. Even with federal-
funded projects, efforts must be made to utilize the current
JBALB co-located server). Database is to make full use of JBALB
AMI platform;
• GPS info must be captured prior to installation.
• Backend software for SWMs is allowed, however, data must be
stored and managed and JBALB co-located server at SAINS data
center.
 JBALB Technical Guidelines for Water Supply System in Sarawak

10.4 System Integration

For integration works to JBALB Central SCADA system, the SCADA gateway will be installed at
the WTP, polling the information from all the PLCs and LV Substation Digital Power Meter (if
applicable). This information will be displayed at the local SCADA gateway touch screen or HMI
(Human Machine Interface). At the same time, the data will also be sent to JBALB HQ Central
SCADA for analysis.

The Contractor for the other SCADA project shall provide the network within the WTP. All PLCs
shall be interconnected and make available network port at WTP Admin Building office, where
the WTP SCADA workstation are located. Please ensure that PLCs are complying to MODBUS
TCP protocol. Some PLCs such as OMRON are not using MODBUS TCP Protocol, but instead,
using IP address. This is also acceptable. Other proprietary PLCs with proprietary
communication protocol (which are part of suite software and ecosystem) are not allowed to
be used.

JBALB HQ SCADA communication gateway will be installed at the same location near the WTP
SCADA workstation and sharing the plant SCADA MODBUS TCP network. For this
interconnection to work, the WTP SCADA contractor shall provide network information, such
as all equipment IP address, system architecture and detailed data mapping addressing.

The interconnection requirement for Digital Power Meter (DPM) Interfacing are as follows:
a) DPM need to be installed at the WTP main switch board (MSB) incoming and provide the
energy consumption for the plant;
b) DPM shall come with Ethernet communication port and support MODBUS TCP protocol;
c) It shall be Schneider PM5320 or equivalent model, which provide the standard address
mapping for the parameters.

WTP SCADA Contractor shall include the following signals, but not limited to:
Location Signal Signal Type
Raw Water Intake River Water Level AI
Raw Water Pump Running Status DI
Raw Water Pump Tripped Status DI
Raw Water Flowrate AI
Raw Water Totalizer AI (Double Word)
Raw Water Delivery Pressure AI
Chemical Plant Chemical Dosing Pump Running (All) DI
(Dosing) Chemical Dosing Pump Tripped (All) DI
Treated Water Treated Water Pump Running Status DI
Pumping Treated Water Pump Tripped Status DI
Clear Water Tank Water Level AI
Backwash Tank Water Level AI
Treated Water Flowrate AI
Treated Water Totalizer AI (Double Word)
Treated Water Delivery Pressure AI
Raw Water Turbidity AI
 JBALB Technical Guidelines for Water Supply System in Sarawak

Location Signal Signal Type

Admin Building/Lab Raw Water pH AI
(Water Quality) Raw Water Colour AI
Settled Water Turbidity AI
Settled Water pH AI
Filtered Water Turbidity AI
Filtered Water pH AI
Clarifier Water Colour AI
Treated Water Turbidity AI
Treated Water pH AI
Treated Water Residual Fluoride AI
Treated Water Residual Chlorine AI
Treated Water Residual Alum AI
Treated Water Colour AI
High Level Tank Water Level (if any) AI
LV Substation Incoming Total Power DPM Comm
Incoming Energy DPM Comm
Incoming Voltage DPM Comm
Incoming Current DPM Comm
Incoming pF DPM Comm
Incoming Reactive Power DPM Comm
Incoming Apparent Power DPM Comm
Legend: AI = Analog Input, DI = Digital Input

BPS SCADA Contractor shall include the following signals, but not limited to:

Location Signal Signal Type

Treated Water Pump Running Status DI
Pumping Pump Tripped Status DI
Suction Tank Water Level AI
Reservoir Tank Water Level AI
Reservoir Tank Outlet Flowrate AI
Reservoir Tank Outlet Totalizer AI (Double Word)
Treated Water Pumping Flowrate AI
Treated Water Pumping Totalizer AI (Double Word)
Treated Water Delivery Pressure AI
(Outgoing Pumping Pressure)
VSD Speed (if applicable) AI
Legend: AI = Analog Input, DI = Digital Input

WTP SCADA contractor shall provide the following documentation for further information
related to the HQ SCADA interfacing, but not limited to:
a) Each PLCs IP address, port no.;
b) MODBUS Mapping addressing for the signal as stated in section 4;
 JBALB Technical Guidelines for Water Supply System in Sarawak

c) Each DPM communication setting, and a set of the MODBUS addressing document;
d) WTP SCADA system architecture diagram;
e) Substation electrical single line diagram;
f) Proposed SCADA signals;
g) Proposed telco for network; and
h) WTP overall process diagram.

Any amendment of the configuration shall require approval from JBALB and submission of
revised documents shall be made prior to approval. SCADA contractors are required to perform
inter-connection testing to verify all MODBUS mapping address are correctly configured. Data
verification must be done and witnessed by JBALB for every testing.

Upon completion and T&C of SCADA setup at the WTP, contractor is required to hand over the
SCADA software installation CD, manual, network subscription (if applicable), together with the
required documents as above to JBALB HQ or JBALB Divisional office.

10.5 Last Mile Internet Connection (LMIC)

All new projects and development under JBALB jurisdiction with SCADA and telemetry (with
exception of smart meters) must not be installed with any internet connection without approval.
During pre-contract phase, the following processes shall apply:
a) Any SCADA installation must be a complete ecosystem within local SCADA network (as per
requirements above);
b) Gateway must be allowed for installation of new LMIC to the network;
c) Architecture design must be submitted to JBALB for submission to SCSDU for installation
of Sarawaknet;
d) In the event that the project has been implemented before this guideline is published,
divisional office must apply for Sarawaknet connectivity for that particular water supply
facilities. If the current network involves usage of VSAT, FWB, ADSL, fibre optic broadband,
mobile broadband or radio telecommunication through subscription, the Sarawaknet
installation shall be done right before subscription expired;
e) Installation of internet network will be borne by SCSDU. Therefore, it shall not be quoted
in the tender document;
f) Scope for installation of SCADA, local SCADA network, gateway and system integration
must be provisioned in the tender documents.
 JBALB Technical Guidelines for Water Supply System in Sarawak

11 Safety and Security

11.1 Security Fencing and Gates

(a) Treatment Plant, Booster Station, Reservoir areas shall be fenced using at least 2.5 m high
security fencing: -
➢ Concrete fence with 3 bard wire or electric fence on top;
➢ Heavy duty welded mesh panel anti-cut fence;
➢ Reinforcing Fabric of Steel (BRC) fence;
➢ Double fence with electric fence inside.
(b) Quarters shall be fenced separated from treatment plant compound with at least 1.5m
chain link security fencing with 3.0 m wide gate.
(c) Treatment Plant, Booster Station, Reservoir area main gate shall be at least 4.9 m wide
with 1.0 m service gate.
(d) A guard house shall be provided at the main entrance to the treatment plant. If the guard
house is located more than 200 m far from any toilet facility, then a toilet and a stand pipe
shall be provided.

11.2 Other Security Consideration

(a) CCTV system shall be provided at specific location in treatment plants and booster stations.
The CCTV shall be a high quality and reliable video digital network with fully integrated
control function. It is required to obtain approval from Unit Keselamatan dan
Penguatkuasaan Sarawak (UKPS) before implementation.
(b) Cameras shall be located to monitor the following areas:
➢ Entry and exit gate
➢ Perimeter security fencing
➢ Entry and exit of administration building
➢ Intake structure
➢ Process building and structure
➢ Inside pumping station
➢ Inside store house
➢ Inside chemical mixing building
(c) Window and door grilles shall be provided in treatment plants and booster stations.

11.3 Safety Requirement

1. Besides fire hydrants, adequate firefighting equipment such as fire extinguishers, hose
reel systems shall be provided in all the buildings.
2. Smoke detectors, heat detectors, fire alarms shall be provided in accordance to BOMBA
requirements.
 JBALB Technical Guidelines for Water Supply System in Sarawak

3. If liquid alum is stored in open tank, a shower/ eye wash area located in a convenient
place near to the chemical tanks as possible shall be provided.
4. The hydrogen release outlet for EC system must be installed minimum 5 m above the
ground level and ensure there is no farmable activities surround the area.
5. Chlorine detection equipment and alarms, extractor fans shall be provided at all
treatment plants.
6. A surge relief valve that protects piping and pipeline systems from pressure surge events
caused by rapid valve closure, emergency shut-down or pump trip situations shall be
provided.
7. All walkways around filters, sedimentation tanks, high level tank, opening platform etc.
where frequently accessed shall be provided with stainless steel or galvanized steel
guardrail with mid-rail either on one side or both sides depending on site conditions. The
top rail should be at least 1.0 m above the floor.

8. Vertical ladders shall be provided with safety devices, such as cage or safety straps.
9. Access ladder inside the reservoir, filter, sediment tank, coagulant tank, raw water intake
structure shall be made of rust-free material, such as aluminum.
10. Steel or Concrete staircase shall be provided for all structural buildings from ground to
top level.
11. All external stairs and ladders shall be provided with hand railings if considered
hazardous.
12. First aid equipment shall be provided in all treatment plants, booster stations and guard
houses.
13. Safety devices and equipment meeting the OSHA requirement and regulation shall be
provided,
➢ Personal Protective Equipment
➢ Safety helmet, hearing protection, eye protection, respiratory protection, glove,
safety harness, safety shoes, safety reflector vest
➢ Portable chlorine detection equipment (for treatment plant and post chlorination
plant)
14. A safety and health officer (SHO) or site safety supervisor (SSS) or Occupational Safety
and Health Coordinator (OSH-C) shall be employed for work as comply with OSHA
requirements.
 JBALB Technical Guidelines for Water Supply System in Sarawak

15. Safety and Health Plan Including Safety and Health Policy, Emergency Response Plan,
Chemical Safety Data Sheet should be provided within a month after Letter of
Acceptance.
16. Monthly Safety Report shall be provided.
17. Hazard Identification, Risk Assessment and Risk Control (HIRARC) should be carried out
and recorded during contract period. Method, materials and equipment should be
selected to remove or minimize risk from work.
18. Traffic management plan documents and helps explain how risks will be managed at the
construction workplace shall be provided. Traffic control by competent person, traffic
and warning signs shall be provided.
19. Main Gate and Hoarding shall be provided at the site to stabilize entrances to a
construction site for control movement of visitors, clients, workers and vehicles, and to
ensure to safe guard the project site and maintain the safety of workers while keeping
the general public out of the construction site.

Construction site shall set up vehicle wash tank with high pressure flushing device
before exit the main entrance.

20. Temporary water supply under conditions of ensuring uninterrupted water supply shall
be allowed.
21. Safety signs shall be provided to draw attention to objects and situations which affect or
could affect health or safety.
➢ Prohibition signs
➢ Warning signs
➢ Mandatory signs
➢ Safe condition signs
22. Supply, erection and dismantle scaffolding, working platform with safety net shall be
provided.
23. Cordoning off working area and provision of public control and safety measures where
lifting operations, moving, shifting, transferring works are carried out outside the
hoarded-up area of the worksite shall be provided.
24. Measures to prevent the breeding of mosquitoes, houseflies, rats, insects and other
dangerous animals on the Site throughout the contract period shall be allowed.
25. A Confined Space entry programme with Safe Working Procedure (SWP) shall be
developed and implemented to enter a confined space.
➢ Provide an adequate and effective ventilation to always maintain the contaminants
concentration level as low as possible, and the level of oxygen within safe range.
➢ Training shall be provided in all work with confined space.
 JBALB Technical Guidelines for Water Supply System in Sarawak

26. Living quarters for workers shall be provided and isolate from the construction operation
zone.
➢ Portable fire extinguishers shall be provided adequately.
➢ Provided with supply of water and electricity.
➢ Toilet and washing building shall separate from living units at least 10 m apart with
septic tank.
27. Permit-To-Work (PTW) must be obtained before any construction activity be carried out.
PTW is a formal, written, safe system of work to control potentially hazardous activities.
The permit details the works to be done and the precautions to be taken (for instance,
they may involve limiting the movement of overhead cranes, the precautions needed for
high voltage work, or they might details rescue arrangement for certain type of works).
28. Booster station should be provided with toilet facilities and office for the attendant.
 JBALB Technical Guidelines for Water Supply System in Sarawak

12 Testing and Commissioning for Water Treatment Plant / Booster Pump

Station
(a) Testing & commissioning for the whole system at Water Treatment Plant shall be 24hours
continuously running for 7 days period.
(b) Testing & commissioning for the whole system at Booster Station shall be 24hours
continuously running for at least three (3) days period.

13 Color Code
1. Quarter
(a) Roof – Bright Blue (#0096FF)

(b) Wall – White (#FFFFFF) at Top

(c) Wall – Grey (#808080) at Bottom

2. Water Treatment Plant and Booster Station

a) Roof – Bright Blue (#0096FF)

b) Wall – Light Blue (#ADD8E6)

c) Column – Denim (#6F8FAF)

3. Tank and tower structure

(a) White (#FFFFFF)

(b) Cotillion Red (#B43D35)

(c) Golden Dome (#FFC035)

(d) Black (#000000)

 JBALB Technical Guidelines for Water Supply System in Sarawak

14 Reference
1. MWA Planning Guidelines and Best Practices Handbook for Water Supply Systems (Volume
1: 2021 Edition)

2. MWA Design Guidelines for Water Supply Systems (December 1994)

3. General Specification for Water Main Construction (October 2011)

4. Guidelines and Requirements For Water Supply Systems In Sarawak (Ref:

SWSCC/DIR.1/2002WTC 1/98)

5. SPAN Uniform Technical Guidelines for the Design of Water Treatment Plants and Related
Water Supply System Components (First Edition, May 2021)

6. Environmental Quality Act 1974: Environmental Quality (Industrial Effluent) Regulations 2009

7. Occupational Safety and Health Act 1994

8. Factory Machinery Act (FMA 1967)

9. Construction Industry Development Board (CIDB) Act 520

10. Building Operations And Works Of Engineering Construction (Safety) Regulations,1986

11. DOSH Guidelines for the Prevention of Falls at Workplaces

12. DOSH Guidelines For Public Safety And Health At Construction Sites (1st Revision: 2007)

13. Best Practice on Occupational Safety and Health in Construction Industry 2019

14. OSH Management in Construction Industry Guideline (OSHCIM 2017)

15. Supply System Components (Second Draft Guidelines Rev. 0-0 9 April 2021)

16. IEC 61557-12 standard - Electrical Installation Guide

17. Communication and Multimedia (Spectrum) Regulations 2000 P.U(A) 128/2000

18. Sarawak Multimedia Authority Ordinance 2017

19. Standard Guideline for Underground Utility Mapping (May 2006)

20. Garis Panduan Pengurusan Peralatan ICT V 1.3 (2018)

21. MS 1759:2004 – Geographic Information/Geomatics – Features and Attribute Codes

22. HP32 - Hydrological Standard for Rainfall Station Instrumentation

23. MS 2320:2010 : Drinking Water – Quality Requirements and Standard Kualiti Air Kebangsaan

24. Guidelines on Design and Planning of Water Treatment Plant and Equipment, dated
29.01.2021. By Technical Advisor Ir. WWA (PPT file)
 JBALB Technical Guidelines for Water Supply System in Sarawak

25. Theory Application and Design of Air Valves along Pipelines. By Cho KM, Chief hydraulic
Engineer, 2012.

26. National Standard for Drinking Water Quality, 2nd revision January 2004, Ministry of Health
Malaysia.
 JBALB Technical Guidelines for Water Supply System in Sarawak

15 Attachment

15.1 Checklist on design report for Watermain, Booster Station and Reservoir

15.2 Check list on tender drawing for Watermain, Booster Station and Reservoir

15.3 Checklist on design report for Water Treatment Facilities

15.4 Testing and Commissioning Document for Booster Station

15.5 Testing and Commissioning Document for Water Treatment Plant

 JBALB Technical Guidelines For Water Supply System In Sarawak

Checklist on design report

for

Watermain, Booster Station and Reservoir

 JABATAN BEKALAN AIR LUAR BANDAR

CHECKLIST FOR WATERMAINS/BOOSTER STATION/RESERVOIR(*)

Name of Project:

Type of Report Sub Title: Conceptual/preliminary/Interim/Draft Final/Final(*) Design Report

Name of Consultant:

(* Delete whichever not applicable; N.A. denotes Not Applicable)

Item Description Status Remarks
(YES/ NO
/N.A.)
(A) GENERAL
1. Is title of project correct?
2. Does front cover has title of project, name of
report, name of client, name of consultant and
month/year of report?
3. Table of contents with paging provided
4. Introduction provided
5. Background & objective of project provided
6. Scope of works of the project provided
7. Description & map of supply area provided in
relation to existing water supply system
8. Cost estimates with detailed breakdown &
overall project cost are provided
9. Proposed schedule of implementation of the
project is provided
10. Wayleave application
11. Please indicate in the remark column the type
of the road:
(i) JKR Road (State)
(ii) JKR Road (Federal)
(iii) Rural Road
(iv) Kampung road
(v) Council road
(vi) Etc (Please state)
12. Siting application
13. Subsurface Investigation works.
(State how many boreholes and Mackintosh
Probes required)
14. Survey works
(B) POPULATION
1. Population statistics for each
kampong/area/school/ institution provided
2. Projected population & water demand provided
3. Is projection period based on design life of 30
years?
4. Is population growth rate based on historical
record?
5. If answer to Item 4 above is no, is population
growth rate used in projection reasonable?
6. Is population projection provided based on 5
yearly intervals?
7. Are the projected population figures
acceptable?

1
 JABATAN BEKALAN AIR LUAR BANDAR

CHECKLIST FOR WATERMAINS/BOOSTER STATION/RESERVOIR(*)

(C) WATER DEMAND

1. Water demand for population based on Design
Guidelines
2. Water demand for commercial area based on
Design Guidelines
3. Water demand for institutions based on Design
Guidelines
4. Water demand for industrial area based on
Design Guidelines
5. Peak consumption factor of 2.5 is used.
6. Fire fighting demand based on Design
Guidelines.
7. Allowance of 25% for non-revenue water
provided.
8. Is the projected total water demand
acceptable?
(D) PROPOSED GRAVITY PIPELINES
1. Layout plan of proposed pipelines in relation to
existing mains provided together with proper
labeling of the pipelines and kampungs
2. Any pipe material comparison analysis including
suitability of pipe in soil & environmental
conditions encountered, material & installation
costs, O & M costs, etc. before selecting the
pipe material to be used?
3. Hydraulic analysis of proposed pipelines are
provided for the following: -
(a) average flow
(b) peak flow
(c) peak flow + fire flow
4.. Node diagrams showing the node junctions,
pipes nos. draw-off rate at each kampung, flow
rate in each of the pipe no., reduced levels at
the kampungs/ reservoirs/suction tanks, names
of kampungs are provided for the following: -
(a) average flow
(b) peak flow
(c) peak flow + fire flow
5. Is the water pressure used in the hydraulic
analyses based on projected pressure in 30
years’ time?
6. Are the input data used in the hydraulic
analyses correct?
7. Are the reports on the results of the hydraulic
analyses provided?
8. Is the residual pressures meet the requirements
of 10 metres for the following cases:-
(a) average flow
(b) peak flow
(c) peak flow + fire flow
9 Can the selected pipe material and pressure
rating withstand 1.5 time of the MSDWP in the
proposed pipeline system?
10. Pipeline design comply to way leave
requirement from JKR

2
 JABATAN BEKALAN AIR LUAR BANDAR

CHECKLIST FOR WATERMAINS/BOOSTER STATION/RESERVOIR(*)

11. Chlorine Residual at the end of proposed

pipeline not less than 0.2ppm according to
National Standard for Drinking Water Quality
12 If chlorine residual at end of existing pipeline
cannot give a chlorine residual of 0.2ppm, then
a system is provided to boost the chlorine to
give sufficient chlorine residual at end of
proposed pipeline
(E) SUBMARINE MAINS
1. Layout plan and longitudinal profile of proposed
submarine main provided.
2. Any pipe material comparison analysis including
suitability in submarine conditions
encountered, material & installation costs,
O & M costs, etc. before selecting the pipe
material to be used?
3. Submarine investigation with regard to current
forces, wave forces, tidal conditions, etc.
carried out and reported in design report.
4. Calculations on the forces acting on the
submarine main provided and found
acceptable.
5. Calculations on the concrete ballasts provided
and found acceptable.
6. Comparison of the options for the installation
of the submarine main such as laying on river
bed, trenching and HDD is provided including
capital and O & M costs before recommending
which option to be used.
7. Is the recommended, option for installation of
the proposed submarine main acceptable?
8.. Is the spacing of the concrete ballasts
acceptable?
9. Are twin submarine mains proposed?
10. Is the spacing between the two submarine
mains acceptable?
11. Are the ends of the submarine mains at the
river banks properly anchored?
12.. Are anchorage signs provided?
13. Are the proposed jointing methods for the
pipes acceptable?
14. Is the installation method of the concrete
ballasts on the submarine main acceptable?
15. Can the selected pipe material and pressure
rating withstand 1.5 time of the MSDWP in the
proposed pipeline system?
16. Comply with Sarawak River Board requirement
(F) PROPOSED PUMPING MAINS
1. Layout plan of proposed pumping mains in
relation to existing or proposed pipeline system
provided.
2. Any pipe material comparison analysis including
suitability of pipe in soil & environmental
conditions encountered, material & installation
costs, O & M costs, etc. before selecting the
pipe material to be used?
3
 JABATAN BEKALAN AIR LUAR BANDAR

CHECKLIST FOR WATERMAINS/BOOSTER STATION/RESERVOIR(*)

3. Calculations on static head, friction losses and

total pumping head provided.
4.. Calculations on surge analysis provided.
5 Adequacy of surge vessel or surge-anticipating
relief valve.
6. Can the selected pipe material and pressure
rating withstand 1.5 time of the MSDWP in the
proposed pipeline system?
7. Pipeline design comply to way leave
requirement from JKR
8. Chlorine Residual at the end of proposed
pipeline not less than 0.2ppm according to
National Standard for Drinking Water Quality
9. If chlorine residual at end of existing pipeline
cannot give a chlorine residual of 0.2ppm, then
a system is provided to boost the chlorine to
give sufficient chlorine residual at end of
proposed pipeline
(G) BOOSTER STASTION
1. GENERAL
(a) Layout plan showing the location of the
proposed booster station site in relation to
existing and proposed water supply system
provided.
(b) Location chosen for the proposed booster
station is acceptable in terms of required
ground level to receive incoming water.
(c) Layout plan of the booster station site
showing the suction tank, pump house, high
level tank (if located at the same site),
generator house, toilet, substation, access road,
drainage system, fencing, etc. is provided and
found to be acceptable.
. (d) Survey plan showing the contours and the
proposed platform levels for the suction tank,
pumphouse and high level tank (if located on
the same site) is provided and found to be
acceptable.
(e) Site proposed for land acquisition has
adequate space for future extension
(f) Is a toilet provided for booster station?
(g) Is Sub-station meet Sarawak Energy Berhad
(SEB) requirement?
(h) All electrical works including switchboard,
cablings lightings, etc are in order.
(i) Minimum security fencing must be provided
of height at least 2.5 meter.
2. SUCTION TANK
(a) Suction tank has a minimum capacity
equivalent to eight (8) hours pumping rate.
(b) Calculations to determine the capacity of
the suction tank are provided and found to be
acceptable.
(c) Material of construction for suction tank is
reinforced concrete unless otherwise approved.

4
 JABATAN BEKALAN AIR LUAR BANDAR

CHECKLIST FOR WATERMAINS/BOOSTER STATION/RESERVOIR(*)

(d) Suction tank with capacity more than 1 ML

shall has a central partition for O & M purposes.
(e) Suction tank has separate suction pipe
connected directly to each pump.
(f) All pipeworks for the suction tank are shown
and in order.
(g) Piling for suction tank is provided.
(h) Painting for the suction tank is provided.
(i) Level indicator is provided.
3. PUMP HOUSE
(a) Internal layout of the pump house showing
the pump plinths, pumps, switchboard,
pipeworks, cable trenches, etc. is provided and
found to be acceptable.
(b) Calculations on the pumping capacity and
head are provided and found to be in order.
(c) Adequate duty and standby pumps are
provided.
(d) The type of pumps proposed is acceptable.
(e) Surge pressure analysis provided to justify
the need for surge tank or surge anticipating
relief valve.
(f) Piling for the pump house is provided.
(g) All electrical works including switchboard,
cablings, lightings, etc are in order.
4. GENERATOR HOUSE
(a) Internal layout of the generator house
showing the generator, switchboard, cable
trenches, etc. is provided and found to be
acceptable.
(b) Calculations on the generator capacity is
provided and found to be in order.
(c) All electrical works including switchboard,
cablings, lightings, etc are in order.
(d) Piling for the generator house is provided.

5
 JABATAN BEKALAN AIR LUAR BANDAR

CHECKLIST FOR WATERMAINS/BOOSTER STATION/RESERVOIR(*)

(H) RESERVOIR
(a) Layout plan showing the location of the
proposed reservoir site in relation to existing
and proposed water supply system provided.
(b) Layout plan of the reservoir site showing
the tank access road, drainage system, fencing,
etc. is provided and found to be acceptable.
(c) Reservoir has minimum capacity of 24 hours
storage.
(d) Calculations to determine the capacity of
the reservoir are provided and found to be in
order.
(e) Material of tank is reinforced concrete
unless otherwise approved
(f) Reservoir with capacity more than 1 ML shall
has a central partition for O & M purposes.
(g) Standby outlet is provided.
(h) Pipeworks for the reservoir are shown.
(i) Piling for the reservoir is provided.
(j) Painting works for the reservoir is provided.
(k) Level indicator is provided.
(l) Bypass system
(m) Minimum security fencing must be provided
of height at least 2.5 meter.
(n) Staircase from the ground to tank
(o) Compound light

6
 JBALB Technical Guidelines For Water Supply System In Sarawak

Checklist on tender drawing

for

Watermain, Booster Station and Reservoir

 JABATAN BEKALAN AIR LUAR BANDAR SARAWAK

CHECKLIST ON TENDER DRAWINGS

FOR WATERMAINS/BOOSTER STATION/RESERVOIR(*)

Name of Project:

Tender Drawings Submitted: 1st Draft / 2nd Draft / 3rd Draft / Final (*)

Name of Consultant:

(* Delete whichever not applicable; N.A. denotes Not Applicable)

Item Description Status Remarks

(Yes / No/ N.A.)
(A) GENERAL
1. Are details on the cover page, including the project title
correct?
2. A list of drawings with details on item no., drawing title
and drawing no. provided.
3. Locality plan is provided.
4. Are survey bench marks shown in all the relevant plans?
5. Have the plans been signed and stamped by the
registered professional engineer responsible for this
project?
6. Are ‘Notes’ provided where required on the relevant
plans?
7. Are ‘Legends’ provided where required on the relevant
plans?
8. Proper drawing scales are shown in all drawings for each
plan or sectional view.
(B) OVERALL LAYOUT PLAN
1. Is overall layout plan showing all the project components
provided? (Note: This overall layout plan should be
based on L & S topographical map)
2. Is the proper drawing scale shown?
3. Are the following project components properly shown
and labeled:
(a) watermains with the sizes, type of material and
pressure ratings indicated.
(b) booster station site showing the pumphouse and
suction tank with storage capacity & material of tank
indicated.
(c) reservoir with storage capacity and material of
reservoir indicated.
4. Are existing pipelines and other water supply facilities
such as intake, treatment plant, reservoirs, booster
station, etc. shown?
5. Are names of town, kampungs, roads, rivers, etc. shown?
(C) SCHEMATIC DIAGRAM
1. Is schematic diagram showing all the project components
in relation to existing facilities provided?

1
 JABATAN BEKALAN AIR LUAR BANDAR SARAWAK

CHECKLIST ON TENDER DRAWINGS

FOR WATERMAINS/BOOSTER STATION/RESERVOIR(*)

2. Are the project components and existing facilities

properly labelled?
3. Are ground levels, bottom and top water levels of water
tanks or reservoirs and other relevant levels shown?
4. Are project components, existing facilities and features
properly labeled?
5. Are interconnection points clearly shown?
6. Are legends provided?
7. The sizes, pressure ratings & lengths of the pipelines, the
tank/reservoir capacities, etc. are shown.
(D) HYDRAULIC PROFILE
1. Is hydraulic profile of the proposed system provided?
2. Are the project components and existing facilities (where
relevant) shown?
3. Are the project components and existing facilities shown
properly labelled?
4. Are the levels at all the project components and existing
facilities shown?
5. Is the existing ground profile shown together with the
distances between the components?
6. Are pump capacities and pumping heads indicated?
7. Is the hydraulic profile correctly shown? (To check
against design report & calculations)
(E) PROPOSED PIPELINES
1. KEY PLANS OF PIPE ROUTES
(a) Key plans showing the overall pipe routes surveyed
together with the drawing nos. for each pipe routes are
provided.
(b) The sizes, pressure ratings, materials and lengths of
pipelines are indicated and in accordance with approved
final design report.
(c) Notes on the requirements for mainlaying works,
material specifications, thrust blocks, marker posts, air
valves, sluice valves, fire hydrants, etc. are provided.
(d) Legends on the proposed pipelines, etc. are provided.
2. PLAN VIEWS OF PIPELINES
(a) Plan views of pipelines are provided.
(b) The alignments of the pipelines are clearly indicated.
(To check they follow the approved wayleaves)
(c) All the pipelines, air valves, sluice valves, washouts,
fire-hydrants, etc. where required are clearly shown and
labeled. The pipe size, pressure rating and material are
clearly indicated.
(d) All the relevant notes and legends on the symbols
used are provided.
(e) All chainages at 20 metre intervals are indicated.
(f) Matchlines are given.
(g) Relevant features such as houses, lot no. &
boundaries, electrical posts, bridges, culverts, rivers,
drains, etc. are shown.
2
 JABATAN BEKALAN AIR LUAR BANDAR SARAWAK

CHECKLIST ON TENDER DRAWINGS

FOR WATERMAINS/BOOSTER STATION/RESERVOIR(*)

3. LONGITUDINAL PROFILES OF PIPELINES

(a) Longitudinal profiles of pipelines are provided.
(b) Existing ground levels of pipeline route are taken at
20 metre intervals.
(c) Existing ground levels of pipeline route are also taken
at points necessary to show any significant changes in
slope.
(d) At all streams, bridge and culvert crossings, the
following information are obtained.
(i) Cross-sections of streams along the pipeline
route giving levels at intervals sufficiently
close to show the bed levels.
(ii) The soffit level of the longitudinal beam of the
bridges, together with their span and the
locations of the column.
(iii) The invert levels and the crown levels of all
culverts.
(e) Longitudinal sections along the pipe route are drawn
to a scale of 1 in 100 (vertical) and 1 in 1000 (horizontal)
(f) The size, material and pressure rating of the pipeline is
stated.
(g) Chainages are clearly indicated.
(h) Proposed pipe invert levels are given and designed to
provide generally a soil cover of 1000 mm. to the top of
the pipeline.
(i) Where the soil cover to the top of the pipes is less
then 450 mm, the pipes are erased in reinforced concrete
surround of minimum 150 mm and provided with
contraction joints.
(j) The pipelines are laid to a minimum gradient of 1:500.
(k) Pipe connections to existing mains are clearly
indicated.
(l) Details of pipe connections to existing mains are
provided.
4. THRUST BLOCKS & ANCHOR BLOCKS
(a) Properly designed thrust blocks or anchor blocks are
provided for the following:
(i) at horizontal and vertical bends, tees, tapers,
reducers, end caps, line valves and at points
where an unbalanced thrust occurs.
(ii) one in every 3 pipe lengths for pipes laid on a 1:12
slope.
(iii) one in every 2 pipe lengths for pipes laid on a 1:8
slope.
(iv) one in every pipe length for pipes laid on a 1:5
slope.
(b) The sizes of the anchor and thrust blocks are as per
design calculations which are based on actual soil bearing
capacity.

3
 JABATAN BEKALAN AIR LUAR BANDAR SARAWAK

CHECKLIST ON TENDER DRAWINGS

FOR WATERMAINS/BOOSTER STATION/RESERVOIR(*)

(c) Where necessary, the pipes or fittings are properly

fastened onto the thrust or anchor blocks using hot
dipped galvanized mild steel straps with 10 mm thick
synthetic rubber padding and hot dipped galvanized mild
steel bolts.
(d) Proper and adequate piling is provided where
required.
5. PIPELINE SLUICE/BUTTERFLY VALVES
(a) The pipelines valves proposed comply with the
following:-
(i) For pipeline up to 400 mm. diameter, sluice valves
are used.
(ii) For pipelines of 450 mm diameter and above,
butterfly valves are used.
(iii) Pipeline valves are spaced at about 1,500 m.
intervals.
(iv) At a tee intersection, two valves are provided.
(v) At a cross intersection, three valves are provided.
6. AIR VALVES
Note:
(1) Double air valves can be of single body or dual body
type depending on design requirement and calculations.
(2) A peak is located by reference to the hydraulic
gradient and not to necessarily to the horizontal datum
line.
(a) Air valves are provided along the pipelines at the
following points:
i. at all peak points
ii. at points of abrupt increase in downward
slope.
iii. at abrupt decrease in upward slope.
iv. single large orifice air valve at downstream of
the pump delivery valves.
v. along long horizontal runs at about 800 m.
intervals.
vi. single air valves at small up and over culvert
crossings.
vii. Double air valves for larger stream and river
crossings.
viii. Double air valves at beginnings of horizontal
runs after ascents.
ix. Double air valves at ends of horizontal runs
before descents.
(b) The types and sizes of the air valves proposed at the
various locations of the pipelines are properly designed
based on design calculations / manufacturer’s
performance graphs for air valves/air valve sizing
software to prevent water hammer, air pockets and
vacuum suction. (Note: To check against design report &
calculations)
4
 JABATAN BEKALAN AIR LUAR BANDAR SARAWAK

CHECKLIST ON TENDER DRAWINGS

FOR WATERMAINS/BOOSTER STATION/RESERVOIR(*)

7. HYDRANTS
Pillar hydrants for the pipelines comply with the
following:
(i) provided only where there are houses,
shophouses, longhouses, office buildings or
institutions along the pipelines.
(ii) spacing interval between hydrants is not more
than 180 metres.
(iii) For high risk installations, the hydrants are
placed not more than 90 metres walking
distance from the installations.
(iv) Screw down/ sluice valve pillar hydrants are
provided at the ends of pipelines
8. WASHOUTS
(a) Washouts are located at all low points of the
pipelines.
(b) Minimum size of washouts is 100 mm.diameter
(c) Washouts are connected to the nearest drains by
HDPE pipes.
(d) Washouts are sized to give a minimum watermain
velocity of 0.8 m/s (Note: To check against design
calculations)
9. VALVE CHAMBERS
(a) All valves for buried pipelines are housed in chambers
(b) Drawings of the valve chambers are provided for the
following:
(i) sluice valves
(ii) butterfly valves
(iii) pillar hydrants
(iv) Screw down / sluice valve pillar hydrants
(v) single air valves
(vi) double air valves
(v) washouts
(vi) pressure reducing valves
(vii) reflux valves
(c) Precast concrete valve chambers are proposed for
the following:
(i) 150 mm, 200 mm. and 250 mm. diameter sluice
valves
(ii) 25 mm and 50 mm single orifice air valves
(iii) 50 mm and 80 mm dual orifice air valves
(iv) 100 mm diameter washouts
(v) pillar hydrants
(vi) sluice valve pillar hydrant
(d) Reinforced concrete or brick chambers are proposed
for the following:
(i) sluice valve of diameter 300mm and above.
(ii) butterfly valves of diameter 450mm and above

5
 JABATAN BEKALAN AIR LUAR BANDAR SARAWAK

CHECKLIST ON TENDER DRAWINGS

FOR WATERMAINS/BOOSTER STATION/RESERVOIR(*)

(e) Reinforced concrete chambers are proposed for the

following cases:
(i) depth of valve chamber greater than 3 meters
(ii) pipes in chambers are of diamaeter greater than
600 mm
(f) Reinforced concrete and brick valve chambers
proposed have the following general features:
(i) the distance between the wall and the edge of the
joint is at least 150 mm for pipes not exceeding 450
mm while for pipes greater than 450 mm, the
distance should be at least 300 mm.
(ii) the chamber width or length shall not be smaller
than 750 mm.
(iii) the base has a minimum thickness of 150 mm.
(iv) valves are installed on mass concrete supports
(v) chambers deeper than 1.0 metre are provided with
20 mm. wrought iron steps spaced at 300 mm
interval.
(vi) valve chambers are provided with reinforced
concrete covers which have lifting facilities.
(vii) the nearest pipe joint outside the chamber has a
flexible mechanical coupling.
(viii) conventional flanged adapters are used for pipes up
to 300mm diameter.
(ix) special flanged adaptors are used for pipes of
diameter greater than 300 mm.
(F) BOOSTER STATION
1. GENERAL
(a) Overall layout plan of booster station site showing
proposed suction tank, pumphouse, generator house,
watermains, high level tank (if on same site), proposed
access road, fencing and drainage system in relation to
existing road, watermains, etc. is provided and found to
be acceptable with the pumphouse located close to the
suction tank.
(b) Survey plan showing the contours and the proposed
platform levels for the suction tank, pumphouse, high
level tank (if on the same site) and required earthworks is
provided and found to be acceptable.
(c) Proposed booster station site is large enough for
future extension of suction tank, pumphouse, generator
house and high level tank (if on same site)
(d) Survey reference points are provided with the
bearings and levels given.
(e) All the components shown are labeled and with the
dimensions, capacities, etc. indicated.
(f) The booster station site is above maximum flood
level.
2. SUCTION TANK

6
 JABATAN BEKALAN AIR LUAR BANDAR SARAWAK

CHECKLIST ON TENDER DRAWINGS

FOR WATERMAINS/BOOSTER STATION/RESERVOIR(*)

(a) Layout plan and sectional views of the suction tank

are provided.
(b) The suction tank 1ML and above has a partition.
(c) All the components including the inlet pipes, suction
pipes, overflow pipes, scour pipes, low level cut off
device with alarm system, manholes, ventilators, level
gauges, modulating float valves, ladders, etc. are shown
in the layout plan and sectional views and are in order.
(d) R.C. drawings of the suction tank are provided.
(e) All the components shown in the construction and
R.C. drawings are labeled and with the dimensions,
capacities, material of construction, etc. indicated.
(f) The length of the suction pipes from the suction tank
to the pumps is kept to the minimum.
(g) Separate suction pipes are provided for each pump.
(h) Valve chambers are provided with details given.
(i) Thrust blocks and anchor blocks are provided for
bends, valves, etc. with details given.
(j) Puddle pipes are used at walls of suction tank and R.C.
valve chambers.
(k) Foundation and piling details for suction tank are
provided.
3. PUMPHOUSE
(a) Layout plan and sectional views of the suction tank
are provided.
(b) layout plan showing all the components such as
pump plinths, pumps, switchboard, instrument panels,
pipeworks, cable trenches, surge tank, electromagnetic
flow meter, future pump plinths, etc is found to be
acceptable.
(c) Sectional views of the pumphouse showing the
traveling crane, pipeworks, cable trenches, pump plinths,
pumps, etc. are found to be acceptable.
(d) R.C. drawings of the pumphouse are provided.
(e) All pipes and cables in the pumphouse are laid in
trenches with chequer plate covers.
(f) The minimum width of the pipe trench is the diameter
of the pipe plus 150mm space on each side of the pipe.
(g) Secondary chlorination is provided at the pumphouse
where residual chlorine at the proposed booster station
site falls below 0.10 ppm. There is enough space for one
duty and one standby chlorinators, a month’s storage of
chlorine cylinders or hypochlorite and the required
pipeworks. Chlorination facilities are housed separately
with separate access.
(h) Provide for the operator’s room and toilet facilities.

7
 JABATAN BEKALAN AIR LUAR BANDAR SARAWAK

CHECKLIST ON TENDER DRAWINGS

FOR WATERMAINS/BOOSTER STATION/RESERVOIR(*)

(i) All the components shown in the drawings are labeled

and with the dimensions, capacities, material of
construction, etc. indicated.
(m) Details of pumphouse foundation and piling are
provided.
(n) The height of the pumphouse building is high enough
for installation and operation of the pump and the lifting
equipment.
(o) Adequate duty and standby pumps are provided.
(p) The type, capacity, material of construction of the
pumps are acceptable. (Note: To check against design
report & calculations).
4. GENERATOR HOUSE
(a) Layout plan and sectional views of the generator
house are provided.
(b) Layout plan showing all the components such as
generators, generator plinths, main switchboard, cable
trenches, fuel tank, bulk tank, lifting equipment, etc. is
found to be acceptable.
(c) Sectional views showing the generators, generator
plinths, main switchboard, cable trenches, fuel tank, bulk
tank, lifting equipment, etc. are found to be acceptable.
(d) R.C. drawings of the generator house are provided.
(e) Details of the generator house foundation and piling
are provided.
(f) The type and capacity of the generator are
acceptable. (Note: To check against design report &
calculations)
(G) RESERVOIR
(1) Overall layout plan of reservoir site showing
reservoir, access road, drainage, fencing, pipeworks, etc.
is acceptable.
(2) Survey plan showing the contours, proposed platform
levels and required earthworks is acceptable.
(3) Layout plan and sectional views of the reservoir are
provided.
(4) The reservoir 1ML and above has a partition,
(5) The layout plan and sectional views showing all the
components such as the inlet pipes, outlet pipes,
overflow pipes, scour pipes, manholes, ventilators,
ladders, level gauges, altitude valve, electromagnetic
flowmeter, etc. are acceptable.
(6) The reservoir is sited away from slopes to avoid
undermining of reservoir due to possible slope erosion.
(7) Erosion prevention measures such as retaining walls,
etc. are provided where necessary.
(8) R.C. drawings of the reservoir are provided.
(9) Valve chambers are provided with details given.
(10) Thrust blocks and anchor blocks for bends, valves,
etc. are provided with details given.
8
 JABATAN BEKALAN AIR LUAR BANDAR SARAWAK

CHECKLIST ON TENDER DRAWINGS

FOR WATERMAINS/BOOSTER STATION/RESERVOIR(*)

(11) Puddle pipes are used at walls for reservoir and R.C.
valve chambers.
(12) Foundation and piling details of reservoir and R.C.
valve chambers are provided.
(13) Lightning arrestor and aircraft warning light are
provided.
(14) Compound lighting at reservoir site is provided.
(15) The capacity and levels of the reservoir and the
height of the tower (where applicable) are acceptable.
(Note: To check against design report & calculations)
(16) Standby outlet pipe provided.
(17) Detailed of bypass system
(H) MECHANICAL AND ELECTRICAL WORKS
(1) Single Line diagrams are provided for the pumphouse
and generator house.
(2) Details of mechanical installation works such as soil,
sanitary and cold water systems are provided and in
order.
(3) Details of electrical installation works such as
lightings, cablings, switchboards, etc. for the pumphouse
and generator house are provided and in order.
(4) Lightning protection installations are provided for the
pumphouse and generator house and are in order.
(5) Details of fire fighting services for pumphouse and
generator house are provided and in order.
(I) TYPICAL WATER SUPPLY DETAILS
Typical water supply details are provided for the
following and are found to be in order:
(a) Thrust blocks and anchor blocks.
(b) Precast concrete chambers for air valves.
(c) Precast concrete chambers for sluice valves.
(d) Precast concrete chambers for washouts.
(e) Precast concrete chambers for pillar hydrants.
(f) Precast concrete chambers for sluice valve pillar
hydrants.
(g) R.C. chambers for sluice valves.
(h) R.C. chambers for butterfly valves.
(i) R.C. chambers for pressure reducing valves.
(j) R.C. chambers for altitude valves.
(k) R.C. chambers for electromagnetic flowmeters.
(l) culvert crossing.
(m) Drain crossings
(n) River crossings.
(o) Pipe supports at bridge crossings.
(p) Marker posts.
(q) Concrete encasement for pipes.

9
 JBALB Technical Guidelines For Water Supply System In Sarawak

Checklist on design report

for

Water Treatment Facilities

 JABATAN BEKALAN AIR LUAR BANDAR SARAWAK

CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

Name of Project:

Type of Report: Draft Final/Final Design Report (*)

Name of Consultant:

(* Delete whichever not applicable; N.A. denotes Not Applicable)

Ite Description Status Remarks
m (Yes / No
/ N.A)
(A) GENERAL
1. Is title of project correct?
2. Does front cover has title of project, name of report, name
of client, name of consultant and month/year of report?
3. Table of contents with paging is provided.
4. Executive Summary is provided.
5. Introduction is provided.
6. Background & objective of project are provided.
7. Scope of works of the project is provided.
8. Description & map of supply area are provided in relation
to existing water supply system.
9. Alternative design proposals with layout plans are
provided together with recommendation of option to be
adopted.
10. Cost estimates with detailed breakdown, overall project
cost or each alternative design proposal are provided.
11. Hydraulic and structural O&M costs and financial analysis
calculations for the various components are provided.
12. Proposed schedule of implementation of the project is
provided.
(B) POPULATION
1. Population statistics for each kampong/area/school/
institution provided.
2. Projected population & water demand provided.
3. Is projection period based on design life of 30 years?
4. Is population growth rate based on historical record?
5. If answer to Item 4 above is no, is population growth rate
used in projection reasonable?
6. Is population projection provided based on 5 yearly
interval?
7. Are the projected population figures acceptable?
(C) WATER DEMAND
1. Water demand for population is based on design
guidelines

1
 JABATAN BEKALAN AIR LUAR BANDAR SARAWAK

CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

2. Water demand for commercial area is based on Design

Guidelines.
3. Water demand for institutions is based on Design
Guidelines.
4. Water demand for industrial area is based on Design
Guidelines.
5. Fire fighting demand is based on Design Guidelines.
6. Allowance of 25% for non-revenue water is provided.
7. Allowance of 20% for treatment plant margin and usage is
provided.
8. Is the projected total water demand acceptable?
(D) EXISTING WATER SUPPLY SYSTEM
1. Description of existing water supply system is provided.
2. Where the existing water supply system provides treated
water, the overall layout showing the raw water intake
and pumping station, water treatment plant, reservoir,
etc. is provided.
3. Shortcomings of existing water supply such as adequacy of
raw water source, treatment plant capacity, reservoir
capacity and distribution system are mentioned together
with proposals for short term with proposals for short
term improvement works (if necessary) and also for long
term solution.
(E) RAW WATER SOURCE
1. Surface Water Source
(a) Various possible options for the surface water source
have been consider.
(b) For each raw water source option, the following
information have been provided:
• Hydrological data, stream flow and weather records.
• Safe yield including all the factors that may affect it.
• Safe yield is based on 7Q50 – low flow frequency
analysis/River survey/rainfall-runoff modeling
outcomes.
• Map of the water catchment (location, size, river
system, land use, etc)
• Existing and potential sources of contamination-
detailed land use map.
• Raw water quality Report-past records & projected
future status (MoH Recommended Raw Water Quality
Standard).
• Source protection issues and measures that need to
be considered or implemented.
• Maximum and lowest water levels (for design of
intake structure and platform levels for pump house
and treatment plant).
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 JABATAN BEKALAN AIR LUAR BANDAR SARAWAK

CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

• Improvement requirements.
• Cost / benefit analysis.
(c) Comparison of the various options for the raw water
source has been carried out (should include costs
advantages & disadvantages, etc.)
(d) For the recommended option, the
reasons/justifications for selecting this option are
given.
(e) Where run of river safe yield is insufficient, adequate
impounded storage for raw water is provided.
(f) The safe yield of the recommended raw water source
satisfied the following conditions:
• Adequate to meet the maximum projected water
demand while not significantly affecting the ecology
of the water course downstream of the intake.
• Provide a reasonable surplus for anticipated growth.
• Adequate to compensate for all losses such as sitting,
evaporation, seepage, etc.
• Adequate to provide ample water for other legal
users of the source.
2. Groundwater Source
a) The following information on the proposed
groundwater source have been provided:
• Reasons for selection.
• Reliable data source & Elevations with respect to
surrounding and flood plain(s).
• Geological conditions such as characteristic of
formations, test holes, abandoned wells or
anticipated interference between proposed and
existing wells.
• Summary of source exploration (test well depths,
location, pumping rates and their duration, water
levels, specific yield, capture area and pumping radius
of influence for production wells, recharge rates, etc.
• Raw water quality report
• Sources of possible contamination such as sewerage
facilities, farming, burial ground, landfills, chemical
facilities, etc.
• Feasibility of preserving existing wells and their
effects on proposed wells.
• Depths of any known water bearing aquifers that will
reduce well yield if penetrated.
• Wellhead and aquifer protection and management
measures & issues.

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 JABATAN BEKALAN AIR LUAR BANDAR SARAWAK

CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

b) Comparison of the various options for the

groundwater source has been carried out (should
include costs advantages & disadvantages, etc.)
c) The yield of the recommended groundwater source
satisfied the following conditions:
• Adequate to meet the maximum projected water
demand.
• Provide a reasonable surplus for anticipated growth.
• Adequate to compensate for all losses such as
seepage, etc.
• Adequate to provide ample water for other legal
users of the source.
(F) RAW WATER INTAKE FACILITIES
1. Locality plan showing the intake facilities is provided.
2. Overall layout plan showing the intake facilities is
provided.
3. The intake is sited on a straight and stable section of the
river, where erosion or deposition will not affect the
intake.
4. The intake is sited near the treatment plant.
5. The intake is located upstream / not affected by any point
of disposal of wastewater, and potential sources of
microbiological and chemical pollution such as poultry or
animal farms, graveyard, etc.
6. Detailed landuse map & Raw water quality analysis (MoH
Recommended Raw Water Quality Standard) is provided.
7. Raw water quality analysis is provided
8. The intake is located at a place from where water level is
always sufficient for abstraction even during the 1 in 50
years 7 days low flow.
9. The intake site is still accessible during floods.
10. The intake site does not accumulate debris.
11. The proposed location of the intake is readily accessible
for operation and maintenance.
12. Proper access to the intake is/will be provided.
13. EIA to be conducted.
14. The design is based on site maximum and minimum water
levels.
15. The intake structure does not obstruct the passage of
vessels in navigable rivers.
16. The intake structure is designed to supply an evenly
distributed flow to the pump suction to prevent formation
of surface or submerged vortices, introduction of air into
the pump, etc.

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CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

17. The size of the intake structure and layout of the pumps
are designed to cater for future upgrading or addition of
pumps to cater for increase in water demand.
18. The intake structure is designed to allow the pumps to
achieve optimum hydraulic performance for all operating
conditions.
19. The intake is equipped with a coarse screen and a fine
screen, both removable.
20. The screens are readily accessible for cleaning (preferably
self-cleaning)
21. Fenders are provided to protect the intake from floating
logs, debris, etc.
22. Lifting hoist of adquate capacity is provided for installation
and maintenance of the pumps, pipes, fittings, valves, etc.
23. Piling is provided.
24. Water proof shed is provided for switchgear, lifting hoist &
other electrical equipment.
25. Switchgear & terminal box are sited above highest flood
level possible.
26. PONTOON INTAKE
The design of pontoon, intake takes into account the
following:
(i) Pontoon structure is properly designed using durable
material.
. (ii) The pumpsets can be securely mounted on the
pontoon.
(iii) The pontoon is securely anchored without risk of
overturning during changes in water level.
(iv) Where mooring ropes are used, they are long enough
and well secured to allow for changes in water level.
(v) The pump’s discharge pipe is long enough and well
secured to allow for changes in water level. Heavy duty
flexible discharge pipe of suitable material are used.
(vi) A housing is provided over the pump(s) and motors
where centrifugal pumps are used.
(vii) Coarse screens are incorporated in the design of the
pontoon to protect the pumps or foot valves from debris,
etc.
(viii) Electrical cables of sufficient length are designed to
allow for highest water level pontoon position.
(ix) Pontoon structure is properly linked with jetty
accessible for operation & maintenance, including hand
operated cart.
27. JETTY INTAKE
The design of jetty intake takes into account the following:

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CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

(i) The jetty is designed to meet the requirements of the

appropriate design codes and standards, to sound
engineering principles and is fit for the intended
purposes.
(ii) The intake jetty is sited on stable ground which is not
subjected to siltation and erosion.
. (iii) The jetty is of reinforced concrete construction.
(iv) The deck of the jetty is above the maximum water
level.
(v) The jetty is designed with platform for inspection,
mounting & dismantling of raw water pumps, valves,
etc.
(vi) Rigid pump base should be provided for installation
of pumps.
(vii) Pump base should be sited at minimum low water
level.
(viii) The jetty width is design for vehicle access for
transporting pumps, valves, pipes, etc, during
maintenance.
28. SUMP INTAKE
The design of the sump intake takes into consideration the
following:
• The sump has sufficient self-weight so that it does not
float by up thrust of water.
• For wet sump, the width of an individual pump cell or
the centre-to-center distance of two pumps if no
dividing wall is used must be two times the bell
diameter of the pump. (i.e.2D)
(Note: D = (760 x Q) 0.5 in mm.
Q = pumping rate in litres/sec)
• For wet sump, the distance from the pump bell
centreline to the entrance of intake and location of the
trash rack is five times the bell diameter (i.e. 5D)
• For wet sump, the distance from the pump bell
centreline to backwall is 0.75D
• For wet sump, the distance from bottom of pump bell
to the floor of sump is 0.3 to 0.5D
• For wet sump, the pump has a minimum submergence
value as computed below:
S = D + (29560x Q)/D/1.5
• For wet sump, the minimum water depth above floor
of sump is S + 0.3 to 0.5D
• The configuration of the sump floor is such that abrupt
changes occur at least five bell diameters from the side
of the pump.

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CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

• The sump is designed with incoming water flowing

parallel to the sump walls and directed toward the
pumps inlets with a minimum of swirl.
• The pump bay has adequate width and depth to ensure
uniform and steady flow with maximum average
velocities of about 0.6 m/sec. for flow into a pump
station and less than 0.3 m/sec for the approach to bell
mouths.
• Pump sumps are sized and arranged to allow each
pump sump to be isolated for cleaning and
maintenance. A minimum of two sumps is provided.
29. Other Items
(i) Stainless steel penstocks are provided for isolation
of chamber
(ii) Desilting facilites are provided for high turbidity
water
(iii) Any pre-sedimentation tasks required? If Yes,
include desludging system, two stages pumping,
etc.
(G) RAW WATER /TREATED WATER (*) PUMPHOUSE
1. LOCATION & SITE CONSIDERATIONS
(a) Locality plan showing the pumphouse is provided.
(b) Overall layout plan showing the pumphouse is
provided.
(c) The pumphouse is located on ground level which is at
least 1 m. above the 100 year flood level or 1 m.
above the highest recorded flood level, whichever is
higher.
(d) The pumphouse is provided with vehicle access to
allow for operation and maintenance and is
accessible at all times.
(e) The pumphouse site is graded to divert surface water
runoff away from the pumphouse and sump.
(f) The pumphouse site is protected from vandalism,
animals or unauthorized persons using chain link
fencing.
(g) The pumphouse site is of sufficient size and
appropriate shape to allow for all equipment and any
necessary maintenance and repair activities.
2. PUMPHOUSE BUILDING
(a) The building is of reinforced concrete construction.
(b) The building has outward opening doors.
(c) The floor of the building is at least 150mm above
finished ground level.

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CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

(d) The floor of the building is sloped to a suitable drain so

as not to endanger the quality of the water being
pumped.
(e) A suitable outlet is provided for drainage from pump
glands and priming without discharging onto the floor.
Drainage sump with drainage pump for draining water
must be provided for pumphouse below ground level.
(f) The building has adequate space for the installation of
additional pumpsets that may be needed during the
next 20 years with adequate space provided around
each unit to allow for equipment and pump access,
removal, re-installation and service.
(g) The pumphouse is designed to accommodate lifting
hoist, hoist beams and other facilities required for
lifting, removing and reinstalling of pumps, motors or
other heavy equipment.
(h) Stairways or ladders are provided between all floors
and in compartments which must be entered for
operation or maintenance of the equipment. (Stairs
shall be provided to areas that must be routinely
entered or where supplies are transported by hand)
(i) The pumphouse is provided with adequate ventilation
for operator comfort and dissipation of excess heat
from the equipment.
(j) In the case of a pumphouse that is manned for
extended period, the station is provided with potable
water, lavatory and toilet facilities. Plumbing is so
installed as to prevent contamination of the public
water supply and wastes are properly discharged
without causing contamination.
(k) Other Items
(i) Suction Pipes
- as short as possible & minimum
bends/joints.
- Suction pipes for negative suction must not be
shared (unlike the positive suction pipes).
- sufficiently sized
- Negative suction pipes do not require any sluice
valves to be installed.
- Foot valve is required for negative suction pipe.
- No tapping points for gauges or priming line
allowed for negative suction.
- No mechanical flexible joints (V-J joints) for
negative suction pipes.

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CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

(ii) The pumphouse is provided with adequate lighting

so that every part of the facility is well lit and all
instrument readings and all maintenance and
operation can be performed without additional
lighting. Light fixtures are located where bulbs can
be readily changed.
(H) RAW/TREATED(*) WATER PUMPING MAINS
1. Layout plan of proposed pumping mains in relation to
existing or proposed pipeline system is provided.
2. Any pipe material comparison analysis including suitability
of pipe in soil & environmental conditions encountered,
material & installation costs, O & M costs, etc, before
selecting the pipe material to be used?
3. Calculation on pumping capacity, static head, friction
losses and total pumping head are provided and found to
be in order.
4. Calculation on surge analysis is provided.
5. Adequacy of surge vessel or surge-anticipating relief valve.
6. Calculations to determine the appropriate wall thickness
of the pipeline are provided for cases where there are
unusual external condition (e.g. depths less than 1 m. or
greater than 2.5m & bridge installations), internal
conditions (e.g. surge pressure) and/or use of steel or
ductile iron pipe.
7. Can the selected pipe material and pressure rating
withstand the total pumping head and the surge pressure?
8. Has wayleave approval for pipeline route been given?
9. The sizing of air valve are provided and found to be in
order.
10. Design calculations for the anchor and thrust blocks are
provided and found to be in order.
11. Design calculations for the piling to the anchor and thrust
blocks are provided and found to be in order.
12. Cathodic protection is provided for steel pipelines.
13. Other Items
(a) External protection e.g. plastic sleeves are provided of
DI pipelines laid in coastal area?
(b) Any scour/wash out provided?
(c) Allow flow of pipeline to be sized for future
upgrading/next phase of the plant.
(d) The velocity of flow is within the range of 0.5 m/s to
1.5 m/s (for raw water) & max. of 2.5 m/s for
distribution main.
(e) Flow meter is provided for measurement of raw water
pumped.

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CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

(f) The raw water flow is 1.02 Q to 1.05 Q. 1Q =

treatment capacity.
(g) For raw water the ‘C’ valves in Hazen William ‘s
formula to be used is 125-140 for plastic pipes and 90-
110 for steel or ductile iron with cement mortar
linings.
(I) TREATMENT PLANT FACILITIES
1. LOCATION
(a) Economical & Technical Criteria
(i) The site is optimally located in relation to the source
of raw water.
(ii) The site is close to source of electricity supply.
(iii) The site is close to public access roads which enable
delivery of chemicals & equipment & also facilitate
construction.
(iv) The site facilitates the use of gravity flow which can
result in lower capital & operating costs.
(v) The shape of the site can accommodate the plant
layout and allows efficient movement of water flow
between individual process units. (A rectangular-
shaped area is preferred).
(vi) The site is optimally located in relation to the area to
be served.
(vii) The site is relatively flat and does not require
extensive cut and fill.
(viii) The site does not have landslide potential which
require substantial site preparation and increased
construction cost to protect the facilities.
(ix) The site sits on dense and hard soil which does not
require piling or over-excavation & backfill as in the
case of soft soil.
(x) The site does not have high groundwater levels
which require dewatering during construction or
require permanent dewatering to avoid permanent
dewatering to avoid uplift on the structure.
(xi) The site does not involve extensive role excavation.
(xii) The site does not require extensive storm drainage
facilities
(xiii) The site is located above the 100 year return period
flood levels.
(xiv) The site does not have major land issues such as
high land cost, susceptibility to land disputes, etc.
(xv) The useable area is sufficient for the proposed
treatment and future extensions of at least two more
bays.

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CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

(xvi) The useable area has excluded wetland, streams,

flood plain area and areas with landslide potential.

(xvii) The useable area has allowed for the required

process units, roadways and operator/ maintenance
facilities.
(xviii) Telecommunication facilities can be made available
to the site.
(b) Environment Criteria
(i) The site will not have an impact on wetland due to
physical modifications such as filling, draining or
vegetation removal.
(ii) The site will not have impact on threatened or
endangered species habitat.
(iii) The development works at the site during
construction and operation will not have an impact
on the surface waters such as streams and rivers.
(c) Community
(i) The site’s usage is compatible with the host
community by taking into account the present and
anticipated future use of the surrounding areas.
(ii) The site does not cause displacement of housing and
business.
(iii) The site will not have adverse impacts on the local
community such as due to adour, gas emmissions,
etc.
2. SELECTION OF TREATMENT PROCESSES
(a) The quality of the raw water at the proposed intake
site has been studied over an extended period to
ascertain the seasonal & yearly variations in the
quality.
(b) Samples of the raw water have been collected at
different times to cover the range of quality
fluctuation.
(c) Physical, chemical & bacteriological analyses of the
samples of raw water have been carried out.
(d) Jar tests have been carried out to determine the types
and dosages of chemicals required for pre-
chlorination, adsorption, coagulation, disinfection &
conditioning.
(e) Marble tests (or calcium carbonate stability test) have
been carried out to determine the alkalinity & pH
which prevail at calcium carbonate equilibrium and
thereby select the lime dosage required.

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CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

(f) Samples of the treated water obtained from the jar

and marble tests are tested chemically & biologically
for compliance to National Drinking Water Quality
Standards.
(g) Based on the results of the above tests carried out, the
treatment processes are selected.
3. PLANT LAYOUT
(a) The specific process elements and support facilities
required have been identified.
(b) A minimum of two (2) treatment trains is provided,
operating in parallel
(c) For a conventional water treatment plant, the
following process elements & supporting facilities
have been included where required:
(i) aerator
(ii) mixing flume/chamber/weir
(iii) flocculation tanks
(iv) sedimentation tanks
(v) filters
(vi) contact clear water tank
(vii) wash water tank
(viii) treated water pumping station
(ix) generator house/electricity supply substation
(x) treated high level tank
(xi) control building
(xii) chemical house
(xiii) operators’ quarters
(xix) sludge treatment facility
(d) A hydraulic design has been carried out to enable
gravity flow from one process unit to another
wherever possible.
(e) The various components of the treatment plant are
located such that requirements for cut-and-fill or the
need for elevated structures are minimized without
sacrificing aesthetic requirements.
(f) Where the components are located on different
ground levels, adequate provision has been made to
protect the slope by providing close turfing, retaining
walls, etc.
(g) All connections between the various treatment units
are direct and as short as possible.
(h) Full consideration is given to easy inspection,
operation & maintenance of the entire treatment
facility by locating the process units which require
more attention than others close to one another and
next to the operations building.

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CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

(i) Adequate access to all process units equipment & for

operation of all valves including adequate working
area for equipment repair & maintenance are
provided.
(j) Access & lifting devices for removal of all major
equipment are provided.
(k) Centralized process operation & control are provided
where possible.
(l) Adequate walkaways with a minimum width of
750mm along the filters, sedimentation tanks &
flocculation basin are provided.
(m) Sufficient access from ground to interconnected
uncovered structures is provided.
(n) Covered walkways are provided between process
units which require greater operator‘s attention.
(o) External concrete steps or galvanized mild steel
ladders are provided at convenient locations.
(p) Operation units such treated water pumping station
& generator house are located separately from the
main operations building to reduce noise problems.
(q) Adequate area has been allowed for future extension
by at least two more bays.
(r) Sanitary & sludge handling facilities such as sewage
pipes, septic tanks, trash pits, etc. are of watertight
construction & located away from the treatment
units to eliminate any potential hazards of
contamination.
(s) The septic tank is placed at the lowest level &
discharge downstream of the intake.
(t) Sufficient premix access roads and service roads of
adequate width are provided.
(u) Adequate parking space for cars and motorcycles are
provided for both plant operating personnel &
visitors.
(v) Adequate landscaping is provided.
(w) 3 nos. of flag poles are provided for the national,
State and Water Authority flags.
(x) Adequate drainage facilities are provided for
discharge of surface water, overflows from the
treatment facilities, waste washwater flows & scour
flows.
(y) Security fencing and gates are provided.
(z) Adequate external lightings are provided.
(za) Other Items
(i) Safety hand rails are provided at all structures
high above ground.

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CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

(ii) Fire protection.

(iii) Sludge lagoon/treatment
4. OPERATIONS BUILDING
(a) The operations buildings is large enough to
accommodate the treatment plant staff & regular
inspection & maintenance people comfortably & is
commensurate with the size of the treatment plant.
(b) The office & meeting room (if provided) have
adequate furniture and are air-conditioned for larger
treatment plant.
(c) The mechanical and electrical spares and tools store
is furnished with proper steel racks for keeping the
spares & tools.
(d) The lobby has the following in place:
(i) clarity bowls
(ii) the main instrumentation panel
(iii) aquarium for monitoring water quality.
(e) The following are provided in the lobby or control
room.
(i) schematic diagram
(ii) general layout of the treatment plant with the
relevant data.
(f) The laboratory is provided with the following:
(i) purpose-built wooden cabinets for storage of
chemicals & water testing equipment.
(ii) sufficient work benches with colour formica
finish table-top complete with sinks.
(iii) proper water supply & drainage facilities.
(iv) direct sampling facilities for raw water, settled
water and filtered water.
(v) air-conditioning.
(vi) Necessary laboratory testing equipment and
apparatus.
(vii) testing reagents and tablets
(g) The filter operating gallery is provided with the
following: -
(i) large clear glass aluminum casement windows &
panels preferably from ceiling to floor on the side
facing the filters, for easy viewing of filter
operations.
(ii) separate operating console for each filter.
(iii) common dial indicators for wash water flow rate,
air scour, etc. of at least 300 mm dia. or digital
indicators.
(iv) a direct access door between the filter operating
gallery and the filters.

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CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

(v) filter operating consoles arranged neatly and in

such a manner that the operator can watch the
filters washing operation easily while operating
the filter consoles.
(h) The filter pipework gallery is provided with the
following: -
(i) adequate ventilation & lighting.
(ii) adequate number of access stairs
(iii) adequate drainage facilities
(iv) minimum floor gradient of 1 in 500 sloping
towards the drain pipe.
(v) neat arrangement of pipeworks with adequate
space for easy access, installation, valves
operation, inspection, maintenance or repair.
(vi) pipeworks are painted according to the required
colour code.
(i) The filtered water outlet chamber has the following:
(i) chamber lined with white glazed tiles on the
inside.
(ii) inspection openings with clear perspex covers.
(iii) vent openings to prevent water vapour collection
on underside of the perspex covers.
(j) The following facilities are provided for the treatment
plant staff and visitors:
(i) adequate separate toilet & bath facilities for men
and ladies
(ii) sufficient locker facilities provided in the rest
room
5. CHEMICAL DOSING FACILITIES & STORE
(a) (i) The suitable types of chemicals are identified
based on lab test of raw water samples.
(ii) Alum, lime and soda ash dosing facilities including
the storage facilities are placed together in the
same building but with separate distinct bay for
each type of chemical.
(b) All chemical dosing are carried out in solution using
metering pumps for plant of 1 MLD & above and by
gravity for plant below 1 MLD
(c) Adequate working space is provided around all
feeding devices so that the equipment can be
maintained easily.
(d) Piping should be arranged to facilitate access
between units and around them. Piping should be of
corrosion resistant material.

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(e) Mixing tanks are of HDPE lined reinforced concrete

or fibreglass lined steel tanks of Grade 316 stainless
steel.
(f) Each tank should be sized for at least 8 hours
continuous operation of the plant at alum
solution/soda ash solution/lime slurry of 5%
strength.
(g) All mixing tanks are provided with waist height
loading platforms to facilitate discharging of
chemicals by hand.
(h) The mixing tanks & the dosing area are provided with
adequate drainage & washing facilities for easy
cleaning.
(i) There is provision of chemicals storage for 3 months
operation.
(j) For all plant the components of the chemical dosing
system are duplicated.
(k) For Plants below 5 MLD, an electrically operated
crane of sufficient capacity is provided.
(l) For plants of 5MLD & above, a forklift is provided in
addition to the travel crane.
(m) For plants of 5 MLD & above, adequate aisle space is
provided easy access using forklift.
(n) The chemicals can be easily moved into storage, out
of storage and to the mixing tanks on a first-in-first-
out basis.
(o) Where lime is used, the lime storage tanks are
provided with adequate facilities for pumping the
lime powder into the silos & to prevent caking of the
lime while in storage.
(p) Entrance to the chemical store is large enough to
allow the supply truck to reverse into the building to
facilitate unloading of chemicals.
(q) A ramp is provided at the entrance for movement of
the supply truck.
(r) A top hung steel shutter door 5m wide & 2.5m high is
provided.
(s) For larger plant with big opening, electricity operated
steel roller shutter door is provided.
(t) Adequate natural ventilation is provided in the
chemical store by using sufficient number of fixed
louvres clear glass windows at the top.
(u) The openings of the louvre windows are covered with
mosquito-proof netting to prevent entry of birds or
insets.

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(v) Other Items

- PPE are provided
- Emergency eye wash and shower stand are provided
at strategic locations.
- Sufficient safety and hazard warning signed are
provided.
6. CHLORINE DOSING FACILITIES & STORE
(a) The chlorine dosing facilities & the chlorine store are
isolated from the rest of the facilities.
(b) For plant of 30 MLD & above, a separate building is
provided for dosing & storage of chlorine.
(c) Corrosion resistant materials such as plastics,
fiberglass or stainless steel are used as construction
material in the chlorine room.
(d) Hoist & other mechanical equipment are protected
against corrosion.
(e) The chlorine dosing room & chlorine store comply
with the following:
(i) They are of fireproof construction remote from fire
risk.
(ii) They are located on ground floor
(iii) There is a minimum of two access door opening
outwards.
(iv) Adequate extractor fans are provided, discharging
outside into open space away from other facilities.
(v) The number & size of the extractor fans are
sufficient for 12 air changes in the room per hour.
(vi) The extractor fans are located at near floor level
with the switches installed outside the room.
(vii) All chlorine stores and dosing rooms are provided
with chlorine leaks detectors with audible alarms
located outside
(viii) Emergency shower facilites are provided outside
the access doors.
(ix) For large plants, a chlorine neutralization gas
scrubbing system is provided.
(x) The chlorine store is designed for 3 months
storage.
(xi) (a) For small plants, storage of 68 kg.
Chlorine cylinder is to be used.
(b) Auto-shut down valve system is provided
upon detection of chlorine leakage.
(xii) For plants of 30 MLD or larger, chlorine drums
(916 kg capacity) are used and placed in store on
concrete drum craddles.

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CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

(xiii) An electrically operated 2 tonne capacity gantry

crane is provided for handling of the chlorine
drums.
(v) Entrance to chlorine store should be large enough
to allow the supply tank to reverse into the
building to facilitate unloading.
(vi) Hazard warning signage is provided.
(vii) Duplicate chlorinators are provided.
(viii) Auto-change over is provided.
7. FLUORIDE DOSING FACILITIES & STORE
(a) The fluoride dosing facilities and store are isolated
from the rest of the facilities.
(b) Fluoride dosing is carried out in solution form.
(c) A stock tank is provided to contain 20 kg. of sodium
silico-fluoride (one full bay) in solution at 0.4%.
(d) An additional storage tank of 2 hours retention is
provided below the level of the main tank to be used
to maintain supply even after the main tank is empty
and to allow time to prepare the next stock solution.
(e) Other Items
(i) Duplicate fluoridator equipment are provided.
(ii) Dust collection system is provided.
(iii) Dosing equipment is provided.
8. PRE-SEDIMENTATION
(a) For raw water with high content of suspended solid,
pre-sedimentation is provided.
(b) Design calculations are provided to show that the
proposed pre-sedimentation basins are sized
according to the treatment plant capacity and
suspended solids content.
(c) The pre-sedimentation basins have hopper bottom or
be equipped with mechanical moving sludge removal
apparatus.
(d) The pre-sedimentation basins have a means of
dewatering the settled sediments.
(e) The pre-sedimentation basins are designed such that
the incoming water is dispersed evenly across the
tank width to prevent short circuiting.
(f) There is a by-pass around each
pre-sedimentation unit.
(g) The pre-sedimentation basins are designed with a
minimum of three (3) hours detention time (actual
detention time is to be determined through
sedimentation tests)
(h) Other Items

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CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

(i) Duplicate pre-sedimentation basins are provided to

allow 1 unit to shutdown for maintenance
(ii) Isolating valves are provided for shut down of 1
unit for maintenance.
9. AERATION
(a) Aeration is used because of the following based on
the results of the raw water quality:
(i) To help remove taste & odour.
(ii) To remove volatile organic matter
(iii) To remove carbon dioxide
(ix) To assist in iron and/or manganese oxidation.
(b) One of the following types of aerator is used with
justifications provided:
(i) Gravity or cascading aerator.
(ii) Fountain aerator.
(iii) Diffused or injection aerator.
(iv) Mechanical aerator
(c) For water into air type of aeration using cascade or
tray aerators, the distribution of water is uniform
over each tray.
(d) For spray aerator, the following are in place:
(i) The hydraulic head is sufficient
(ii) The sizes, number and spacing of the nozzles are
properly designed based on the flow rate, space
and amount of head available.
(iii) There is an enclosed basin to contain the spray.
(iv) Design calculations are provided.
(e) The aerator is constructed of durable material
resistant to aggressiveness of water & dissolved
gases.
10. MIXING
(a) One of the following types of mixer is used with
justifications provided:
(i) mixing flume
(ii) weir
(iii) flash mixer
(iv) mechanical mixer
(b) Mixing Flume
11. FILTERS
(i) General requirement for design of filter such as
follows:
(a) Filtration rate (5 m3/m2 /hr)
(b) Length and breadth ratio
(c) Size of filter
(d) Tank depth
(e) Free board
19
 JABATAN BEKALAN AIR LUAR BANDAR SARAWAK

CHECKLIST ON DESIGN REPORT FOR WATER TREATMENT SYSTEMS

(f) Water depth

(g) Loss of head
(h) Media depth (0.6-1.0m)
(ii) To provide the filter pipes sizing
(iii) To provide the recommended flow velocity of the
pipe and channel.
(iv) To provide the design requirement for filter
backwash systems such as below:
(a) Separate air & water wash
(b) Combine air & water wash.
(v) Summary of the results for design of filter such as
follows:
(a) Number of filter used.
(b) Settle water inlet pipe diameter
(c) Filtered water outlet pipe diameter
(d) Air scour inlet pipe diameter
(e) Backwash water diameter
(f) Filter washout pipe diameter
(g) Air blower capacity
(vi) All design calculations for the sizing of the filters are
to be provided.
(vii) Filter underdrain system design is provided –
(a) No. & type of nozzles
(b) Spacing
(c) type of underdrain (lateral manfold system
or false bottom)
(viii) Filter media is acceptable.
(vix) Filter floors are designed to sustain the entire weight
of the filter media.
(x) Filter floors are designed to withstand the upthrust of
the backwashing water.

20
JABATAN BEKALAN AIR LUAR BANDAR (JBALB) SARAWAK

TESTING AND COMMISSIONING DOCUMENT

FOR

BOOSTER PUMPING STATION

........................ DIVISION

CONTRACT NO: ………………………………

 TABLE OF CONTENTS

No. Description Pages

1 Pre-requirement for Document Submission Prior to Testing & Commissioning 1
Activity
2 Process flow for Commissioning of Booster Pump Station 2
Methodology
3 Method Statement - Booster Pump Station Pre & Post Commissioning 8
4 Guidelines and Checklist for Full Testing & Commissioning of Booster Pump 11
Station
5 General Notes for Pre-commissioning, Commissioning and Acceptance Test for 12
Booster Pump Station
6 Commissioning Checklist for Booster Pump Station 17
7 Acceptance Tests for Treatment Works 23
8 Table A : Pump Monitoring Table 27
9 Table B : Pump Test Certificate 28
10 List of Equipment 29
11 Appendix (A) Pre-commissioning Checklist for Booster Pump Station 32
 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER Rev: 1
PUMPING STATION Date:

PRE-REQUIREMENT FOR DOCUMENT SUBMISSION PRIOR TO

TESTING & COMMISSIONING ACTIVITY

No Item YES NO N/A REMARKS

1 Method Statement Of T&C

2 Operation & Manual (O&M)

3 Factory Acceptance Test Report (FAT)

4 Site Acceptance Test Report (SAT)

5 Testing and Commissioning checklist

QAQC check records documentation review before
Testing and Commissioning (T&C) but not limited to:
I. Equipment data sheet
II. Equipment manufacture test certificate
6
III. Instrument/Equipment calibration certificate
IV. As build Drawing
 Mechanical & Electrical
 Civil & Structure
7 Site walk/Inspection prior to readiness of T&C

Training on equipment in regards to safety, operating,

9
maintenance and emergency practice/ procedure

10 Punch list closed – if any

11 Non Conformance Report (NCR) closed – if any

Above requirement shall be submitted 2 weeks before T&C except FAT report:

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER Rev: 1
PUMPING STATION Date:

PROCESS FLOW FOR COMMISSIONING OF

BOOSTER PUMPING STATION

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER Rev: 1
PUMPING STATION Date:

COMMISSIONING OF NEW JBALB BOOSTER PUMPING STATIONS

1.0 Commissioning Team

The commissioning of all new Booster Pump Stations shall be carried out by designated officers
coordinated from Jabatan Bekalan Air Luar Bandar (JBALB) Headquarters. The commissioning
team shall consist of the following: -

1.1 JBALB Headquarters

a) Mechanical Engineer
b) Electrical Engineer
c) Civil Engineer (Related Project)
d) Chemist
e) Assistant Engineer

1.2 JBALB Divisional

a) Divisional Water Engineer (DWE)/ Officer Incharge of Division (OIC)
b) Assistant Engineer, J29

1.3 JBALB Project Management Team

a) Divisional Water Engineer (DWE)/ Officer Incharge of Division (OIC).

b) Assistant Engineer, J29

Team Formation

JBALB Headquarters
Testing & JBALB Divisional/Project Contractor and
Commissioning Team Team Consultant
(Refer to name list (Refer to name list detail)
detail)

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER Rev: 1
PUMPING STATION Date:

2.0 Methodology

2.1 The Mechanical Engineer from JBALB PRE-COMM/COMMISSIONING

Headquarters will head the commissioning team and PROCESS (Booster Pump Station)
the Divisional Water Engineer (DWE), Assistant
Engineer and Assistant Technician/Technician are
allocated the following tasks to assist in the PRE-COMMISSIONING PROCESS
commissioning. What to check?
Physical and visual check of control
equipment i.e. Pumps, Valves, PLC’s,
2.2 Pembantu Kemahiran H17 & Pembantu Awam Genset, MSB, etc. as per Guidelines of Pre-
H11/14 will assist the commissioning teams and Commissioning Checklists & Contract
will take over the plant operation after successful Document.
commissioning and handing over. In this respect,
they will get hands-on experience in the plant
operation.
COMMISSIONING PROCESS
2.3 Project Management Team from JBALB What to check?
Divisional/Regional Office’s role is to be the Individual System Checks as per Guidelines
coordinator to instruct consultant/contractor to of Commissioning Checklists and Data
execute and implement the commissioning process Sheets.
as per guidelines and checklist. They are
responsible to coordinate with JBALB Headquarters
Commissioning Team to ensure that proper Commissioning
guidelines and procedure is implemented prior to successful
the commissioning of Booster Pump Station are in
accordance with the guidelines before handing over
to JBALB Division.

DOCUMENTATION / HANDOVER
Parties involved: Divisional Office and
JBALB Headquarters

REFRESHER/ TRAINING
 As per contract (external)
 To be conducted by JBALB
Divisional and JBALB HQ
(recommended once every six (6)
month)

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER Rev: 1
PUMPING STATION Date:

3.0 Tasks and Duties

i) The commissioning team will witness the testing of all items of equipment, pipework, fittings
and appurtenant (accessories) works to ensure that they are correctly installed and capable of
proper operation.

ii) The team will witness start up and running each item of equipment separately until they are
satisfied that it is capable of proper operation.

iii) After each item of equipment has been tested separately, the various items will be run
concurrently to commission the plant.

3.1 In carrying out (i) to (iii) above, the team shall ensure that: -

i) The correct sequence of operation of the plant is checked and documented.

ii) Plant control systems are checked.

iii) Calibration on Testing and Measuring tools is carried out.

iv) Switchboards, control panels, alarm systems, overloads, and safety equipment are tested.

v) The alignment, mounting and configuration of pumps and drives, including the direction of
rotation are checked.

vi) The various lubrication systems and greasing systems are checked, including pump shaft
lubrication and stuffing box seal requirements.

vii) The pipework valves and gauges are correctly installed and operate satisfactorily. The
appropriate valve positions shall be determined for the different modes of operation of the
plant and documented.

viii) The chemical mixing, feeding and dosing equipment shall be tested and calibrated.

ix) Load tests are carried out on lifting equipment.

x) The necessary chemical testing equipment is provided and in working order.

xi) All other tools and equipment necessary have been provided and are in working order.

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER Rev: 1
PUMPING STATION Date:

3.2 During the commissioning of the plant, the team shall ensure that: -

i) The limits of hydraulic operation of the various units of the plant are determined.

ii) The appropriate flow rate through the plant is determined to minimize “on-off” operation.
Guides on pumping rates for the raw water and treated water pumps shall be established.

iii) The clarifiers are operated with the appropriate level of coagulant to achieve a well developed
floc blanket.

iv) The rate of desludging of the clarifiers is determined.

v) The filters are operated sufficiently long to establish head loss characteristics and backwash
requirements.
vi) The filter backwash system and air scour are operated correctly. The correct procedure for
backwashing of the filters is determined and documented.

vii) As far as possible, the appropriate levels of dosing of chemicals for the plant are determined.
In particular, the appropriate level of post dosing for pH correction is determined.

3.3 Documents and operation manuals

The following documents shall form part of the commissioning:

i) JKR MS ISO 9001 Quality Procedures on Water Treatment Process;

ii) Buku Panduan Kerja Pertukangan Atenden Loji Bekalan Air;
iii) Buku Panduan Kerja Pertukangan Atenden Pam Bekalan Air;
iv) Buku Panduan Kerja Pertukangan Atenden Enjin Bekalan Air;
v) Perintah-Perintah Tetap Pihak Berkuasa Bekalan Air JKR;
vi) Other operation manuals for the pumps and equipment.

3.4 Refresher/Induction Training

During the commissioning of the plant, the Divisional Water Engineer (DWE), Assistant
Engineer, Assistant Technician/Technician and attendants allocated to assist the teams, will
undergo “hands on” training in preparation for accepting responsibility for operation of the plant.
This training role will be a significant aspect of the duties of the commissioning team.

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER Rev: 1
PUMPING STATION Date:

3.5 Handing Over and Documentation

3.5.1 When the plant is operating satisfactorily and treated water has been supplied into the existing
reticulation system, it will be handed over to the JBALB Division staff.

3.5.2 The commissioning team will prepare four (4) copies of the commissioning report, (1) one copy
to the Regional Manager, (1) one copy to the Divisional Water Engineer and (2) two copies to
JBALB Headquarters.

3.5.3 The report shall contain as a separate section, the recommended procedure for operating the
various items of the plant including the following:

i. Valve on-off schedules

ii. Switchboard operation and use of control panels and monitors.
iii. Observed rate of desludging of clarifiers and backwashing of filters.
iv. Operation of the raw water pumps and clear well pumps to integrate the plant into the
existing system and optimize its operation.

3.5.4 An assessment of the induction training of operator staff shall be given.

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER Rev: 1
PUMPING STATION Date:

METHOD STATEMENT
BOOSTER PUMP STATION PRE & POST COMMISSIONING

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER Rev: 1
PUMPING STATION Date:

METHOD STATEMENT
Booster Pump Station Pre & Post Commissioning

Background Information

Project Name

Contract No.

Pre & Post Commissioning Implementation

Divisional Involvement 1. Divisional Office representative shall be present during pre-

commissioning and commissioning stage to witness and
comment any dissatisfaction /query through Project
Management Team / Commissioning Team representative.
2. Divisional Office representative shall be at least Assistant
Engineer, J29 of Mechanical or Electrical to be involved
during pre-commissioning and commissioning stage
(especially M&E equipment testing).
3. Booster Pump Station Operator shall be involved during
system operational testing for the purpose of familiarization of
new booster pump station. Certificate of Practical Completion
(CPC) shall be to the satisfaction of JBALB Commissioning
Team and JBALB Divisional Office SO/SOR/OIC. This is to
ensure proper handing over and operational needs are met and
achieved as per design in the Contract.

New Pipe interconnection to existing 1. JBALB Project Management Team concerned shall notify
piping system any pipe interconnection and submit method statement for
interconnection work to JBALB Divisional Office prior to
the commencement of actual work.
2. Method statement must be agreed between Project
Management Team and Respective JBALB Divisional
Office before any work can proceed.
3. Upon agreement on the interconnection Method Statement,
the affected Divisional Office (DWE/OIC) shall issue notice
of water supply interruption to the public prior to the
execution of interconnection work either via Corporate
Communication or Information Department (which ever) is
more efficient and cost effective within a weeks notice.
4. Any actual shutdown to the existing system shall be done by
representative from JBALB Divisional Office assisted by the
Contractor involved.
5. The interconnection work and any reinstatement work which
is affected by the interconnection process shall be done by
the contractor involved to the satisfaction of representative
of both Project Team and Divisional Office.

Consumables Requirement 1. After every successful Testing and Commissioning, it is

crucial that the Appointed Contractor/Consultant prepare
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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER Rev: 1
PUMPING STATION Date:

and advice on the usage and quantity of consumable

chemical required such as; chlorine, aluminum sulphate,
polymer and soda ash shall be made available as stock for at
least 3 to 6 months (subject to availability & plant locality)
for operational use after project completion (CPC).
2. It is recommended that the information on where and how to
acquire these required consumable shall be made known to
the JBALB Divisional Office for reference of their planning
and procurement process by the users.
3. Material acquisition inclusive of M&E parts shall be
identified and JBALB Divisional Office is recommended to
acquire major parts for major pumps and dosing pump for
stock in advance for the ease of maintenance after the end of
Defect Liability Period (DLP).
Recommendation on Operational and/Or 1. Operation and maintenance manual for the booster pump
Overall Maintenance Plan station shall be provided by the contractor to the JBALB
Divisional Office and JBALB Headquarters for references on
operational matters.
2. JBALB Divisional Office shall produce the Maintenance Plan
which include periodic and preventive/predictive maintenance
of all major equipment i.e. booster pump, control panels,
generator set. It is recommended that all major equipment is
checked and inspected at a regular interval of three (3) months
(minimum) by Audit or representatives from JBALB
Headquarters.
3. JBALB Divisional Office shall coordinate with JBALB
Headquarters regarding procedure, schedule and costing for
maintenance of all equipment. It is advisable that this
coordination is initiated prior to the end of project’s DLP.
Recommendation on manpower 1. It is recommended that DWE/OIC’s to review their current
requirement for new Booster Pump operation setup and manpower requirement to suit the new
Station (BPS) BPS prior to the completion of the project.
2. For the operation of BPS, additional manpower should be
allocated sufficiently to oversee the operation of isolated BPS.
This would help to avoid or reduce the occurrence of
vandalism especially to this isolated BPS. Any failure at this
BPS will jeopardize the reliability of water supply to which
the BPS cater.

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER PUMPING Rev: 1
STATION
Date:

GUIDELINES AND CHECKLIST FOR FULL TESTING & COMMISSIONING

OF BOOSTER PUMP STATION

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER PUMPING Rev: 1
STATION
Date:

General Notes for Pre-commissioning,

Commissioning and Acceptance Test

Booster Pump Stations

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER PUMPING Rev: 1
STATION
Date:

GENERAL NOTES FOR

PRE-COMMISSIONING, COMMISSIONING AND ACCEPTANCE TESTING

OF BOOSTER PUMP STATIONS

The following notes are intended as a guide to the completion of Pre-Commissioning and
Commissioning Works in a manner which will be consistent throughout all new Booster Pump
Stations.

Guidelines and Checklist for Pre-commissioning (Appendix A)

These are checks which are required to be undertaken by the Mechanical/Electrical Sub-Contractor
and are supervised by Contractor’s staff. They are intended as a virtual 'check list’ to ensure that all
items of equipment have been installed according to manufactures/supplies requirement and have
been prepared for commissioning/operation.

Guidelines and Checklist for Commissioning

These are checks which are required to be undertaken by Contractor’s staff in the presence of Jabatan
Bekalan Air Luar Bandar (JBALB) staff.

It is essential that JBALB staffs are present in order to witness measurements, readings, and
observations made during these checks. For this reason, sufficient notice should be given by
Contractor to JBALB (UPT). The contractual requirement is for 21 days’ notice. It is possible
however, to advise late changes to programme by facsimile/telephone when absolutely necessary.

Guidelines and Checklist for Commissioning are intended to be applicable to ALL Booster Pump
Stations. It is unavoidable, therefore, that certain sections will not be applicable to a particular
scheme. Inapplicable sections will normally have been crossed out or struck through before the time
of commissioning. If this is not the case, then a comment should be made by the signatories indicating
which sections have not been undertaken or witnessed.

It is absolutely essential that Mechanical and Electrical competent personnel are delegated to witness
the commissioning of Mechanical and Electrical equipment in order to avoid protracted discussions
and arguments on methods/techniques employed to generate the data.

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER PUMPING Rev: 1
STATION
Date:

Specific Guidance: Pre-Commissioning / Commissioning

1. Check pumps stop when reservoir full..........

If the reservoir is greater than 1 km-from the Booster Station, pumps are stopped by a
differential pressure switch which is operated on a decrease in flow. It may not be convenient
to wait for what could amount to several hours in order to demonstrate the correct operation
of this cut-out. All that is necessary in this case is to slowly close the pump discharge valve
and note the flow at which the pump trips.

For reservoirs less than 1 km from the Booster Station, pumps are stopped by level electrodes
which respond to the conduction of an electric current between them (when both are
immersed in water). Again, correct operation can be demonstrated by lowering the High
Level electrode into the water, or by shorting the Reference and High Electrodes
momentarily.

2. Check pumps restart automatically.........

If a low flow trip, then re-start is by an adjustable timer. All that is necessary in this case to
demonstrate correct operation, without having to wait for an excessive time, is to temporarily
adjust the timer to a value of a few minutes.

Where trip is by electrode, re-start is also by electrodes, in this case by a break in the flow of
electric current between them. (When the water level falls below the Low Level Electrode)
Correct operation can be demonstrated in this case by raising the Low Level Electrode clear
of the water surface, or by momentarily disconnecting the connection to the Low Level
Electrode.

3. Check pumps stop when suction tank is at low level; Check pumps re-start
automatically.............

In the case of a suction tank, trip and re-set are both by electrode and the same comments
made above apply here. In some situations, however, where there is uncertainty as to the
precise details of existing water reservoirs, it will be necessary to check correct tripping by
draining or drawing down the feed reservoir.

4. Motor rated speed + measured speed

This is determined by either an optical or a contact tachometer.

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER PUMPING Rev: 1
STATION
Date:

5. Travelling Crane

The JKKP Certificate for the crane should be issued and available for record.

6. Surge Suppression Equipment.

After the surge suppression equipment is commissioned, all that is required under this section
is to observe the maximum and minimum pressures indicated on the surge arrestor pressure
gauge on starting and stopping the pump from a position of pressure equilibrium. The JKKP
Certificate for the Surge Suppression Equipment should be issued and available for record.

7. Generating Sets

Department of Environment (DOE) Approval Certificate for installation of Generating Set

should be issued and available for record.

8. Fire Protection System

Bomba Approval on all Fire Protection System should be issued and available for record.

9. Chlorination System

To check whether chlorination system synchronizes with booster pump or not.

Table A - Pump Bearings/Vibration

Correct operation of pumps can only be assessed by mechanically competent and experienced
personnel. Manufacturers’ literature states that bearing temperature should check by hand: If a normal
person can hold a bearing cover without feeling pain, then it is highly probable that the temperature is
below 60 degree C and that the bearing is running normally.

If the bearing is running hot, this does not necessarily mean that it is defective, in nine cases out of ten
it is usually found that it has been over packed with grease, and that cleaning and repacking the
bearing will reduce its operating temperature.

‘Abnormal’ noise and vibration is a very subjective assessment and again, should be left to
experienced personnel.

Table B - Pump Test Sheet

Readings are taken over the operating range of the pumps. Data are calculated and graphs drawn
SUBSEQUENT to the commissioning of the booster stations. JBALB personnel/representative should
witness the readings taken. There will be one TABLE A, and one TABLE B for each pump set.

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER PUMPING Rev: 1
STATION
Date:

Guidelines for Acceptance Test

Most of the data entered onto the Acceptance Test Guidelines will be abstracted from the Pre-
Commissioning and Commissioning Guidelines. The main purpose of the acceptance test is to
demonstrate the system as a whole will function satisfactorily over a period of 14 days (or less
depending upon the operational requirements of JBALB).

All that is required is for JBALB representatives to acknowledge the period of operation defined as
the 'Acceptance Test’.

N.B. JBALB representatives are not being asked to 'accept' or takeover schemes. All that is
required of them is to witness the proceedings and if necessary, to draw up a 'snag list’ of
items considered incomplete or defective. This snag list, together with any comments
considered appropriate, should be referred to JBALB Divisional who are the agency
responsible for accepting schemes.

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 Contract No:
TESTING AND COMMISSIONING
Rev: 1
DOCUMENT FOR BOOSTER PUMPING
STATION Date:

COMMISSIONING CHECKLIST FOR BOOSTER PUMPING STATION

COMMISSIONING CHECKLIST FOR BOOSTER PUMPING STATION

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 Contract No:
TESTING AND COMMISSIONING
Rev: 1
DOCUMENT FOR BOOSTER PUMPING
STATION Date:

COMMISSIONING CHECKLIST FOR BOOSTER PUMPING STATION

Project Name …………………………… Pump Type………………………

Work Contract No.

………………………………… Serial Nos. PUMP ………………………..

Booster Stations ……………………………… PUMP ………………………..

Name & Location ……………………………. PUMP ………………………..

PUMP ………………………..

1. REFERENCE DOCUMENTS Compliance checked by Consultant

Location Plan
Scheme Specific
Pipeline Profiles
Booster Station Assembly drawings
Manufacturers Pump set test cert. (attached)
O&M manual (draft)
Witnessed by JBALB
2. PUMPS Checked by Consultant
Representative
a) Refer to Operation & Maintenance
Manual (2.2.5 Operating Procedure -
Booster Pump. Station)

b) Run each pump for 2 hours or until

Bearing temperature is constant.
Check Bearing temperature in motor
and pump, noise, vibration and gland
leakage (see table. A, Data Sheet)

c) Take readings at approximately 25%,

50% and 100% Discharge valves
open condition (see table B, Data
Sheet)
d) Check pumps stop when reservoir-full
Actual level: m
e) Check pump re-starts automatically
Actual level: m

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 Contract No:
TESTING AND COMMISSIONING
Rev: 1
DOCUMENT FOR BOOSTER PUMPING
STATION Date:

COMMISSIONING CHECKLIST FOR BOOSTER PUMPING STATION

f) Check pumps stop when

suction tank is at low level
Actual leveI: m
g) Check pumps re-start
automatically after 1 hour (if
water is available)
Actual leveI: m

3. MOTORS PUMP PUMP PUMP PUMP

a) Rated speed (rpm)

Measured speed.(rpm) (full
b) load)

4. OVERHEAD TRAVELLING CRANE Yes No

a) Alignment check complete

b) Manufacturers test certificate attached
Vertical Deflection test of crane bridge
caused by hoist plus SWL in central Position Span Def
Permitted max. def. (Span - 750) Def
d) Load hook through full travel
e) Crane travelled full length with Safe Working Load (SWL)
f) JKKP type approval
g) JKKP installation approval & Certificate (See
Attached Certificate)

5. DIESEL GENERATOR SET

a) Manufacturers Test Certificate attached
b) D.O.E. Application
c) Factory Acceptance Test (FAT) attached

Rated Actual
d) Oil pressure switch operation kPA kPA
O O
e) Water temperature switch C C
operation
f) Engine over speed switch rpm rpm
operation

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 Contract No:
TESTING AND COMMISSIONING
Rev: 1
DOCUMENT FOR BOOSTER PUMPING
STATION Date:

COMMISSIONING CHECKLIST FOR BOOSTER PUMPING STATION

g) Trip-on control circuit voltage failure

h) Noise measurement (dBA) North South East West
Measured 3 m from exhaust
Measured 3 m from outer wall
i) Test generator over six Yes No
consecutive starts

6. SURGE SUPPRESSION EQUIPMENT

(Where Surge Suppression Equipment fitted, commissioning will be carried out under section 2)
a) Pump start up: Observed
Max. Min.
pressure
Pump shut Observed
Max. Min.
down: pressure
Pressure Set Point: Bar
Level Set Point: M
7. CHLORINE DOSING SYSTEM
Check all gas pipework joints for leaks using ammonia vapor.
Manufacturers pre-start up checks complete Yes No

Satisfactory Unit Yes No

Chlorine
Dosing
Chlorine
Dosing
Chlorine
Dosing
Check operation changeover panel.
Commissioning complete, system ready for use. Yes No
Remarks:

Checked By Certified by Witnessed by JBALB

Contractor Consultant Representative
Name
Signature
Designation
Date

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 Contract No:
TESTING AND COMMISSIONING
Rev: 1
DOCUMENT FOR BOOSTER PUMPING
STATION Date:

COMMISSIONING CHECKLIST FOR BOOSTER PUMPING STATION

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

TELEMETRY SYSTEM

Station Name: ……………………………………………….

1. I/O Check
PROCEDURE
- For Input/output signal to/from the PLC DI Card. Use signal simulator or wire to simulate at the
respective terminal block, simulate the selector switch, push button and equipment.
- Verify correct input/output status at PLC DI Card and indicating light/alarm annunciator and
Graphic SCADA System.

TEST CRITERIA
- The PLC DI and SCADA System shall receive the signal.
- The LED status at the PLC DI module and equipment status at SCADA shall turn off when the
simulated signal is disabled.
DIGITAL SCADA
INPUT/ GRAPHIC
DESCRIPTION REMARKS
OUTPUT
ADDRESS YES NO

Certified by Witnessed by JBALB

Checked by Contractor
Consultant Representative
Name
Signature
Designation
Date

Project Name : Capacity : m3/hr

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 Contract No:
TESTING AND COMMISSIONING
Rev: 1
DOCUMENT FOR BOOSTER PUMPING
STATION Date:

COMMISSIONING CHECKLIST FOR BOOSTER PUMPING STATION

Work Contract No. : Operation : hr/d

2. ANALOG INPUT/OUTPUT SIGNAL TO/FROM SCADA (PLC LOGIC TEST)
PROCEDURE
1. Determine the loop is internally powered or externally powered from the schematic
diagram.
2. Connect the + and – wires of the signal injector to the 4-20mA input terminals
at…(Station Name)….……..Panel and set the signal injector according to the loop
power condition.
3. Simulate the signal to 0%, 25%, 50%, 75%, 100% of the instrument range.

TEST CRITERIA
- The SCADA shall give the output signal according to signal simulated.

Equip. Description :
Simulated Range : 4 – 20 mA
Input Range :

Simulated Range (mA) Desired Value Displayed Value Remarks

4
8
12
16
20
Commissioning complete systems ready for use.
Remarks:

Certified by Witnessed by JBALB

Checked by Contractor
Consultant Representative
Name
Signature
Designation
Date

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER PUMPING Rev: 1
STATION
Effective date: 3rd February
2020

ACCEPTANCE TEST FOR BOOSTER PUMP STATION

ACCEPTANCE TEST FOR BOOSTER PUMP STATION

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 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER PUMPING Rev: 1
STATION
Effective date: 3rd February
2020

ACCEPTANCE TEST FOR BOOSTER PUMP STATION

Project Name ……………………………………………….

Work Contract No. ……………………………………………….

1. Design Assumption: (See attached sheet)

2. Start Date for Test:

3. JBALB Required From:

4. JBALB State Representative Required for JBALB Valve/Filling

Operation From: …………………………………… to ……………………………

5. Disinfection successfully completed: Pipelines

Surge Vessels

Suction Tank

Reservoirs
6. Equipment used for measurement Pipelines Tanks

Flow

Range of flowmeter

Head loss through flowmeter

Comments

Pressure

Range of instrument

Comments

Level

Comments

Page | 24
 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER PUMPING Rev: 1
STATION
Effective date: 3rd February
2020

ACCEPTANCE TEST FOR BOOSTER PUMP STATION

7. CRITERIA FOR PASSING TEST

Booster Station Name:

Operating hours: hr/day

Start pumping:
Stop pumping:

* These are shift times. The pump will stop and start during this period if the Storage Reservoir
fills.
Required output: 1.1 times Average Daily Year 2000 Flow
= 1.1 x ____________ = _______________

8. Pipelines Year 2000 Flow Required Recorded

Flow* Measured Pressure Pressure

* or highest available flow (see attached graph)

9. Reservoir Name
Overflow measured at full pump output (outlet valve closed,
inlet valve held open)
Bypass flow (if applicable)
Required year 2000 inflow
Actual max. pumped inflow
Peak outflow measured

Page | 25
 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER PUMPING Rev: 1
STATION
Effective date: 3rd February
2020

ACCEPTANCE TEST FOR BOOSTER PUMP STATION

10. Test conducted for 14 days/ ……… (OR as agreed with JBALB)
11. OVERHEAD CRANE
Yes No
JKKP Approval Required
If Yes, JKKP Certificate
If No, JBALB Approval At Commissioning
12. DIESEL GENERATOR SET
Yes No
D.O.E Approval
13. SURGE SUPPRESSION EQUIPMENT
Yes No
JKKP Type Approval
JKKP Installation Approval
14 CHLORINE DOSING SYSTEM Yes No
Functioning in line with booster pump
Remarks:

Checked By Certified by Witnessed by JBALB

Contractor Consultant Representative
Signature
Name
Designation
Date

Page | 26
 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR BOOSTER PUMPING Rev: 1
STATION
Effective date: 3rd February
2020

ACCEPTANCE TEST FOR BOOSTER PUMP STATION

TABLE A
Bearing Check 40 - 60 C
Time (Every Abnormal Noise
Motor Pump Any leaks visible
Hour) and/or vibration
DE NDE DE NDE

Certified by Witnessed by JBALB

Checked By Contractor
Consultant Representative
Name
Signature
Designation
Date

Page | 27
TABLE B: Unless otherwise specified Tests carried out in accordance with BS5316 Part
PUMP TEST CERTIFICATE 1, Class C

PUMP TESTED:
CUSTOMER/PROJECT:
PUMP SIZE: SERIAL NO:
INLET/OUTLET
DRIVER: IMPELLER DIA: MM DIA: MM
ORIFICE PLATE
TYPE: DIA: MM
MAKE: FLOW RATE: m3/h
MODEL: RPM: HP TOTAL HEAD: M
POWER: kW AMP: I
VOLTAGE: V PHASE:
SUCTION PRESSURE GAUGE LEVEL: M
DISCHARGE PRESSURE GAUGE LEVEL: M

VOLT MOTOR PUMP

TEST FLOW DISCHARGE SUCTION TDH AMP(A) P.F.
V2/2g (V) RPM
NO. (m3/h) PRESSURE PRESSURE INPUT POWER BHP WHP EFF
(M) EFF %
(M) (M) (M) (kW) (kW) (kW) %

Checked By Contractor Certified by Consultant Witnessed by JBALB Representative

Name
Signature
Designation
Date

Page | 28
LIST OF EQUIPMENTS

1. Treated Water Pump

Pump Brand/Make
Pump Model
Pump Serial No.
Pump Head m
Design Flow Rate m3/hr
Horsepower HP
Power kW
Rated current A
Voltage/Phase V/Phase
Motor Brand/Make
Motor Model
Motor Serial No.
Motor Speed rpm
Motor Frequency Hz
Class

Page | 29
2. Chlorination System
2.1 Vacuum Regulator
Brand/Make
Type
Model
Heater Make
Heater Type
Power Rating V/A/W
Rated Frequency Hz
2.2 Chlorinator
Brand/Make
Type
Model
Max Capacity kg/hr
Motor Make
Motor Type
Power Rating V/A/W
Rated Frequency Hz
2.3 Changeover Manifold
Brand/Make
Type
Serial No.
Range
2.4 Injector
Brand/Make
Type
Serial No.
Max Capacity kg/hr

Page | 30
3. Pressure Transmitter
Instrument Brand/Make
Instrument Model
Instrument Serial No.
Measure (i.e. pH,
NTU,mg/l)
Output current mA
Rated current A
Voltage/Phase V/Phase
Rated Frequency Hz
Class

4 Crane
Brand/Make
Type
Model
Country
Year
Equipment Serial No.
Hoist Serial No.
PMA Registration No.
Hoisting Capacity Ton
Voltage/Phase/Current V/Phase/
A

Page | 31
5. Surge Vessel (If
Applicable)
5.1 Compressor
Brand/Make
Model
Serial No.
Piston Displacement
Max Discharge Pressure Bar
Design Duty Pressure Bar
Free Air
Noise Level dB
5.2 Motor
Brand/Make
Type
Model
Serial No
Power kW
Voltage/Phase V/Phase
Rated Current A
Speed Rpm
Class

Page | 32
APPENDIX
 PRE-COMMISSIONING CHECKLIST FOR BOOSTER PUMP STATION

Appendix (A)

PRE-COMMISSIONING CHECKLIST FOR BOOSTER PUMP STATION

Appendix (A) Page | 32

 PRE-COMMISSIONING CHECKLIST FOR BOOSTER PUMP STATION

Project Name Pump Type

……………………………………………………… ………………………………………..
Work Contract No. Pump
………………………….……………………... Serial Nos. ………………………..
Booster Stations Pump
.…………………………………………….… ………………………..
Name & Location Pump
……………………………………………… ………………………..
Pump
………………………..

1. VALVES

Function Checks Direction Open Seats

a) Washdown/Priming Valves
b) Suction Valves
c) Discharge Valves
d) Non-Return Valves
e) Air Release Valves

2. PUMPS
i) Manufacturers Pre-Start Up Checks (see attached PUMP PUMP PUMP PUMP
sheets) completed
ii) Alignment Checks
See manual Parallel (mm) Angular (mm)
No.
for procedure PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP
Reading with 1
pipework 2
uncoupled
3
4
Reading with 1
pipework 2
coupled
3
4
Manufacturers tolerance: Parallel ………………… mm
Angular ………………. mm

Appendix (A) Page | 33

 PRE-COMMISSIONING CHECKLIST FOR BOOSTER PUMP STATION

3. ELECTRICAL

i) Earthing Protection Check S.B PUMP PUMP PUMP PUMP

a) Earth Resistance on
Electrical Systems (<1
Ohm)
b) Insulation Resistance Test
Resistance Cables ……… See attached data sheet D (i) A

c) Polarity check
d) Earth Resistance Test for Lighting Protection System = ohms
(≤10 ohms)
ii) Switchgear Protection Setting Checked by
a) Over current protection
b) Earth leakage setting
iii) Pump Motor Insulation
Pump Pump Pump Pump
Resistance Test
R-Y
Y-B
B-R
L-N
L-E
4. INSTRUMENTATION

Yes No
a) Installation/Assembly complete and in
accordance with drawing
b) Control cables insulation check (see attached sheet D(i))
c) Isolation and Balancing Valves, bleed screws
checked for operation over full strokes
Instrument
Instrument
Instrument
Instrument

Appendix (A) Page | 34

 PRE-COMMISSIONING CHECKLIST FOR BOOSTER PUMP STATION

d) Instrument lines clear of obstruction,

Yes No
flushed through and checked for leaks
Instrument
Instrument
Instrument
Instrument

e) Check Zero Calibration of Primary Loop Element:

With balancing valves on DP transmitter open, energise supply to instruments and measure
loop current after 10 minutes

Expected Actual
Instrument 4,00 mA mA
Instrument 4,00 mA mA
Instrument 4,00 mA mA
Instrument 4,00 mA mA

If a value differs from that expected by more than 0.01 mA, reconfirm sensor range with D.P.
range stamped on D all Tube/Orifice Plate, and then refer to manufacturers operating
instructions for procedure to set zero and coarse span.

N.B. The fine span is pre-set at the factory and should not be adjusted unless there
is reason to suspect an unexpected change in calibration. A precision pressure
source is required before adjusting the fine span potentiometer.

Appendix (A) Page | 35

 PRE-COMMISSIONING CHECKLIST FOR BOOSTER PUMP STATION

f) Check Integrator/Analogue Converter Calibration:

Confirm that the Meter Factor (written on the inside of the connection compartment) matches
the settings of " switches S1, S2, S3 and S4 and link Ll.

(Details of the calibration necessary to determine the Meter Factor are contained in Appendix
A of the Manufacturers’ Instruction Manual).

Refer to 'Analogue Converter Scaling’ a page 10 of the Manufacturers’ Instruction Manual

for the procedure to check the calibration.
Zero Proportion or FS
Expected Actual Expected Actual
Instrument 0,00 mA mA mA mA
Instrument 0,00 mA mA mA mA
Instrument 0,00 mA mA mA mA
Instrument 0,00 mA mA mA mA

5. PUMP PROTECTION
a) Low Level Probe in suction tank m
b) High Level Probe in suction tank m
c) High Level Probe in receiving reservoir m
3
d) Differential Pressure (D.P.) switch in discharge pipeline m /h

6. MOTORS
a) Check motor insulation resistance Pump Pump Pump
R-Y
Y-B
B-R
L-E
c)
b) Motor winding resistance (Ohm)
U1-U2
V1-V2
W1-W2

Appendix (A) Page | 36

 PRE-COMMISSIONING CHECKLIST FOR BOOSTER PUMP STATION

c) Check motor direction (CW/CCW) Yes No

PUMP
PUMP
PUMP
PUMP

d) Yes No
Check thermister trip for motor over 37 kW
(by shorting thermister) PUMP
PUMP
PUMP
PUMP

7. OVERHEAD TRAVELLING CRANE

Yes No
a) Tapes over breather holes removed
b) All damaged paintwork repaired
c) Alignment check Drawing
(N/A to monorail hoists) Dimension Measured Dimension Permitted Tolerances
i) Crane span at each end ±6 mm
of carriages
ii) Diagonal centres of ±6 mm
crane wheels
iii) Crane span at crane ±6 mm
rail level
Yes
d) Safe work load ______________tonnes painted on frame

Appendix (A) Page | 37

 PRE-COMMISSIONING CHECKLIST FOR BOOSTER PUMP STATION

8. GENERATORS

Generator Unit
a) Manufacturers pre-start checks
completed (see attached sheets)

b) Insulation Resistance Tests (MΩ)

(see attached data sheet D(i) C) Measured Required
i) Between load terminals and plant >50 MΩ
structure
ii) Between generator terminals and >50 MΩ
structure
iii) Between generator phases R-Y >50 MΩ
Y-B >50 MΩ
B-R >50 MΩ
iv) Ancillary equipment: Heaters >1 MΩ
c) Continuity tests: Yes No
Phase and circuit connections checked
d) Earthing protection check Measured Required
i) Earth resistance on electrical system < 1 ohm

ii) Polarity verified Yes No

iii) Generator neutral earthing Yes No
e) Battery Checks Measured
i) Standing voltage measured Volts
ii) Starting voltage measured Volts
iii) Specific gravity
iv) Level of electrolyte
v) Trickle charger checked for correct Amps
operation

Appendix (A) Page | 38

 PRE-COMMISSIONING CHECKLIST FOR BOOSTER PUMP STATION

f) Fuel system Yes No

i) Fuel tank level sensors checked for
correct operation of pump and alarms
ii) Fuel lines purged of air
g) Before starting Yes No
i) All lubrication systems checked as correct

ii) Ambient temperature of area

iii) Cooling water gauge reading
h) Fire/safety Yes No
i) Fire extinguishers installed and fully
charged
ii) Fire fuel shut-off valve checked (remove
fusible link)

9. SURGE SUPPRESSION EQUIPMENT

a) Compressors: Compressor A Compressor B

Manufacturers pre-start up checks
complete (see attached sheets)
b) Pipeline length m m
c) Double orifice vented NRV's: No.
d) Double orifice inflow check NRV's: No.
e) Vessel size m3 m3
f) Outlet size mm mm
g) Outlet NRV Yes/No Yes/No
h) Normal operating pressure kPA kPA
i) PRV setting kPA kPA
j) Maximum surge pressure kPA kPA
k) Minimum Surge pressure kPA kPA

Appendix (A) Page | 39

 PRE-COMMISSIONING CHECKLIST FOR BOOSTER PUMP STATION

High Low
Rated Actual Rated Actual
l) Alarm setting high/low mm mm mm mm
Stop Start
Rated Actual Rated Actual
m) Compressor settings start/stop mm mm mm mm
n) JKKP type approval Yes/No
o) JKKP installation approval Yes/No/NA

Above checks satisfactorily completed.

Remarks:

Supervised by Witnessed by JBALB

Checked By Contractor
Consultant Representative
Name
Signature
Designation
Date

Appendix (A) Page | 40

 PRE-COMMISSIONING CHECKLIST FOR BOOSTER PUMP STATION

CABLE CHECK SHEET

Project Name: Capacity: m3/hr
………………………………………………. ………………………………….

Work Contract No.: Operation: hr/d

………………………………………………….. ………………………………

Site Location:
Power/Control Cables
…………………………………………………

Insulation
Cable Type of No. of Rated
Cable Name From To Resistance
Tagging Cable Cable Voltage (V)
Test (MΩ)

The above checks have been completed satisfactorily. Yes No

Remarks:

Witnessed by JBALB
Checked By Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

Appendix (A) Page | 41

JABATAN BEKALAN AIR LUAR BANDAR (JBALB) SARAWAK

TESTING AND COMMISSIONING DOCUMENT

FOR

WATER TREATMENT PLANT

........................ DIVISION

CONTRACT NO: ……………………………

 TABLE OF CONTENTS

No. Description Pages

1 Pre-Requirement for Document Submission Prior To Testing and 1

Commissioning Activity
2 Process flow for Commissioning of Water Treatment Plant 2-7
3 Method Statement - Water Treatment Plant Pre & Post Commissioning 8-10
4 Guidelines and Checklist for Full Testing & Commissioning of Water
11
Treatment Plants
5 General Notes for Pre-commissioning, Commissioning and Acceptance Test
12-18
for Water Treatment Plants
6 Commissioning Checklist For Water Treatment Plant 19-43
7 Acceptance Tests for Treatment Works 44-47
8 Table A : Pump Monitoring Table 49
9 Table B : Pump Test Certificate 50
10 List of Equipment 51-57
11 Appendix (A) Pre-Commissioning Checklist for Water Treatment Plants 58-90
12 Appendix (A) - Cable Check Sheet 91
 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

PRE-REQUIREMENT FOR DOCUMENT SUBMISSION PRIOR TO

TESTING & COMMISSIONING ACTIVITY

No Item YES NO N/A REMARKS

1 Method Statement Of T&C

2 Operation & Manual (O&M)

3 Factory Acceptance Test Report (FAT)

4 Site Acceptance Test Report (SAT)

5 Testing and commissioning checklist

QAQC check records documentation review before

Testing and Commissioning (T&C) but not limited to:
I. Equipment data sheet
II. Equipment manufacture test certificate
6
III. Instrument calibration certificate
IV. As build Drawing
 Mechanical & Electrical
 Civil & Structure

7 Site walk/Inspection prior to readiness of T&C

Training on equipment in regards to safety, operating,

9
maintenance and emergency practice/ procedure

10 Punch list closed – if any

11 Non Conformance Report (NCR) closed – if any

Above requirement shall be submitted 2 weeks before T&C except FAT report:

Page | 1
 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

PROCESS FLOW FOR COMMISSIONING OF

WATER TREATMENT PLANT

Page | 2
 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

COMMISSIONING OF NEW JBALB WATER TREATMENT PLANTS

1.0 Commissioning Team

The commissioning of all new JBALB water treatment plants shall be carried out by designated
officers coordinated Jabatan Bekalan Air Luar Bandar (JBALB) Headquarters. The
commissioning team shall consist of the following: -

1.1 JBALB Headquarters

a) Mechanical Engineer
b) Electrical Engineer
c) Civil Engineer (Related Project)
d) Chemist
e) Assistant Engineer

1.2 JBALB Divisional

a) Divisional Water Engineer (DWE)/Officer Incharge of Division(OIC)
b) Assistant Engineer, J29

1.3 JBALB Project Management Team

a) Divisional Water Engineer (DWE)/Officer Incharge of Division(OIC)

b) Assistant Engineer, J29

Team Formation

JBALB Headquarters & JBALB Divisional/Project

Commissioning Team Contractor and
Team
(Refer to name lists detail) Consultant
(Refer to name lists detail)

Page | 3
 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

2.0 Methodology

2.1 The Mechanical Engineer from JBALB PRE-COMM/COMMISSIONING

Headquarters will head the commissioning team and PROCESS (Water Treatment Plant)
the Divisional Water Engineer (DWE), Assistant
Engineer and Assistant Technician/Technician are
allocated the following tasks to assist in the PRE-COMMISSIONING PROCESS
commissioning. What to check?
Physical and visual check of control
2.2 Pembantu Kemahiran H17 & Pembantu Awam equipment i.e. Pumps, Valves, PLC’s,
H11/14 will assist the commissioning teams and Generator set, MSB, etc. as per Guidelines of
will take over the plant operation after successful Pre-Commissioning Checklists & Contract
commissioning and handing over. In this respect, Document.
they will get hands-on experience in the plant
operation.

2.3 Project Management Team from JBALB

COMMISSIONING PROCESS
Divisional/Regional Office’s role is to be the
What to check?
coordinator to instruct consultant/contractor to
Individual System Checks as per Guidelines
execute and implement the commissioning process
of Commissioning Checklists and Data
as per guidelines and checklist. They are
Sheets.
responsible to coordinate with JBALB Headquarters
Commissioning Team to ensure that proper
guidelines and procedure is implemented prior to
the commissioning of Booster Pump Station are in Commissioning
accordance with the guidelines before handing over successful
to JBALB Division.

DOCUMENTATION / HANDOVER
Parties involved: Divisional Office and
JBALB Headquarters

REFRESHER/ TRAINING
 As per contract (external)
 To be conducted by JBALB
Divisional and JBALB HQ
(recommended once every six (6)
month)

Page | 4
 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

3.0 Tasks and Duties

i) The commissioning team will witness the testing of all items of equipment, pipework, fittings
and appurtenant (accessories) works to ensure that they are correctly installed and capable of
proper operation.

ii) The team will witness start up and running each item of equipment separately until they are
satisfied that it is capable of proper operation.

iii) After each item of equipment has been tested separately, the various items will be run
concurrently to commission the plant.

3.1 In carrying out (i) to (iii) above, the team shall ensure that:-

i) The correct sequence of operation of the plant is checked and documented.

ii) Plant control systems are checked.

iii) Calibration on Testing and Measuring tools is carried out.

iv) Switchboards, control panels, alarm systems, overloads, and safety equipment are tested.

v) The alignment, mounting and configuration of pumps and drives, including the direction of
rotation are checked.

vi) The various lubrication systems and greasing systems are checked, including pump shaft
lubrication and stuffing box seal requirements.

vii) The pipework valves and gauges are correctly installed and operate satisfactorily. The
appropriate valve positions shall be determined for the different modes of operation of the
plant and documented.

viii) The chemical mixing, feeding and dosing equipment shall be tested and calibrated.

ix) Load tests are carried out on lifting equipment.

x) The necessary chemical testing equipment is provided and in working order.

xi) All other tools and equipment necessary have been provided and are in working order.

Page | 5
 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

3.2 During the commissioning of the plant, the team shall ensure that: -

i) The limits of hydraulic operation of the various units of the plant are determined.

ii) The appropriate flow rate through the plant is determined to minimize “on-off” operation.
Guides on pumping rates for the raw water and treated water pumps shall be established.

iii) The clarifiers are operated with the appropriate level of coagulant to achieve a well developed
floc blanket.

iv) The rate of de-sludging of the clarifiers is determined.

v) The filters are operated sufficiently long to establish head loss characteristics and backwash
requirements.
vi) The filter backwash system and air scour are operated correctly. The correct procedure for
backwashing of the filters is determined and documented.

vii) As far as possible, the appropriate levels of dosing of chemicals for the plant are determined.
In particular, the appropriate level of post dosing for pH correction is determined.

3.3 Documents and operation manuals

The following documents shall form part of the commissioning:

i) Procedures on water treatment process;

ii) Buku Panduan Kerja Pertukangan Atenden Loji Bekalan Air;
iii) Buku Panduan Kerja Pertukangan Atenden Pam Bekalan Air;
iv) Buku Panduan Kerja Pertukangan Atenden Enjin Bekalan Air;
v) Perintah-Perintah Tetap Pihak Berkuasa Bekalan Air JKR;
vi) Other operation manuals for the s and equipment.

3.4 Refresher/Induction Training

During the commissioning of the plant, the Divisional Water Engineer (DWE), Assistant
Engineer, Assistant Technician/Technician and attendants allocated to assist the teams, will
undergo “hands on” training in preparation for accepting responsibility for operation of the plant.
This training role will be a significant aspect of the duties of the commissioning team.

Page | 6
 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

3.5 Handing Over and Documentation

3.5.1 When the plant is operating satisfactorily and treated water has been supplied into the existing
reticulation system, it will be handed over to the JBALB Divisional staff.

3.5.2 The commissioning team will prepare four (4) copies of the commissioning report, (1) one copy
to the Regional Manager, (1) one copy to the Divisional Water Engineer and (2) two copies to
JBALB Headquarters.

3.5.3 The report shall contain as a separate section, the recommended procedure for operating the
various items of the plant including the following:

i) Valve on-off schedules,

ii) Switchboard operation and use of control panels and monitors.
iii) Observed rate of desludging of clarifiers and backwashing of filters
iv) Operation of the raw water pumps and clear well pumps to integrate the plant into the
existing system and optimize its operation.

3.5.4 An assessment of the induction training of operator staff shall be given.

Page | 7
 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

METHOD STATEMENT
WATER TREATMENT PLANT PRE & POST COMMISSIONING

Page | 8
 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

METHOD STATEMENT
Water Treatment Plant Pre & Post Commissioning

Background Information

Project Name

Contract No.

Pre & Post Commissioning Implementation

Divisional Involvement 1. Divisional Office representative shall be present during

pre-commissioning and commissioning stage to witness
and comment any dissatisfaction /query through Project
Management Team / Commissioning Team representative.
2. Divisional Office representative shall be at least Assistant
Engineer, J29 of Mechanical or Electrical to be involved
during pre-commissioning and commissioning stage
(especially M&E equipment testing).
3. Water treatment plant operator (PRAK) shall be involved
during system operational testing for the purpose of
familiarization of new treatment plant. Certificate of
Practical Completion (CPC) shall be to the satisfaction of
JBALB Commissioning Team and JBALB Divisional
Office SO/SOR/OIC. This is to ensure proper handing over
and operational needs are met and achieved as per design in
the Contract.
New Pipe interconnection to 1. JBALB Project Management Team concerned shall notify
existing piping system any pipe interconnection and submit method statement for
interconnection work to JBALB Divisional Office prior to
the commencement of actual work.
2. Method statement must be agreed between Project
Management Team and Respective JBALB Divisional
Office before any work can proceed.
3. Upon agreement on the interconnection Method
Statement, the affected Divisional Office (DWE/OIC)
shall issue notice of water supply interruption to the
public prior to the execution of interconnection work
either via Corporate Communication or Information
Department (which ever) is more efficient and cost
effective within a weeks notice.
4. Any actual shutdown to the existing system shall be done
by JBALB Project Management Team or representative
from JBALB Divisional Office assisted by the Contractor
involved.
5. The interconnection work and any reinstatement work
which is affected by the interconnection process shall be
done by the contractor involved to the satisfaction of
representative of both PMT and Divisional Office.

Page | 9
 Contract No:
TESTING AND COMMISSIONING
DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

Consumables Requirement 1. After every successful Testing and Commissioning, it is

crucial that the Appointed Contractor/Consultant prepare
and advice on the usage and quantity of consumable
required like chlorine, aluminum sulphate, polymer and
soda ash shall be made available as stock for at least 3 to
6 months (subject to availability & plant locality) for
operational use after project completion (CPC).
2. It is recommended that the information on where and how
to acquire these required consumable shall be made
known to the JBALB Divisional Office for reference of
their planning and procurement process by the users.
3. Material acquisition inclusive of M&E parts shall be
identified and JBALB Divisional Office is recommended
to acquire major parts for major pumps and dosing pump
for stock in advance for the ease of maintenance after the
end of Defect Liability Period (DLP).
Recommendation on Operational 1. Operation and maintenance manual for the water treatment
and/Or Overall Maintenance Plan plant shall be provided by the contractor to the JBALB
Divisional Office and JBALB Headquarters for references
on operational matters.
2. JBALB Divisional Office shall produce the Maintenance
Plan which include periodic and preventive/predictive
maintenance of all major equipment i.e. Treated water
pump, submersible water intake pump and control panels.
It is recommended that all major equipment is checked and
inspected at a regular interval of three (3) months
(minimum) by Audit or representatives from JBALB
Headquarters.
3. Divisional Office shall coordinate with JBALB
Headquarters regarding procedure, schedule and costing for
maintenance of all equipment. It is advisable that this
coordination is initiated prior to the end of project’s DLP.
Recommendation on manpower 1. It is recommended that DWE/OIC’s to review their current
requirement of new Water operation setup and manpower requirement to suit the new
Treatment Plant (WTP) WTP prior to the completion of the project. It would be
best that proper proposal on operation of new WTP to be
worked out at the commissioning stage since forecast on
actual manpower required can be identified clearly with the
involvement of Divisional Office at this stage.

Page | 10
 Contract No:

TESTING AND COMMISSIONING

DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

GUIDELINES AND CHECKLIST FOR FULL

TESTING & COMMISSIONING OF WATER TREATMENT PLANT

Page | 11
 Contract No:

TESTING AND COMMISSIONING

DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

General Notes for Pre-commissioning,

Commissioning and Acceptance Tests

Water Treatment Plant

Page | 12
 Contract No:

TESTING AND COMMISSIONING

DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

GENERAL NOTES FOR

COMMISSIONING AND ACCEPTANCE TESTING

OF WATER TREATMENT PLANT

The following notes are intended as a guide to the completion Pre-Commissioning and
Commissioning Works in a manner which will be consistent throughout all new Treatment Plants.

Guidelines and Checklists for Pre-commissioning (Appendix A)

These are checks which are required to be undertaken by the Mechanical/Electrical Sub-Contractor
and are supervised by Contractor’s staff. They are intended as a virtual 'check list’ to ensure that all
items of equipment have been installed correctly and have been prepared for
commissioning/operation.

Guidelines and Checklists for Commissioning

These are checks which are required to be undertaken by Contractor’s staff in the presence of Jabatan
Bekalan Air Luar Bandar (JBALB) staff.

It is essential that JBALB staffs are present in order to witness measurements, readings, and
observations made during these checks. For this reason, sufficient notice should be given by
Contractor to JBALB. The contractual requirement is for 21 days’ notice. It is possible however,
to advise later changes to programme by facsimile/telephone when absolutely necessary.

Guidelines and Checklists for Commissioning are intended to be applicable to ALL Treatment Plants.
It is unavoidable, therefore, that certain sections will not be applicable to a particular scheme.
Inapplicable sections will normally have been crossed out or struck through before the time of
commissioning. If this is not the case, then a comment should be made by the signatories indicating
which sections have not been undertaken or witnessed.

It is absolutely essential that Mechanically/Electrically competent personnel are delegated to witness

the commissioning of Mechanical and Electrical equipment in order to avoid protracted discussions
and arguments on methods/techniques employed to generate the data.

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 Contract No:

TESTING AND COMMISSIONING

DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

Specific Guidance: Pre-Commissioning / Commissioning

1. Intake/Raw Water Pump

Pump Test Sheet - when recording pump performance data, it is useful if a sample check on
flow rate can be performance in order to verify the flowmeter accuracy.

Readings are taken over the operating range of the pumps. Data are calculated and graphs
drawn SUBSEQUENT to the commissioning. JBALB should witness the result taken; results
will be presented to JBALB personnel at a later date.

2. Aerators

It is only important to test the performance of the aerators when:

a) There is pollution and the dissolved oxygen in the river is low, or

b) The water is coming from a borehole and dissolved carbon dioxide is high.

3. Flocculators

The operation of the torque switch is only checked electrically.

4. Backwash Pumps

Table A: The correct operation of pumps can only be assessed by Mechanically competent
and experienced personnel. Manufacturers’ literature states that bearing temperature should
be checked by hand: if a normal person can hold a bearing cover without feeling pain, then it
is highly probable that the temperature is below 60 degree C and that the bearing is running
normally. However, if available, an electronic surface temperature meter should be used to
verify the actual temperature.

If the bearing is running hot, this does not necessarily mean that it is defective; in nine cases
out of ten, it is usually found that it has been over packed with grease, and that cleaning and
re-packing cures the problem.

‘Abnormal’ noise and vibration is a very subjective assessment and again should be left to
experienced personnel.

Table B: Readings are taken over the operating range of the pumps. Data are calculated and
graphs drawn subsequent to the commissioning of the Treatment Plant. JBALB personnel
should witness the readings taken, results will be presented to JBALB Divisional at a later
date.

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 Contract No:

TESTING AND COMMISSIONING

DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

5. Treated Water Pumps

Similar comments as for Backwash Pumps apply regarding Table A and B.

a) Check high Reservoir level shut off control

If the reservoir is greater than l km from the Treatment Plant, pumps are stopped by a
differential pressure switch which is operated on a decrease in flow. It may not be
convenient to wait for what could amount to several hours in order to demonstrate the
correct operation of this cut-out. All that is necessary in this case is to slowly close the
pump discharge valve and note the flow at which the pump trips.

For reservoirs less than 1 km from the Treatment Plant, pumps are stopped by level
electrodes which respond to the conduction of an electric current between them (when
both are immersed in water). Again, correct operation can be demonstrated by lowering
the High Level electrode into the water, or by shorting the Reference and High Electrodes
momentarily.

b) Check Pumps restart automatically

If a low flow trip, then re-start is by an adjustable timer. All that is necessary in this case
to demonstrate correct operation, without having to wait for an excessive time, is to
temporarily adjust the timer to a value of a few minutes.

Where trip is by electrode, re-start is also by electrodes, in this case by a break in the flow
of electric current between them. (When the water level falls below the Low Level
Electrode) Correct operation can be demonstrated in this case by raising the Low Level
Electrode clear of the water surface, or by momentarily disconnecting the connection to
the Low Level Electrode.

c) Check Pumps stop when Balance tank is at low level; Check pumps re-start automatically

In the case of a balance tank, trip and re-set are both by electrode and the same comments
made above apply here.

6. Air Blowers

The un-loader valves should be permanently shut for normal operation, after initial checks are
complete.

The operation of the relief valves is checked by running the blower with the discharge valve
closed and the un-loader valve open: The un-loader valve is then slowly closed until the relief
valve lifts. The pressure can then be read from the discharge pressure gauge.

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 Contract No:

TESTING AND COMMISSIONING

DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

7. Sludge Tank/Pumps

After shut off at low level, the pumps require manual re-setting to re-start.

8. Alum Dosing System

Assume top water level to be at the invert level of the overflow outlet. This ensures that the
operator consistently makes up a correct known volume of dosing solution.

Dosing solutions should always be 5% alumina content, as the flow-meter is calibrated for the
appropriate specific gravity. If the required dose rate is outside the flow-meters range and a
different dosing solution strength is necessary, then a check of actual flow rate should be
made to determine the correction factor.

9. Soda Ash Dosing System

To check the powder feed rate at different potentiometer settings; waits for a vibration period
to start and collect powder for 1 to 2 minutes (depending on setting). The powder collected is
then weighed and the kg/hr rate computed.

10. Travelling Crane

The JKKP Certificate for the crane should be issued and available for record.

11. Surge Suppression Equipment

After the surge suppression equipment is commissioned, all that is required under this section
is to observe the maximum and minimum pressures indicated on the surge arrestor pressure
gauge on starting and stopping the pump from a position of pressure equilibrium. The JKKP
Certificate for the Surge Suppression Equipment should be issued and available for record.

12. Generating Sets

Department of Environment (DOE) Approval Certificate for installation of Generating Set

should be issued and available for record.

13. Fire Protection System

Bomba Approval on all Fire Protection System should be issued and available for record.

14. Fuel Storage System

Department of Environment (DOE) Approval Certificate for installation of Fuel Storage

System should be issued and available for record.

Page | 16
 Contract No:

TESTING AND COMMISSIONING

DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

Specific Guidance: Acceptance Tests

1. Water Quality Record

The JBALB operators will normally carry out the following tests:

- pH

- Turbidity

- Colour

- Chlorine (free or total)

- Aluminium

- Fluoride

2. Flow and Dosing Record

This data will normally be recorded by JBALB operators but Contractor’s staff may assist if
necessary.

3. Machinery Operating Records (currents and pressures)

As per the flow and dosing records.

4. Calculation of the Saturation pH

These calculations and tests will be carried out by Contractor’s commissioning staff. In the
event of the target pH being higher than maximum Malaysia Water Supply Quality Standard
drinking water pH, a suitable target pH will be decided in consultation with JBALB. In any
event, if daily monitoring indicates no significant change in the saturation pH, the frequency
of testing maybe decreased.

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 Contract No:

TESTING AND COMMISSIONING

DOCUMENT FOR WATER Rev: 1
TREATMENT PLANT Date:

General Acceptance Tests Guidance

The commissioning team will instruct the operators and Contractor’s staff on the use of appropriate
test equipment.

Additionally, full instruction will be given on determination of chemical dose rates and operational
procedures to achieve them.

The Acceptance Test will normally be the responsibility of contractor’s staff, but commissioning staff
will be available for process advice when necessary.

Collection of water samples and subsequent delivery to an independent laboratory will be the
responsibility of Contractor’s staff.

It should be noted that samples for bacteriological analysis should be tested as soon as possible after
collection. Samples for chemical analysis are not so critical.

It is required is of JBALB representatives that they acknowledge the period of operation defined as
the acceptance test.

Quality based on the results must be to National Water Quality Standard for Malaysia (NWQS). What
are specified must meet the NWQS standard to achieve KPI.

N.B. JBALB representatives are not being asked to 'accept' or take over schemes. All that is
required of them is to witness the proceedings and if necessary, to draw up a 'snag list’ of
items considered incomplete or defective. This snag list, together with any comments
considered appropriate, should be referred to JBALB Regional Office/JBALB Divisional who
is the agency responsible for accepting schemes.

Page | 18
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Page | 19
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

INTAKE/RAW WATER PUMP

1. Run each pump for approximately 1 hour to check current consumption.
Rated Full Measured FLC (A) Measured FLC (A)
Load
Unit
Current R Y B R Y B
(FLC) (A)
PUMP 1
PUMP 2
PUMP 3
PUMP 4

2. Close inlet penstocks/valves and run pumps to check

operation of low level shut-off

Water level at shut-off Meter

3. Check drawdown in sump; inside/outside level difference Meter

4. Run pumps until steady state conditions achieved; note

discharge pressure and flow rate (see attached data sheet
A). Note: To simulate output at 0%, 25%, 50%, 75% &
100% via manual valve control or via Variable Speed Drive
(VSD) control.
Plot data on manufacturers test certificate performance Yes No
satisfactory
Commissioning complete, system ready for use. Yes No

Remarks:

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date
Page | 20
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

AERATOR
1. With system in operation, check weir levels under dynamic conditions.
Unit No. Top Mid Lower
North
East
South
West

Yes No

Within tolerance ± 3mm

Commissioning complete, system ready for use. Yes No

Remarks:

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

Page | 21
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
FLOCCULATORS

1. With units in operation, check weir levels.

Unit No.1 (Meter) Unit No.2 (Meter) Unit No.3 (Meter)
North
East
South
West

Within tolerance ±3mm

Yes No

2. Run Flocculator/scraper gearboxes for 1 Hours to check current consumption.

Unit No.1 Flocc G/bx A Floc G/bx B S per G/bx

Rated FLC (A)
Measured FLC (A) R Y B R Y B R Y B
Design S speed (RPM)
Actual S speed (RPM)
Unit No.2 Flocc G/bx A Flocc G/bx B Scraper G/bx
Rated FLC (A)
Measured FLC (A) R Y B R Y B R Y B
Design S speed (RPM)
Actual S speed (RPM)
Unit No.3 Flocc G/bx A Flocc G/bx B Scraper G/bx
Rated FLC (A)
Measured FLC (A) R Y B R Y B R Y B
Design S speed RPM)
Actual S speed (RPM)

Check for uncharacteristic noise or vibration whilst gearboxes are in operation.

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 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

3. Check operation of torque switch; Yes No

Satisfactory

4. Unit performance check

Turbidity (water in) Turbidity (water out)
Unit No.
Unit No.
Unit No.

Yes No
Commissioning complete, system ready for use.

Remarks:

Certified by Witnessed by JBALB

Checked by Contractor
Consultant Representative
Name
Signature
Designation
Date

Page | 23
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

FLOCCULATOR/CLARIFIERS/SEDIMENTATION TANK

1. With unit in operation, check weir levels.

Percentage length of Unit No. Unit No. Unit No.
weir (%)
0
33
67
100

Yes No
Within tolerance ±3mm
2. Check drainage line adequacy during conditions of unit
draindown and overflow. Satisfactory

3. Performance check: Turbidity

Turbidity Turbidity (water
(water in) out)
Unit No.
Unit No.
Unit No.
Commissioning complete, system ready for use Yes No

Remarks:

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

Page | 24
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

RAPID GRAVITY FILTERS

1. Check filters performances at normal and maximum rated flows.
Plant throughput ……………….m3/hour (as measured by plant inlet flow meter)
Head over
Filter No. Filter No. Filter No. Filter No.
cleaned media
Normal rated
flow
…………m3/ho
ur
Max flow (1 unit
back-washing)
………….m3/ho
ur
Backwash (w/o
air) head over
weir
Backwash (with
air) head over
weir
Yes No
2. Drain down filters to backwash weir level and check
even air distribution; satisfactory
3. Backwash flow rate (w/o air) set at m3/hour
4. Backwash flow rate (with air) set at m3/hour
5. Air scour pressure from blower bar
3
6. Design air flow rate m /min
Yes No
7. Check media surfaces level after backwashing
8. Check drainage line adequacy during conditions of
drain down and backwash – Satisfactory
9. Unit drain down time from full

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 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

10. System performance check

Turbidity (water in) Turbidity (water out)

Filter No.
Filter No.
Filter No.
Filter No.

Yes No
Commissioning complete systems ready for use.

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

Page | 26
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

BACKWASH PUMPS
1. Run each pump for 10mins to check current consumption.
Measured Full Load Current
Unit Rated Full Load Current (FLC) (A) (FLC) (A)
R B Y
Pump
Pump
Pump

2. Run each pump for 2 hours or until bearing/gland

temperature is stabilized; check temperature. Check
motor and pump for noise, vibration, adjust gland
leakage. Yes No
Satisfactory Pump
Pump
Pump
3. Check pump controls:
Balance tank low level shut off
Backwash tank high level shut off
4. Run pumps; take readings of discharge pressure and
flow rate (see data sheets …………… attached). Note:
To simulate output at 0%, 25%, 50%, 75% & 100% via
manual valve control. or via Variable Speed Drive
(VSD) control.
Plot points on manufacturers test curve Yes No
Performance satisfactory Pump
Pump
Pump

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 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

5. Checks pumps speeds at maximum flow (valves fully open)

Unit Rated speed (RPM) Measured speed (RPM)

Pump
Pump
Pump

Commissioning complete systems ready for use. Yes No

Remarks:

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

Page | 28
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

TREATED WATER PUMPS

1. Manufacturers pre-start checks complete Yes No

2. Run each pump for approx. 60 minutes, to check current consumption.

Unit Rated Full Load Measured Full Load Current (FLC), (A)
Current
(FLC),(A) R Y B

Pump
Pump
Pump
Pump
Pump
Pump

3. Run each pump for 2 hours or until Bearing/Gland temperature is constant. Check motor and pump for
uncharacteristic noises or vibration. Adjust gland leakage.
Satisfactory Unit Yes No
Pump
Pump
Pump
Pump
Pump
Pump

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 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

5. Check pump controls Unit Low Level High Level

(Balance Tank) (Treated W.T)
Pump
Pump
Pump
Pump
Pump
Pump
Time Level
Pumps restart automatically after
6. Run pumps; take readings of Unit Yes No
discharge pressure and flow rate
Pump
(see data sheet …………)
Pump
Pump
Note: To simulate output at 0%,
25%, 50%, 75% & 100% via Pump
manual valve control. or via Pump
Variable Speed Drive (VSD) Pump
control.

Performance satisfactory
7. Check pump/motor speeds
Unit Pump Pump Pump Pump Pump Pump
Rated speed (RPM)
Measured speed (RPM)
Commissioning complete; system ready for use Yes No

Remarks:

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

Page | 30
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

AIR BLOWERS
1. Manufacturers start-up procedure complete Unit Yes No
Blower
Blower

2. Measure current consumption under load (A)

Unit Rated D. Actual D. Rated FLC Measured FLC (A)

Pressure (kPA) Pressure (A)
(kPA)
Blower R Y B
Blower

Yes No
Satisfactory

3. Blower Speed Unit Rated Flow Rate (m3/h) Actual Flow Rate (m3/h)
Blower
Blower
4. Remote start checked Yes No

5. Check operation of air relief valves

Unit Rated Relief Pressure Actual Relief Pressure (Kpa)
(kPA)
Blower
Blower

6. Measure noise level (1m) Blower dBA

Blower dBA

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

Page | 31
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

MOTIVE WATER PUMP

1. Manufacturer pre-start checks complete Yes No
Pump
Pump

2. Check current consumption under operating conditions:

5 eductors in service
Measured FLC (A) Discharge Discharge
Unit No. Rated FLC (A) Pressure Flowrate
R Y B (kPA) (kPA)
Pump
Pump

3. Check pump controls: Low level shut-off:

Unit No. Level in Balance Tank
Pump
Pump

4. Check discharge pressure with educator in service.

Unit No. 3 Eductor 4 Eductor 5 Eductor
Pump
Pump

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

Page | 32
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

SLUDGE TANK
1. Manufacturer pre-start checks complete Yes No

2. Run each pump for approximately 60 minutes to check current consumption

Measured FLC (A)
Unit No. Rated FLC (A)
R Y B
Pump
Pump

3. Run pumps to low level in order to check automatic shut off; level at shut off.
4. Check pump discharge capacity by volumetric method
Pump Pump
Time Interval hours hours
Draw down volume m3 m3
3 3
Estimated flow rate m /h m /h
Yes No
Commissioning complete, system ready to use.

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

Page | 33
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

ALUM DOSING SYSTEM

1. Fill mixing tanks; check operation of mixer
Measured FLC (A) Rated Speed Measure Speed
Unit Rated FLC (A)
R Y B (RPM) (RPM)
Mixer
Mixer

2. Measure usable volume

Unit Length Width Depth Volume
Tank
Tank
3. Fill constant head tank; connect system to appropriate educator; check capacity is sufficient for
full flow meter reading
Satisfactory Unit Yes No
Educator
Educator

Commissioning complete, system ready to use.

Yes No

Remarks:

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

Page | 34
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

SODA ASH DOSING SYSTEM

1. Fill mixing tanks; check operation of Feeders, vibrators, and mixer motors.
Rated Measured FLC (A)
Unit
FLC (A) R Y B
Feeder
Feeder
Mixer
Mixer
Vibrator
Vibrator

2. Check mixer speeds

Unit Rated Speed (RPM) Measured Speed (RPM)
Mixer
Mixer
3. Vibrator operation checks
Unit No. Interval Set Interval Measured Duration Set Duration
Measured
Vibrator
Vibrator
4. Heater operation check
Unit No. Temperature Set (ºC)
Heater
Heater
Measured Current
Unit No Rated Current (A)
(A)
Heater
Heater

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 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

5. Check calibration of powder feeders.

6. Connect systems to appropriate educators and check educator capacity is sufficient for
maximum weir settings
Satisfactory System Yes No
No.
No.

7. Check operation of dust collection system.

Measured FLC (A)
Unit Rated FLC (A)
R Y B
Fan motor

Commissioning complete, system ready for use. Yes No

Remarks:

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

Page | 36
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

CHLORINE DOSING SYSTEM

1. Check all gas pipework joints for leaks using ammonia vapor.
Yes No
2. Manufacturers pre-start up checks complete

Satisfactory Unit Yes No

Chlorine
Dosing
Chlorine
Dosing
Chlorine
Dosing
3. Check operation changeover panel.

Commissioning complete, system ready for use. Yes No

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

Page | 37
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

OVERHEAD TRAVELLING CRANE

Yes No
1. Alignment check complete
2. Manufacturers test certificate attached

3. Vertical deflection test of crane bridge caused by hoist plus Safe Working Load (SWL) in
central position.
Span
Permitted maximum deflection (span – 750)
Measured deflection To Be Inspected by JKKP
4. Load hook through full travel with Safe Working Load
5. Crane travelled full length with Safe Working Load
Yes No
6. JKKP type approval
7. JKKP installation approval & Certificate (See Attached
Certificate)

Commissioning complete, system ready for use. Yes No

Remarks:

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

Page | 38
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

GENERATORS
Yes No
1. Manufacturers test certificate attached
2. D.O.E Application
Rated Actual
3. Oil pressure switch operation kPA kPA
o o
4. Water temperature switch operation C C
5. Engine over-speed switch operation rpm rpm
6. Trip-on control circuit voltage failure
7. Noise measured (in dBA) North South East West
Measured 3 m from exhaust
Measured 3 m from outer wall
Yes No
8. Test generator over six consecutive starts

Commissioning complete, system ready for use. Yes No

Remarks:

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

Page | 39
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

SURGE SUPPRESSION EQUIPMENT

(Where Surge Suppression Equipment fitted, commissioning will be carried out under section
2)
a) Pump start up: Observed pressure Max Min
b) Pump shut down: Observed pressure Max Min

Pressure Set Point: bar

Level Set Point: m

Yes No

JKKP type approval

JKKP installation approval & Certificate (See Attached
Certificate)

Commissioning completed. Yes No

Remarks:

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

Page | 40
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

CLARITY BOWL/SAMPLING SYSTEM

Pumps
1. Manufacturers pre-start checks complete Units Yes No
RW Pump
SW Pump
FW Pump
TW Pump

2. Run each pump for 10 minutes to check current consumption

Unit Rated FLC (A) Measured FLC (A)
RW Pump
SW Pump
FW Pump
TW Pump
3. Run each pump for 60 minutes to checks running temperature, no mechanical seal leakage and
no uncharacteristic noise or vibration
4. If sample points supplied by gravity, check discharge into clarity bowl is sufficient
Sample Point Yes No
RW
SW
FW
TW
Commissioning complete, system ready for use. Yes No

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

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 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
TELEMETRY SYSTEM

Station Name: ……………………………………………….

1. I/O Check
PROCEDURE
- For input/output signal to/from the PLC DI Card. Use signal simulator or wire to
simulate at the respective terminal block, simulate the selector switch, push button
and equipment.
- Verify correct input/output status at PLC DI Card and indicating light/alarm
annunciator and Graphic SCADA System.

TEST CRITERIA
- The PLC DI and SCADA System shall receive the signal.
- The LED status at the PLC DI module and equipment status at SCADA shall turn off when the
simulated signal is disabled.
DIGITA
L INPUT SCADA GRAPHIC
DESCRIPTION /OUTPU REMARKS
TADDR YES NO
ESS

Certified by Witnessed by JBALB

Checked by Contractor
Consultant Representative
Name
Signature
Designation
Date

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 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
2. ANALOG INPUT/OUTPUT SIGNAL TO/FROM SCADA (PLC LOGIC TEST)
PROCEDURE
1. Determine the loop is internally powered or externally powered from the schematic
diagram.
2. Connect the + and – wires of the signal injector to the 4-20mA input terminals
at…(Station Name)….……..Panel and set the signal injector according to the loop power
condition.
3. Simulate the signal to 0%, 25%, 50%, 75%, 100% of the instrument range.

TEST CRITERIA
- The SCADA shall give the output signal according to signal simulated.

Equip. Description :
Simulated Range : 4 – 20 mA
Input Range :
Simulated Range
Desired Value Displayed Value Remarks
(mA)
4
8
12
16
20

Commissioning complete systems ready for use.

Certified by Witnessed by JBALB

Checked by Contractor
Consultant Representative
Name
Signature
Designation
Date

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 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

ACCEPTANCE TESTS FOR WATER TREATMENT PLANTS

ACCEPTANCE TESTS FOR TREATMENT WORKS

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 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

ACCEPTANCE TESTS FOR WATER TREATMENT PLANTS

FILTER PERFORMANCE TESTS

1. Establishment of Service Duration

Record head loss due to progressive clogging, and turbidity, commencing immediately after
an extended backwash (to ensure clean media). See data sheet attached.

Filter No. Bed Area m2

Max head loss (Design) m
Recommended Service Duration hours
Head loss at end of Service Duration m

2. Backwash Performance (as applicable)

2.1 Separate Air Scour/ Water Wash

Record Turbidity of wash water during backwash (see attached sheet)

Design Recommended
Air Scour Duration minutes minutes
Backwash Duration minutes minutes
Backwash Flow m3/hr m3/hr

2.2 Combined Air Water Scour/Water backwash

Record Turbidity of wash water during both sequences (see attached sheet)

Design Recommended
Air/Water Scour Duration minutes minutes
Air/Water Scour Flow m3/hr m3/hr
Wash Water Duration minutes minutes
Wash Water Flow m3/hr m3/hr

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 Contract No:

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PLANT Date:

ACCEPTANCE TESTS FOR WATER TREATMENT PLANTS

3. Performance Check for Multiple Filter Banks

Check filters bank performance under conditions of increased unit flow due to filter washing
in progress.

Total number of filter units

Filter in service
Filter undergoing wash sequence
Plant flow m3/hr
Normal flow per unit m3/hr
Flow during wash sequence (max) m3/hr
Filter under test
Hours in service

Flow Normal Flow Max

Turbidity of Influent
Turbidity of Effluent
Aluminium Cont. Influent
Aluminium Cont. Effluent

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 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

ACCEPTANCE TESTS FOR WATER TREATMENT PLANTS

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 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

ACCEPTANCE TESTS FOR WATER TREATMENT PLANTS

Project Name : Capacity : m3/hr
Work Contract No. : Operation : hr/d

JAR TEST REPORT

Sample: Date:
Raw Water Quality
pH Al, mg/L
Turbidity, NTU Iron, mg/L
Colour, Pt.Co Mn, mg/L
Alkalinity, mg/L
Jar Test
Jar No. 1 2 3 4 5 6
Pre-Soda Ash %, mg/L
1st pH Reading
Alum %, mg/L
Coagulant Aid ( %), mg/L

Rapid Mixing, rpm ( rpm)

Flocculants % ppm

Med Mixing, rpm ( rpm)

Slow Mixing, rpm ( rpm)

Water Settling Time ( ) min

Floc Size
Settled Water Turbidity, NTU
Settled Water pH
Settled Water Colour, Pt.Co
Alkalinity, mg/L
Residue Mn, mg/L
Residue Iron, mg/L
Residue Aluminium, mg/L

Filtered Water Turbidity, mg/L

Filtered Water Colour, Pt.Co

Best Selection
Comment :

Witnessed by JBALB
Checked by Contractor Certified by Consultant
Representative
Name
Signature
Designation
Date

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 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

ACCEPTANCE TESTS FOR WATER TREATMENT PLANTS

TABLE A : Pump Monitoring Checklist

Pump Tested:
Bearing Check 40 -60 C
Motor Abnormal Noise
Time (Every Hour) Pump Any leaks visible
and/or vibration
DE NDE DE NDE

Remarks:

Note:
DE – Drive End
NDE – Non Drive End

Certified by Witnessed by JBALB

Checked By Contractor
Consultant Representative
Name
Signature
Designation
Date

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 Contract No:

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Rev: 1
PLANT Date:

TABLE B: Unless otherwise specified Tests carried out in accordance

PUMP TEST CERTIFICATE with BS5316 Part 1, Class C
PROJECT: PUMP TESTED:

PUMP SIZE: SERIAL NO:

DRIVER: IMPELLER DIA: MM INLET/OUTLET DIA: MM
TYPE: ORIFICE PLATE
MM
DIA:
MAKE: FLOW RATE: m3/h
MODEL: RPM: TOTAL HEAD: M
POWER: CURRENT:
VOLTAGE: PHASE:
SUCTION PRESSURE GAUGE LEVEL: M
DISCHARGE PRESSURE GAUGE LEVEL: M
DISCHARGE SUCTION V2/2g TDH VOLT AMP P.F PUMP
MOTOR
FLOW PRESSURE PRESSURE .
TEST
(m3/h) (M) (M) BHP WHP EFF RPM
NO. INPUT POWER EFF %
%
(M) (M) (V) (kW) kW kW

Checked By Contractor Certified by Consultant Witnessed by JBALB Representative

Name
Signature
Designation
Date

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 Contract No:
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PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

LIST OF EQUIPMENT

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PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

LIST OF EQUIPMENTS

1. Raw Water Intake Pump

Pump Brand/Make
Pump Model
Pump Serial No.
Pump Head m
Design Flow Rate m3/hr
HP
Power kW
Rated current A
Voltage/Phase V/Phase
Motor Brand/Make
Motor Model
Motor Serial No.
Motor Speed rpm
Motor Frequency Hz
Class

2. Treated Water Pump

Pump Brand/Make
Pump Model
Pump Serial No.
Pump Head m
Design Flow Rate m3/hr
HP
Power kW
Rated current A
Voltage/Phase V/Phase
Motor Brand/Make
Motor Model
Motor Serial No.
Motor Speed rpm
Motor Frequency Hz
Class

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PLANT Date:

3. Back Wash Water Pump

Pump Brand/Make
Pump Model
Pump Serial No.
Pump Head m
Design Flow Rate m3/hr
HP
Power kW
Rated current A
Voltage/Phase V/Phase
Motor Brand/Make
Motor Model
Motor Serial No.
Motor Speed rpm
Motor Frequency Hz
Class

4. Air Blower
Blower Brand/Make
Blower Model
Blower Serial No.
Blower Capacity m3/hr

Blower Discharge Pressure bar

Motor Brand/Make
Motor Model
Motor Serial No.
Motor Power kW
Motor Rated current A
Motor Voltage/Phase V/Phase
Motor Speed rpm
Motor Frequency Hz
Class

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 Contract No:
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PLANT Date:

5. Sampling Pump
Sample Type
Pump Brand/Make
Pump Model
Pump Serial No.
Pump Head m
Design Flow Rate l/min
Power kW
Rated current A
Voltage/Phase V/Phase
Motor Speed rpm
Motor Frequency Hz
Class

6. Chemical Dosing Pump

Chemical Type
Pump Brand/Make
Pump Model
Pump Serial No.
Max Pressure Bar
Max Flow Rate l/hr
Rated current A
Voltage/Phase V/Phase
Motor Speed rpm
Motor Frequency Hz
Class

7. Agitator/Mixer
Chemical Type
Brand/Make
Model
Serial No.
Motor Brand/Make
Motor Model
Motor Power kW
Motor Rated current A
Voltage/Phase V/Phase
Motor Speed Rpm
Motor Frequency Hz
Gear Model
Gear Speed Rpm

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PLANT Date:

8. Monitoring Instruments
Parameter monitored
Instrument Brand/Make
Instrument Model
Instrument Serial No.
Measure (ie pH, NTU,mg/l)
Output mA
Rated current A
Voltage/Phase Voltage/Pha
se
Rated Frequency Hz
Class

9. Chlorination System
9.1 Vacuum Regulator
Brand/Make
Type
Model
Heater Make
Heater Type
Power Rating kW
Voltage/Frequency/Current V/Hz/A
9.2 Chlorinator
Brand/Make
Type
Model
Max Capacity kg/hr
Motor Make
Motor Type
Power Rating kW
9.3 Changeover Manifold
Brand/Make
Type
Serial No.
Range
9.4 Injector
Brand/Make
Type
Serial No.
Max Capacity kg/hr

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 Contract No:
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PLANT Date:

10. Fluoride System

Brand/Make
Model
Serial No.
Power Rating kW
Class
Voltage/Frequency/Current V/Hz/A
11. Pressure Transmitter
Instrument Brand/Make
Instrument Model
Instrument Serial No.
Measure (ie pH, NTU,mg/l)
Output mA
Rated current A
Voltage/Phase V/Phase
Rated Frequency Hz
Class

12 Crane
Brand/Make
Type
Model
Country
Year
Equipment Serial No.
Hoist Serial No.
PMA Registration No.
Hoisting Capacity Ton

13. Sludge Collector

Type
Brand/Make
Model
Serial No.
Speed Rpm
Power kW
Rated Current A

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 Contract No:
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PLANT Date:

14. Air Compressor

14.1 Compressor
Brand/Make
Model
Serial No.
Piston Displacement
Max Discharge Pressure Bar
Design Duty Pressure Bar
Free Air
Noise Level dB
14.2 Motor
Brand/Make
Type
Model
Serial No
Power kW
Voltage/Phase V/Phase
Rated Current A
Speed Rpm
Class

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 Contract No:
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PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

Appendix
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Appendix (A)

PRE-COMMISSIONING CHECKLISTS FOR WATER TREATMENT PLANTS

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 Contract No:

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PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
INTAKE

General Yes No
1. Installation/assembly complete and in accordance with drawings
2. Forebays and sumps free from construction debris

3. Screens cleaned

4. Penstocks operated over full travel

5. Penstocks tested for leaks at high river level

6. Pump discharge valves: Operated over full travel

7. Pump discharge NRV’s: Correctly installed

8. Raw water pipeline: Valves operated over full travel

9. Raw water pipeline: Pressure test completed (see attached sheets)

10. Cables: Insulation/termination checks completed (see attached data

sheets)
11. Surge protection checked

Lifting Gear
1. Safe Working Load painted on lifting gear ……………….Tonnes

2. Chain lubricated

3. Load hook operated over full travel

4. Raw water pumps: Removed and installed

5. For ‘A’ frame: Travelled full length with pump
Travelled full width with pump
6. Paintwork satisfactorily/made good
Pumps
1. Pump manufacturers pre-start up checks complete (see attached sheets) Yes No
Pump
Pump
Pump
Pump
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PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

2. Raw water pipeline ready to receive and dispose of water

3. Intake sump: Adequate water level
4. Intake sumps LLS electrode checked and operational (test by shorting
link)
5. MCC function check (main fused removed)
Motors
1. Pump motor insulation resistance check (≥20MegaOhm) R (MΩ) Y (MΩ) B (MΩ)
Pump
Pump
Pump
2. Switchgear over current protection set at :
Pump A

Pump A

Pump A

Pump A

Yes No
1. Motor winding thermister checked
2. Pump/motor rotation check: (CCW/CW) Pump

Pump

Pump

Pump
3. Earth conductivity tests carried out ( see attached data sheets)
Above checks satisfactorily completed
Witnessed by JBALB
Checked Sub-Contractor Supervised by Consultant
Representatives
Name
Signature
Designation
Date

Page | 60
 Contract No:

TESTING AND COMMISSIONING

PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

AERATOR Yes No
1. Installation/assembly complete and in accordance with drawings.
2. Aerator channels and chambers cleared of construction debris and
flushed through.
3. Aerator inlet and drain valves operated over full travel.
4. Leakage test completed.
5. Check dosing points in accordance with drawings.
Above checks satisfactorily completed.

Witnessed by JBALB
Checked Sub-Contractor Supervised by Consultant
Representatives
Name
Signature
Designation
Date

Page | 61
 Contract No:

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PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
FLOCCULATORS Yes No
1. Installation/assembly complete and in accordance with drawings
2. All clarifier channels, sumps and pipes flushed through
3. Overflows and drains ready to receive and dispose of water
4. All valves operated over full travel
5. Path of scraper assembly checked for obstruction; clearance………
6. Scraper paintwork checked
7. Scraper torque limit switch set Unit No.
Unit No.
Unit No.
8. Gearbox oil levels checked: Unit No. Flocc G/bx A
Flocc G/bx B
Scraper G/bx
Unit No. Flocc G/bx A
Flocc G/bx B
Scraper G/bx
Unit No. Flocc G/bx A
Flocc G/bx B
Scraper G/bx
9. Switchgear over current protection Unit No. Flocc G/bx A
set at MCC: Flocc G/bx B
Scraper G/bx
Unit No. Flocc G/bx A
Flocc G/bx B
Scraper G/bx
Unit No. Flocc G/bx A
Flocc G/bx B
Scraper G/bx

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PLANT Date:

PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

10. Motor Insulation Resistance checks (≥20 MegaOhm) R (MΩ) Y (MΩ) B (MΩ)
Unit No. Flocc G/bx A
Flocc G/bx B
Scraper G/bx
Unit No. Flocc G/bx A
Flocc G/bx B
Scraper G/bx
Yes No
11. Rotation correct (CCW/CW) Unit No. Flocc G/bx A
Flocc G/bx B
Scraper G/bx
Unit No. Flocc G/bx A
Flocc G/bx B
Scraper G/bx
Unit No. Flocc G/bx A
Flocc G/bx B
Scraper G/bx
Above checks completed satisfactorily :
Unit No.
Unit No.
Unit No.
Remarks:

Checked Sub- Supervised by Witnessed by JBALB

Contractor Consultant Representatives
Name
Signature
Designation
Date

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PLANT Date:

PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

FLOCCULATOR/CLARIFIERS Yes No

1. Installation/assembly complete and in accordance with drawings.

2. All flocculator/clarifier channels, sumps, pipes, spaces and launders
cleared of construction debris, and flushed through.
3. Penstocks and valves operated over full travel.
4. Overflows and drains ready to receive and dispose of water.
5. Leakage test carried out (see attached cert.)
Above checks completed satisfactorily:
Unit No.
Unit No.
Unit No.

Remarks:

Checked Sub-Contractor Supervised by Witnessed by JBALB

Consultant Representatives
Name
Signature
Designation
Date

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 Contract No:
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PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

RAPID GRAVITY FILTERS Yes No

1. Installation/assembly complete and in accordance with drawings

2. All channels, sumps, pipes and spaces cleared of construction debris
3. Penstocks and valves tested over full travel
4. Overflows, drains and weir ready to receive water
5. Pipework pressure tests completed (see attached cert.)
6. Tank leakage test completed (see attached cert.)
7. Filter media placed, levelled, depth checked
depth of gravel
depth of sand

Test results for media, see attached sheets

8. Wash water weir level check

Weir length % Filter No. Filter No. Filter No. Filter No. Filter No. Filter No.
0
33
67
100
Yes No
Within tolerance +3 m
9. Inlet penstock weir level checked
10. Air blower delivery rate ( from manufacturers cert.)

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PLANT Date:

PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Above checks completed satisfactorily : Yes No

Unit No.
Unit No.
Unit No.
Unit No.
Unit No.
Unit No.

Witnessed by JBALB
Checked Sub-Contractor Supervised by Consultant
Representatives
Name
Signature
Designation
Date

Page | 66
 Contract No:
TESTING AND COMMISSIONING
PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
BACKWASH PUMPS Yes No
1. Installation/assembly complete and in accordance with drawings
2. Pumps suction/discharge valves operated over full travel
3. Pumps NRV’s correctly installed
4. Air release isolating valves operated over full travel
5. Pipeline pressure tests complete (see attached cert.)
6. Cables: Insulation/determination checks complete
(see data sheet……………….)
7. Adequate level in balance tank
8. Coupling alignment checks
Pump No. Parallel (mm) Angular (mm)
Pipework Pump / /
coupled Pump / /
Pump / /

Pipework Pump / /
uncoupled
Pump / /

Pump / /

Manufacturers permitted tolerance:

Parallel (mm)
Angular (mm)
Values within permitted range: Yes No
Pump
Pump
Pump

Sub-Contractor Supervised by Consultant Witnessed by JBALB

Name
Signature
Designation
Date
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PLANT Date:

PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
R Y B
MOTORS
(MΩ) (MΩ) (MΩ)
Motor insulation resistance check (≥20 MegaOhm)
1. Pump
Pump
Pump
2. Switchgear over current protection set at;
Pump Amps
Pump Amps
Pump Amps
3. Pump/motor rotation check carried out; (CCW/CW) Yes No
Pump
Pump
Pump
4. Earth conductivity tests carried out (see data sheet…………………….)
Remarks:

Witnessed by JBALB
Checked Sub-Contractor Supervised by Consultant
Representatives
Name
Signature
Designation
Date

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 Contract No:
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PLAN FOR WATER TREATMENT Rev: 1
PLANT Date:

PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
TREATED WATER PUMPS Yes No
1. Installation/assembly complete and in accordance with drawings
2. Pumps suction/discharge valves operated over full travel
3. Pumps NRV’s correctly installed
4. Air release isolating valves operated over full travel
5. Pipeline pressure tests complete (see attached cert.)
6. Cables: Insulation/determination test complete (see attached data sheet)
7. Adequate water level in balance tank
8. Coupling alignment checks
Pump No. Parallel (mm) Angular (mm)
Pipework Pump / /
uncoupled Pump / /
Pump / /
Pump / /
Pipework Pump / /
coupled Pump / /
Pump / /
Pump / /

Yes No
Values within manufacturers range

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PLANT Date:

PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

MOTORS
1. Motor insulation resistance check (≥20Megaohm) R (MΩ) Y (MΩ) B (MΩ)
Pump .
Pump .
Pump .
Pump .
2. Switchgear over current set Unit Current (A)
Pump
Pump
Pump
Pump
Pump
Pump
3. Pump/motor rotation check: Clockwise (CW) Counter
clockwise (CW)
Pump
Pump
Pump
Pump
Pump
Pump
Yes No
4. Earth continuity checks carried out (see attached data sheet )
5. Low level shut-off probes checked (by shorting)

Above checks satisfactorily completed

Checked Sub-Contractor Supervised by Witnessed by JBALB
Consultant Representatives
Name
Signature
Designation
Date

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PLANT Date:

PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
AIR BLOWERS Yes No
1. Installation/assembly complete and in accordance with drawings
2. All valves operated over full travel
3. NRV’s correctly installed
4. Belt alignment/tension check (see manufacturers instruction Blower
attached) Blower
5. Cables: Insulation/determination checks complete (see data sheets…)
MOTOR
6. Insulation resistance checked
R(MΩ) Y (MΩ) B (MΩ)
Blower
Blower
Units Amps
7. Switchgear over current protection set Blower
Blower
8. Blower/motor rotation check: Units Clockwise Counterclock
(CW) wise (CCW)
Blower
Blower
9. Earth continuity checks carried out ( see data sheet................)
Above checks satisfactorily completed.

Checked Sub- Supervised by Witnessed by JBALB

Contractor Consultant Representatives
Name
Signature
Designation
Date

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PLANT Date:

PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

MOTIVE WATER PUMPS (Submersible Pump) Yes No

1. Installation/assembly complete and in accordance with drawings
2. Pumps suction/discharge valves operated over full travel
3. Pump NRV’s correctly installed
4. Air release isolating valves operated over full travel
5. Eductor isolating valves operated over full travel
6. Pipeline pressure tests complete (see attached cert.)
7. Cables: Insulation/determination tests complete (see data sheet................)
8. Measure motor insulation resistance (≥20 MegaOhm)
Unit No. R (MΩ) Y (MΩ) B (MΩ)
Motor
Motor
9. Switchgear over current protection set Units Amps
Pump
Pump
10. Earth continuity checks carried out ( see data sheet................)

Above checks satisfactorily completed.

Checked Sub- Supervised by Witnessed by JBALB

Contractor Consultant Representatives
Name
Signature
Designation
Date

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PLANT Date:

PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

BACKWASH TANK (CLEAR WATER TANK) Yes No

1. Installation/assembly complete and in accordance with drawings
2. Tank clean internally and free from construction debris
3. Valves operated over full travel.
4. Pipework pressure tests complete. (see attached cert.)
5. Airvent clear, screen in position.
6. Surface coating checked.
7. Tank leakage test complete (see attached cert.)
8. Tank disinfection complete (see attached cert.)

Above checks satisfactorily completed, system ready for use.

Checked Sub- Supervised by Witnessed by JBALB

Contractor Consultant Representatives
Name
Signature
Designation
Date

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Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
CONTACT/BALANCE TANK ( ML Reservoir ) Yes No

1. Installation/assembly complete and in accordance with drawings.

2. All channels, sumps, pipes and spaces cleared of construction debris and
flushed through.
3. Valves operated over full travel.
4. Over flows and drains ready to receive and dispose of water.
5. Surface coating checked ( where applicable ).
6. Pipeline pressure tests complete (see attached cert.).
7. Tank leakage test complete (see attached cert.).
8. Tank disinfection complete (see attached cert.).
9. Check adequacy of drainage under conditions of overflow and tank drain
down, satisfactory.
10. Time taken to drain unit from full.

Above checks satisfactorily completed, system ready for use.

Checked Sub-Contractor Supervised by Witnessed by JBALB

Consultant Representatives
Name
Signature
Designation
Date

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Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
Yes No
SLUDGE TANK
General
1. Installation/assembly complete and in accordance with drawings
2. Tank/sump free from construction debris
3. Pumps discharge valves operated over full travel
4. Pump discharge NRV’s correctly installed
5. Pipeline tests complete (see attached cert.)
6. Cables: Insulation/determination tests complete (see data sheet................)

Lifting Gear
1. SWL..................................painted on lighting gear
2. Chain lubricated
3. Load hook operated over full travel
4. Sludge pumps removed and re-installed
5. Paint work made good

Pumps
1. Pump manufacturers pre-start up checks complete (see attached Pump
sheets)
Pump
Pump
2. Adequate water level in tank
3. LLS electrode checked (by shorting link)

Motors
1. Motor insulation resistance check (≥20 MegaOhm):
Unit R (MΩ) Y (MΩ) B (MΩ)
Pump
` Pump
Pump

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2. Switchgear over current protection set; Pump Amps

Pump Amps
Pump Amps
3. Pump rotation check: correct Yes No
Pump
Pump
Pump
4. Earth continuity tests carried out (see attached data sheet.........................)

Above checks satisfactorily completed.

Checked Sub- Supervised by Witnessed by JBALB

Contractor Consultant Representatives
Name
Signature
Designation
Date

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PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
ALUM DOSING SYSTEM Yes No
1. Installation/assembly complete and in accordance with drawings
2. Tanks and pipework free from construction debris
3. All valves operated over full travel
4. NRV’s correctly installed
5. Mixing tank linings, visually checked.
6. Leakage test complete (see attached cert. )
7. Cables: Insulation/determination tests complete (see data sheet................)
8. Mixer motors insulation resistance (≥20 MegaOhm)
Unit No. R (MΩ) Y (MΩ) B (MΩ)
Motor
Motor
9. Switchgear over current protection set: Unit No. Current (A)
Motor
Motor

Yes No
10. Earth continuity checks carried out (see attached data sheet..........)

Above checks satisfactorily completed.

Checked Sub- Supervised by Witnessed by JBALB

Contractor Consultant Representatives
Name
Signature
Designation
Date

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Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
SODA ASH DOSING SYSTEM Yes No
1. Installation/assembly complete and in accordance with drawings.
2. Tanks and pipework free from construction debris.
3. All valves operated over full travel.
4. Cables: Insulation/determination tests complete (see data sheet................)
5. ‘V’ notch weirs adjusted over full travel.
6. Hopper vibrator air gap set at 2.54mm. Feeder
Feeder
7. Hopper vibrator timer set Unit Duration Interval
Feeder
Feeder 2
8. Hopper heater timer set Unit Temperature (ºC)
Feeder
Feeder
9. Motor insulation resistance checked (≥20MegaOhm)
Unit No. R (MΩ) Y (MΩ) B (MΩ)
Feeder
Feeder
Mixer
Mixer
Vibrator
Vibrator
10. Switchgear over current protection set: Unit No. Current (A)
Feeder
Feeder
Mixer
Mixer
Vibrator
Vibrator

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11. Dust extractor fan motor insulation check

R (MΩ) Y (MΩ) B (MΩ)

12. Fan motor over current protection set Amps

Above checks satisfactorily completed.

Checked Sub- Supervised by Witnessed by JBALB

Contractor Consultant Representatives
Name
Signature
Designation
Date

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Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
CHLORINE DOSING SYSTEM Yes No
1. Installation/assembly complete and in accordance with drawings
2. Valves operated over full travel
3. Cables: Insulation/determination tests complete (see data sheet................)
4. Chlorine gas detector: installed and operative
5. Chlorine gas exhaust fan operational
Insulation resistance check R (MΩ) Y (MΩ) B (MΩ)
Over current protection set Amps Amps Amps
Rated FLC (A) Measured FLC (A)
Measure running current R Y B
Yes No
6. Hazard warning labels fitted outside chlorine room and chlorine store
7. Safety wall chart: Yes No
a) Operation of chlorine equipment
b) Location of safety/First Aid Equipment

c) First Aid Instructions

8. First Aid Kit complete and in place
9. Safety clothing, respirators/breathing apparatus in place and functioning
10. Cylinder weighing balance checked

Above checks satisfactorily completed.

Checked Sub- Supervised by Witnessed by JBALB

Contractor Consultant Representatives
Name
Signature
Designation
Date

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PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
OVERHEAD TRAVELLING CRANE Yes No
1. Installation/assembly complete and in accordance with drawings
2. Tapes over breather holes removed
3. All damaged paintwork repaired
4. Alignment check ( N.A. to monorail hoists )
Drawing Dim. Measured Dim. Permitted Total
Crane span at each of cars
Diagnostic Controls of crane wheels
Crane span at rail level
Yes No
5. Safe working load..............................painted on frame
Location of crane Safe Working
Load (kg)

Above checks satisfactorily completed.

Checked Sub- Supervised by Witnessed by JBALB

Contractor Consultant Representatives
Name
Signature
Designation
Date

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Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
GENERATORS Generator Unit
1. Manufacturers pre-start checks

Completed

2. Insulation Tests (Resistance in Mohms)

Measured Required
(see attached data sheet......................)
a) Between load terminals and plant structure  50
b) Between generator terminals and structure  50
c) Between generator phases R-Y  50
Y-B  50
B-R  50
d) Ancilliary equipment: Heaters  1
3. Continuity tests: Yes No
Phase and circuit connections checked
4. Earthing protection check Measured Required
a) Earth resistance on electrical system  1 ohm
b) Polarity verified Yes No
c) Generator neutral earthing Yes No
5. Battery checks Measured
a) Standing voltage measured Volts
b) Starting voltage measured Volts
c) Specific gravity
d) Level of electrolyte
e) Trickle charger checked for correct operation Amps
6. Fuel system Yes No
a) Fuel tank level sensors checked for correct operation of pump and
alarms
b) Fuel lines purged of air

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7. Before starting Yes No

a) All lubrication systems checked as correct
b) Ambient temperature of area
Yes No
c) Cooling water gauge reading
8. Fire/safety Yes No
a) Fire extinguishers installed and fully charged
b) Fire fuel shut-off valve checked ( remove fusible link )

Above checks satisfactorily completed.

Checked Sub- Supervised by Witnessed by JBALB

Contractor Consultant Representatives
Name
Signature
Designation
Date

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PRE-COMMISSIONING CHECKLIST FOR WATER TREATMENT PLANT

Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

SURGE SUPPRESSION EQUIPMENT Yes No

1. Installation/assembly complete and in accordance with drawings
2. Valves operated over full travel
3. Cables: Insulation/determination tests complete
4. Compressors: Comp. Comp.
Manufacturers pre-start up checks complete (see
attached sheets )
5. Pipeline length m
6. Double orifice vented NRV’s: No.
7. Double orifice inflow check NRV’s: No.
8. Vessel size m3
9. Outlet size mm
10. Outlet NRV Yes/No
11. Normal operating pressure kPA
12. PRV setting kPA
13. Maximum surge pressure kPA
14. Minimum surge pressure kPA
High Low
Rated Act Rated Act
15. Alarm settings high/low mm mm mm mm
Stop Start
Rated Act Rated Act
16. Compressor settings stop/start mm mm mm mm
17. JKKP type approval Yes/No
18. JKKP installation approval Yes/No/NA

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Above checks satisfactorily completed.

Checked Sub- Supervised by Consultant Witnessed by JBALB

Contractor Representatives
Name
Signature
Designation
Date

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Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d
Yes No
INSTRUMENTATION
Flow Measurement
1. Installation/assembly complete and in accordance with drawings
2. Control cables insulation check ( see attached sheets................)
3. Isolation and balancing valves, bleed screws checked for operation over full
stroke
Raw water
Inlet flow ( Treated water flow)
Backwash flow
Air scour flow
4. Instrument lines clear of obstruction, flushed through and checked for leaks
Raw water
Inlet flow ( Treated water flow)
Backwash flow
Air scour flow
5. Check zero calibration of primary loop element:
With balancing valves on DP transmitter open, energise supply to instruments and measure loop
current after 10 minutes
Expected Actual
Raw water 4,00 mA mA
Inlet flow ( Treated water flow) 4,00 mA mA
Backwash flow 4,00 mA mA
Air scour flow 4,00 mA mA

If a value differs from that expected by more than ±0,01 mA, reconfirm sensor range with D.P. range
stamped on Dall Tube/Orifice Plate, then refer to manufacturers operating instructions for procedure to
set zero and coarse span.

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N.B. The fine span is pre-set at the factory and should not be adjusted unless there is reason to
suspect an unexpected change in calibration. A precision pressure source is required before adjusting
the fine span potentiometer.

6. Check integrator accuracy:

With the current loop set at 20mA, measure the time taken for the flow integrator (totaliser) to register
an increase of exactly 10 m3. Convert this measure to an accuracy (% of full scale).
(See attached sheet for readings and calculation ) %
Backwash flow
Treated water flow
Permitted error : ±2%

Level Measurement Yes No

1. Installation/assembly complete and in accordance with drawings
2. Control cables insulation check ( see attached sheets......................)
3. Check zero calibration of primary loop element:
With tank empty, or with transducer lifted clear of the water, energise supply to instruments and
measure loop current after 10 minutes.
Expected Actual
Backwash tank 4,00 mA mA
Contact/balance tank 4,00 mA mA

If a measured value differs from that expected by more than ± 0,01 mA, refer to the
manufacturers’ operating instructions for the procedure to adjust the zero.

N.B. Integral transducer/transmitters such as model no. SH3102 have no provision for zero
adjustment, they are supplied pre-calibrated.
4. Check span of primary loop element:
With tank full, and with transducer lowered to the bottom of the tank such that the depth of water
above the transducer is as specified on the Instrument Data Sheet (............................................),
measure the loop current.
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Expected Actual
Backwash tank 20,00 mA mA
Contact/balance tank 20,00 mA mA

If a measured value differs from that expected by more than ± 0,02 mA, refer to the manufacturers
operating instruction for the procedure to adjust the span (range)

N.B. Integral transducer/transmitters such as model no. SH3102 have no provision for span
adjustment, they are supplied pre-calibrated.

Above checks satisfactorily completed.

Checked Sub- Supervised by Witnessed by JBALB

Contractor Consultant Representatives
Name
Signature
Designation
Date

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Project Name : Capacity : m3/hr

Work Contract No. : Operation : hr/d

CLARITY BOWL/SAMPLING SYSTEM

General
1. Check installation in accordance with drawings.
2. Isolating valves tested over full travel.
3. All hose clips securely tightened.
4. Clarity bowl unit drain in place.
5. Clarity blows labelled ‘Raw Water’, ‘Clarified Water’ and ‘Filtered Water’.

Sample Pumps

1. Cables: Insulation/determination checks complete ( see data sheet..........................)

2. Motor insulation resistance (≥20MegaOhm ) Unit MΩ
RW
SW

FW

TW
3. Switchgear over current protection set at: Unit Amps

RW
SW
FW
TW
4. Pump/motor rotation checks carried out correct. Clockwise Counterclock
Unit (CW) wise (CCW)
RW

SW

FW

TW

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Above checks satisfactorily completed.

Checked Sub- Supervised by Consultant Witnessed by JBALB

Contractor Representatives
Name
Signature
Designation
Date

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 Contract No:
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PLANT Date:

CABLE CHECK SHEET

Project Name: Capacity: m3/hr

………………………………………………. ………………………………….

Work Contract No.: Operation: hr/d

………………………………………………….. ………………………………

Site Location
Power/Control Cables
Rated Rated Voltage
Cable Resistance Loading
Cable Tag From To Voltage Current Drop
Type (Ω) (kW)
(V) (A) (V)

Values should exceed 1 MΩ

The above checks have been completed satisfactorily.

Checked By Certified by Witnessed by JBALB

Contractor Consultant Representative
Name
Signature
Designation
Date

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