T ENDER N O .

IITH/SE/NIT/CPPP/2017-18/01

D ESIGN , S UPPLY, I NSTALLATION , TESTING

AND COMMISSIONING (DSITC) OF

ELECTRO - MECHANICAL , INSTRUMENTATION

COMPONENTS FOR 650 KLD CAPACITY STP

AT IIT H YDERABAD INCLUDING 3 YEARS OF

POST - COMMISSIONING OPERATION AND

MAINTENANCE OF THE PLANT

Contents

0.1 Instructions to Bidders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

0.2 Initial criteria of qualification for bidding . . . . . . . . . . . . . . . . . . . . . 2

0.3 Deadline of Submission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

0.4 Sale of Tender Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

0.5 Submission of Bids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

0.5.1 Methodology of Submission . . . . . . . . . . . . . . . . . . . . . . . . . 4

0.5.2 Deadlines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

0.5.3 Bids to be Sealed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

0.5.4 Unopened Bids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

0.6 Pre-bid Meeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

0.7 Date of Commencement and Period of Completion . . . . . . . . . . . . . . . 8

0.8 Validity of Bids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

0.9 Performance Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

0.10 Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

0.11 Currency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

0.12 Security Deposit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

0.13 Award of Work and Signing of the Agreement . . . . . . . . . . . . . . . . . . 10

0.14 Form of Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

0.15 Integrity Pact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1 Information and Instructions to Bidders 22

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.2 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.3 Method of application: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.4 Final decision making authority: . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.5 Particulars provisional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.6 Site visit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.7 Criteria for eligibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.8 Evaluation criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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 1.9 Disqualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.10 Financial information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.11 Experience in Similar Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.12 Organization information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.13 Construction Plant and Machinery . . . . . . . . . . . . . . . . . . . . . . . . 26

1.14 EPF Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.15 Goods and Services Tax (GST ) . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.16 Opening of price bid (financial bid) its validity . . . . . . . . . . . . . . . . . 27

1.17 Award criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.17.1Award . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.18 Appendix-I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2 Conditions of the Contract 29

2.1 General Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.2 Tender Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.3 Specialized Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.4 Taxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.5 Mobilization Advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.5.1 Interest on Mobilization Advance . . . . . . . . . . . . . . . . . . . . . 34

2.5.2 Recovery of Mobilization Advance . . . . . . . . . . . . . . . . . . . . . 34

2.6 Payment for additions and deductions for Omissions . . . . . . . . . . . . . . 35

2.7 No Payment for Unsanctioned Extras . . . . . . . . . . . . . . . . . . . . . . 35

2.8 Penalty for not fulfilling Effluent Characteristics . . . . . . . . . . . . . . . . 35

2.9 Defect Liability Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.10 Record of Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.11 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.12 Disputes and Arbitration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.13 Force Majeure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.14 Price Escalation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.15 Time Extension of Contract Period . . . . . . . . . . . . . . . . . . . . . . . . 37

2.16 Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.17 Foreign Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.18 Compensation for Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.19 Milestones of the Contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.20 Documents to be submitted to IITH . . . . . . . . . . . . . . . . . . . . . . . . 41

2.21 Labour huts, watch and ward, storage of equipment . . . . . . . . . . . . . . 41

2.22 Transfer of Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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 2.23 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2.23.1Abbreviations-Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3 Special Conditions of Contract 45

3.1 Special Conditions of Contract (SCC)-Part A . . . . . . . . . . . . . . . . . . . 45

3.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.1.2 Design Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.1.3 Design-Build Documents . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.1.4 Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.1.5 Design Responsibilities On Site Issues . . . . . . . . . . . . . . . . . . 48

3.1.6 Sewerage Treatment Plant Layout and operation sequence . . . . . . 48

3.1.7 Influent Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.1.8 Influent Flow Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.1.9 Operation Basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.1.10Required Effluent Quality . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.1.11Site Administrative Facility . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.1.12Equipment Installation Services . . . . . . . . . . . . . . . . . . . . . . 51

3.1.13Procurement and Transportation . . . . . . . . . . . . . . . . . . . . . 51

3.1.14Temporary Supports, Structures and Utility Services . . . . . . . . . . 52

3.1.15Document Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.1.16Plant and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.1.17Documents at the Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.1.18Use of the STP site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.1.19Setting Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.1.20Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.1.21Site Regulations and Safety . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.1.22Contractor‘s Equipment (Design-Build) and Site Clearance . . . . . . 54

3.1.23Protection of the Environment . . . . . . . . . . . . . . . . . . . . . . . 55

3.1.24Security of the STP site . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3.1.25Emergency Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.1.26Tests and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.1.27Start-Up and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . 57

3.1.28Tests on Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3.1.29Review of Works and Monthly Progress Report (Part-A) . . . . . . . . . 59

3.1.30Issue of Completion Certificate for Part-A of Contract . . . . . . . . . 60

3.1.31Key Staff to be deployed at site . . . . . . . . . . . . . . . . . . . . . . . 61

3.2 Special Conditions of Contract(SCC)-Part:B . . . . . . . . . . . . . . . . . . . 62

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 3.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

3.3 Effective date of commencement of Part B . . . . . . . . . . . . . . . . . . . . 62

3.4 Scope of Operation and Maintenance Services . . . . . . . . . . . . . . . . . . 62

3.4.1 Calibration of Instruments . . . . . . . . . . . . . . . . . . . . . . . . . 69

3.4.2 Contractors staff during OM period . . . . . . . . . . . . . . . . . . . . 69

3.4.3 Safety and Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

3.4.4 Responsibility for damages . . . . . . . . . . . . . . . . . . . . . . . . . 70

3.4.5 Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

3.4.6 Record Keeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

3.4.7 Site Order Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.4.8 Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.4.9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

3.4.10Routine, Preventive, Minor & Major maintenance . . . . . . . . . . . . 77

3.4.11Release of Hazardous Substances or waste, if any . . . . . . . . . . . 78

3.4.12Technical Audit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

3.4.13 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

3.4.14Taking Over of Plant after Completion of O & M Period . . . . . . . . . 79

4 Scope of Work and Services 80

4.1 Scope of Part-A of the Contract . . . . . . . . . . . . . . . . . . . . . . . . . . 80

4.1.1 Contractor‘s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . 81

4.2 Details of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4.3 Works in the scope of IITH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4.4 Contractors Scope of supply for Design and Detail Engineering . . . . . . . 90

4.5 Scope of Technology Provider . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

4.5.1 Technical Advisory Services during Pre-Construction . . . . . . . . . . 93

4.5.2 Technical Advisory Services during Equipment Installation . . . . . . 93

4.5.3 Technical Advisory Services during Post-Installation . . . . . . . . . . 93

4.5.4 Technical Advisory Services during Equipment trial run . . . . . . . . 93

4.5.5 Technical Advisory Services during Commissioning of plant (Perfor-

mance Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

4.5.6 Formal Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

4.5.7 Other Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

4.5.8 Performance Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

4.6 Scope of Part-B of the Contract . . . . . . . . . . . . . . . . . . . . . . . . . . 94

4.7 Schematic P&ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

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5 Technical Specifications 110

5.1 General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

5.1.1 Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

5.1.2 Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

5.1.3 Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

5.1.4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

5.1.5 Name Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

5.1.6 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

5.1.7 Supports for Pipe Work Valves . . . . . . . . . . . . . . . . . . . . . . . 113

5.2 Indicative Ultra Filtration Membrane System Design . . . . . . . . . . . . . . 113

5.2.1 Major Process Components for MBR system . . . . . . . . . . . . . . . 115

5.2.2 Permeate pumps/back pulse pumps (process pumps) with VFD . . . 116

5.2.3 Permeate Pump Priming system -Ejector system . . . . . . . . . . . . 117

5.2.4 Air Scour Blowers for Membrane Aeration . . . . . . . . . . . . . . . . 117

5.2.5 Conventional Cyclic aeration . . . . . . . . . . . . . . . . . . . . . . . 117

5.2.6 Recirculation Pump (RAS pumps) & Membrane tank Drain pump . . 118

5.3 Membrane system operation modes & Cleaning processes . . . . . . . . . . . 118

5.4 Membrane Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

5.5 System Design Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

5.6 Ultrafiltration System Design . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

5.7 Control Narrative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

5.7.1 Coagulant, Acetic Acid Dosing Control . . . . . . . . . . . . . . . . . . 125

5.7.2 ZeeWeed UF Train Modes States of Operation . . . . . . . . . . . . . . 126

5.7.3 Production Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

5.7.4 ZeeWeed UF Train Modes . . . . . . . . . . . . . . . . . . . . . . . . . . 127

5.7.5 UF Train States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

5.7.6 Priming System Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

5.7.7 Standby and the Production Cycle . . . . . . . . . . . . . . . . . . . . . 129

5.7.8 Membrane Tanks Level Permeate Flow Control . . . . . . . . . . . . 131

5.7.9 Production Trans Membrane Pressure (TMP) . . . . . . . . . . . . . . 131

5.7.10 Start Stop Train Triggers . . . . . . . . . . . . . . . . . . . . . . . . . 133

5.7.11Permeate/Back pulse Pump . . . . . . . . . . . . . . . . . . . . . . . . 133

5.7.12Sodium Hypochlorite Dosing Permeate Line . . . . . . . . . . . . . . . 133

5.7.13Membrane Aeration Control . . . . . . . . . . . . . . . . . . . . . . . . 134

5.7.14Turbidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

5.7.15ZeeWeed UF Train Triggers Alarms . . . . . . . . . . . . . . . . . . . . 134

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 5.7.16 ZeeWeed Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

5.7.17 Password Access Privileges . . . . . . . . . . . . . . . . . . . . . . . . 138

5.7.18 Screen Color-Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

5.7.19 Power Interruption / Power Up . . . . . . . . . . . . . . . . . . . . . . 139

5.8 Specifications of Membranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

5.9 Manual Coarse Screen 16mm and Manual Fine Screen 6mm . . . . . . . . . 139

5.10 Sludge Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

5.11 Air blowers for Oxygenation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

5.11.1General Design Requirements . . . . . . . . . . . . . . . . . . . . . . . 141

5.11.2Blower General Arrangement . . . . . . . . . . . . . . . . . . . . . . . . 142

5.11.3Ancillary Equipment for Blowers . . . . . . . . . . . . . . . . . . . . . . 142

5.11.4Blower Noise limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

5.11.5Materials of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . 143

5.11.6Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

5.11.7Filters and Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

5.11.8Flexible Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

5.11.9Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

5.11.10
Non-Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

5.11.11
Isolating Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

5.11.12
Temperature Measurement . . . . . . . . . . . . . . . . . . . . . . . . . 145

5.11.13
Piping Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

5.11.14
Air Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

5.12 Diffused Air Aeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

5.12.1Aeration diffusers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

5.12.2Air Supply pipe work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

5.12.3Air Supply Headers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

5.12.4Blower Discharge Pipe work . . . . . . . . . . . . . . . . . . . . . . . . 149

5.12.5 Air Flow Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

5.12.6Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

5.12.7Leak and Pattern Testing of Diffuser System . . . . . . . . . . . . . . . 150

5.13 Sluice Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

5.13.1Design Requirements and Construction Features . . . . . . . . . . . . 150

5.13.2Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

5.13.3Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

5.13.4Wedging Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

5.13.5Lifting Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

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 5.13.6Lifting Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

5.13.7Flush Bottom Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

5.14 Open channel Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

5.15 Hand Operated Hoists and Trolleys . . . . . . . . . . . . . . . . . . . . . . . . 153

5.16 Pipe Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

5.17 Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

5.17.1uPVC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

5.17.2 CPVC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

5.17.3 Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

5.17.4Galvanized Iron pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

5.17.5Unplasticized Poly Vinyl Chloride (uPVC) Pipes . . . . . . . . . . . . . 156

5.17.6Ductile Iron Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

5.18 Sluice Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

5.19 Knife Gate Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

5.20 Butterfly Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

5.21 Non Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

5.22 Telescopic Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

5.23 Pressure / Vacuum relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . 161

5.24 Reduction Gear Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

5.25 Propeller Exhaust Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

5.26 Air conditioning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

5.27 Domestic Water Pump sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

5.28 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

5.28.1Open well Submersible Pumps . . . . . . . . . . . . . . . . . . . . . . . 163

5.28.2Submersible Pumps: Features of Construction . . . . . . . . . . . . . 164

5.29 Centrifugal Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

5.30 End Suction Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

5.31 Pump Performance Guarantees . . . . . . . . . . . . . . . . . . . . . . . . . . 169

5.31.1Single Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

5.31.2Parallel Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 171

5.32 Progressive Cavity Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

5.33 Chemical Dosing Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

5.34 Induction Motor (Submersible Motor) . . . . . . . . . . . . . . . . . . . . . . . 174

5.34.1Design Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

5.34.2 Performance and Characteristics . . . . . . . . . . . . . . . . . . . . . 174

5.34.3Submersible Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

viii
 5.34.4 Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

5.34.5Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

5.34.6Temperature Rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

5.34.7 Constructional Features . . . . . . . . . . . . . . . . . . . . . . . . . . 176

5.34.8 Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

5.35 Induction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

5.35.1General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

5.35.2Performance and Characteristics . . . . . . . . . . . . . . . . . . . . . 177

5.35.3 Constructional Features . . . . . . . . . . . . . . . . . . . . . . . . . . 179

5.35.4Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

5.35.5Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

5.35.6Heating during Idle Period . . . . . . . . . . . . . . . . . . . . . . . . . 180

5.35.7Earthing Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

5.35.8Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

5.35.9Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

5.36 Equipment selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

5.37 Manufacturer’s Experience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

5.38 SPECIFICATIONS FOR ELECTRICAL WORKS . . . . . . . . . . . . . . . . . . 183

5.38.1Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

5.38.2Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

5.38.3Safety and security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

5.38.4Electrical switchgear room environment . . . . . . . . . . . . . . . . . 192

5.38.5Drawing, Instructions and Certificates . . . . . . . . . . . . . . . . . . 192

5.38.6 Voltage and frequency variations . . . . . . . . . . . . . . . . . . . . . 192

5.38.7Phase sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

5.38.8Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

5.38.9Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

5.38.10Potentially explosive areas . . . . . . . . . . . . . . . . . . . . . . . . . 193

5.38.11
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

5.38.12
Harmonics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

5.38.13
Surge Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

5.38.14
Cable Support Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

5.39 LV switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

5.40 Measured Values requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

5.41 Motor Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

5.41.1 Voltage regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

ix
5.42 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

5.42.1Cable Termination Facilities . . . . . . . . . . . . . . . . . . . . . . . . 209

5.42.2Other Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

5.43 Portable Emergency luminaries . . . . . . . . . . . . . . . . . . . . . . . . . . 210

5.44 Electrical Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

5.45 Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

5.46 Equipment Erection and Commissioning . . . . . . . . . . . . . . . . . . . . . 213

5.47 Erection, Testing and Commissioning . . . . . . . . . . . . . . . . . . . . . . 216

5.47.1Testing General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

5.47.2Inspection at Manufacturer‘s Premises . . . . . . . . . . . . . . . . . . 216

5.48 Automation of Sewage Treatment Plant . . . . . . . . . . . . . . . . . . . . . . 217

5.49 Instrumentation & Automation Specifications . . . . . . . . . . . . . . . . . 217

5.49.1PLC Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

5.49.2MCC Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

5.49.3Reference Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

5.50 Qualification Criteria for Instrumentation and Automation System integrator 225

5.50.1Documents to be submitted during Bid Submission . . . . . . . . . . 226

5.51 General Submissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

5.51.1Functional design specification . . . . . . . . . . . . . . . . . . . . . . 228

5.51.2 Drawings and schedules . . . . . . . . . . . . . . . . . . . . . . . . . . 228

5.51.3 Data and calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

5.51.4Operation and maintenance instructions . . . . . . . . . . . . . . . . . 230

5.52 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

5.52.1Basic Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

5.52.2Design Requirements for Instrumentation, Control, Automation (PLC/SCADA

/ HMI) Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

5.52.3Site Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

5.52.4Enclosure/Panel Details . . . . . . . . . . . . . . . . . . . . . . . . . . 232

5.52.5Panel design and construction . . . . . . . . . . . . . . . . . . . . . . . 233

5.52.6Panels Major . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

5.52.7Panels Minor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

5.53 Instruments and ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

5.54 Process Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

5.55 Flow Measuring Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

5.56 Open Channel Flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

5.57 Level Measuring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

x
 5.57.1Ultrasonic Level Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

5.57.2Conductivity Level Switches . . . . . . . . . . . . . . . . . . . . . . . . 261

5.57.3Strain-gauge pressure transducers and transmitters . . . . . . . . . . 262

5.58 Analytical Analyzers and Transmitters . . . . . . . . . . . . . . . . . . . . . . 263

5.58.1Sensor Measurement Principles and Features . . . . . . . . . . . . . . 264

5.58.2Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

5.58.3Total Dissolved Oxygen Monitoring System . . . . . . . . . . . . . . . 264

5.59 Surge Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

5.60 Programmable Logic Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . 266

5.60.1PLC Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

5.61 HMI (Human Machine Interface)/SCADA . . . . . . . . . . . . . . . . . . . . . 267

5.61.1Human Machine Interfaces (HMI) . . . . . . . . . . . . . . . . . . . . . 267

5.61.2Uninterruptible Power Supply (UPS) . . . . . . . . . . . . . . . . . . . . 268

5.62 Major Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

5.62.1Air Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

5.62.2Process Pumps (RAS Pump) . . . . . . . . . . . . . . . . . . . . . . . . 268

5.63 Centrifuge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

5.64 Ejectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

5.65 Chemical Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

5.65.1Metering Pump (Chemical Dosing Pumps) . . . . . . . . . . . . . . . . 270

5.66 Air Compressors Driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

5.66.1Air Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

5.66.2Air Receivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

5.66.3Refrigerated Air Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

5.67 Miscellaneous Appurtenances . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

5.68 Pre-Screening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

5.68.1Coarse and Fine Screen (6mm Mechanical Screen) . . . . . . . . . . . 272

5.68.22 mm punched hole Screen . . . . . . . . . . . . . . . . . . . . . . . . . 272

5.69 Fine Bubble Diffuser System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

5.70 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

5.70.1Butterfly Valve 4 to 12“ diameter . . . . . . . . . . . . . . . . . . . . . 273

5.70.2Butterfly Valve 14 to 24“ diameter . . . . . . . . . . . . . . . . . . . . . 273

5.70.3Process check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

5.70.4Chemical Feed Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

5.70.5Waste water, Mixed Liquor and Sludge Lines . . . . . . . . . . . . . . 274

5.70.6Chemical Feed Lines (<3“) . . . . . . . . . . . . . . . . . . . . . . . . . 274

xi
 5.70.7Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

5.71 Miscellaneous Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

5.71.1Instrument Isolation Valves . . . . . . . . . . . . . . . . . . . . . . . . . 275

5.71.2Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

5.71.3Pneumatic Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

5.71.4General Service PVC Valves . . . . . . . . . . . . . . . . . . . . . . . . 276

5.72 Process Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

5.72.1Flow switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

5.72.2Electromagnetic Flow meters (Flow transmitter) . . . . . . . . . . . . . 277

5.72.3Level transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

5.72.4Pressure Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

5.72.5Turbidi meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

5.72.6Dissolved Oxygen Sensors Analyzers . . . . . . . . . . . . . . . . . . . 279

5.72.7Float Level Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

5.72.8Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

5.72.9Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

5.73 Motor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

5.74 Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

5.74.1Motor Control Center (MCC) . . . . . . . . . . . . . . . . . . . . . . . . 280

5.74.2Variable Frequency Drives . . . . . . . . . . . . . . . . . . . . . . . . . 281

5.75 Major Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

5.75.1Air Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

5.75.2Process Pumps (RAS Pump) . . . . . . . . . . . . . . . . . . . . . . . . 282

5.76 Centrifuge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

5.77 Ejectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

5.78 Chemical Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

5.78.1Metering Pump (Chemical Dosing Pumps) . . . . . . . . . . . . . . . . 283

5.79 Air Compressors Driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

5.79.1Air Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

5.79.2Air Receivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

5.79.3Refrigerated Air Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

5.80 Miscellaneous Appurtenances . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

5.81 Pre-Screening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

5.81.1Coarse and Fine Screen (6mm Mechanical Screen) . . . . . . . . . . . 286

5.81.22 mm punched hole Screen . . . . . . . . . . . . . . . . . . . . . . . . . 286

5.82 Fine Bubble Diffuser System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

xii
 5.83 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

5.83.1Butterfly Valve 4 to 12“ diameter . . . . . . . . . . . . . . . . . . . . . 287

5.83.2Butterfly Valve 14 to 24“ diameter . . . . . . . . . . . . . . . . . . . . . 287

5.83.3Process check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

5.83.4Chemical Feed Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

5.83.5Waste water, Mixed Liquor and Sludge Lines . . . . . . . . . . . . . . 288

5.83.6Chemical Feed Lines (<3“) . . . . . . . . . . . . . . . . . . . . . . . . . 288

5.83.7Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

5.84 Miscellaneous Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

5.84.1Instrument Isolation Valves . . . . . . . . . . . . . . . . . . . . . . . . . 289

5.84.2Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

5.84.3Pneumatic Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

5.84.4General Service PVC Valves . . . . . . . . . . . . . . . . . . . . . . . . 290

5.85 Process Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

5.85.1Flow switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

5.85.2Electromagnetic Flow meters (Flow transmitter) . . . . . . . . . . . . . 291

5.85.3Level transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

5.85.4Pressure Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

5.85.5Turbidi meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

5.85.6Dissolved Oxygen Sensors Analyzers . . . . . . . . . . . . . . . . . . . 293

5.85.7Float Level Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

5.85.8Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

5.85.9Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

5.86 Motor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

5.87 Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

5.87.1Motor Control Center (MCC) . . . . . . . . . . . . . . . . . . . . . . . . 294

5.87.2Variable Frequency Drives . . . . . . . . . . . . . . . . . . . . . . . . . 295

6 List Of Approved Makes 296

6.1 List of Approved Makes for STP Components . . . . . . . . . . . . . . . . . . 296

6.2 List Of Approved Makes for Electrical Works . . . . . . . . . . . . . . . . . . . 301

6.3 Preferred makes for Instrumentation and Automation Equipment . . . . . . 302

7 Annexures 303

7.1 Form of Performance Security (Guarantee) Bank Guarantee Bond . . . . . . 303

7.2 Form of Earnest Money Deposit Bank Guarantee Bond . . . . . . . . . . . . 305

7.3 Affidavit to be submitted by the bidder . . . . . . . . . . . . . . . . . . . . . . 307

xiii
7.4 Form of Supplementary Agreement . . . . . . . . . . . . . . . . . . . . . . . . 308

7.5 Proforma of Guarantee Bond for Performance of Treatment System . . . . . 310

7.6 Information Regarding Eligibility Letter of Transmittal . . . . . . . . . . . . . 312

7.7 Proforma of Forms A,B,C,D,E,F,G for Evaluation Criteria . . . . . . . . . . . 313

7.8 Projects Under Execution or Awarded . . . . . . . . . . . . . . . . . . . . . . . 316

7.9 Performance Report of Works . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

7.10 Structure & Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

7.11 Details of Technical & Administrative Personnel to Be Employed for The Work 320

7.12 Details of Construction Plant and Equipment Likely To Be Used in Carrying

Out the Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

7.13 Application Form for Purchase of Bid Documents . . . . . . . . . . . . . . . . 322

7.14 Running Account Bill Form 27A and Final Bill Form 27B (For scheduled

payments to Contractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

7.15 MoU with Technology Provider . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

7.15.1Technical Advisory Services during Pre-Construction . . . . . . . . . . 334

7.15.2Technical Advisory Services during Equipment Installation . . . . . . 334

7.15.3Technical Advisory Services during Post-Installation . . . . . . . . . . 334

7.15.4Technical Advisory Services during Equipment trial run . . . . . . . . 334

7.15.5Technical Advisory Services during Commissioning of plant (Perfor-

mance Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

7.15.6Formal Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

7.15.7Other Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

7.15.8Performance Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

xiv
Notice Inviting Tender (NIT)

On behalf of the Director, Indian Institute of Technology Hyderabad invites lump

sum bids from specialized agencies of repute in two bid system for the following
1 2
work:

1. NIT No.: IITH/SE/NIT/CPPP/2017-18/01

2. Name of Work: Design, Supply, Installation, testing and commissioning (DSITC)

of electro-mechanical, instrumentation components pertaining to 650 KLD capacity

Sewage Treatment Plant (STP) at IITH Permanent Campus with GE MBR technology

and 3 years of post- commissioning operation and maintenance of the plant.

3. Estimated Cost : Rs 484,83,800.00

4. Earnest Money Deposit (EMD: Rs 9,69,700.00

5. Period of Completion : Part A: 9 Months, Part B: 3 years

6. Last date and time of submission of bids: 22 January 2018, 3 PM

7. Time and date of opening of technical bid: 22 Jan 2018 at 330 PM

0.1 Instructions to Bidders

• Components The entire scope of this contract is split into two components, namely :

Part A*: DSITC Works of electro-mechanical, instrumentation ,electrical, piping,

automation including supply, installation, trial run, commissioning of 650 KLD ca-

pacity STP with tertiary treatment process

(* Civil construction work of the plant like RCC common collection sump, equaliza-

tion tank, anoxic tank, aeration tank, membrane tank, treated water tanks, pump

room ,control room building etc., is in progress which shall be handed over to the

contractor for DSITC Works)

1 Contractor, Vendor, Bidder are used interchangeably in this document
2 IITH, Institute, IIT Hyderabad are used interchangeably in this document and represent Director, IIT Hyder-
abad

1
 • Part B: Operation & Maintenance of STP for a period of three years after completion

of Part-A component.

• Contract Period :

Part A: Nine Months for DSITC (Period of Original Agreement)

Part B : Three Years (Period of Supplementary Agreement.)

After completion of Part-A (Original Agreement) of the contract by the successful

bidder, the contract will be provisionally closed and a Supplementary Agreement

will be drawn up with successful bidder for Part-B component. The entire contract

will be closed on completion of Supplementary Agreement.

• The defect-liability period for DSITC Works component is two years from the date of

completion of Part-A.

• The proposed work is treated as a specialized work.

• The site for the work is available.

• The proposed STP shall be developed using Hollow Fibre Ultra Filtration (UF) MBR

Technology of Suez Water Technologies & Solutions (I) Pvt. Ltd., formerly ”GE In-

dia Industrial Pvt. Ltd.,” . Henceforth, the phrase Technology Provider in this bid

document shall mean and imply Suez Water Technologies & Solutions (I) Pvt. Ltd.,.

0.2 Initial criteria of qualification for bidding

Contractors who fulfil the following requirements shall be deemed to be qualified for

bidding for the work.

1. Single Bidder on his own should meet the stipulated criterion and no consortium or

Joint Venture shall be allowed.

2. The Bidder along with the bid must submit a Memorandum of Understanding (MoU)

from the Technology Provider (Suez Water Technologies & Solutions (I) Pvt. Ltd.,formerly

GE India Industrial Pvt. Ltd.,) for UF Membrane Bioreactor (MBR) technology for the

proposed STP. Technology provider, i.e., Suez Water Technologies & Solutions (I)

Pvt. Ltd.,, the membrane manufacturer, shall additionally also provide the design

and engineering guidelines for the MBR process. It is mandatory for the Contractor

to submit guarantee bond for the performance of treatment system together with the

Technology Provider.

The Draft MoU is enclosed at Section 7.15.

The draft Performance Guarantee bond is placed at Section 7.5

2
3. The bidder should have experience of similar works where he has successfully de-

signed the process, supplied, installed and commissioned at least 3 STPs of 200 to

399 KLD or 2 STPs of 400 to 499 KLD or 1 STP of 500 KLD or above. The qualifying

plant(s), should have been completed and commissioned by using GE Hollow Fibre

Membrane in India in the last seven(7) years. The reference STPs needs to be suc-

cessfully commissioned as on previous day of last date of submission of application

for this bid.

4. ”Similar work” means :

–construction of Sewage Treatment Plant including design, supply, installation, test-

ing and commissioning of the Membrane Bio Reactor (MBR) type using GE Hollow

fibre membranes(excluding Civil works).

– treatment plant of industrial waste water shall not be considered as similar work.

5. At the time of purchasing bid documents, the bidder shall furnish an affidavit in a

proforma specified in Section 7.3 of bid document. In case , the bid documents are

downloaded from the website of IITH, the affidavit specified in section 7.3 shall be

submitted along with other bid documents.

6. The bidder should have had average annual financial turn over (gross) of Rs.5.00

Crore out of execution of similar works during the immediate last three consecutive

financial years. This should be duly certified by a Chartered Accountant. Year in

which no turnover is shown would also be considered for working out the average.

7. The bidder should not have incurred any loss in more than two years during the

immediate last five consecutive financial years, duly certified by the Chartered Ac-

countant.

8. The bidding capacity of the contractor should be equal to or more than the estimated

cost of the work put to bid. The bidding capacity shall be worked out by the following

formula:

Bidding Capacity =

AxN x2 − B

, where,

A = Maximum value of Similar works executed in any year during the last seven

years taking into account the completed as well as works in progress.

N = Number of years prescribed for completion of work for which bids has been

invited (0.75 years i.e., 9 months)

B = Value of existing commitments and ongoing works to be completed during the

3
 period of completion of work for which bids have been invited.

9. The bidder should have a solvency of Rs.5.00 Crore certified by his Bankers.

0.3 Deadline of Submission

The last date of receipt of applications for issue of tender documents in prescribed format

(Tender documents can also be downloaded form IITH website www.iith.ac.in) and date

of issue of tender documents from IITH Office shall be as follows:

i) Last date of receipt of application :05 January 2018 up to 16.00 hours

ii) Last date of issue of bid forms :08 January 2018 up to 16.00 hours

0.4 Sale of Tender Documents

Bid documents consisting of the schedule of Contract Price (Price Bid and Payment

Terms0 of the work to be done and set of terms and conditions of the contract to be

complied with by the Contractor whose bid may be accepted and other necessary docu-

ments, can either be downloaded from the IITH website www.iith.ac.in or be seen in the

office of the Engineer-in-Charge, IIT Hyderabad between 11.00 hours & 16.00 hours from

28 December 2017 to 08 January 2018 , Monday through Friday except on Public Holi-

days. Bid documents shall be issued from his office, during the days and hours specified

above on payment of the following amount towards cost of bid documents:-

(i) Rs 1500 + 18% GST=Total Rs 1770.00

(ii) Bid document cost is non-refundable and is accepted in form of Demand Draft

drawn on any Scheduled Bank in favour of ”IIT Hyderabad” payable at Hyderabad.

0.5 Submission of Bids

The bid shall be accompanied by Earnest Money along with cost of bid, if not paid earlier

as in the case of downloaded bid from Website in the form as detailed below:

(i) Earnest money of as indicated in the Notice Inviting Tender (NIT) in the form of Bank

Guarantee issued by any Scheduled Bank in prescribed format as given in Section 7.2

having validity up to 90 (Ninety) days from last date of submission of bids.

0.5.1 Methodology of Submission

Bid shall be submitted in following manner:

4
 • Envelope 1 marked Earnest Money Deposit:

Earnest money plus cost of bid documents in case the bid document is downloaded

from IITH website and the Earnest Money plus Proof /receipt of paying the cost of

bid in case the tender documents are purchased from the Institute in hard copy

form shall be placed in sealed envelope-1 marked Earnest Money Deposit.

• Envelope 2: marked Technical Documents

The eligibility documents are to be submitted as per the information / instruc-

tions/specimen forms given shall be kept in Envelope-2.

• Envelope 3: marked Financial Bid The Financial Bid shall be placed in sealed

Envelope-3 and should be super scripted as Financial Bid.

• Final Envelope: marked Tender Documents for STP at IIT Hyderabad The sealed

envelopes no. 1,2 & 3 as above shall be placed in another sealed envelope which

shall be submitted before the deadline for submission of the bids.

• All the envelopes shall be super scripted with following data on it.

(i) Name of work

(ii) Name of bidder

(iii) Last date of receipt of bid

0.5.2 Deadlines

Bids, which should always be placed in sealed envelope, in the manner detailed at para

0.5 above shall be received by the Executive Engineer, IIT Hyderabad up to 15.00 Hrs.

on 22 January 2018 and shall be opened by him or his authorized representative in his

office on the same day at 15.30 Hrs. After opening the main envelope 4, the envelope 1

containing the EMD shall be opened first. Bids without EMD or EMD not in the prescribed

form shall be summarily rejected. Envelope 2 of those bids with valid EMD shall then be

opened for technical evaluation. The envelope 3 containing financial bid shall be opened

only for those bidders whose eligibility documents are found in order as per qualifying

and experience criteria given in the bid document after technical evaluation. The date

and time of opening the financial bids shall be communicated at a later date.

0.5.3 Bids to be Sealed

The bid in which rates are to be quoted should be properly bound and Sealed ( Sta-

pled/Stitched Taped / Wax sealed ). Loose / spiral bound submission (in case the bid is

5
down loaded from website) shall be rejected out rightly. In case of any correction / ad-

dition / alteration /omission in bid document vis--vis bid document available on website

shall be treated as non-responsive and shall be summarily rejected.

0.5.4 Unopened Bids

Un-opened financial bids shall be returned to the bidders after the final decision on the

bid is reached.

0.6 Pre-bid Meeting

(i) A pre bid meeting with the bidders shall be held on 10 January 2018 at 1030 Hrs.

at Conference hall (Project Office, IIT Hyderabad). Bidders may seek clarifications in

regards to the bid documents and methodology for submitting the bid document, in

writing so as to reach The Engineer-in-Charge, IIT Hyderabad (the official nominated

for this purpose) not later than 3 (three) days before the date fixed for the meeting. No

request for clarification shall be considered thereafter. Pre-bid queries may also be

sent through email to [email protected] before the deadline for sending the queries

as stated above.

(ii) The purpose of the meeting shall be to clarify the issues raised by the bidders. Min-

utes of the meeting including the text of the questions raised (without identifying

the source of enquiry) and the responses given shall be uploaded on IITH website.

Any modifications of the Bid Document which may become necessary as a result of

the Pre-bid Meeting shall be made exclusively through the issue of an Addendum /

Corrigendum and not through the Minutes of the Pre-Bid Meeting.

(iii) Pre-bid clarifications shall not be sent to the bidders directly. Bidders shall check

the website of the Institute regularly for the same. IITH shall not assume any re-

sponsibility over the failure of bidders to check Institute’s website for clarifications.

(iv) The Minutes of the Meeting as described above and the Addendum / Corrigendum,

if any, shall be uploaded on IITH website only and it shall become part of the con-

tract documents. Non-attendance at the Pre-bid Meeting shall not be a cause for

disqualification of a bidder.

(v) IITH reserves the right to reject any prospective application without assigning any

reason and to restrict the list of qualified bidders to any number deemed suitable by

it, if too many bids are received satisfying the laid down criterion.

(vi) The bidder shall not be permitted to bid for works in IITH responsible for award and

execution of contracts, in which his near relative is posted a Faculty or as an officer,

6
 or engineer in any capacity between the grades of Engineer-in-Charge and Junior

Engineer (both inclusive). He shall also intimate the names of persons who are work-

ing with him in any capacity or are subsequently employed by him and who are near

relatives to any gazette officer in the IITH or in MHRD. Any breach of this condition

by the contractor would render him liable to be removed from the approved list of

contractors of this IITH. Near relative(s) for this purpose is/are defined as:-

(i) Member of Hindu Undivided family (HUF).

(ii) They are Husband and Wife.

(iii) The one is related to other in the manner as Father, Mother, Son(s), Sons wife

(daughter-in-law),Daughter(s), Daughters husband (son-in-law) Brother(s), Brothers

wife, Sister(s), Sisters husband(brother-in-law).

(vii) No Engineer of gazette rank or other Gazetted Officer employed in Engineering or

Administrative duties in IITH is allowed to work as a contractor for a period of one

year after his retirement from Government service, without the previous permission

of the Institute in writing. All the intending bidders shall have to give a declaration,

that none of his / her such near relative(s) as defined above is/are working in the IIT

Hyderabad where he is going to apply for bid / work.

Such certificate in case of Proprietorship Firm shall be given by the proprietor, for

Partnership Firm certificate shall be given by all partners and in case of Limited

Company, by all Directors of the company. However, Government of India / Financial

Institutions nominees and independent non-official part-time Directors appointed

by Govt. of India or the Governor of the State are excluded from the purview of

submission of this certificate while submitting bids by Limited Companies.

(viii) Any breach of these conditions by the Company or Firm or any other person, the Bid

/ work shall be cancelled and Earnest Money / Security Deposit shall be forfeited

at any stage, whenever it is so noticed. IITH shall not pay any damages to the

Company or Firm or the concerned person but damages arising on account of such

cancellation to be borne by the contractor. The Company or Firm or the person shall

also be debarred for further participation in the bid in IITH. Further, any breach of

this condition by the bidder would also render him liable to be removed from the

approved list of contractors of IITH.

(ix) The bidder shall furnish a declaration to the effect (In case of downloaded bid) that no

addition / deletion / correction have been made in the bid document submitted and

it is identical to the bid document appearing on website. Every page of downloaded

7
 bid shall be signed by the bidder with stamp (seal) of his firm / organization.

(x) Any information furnished by the bidder found to be incorrect either immediately or

at a later date, would render him liable to be debarred from biding/taking up of work

in IITH. If such bidder happens to be enlisted contractor of any class in IITH, his

name shall also be removed from the approved list of contractors.

(xi) Agreement shall be drawn with the successful bidder. Bidder shall quote his rates as

per various terms and conditions of the bid document which shall form part of the

agreement.

0.7 Date of Commencement and Period of Completion

The time allowed for carrying out the work shall be Nine (9) months for execution plus

Three (3) years of operation and maintenance. The date of commencement of work shall

be reckoned from the 15th day after the date of issue of letter of award of work, or, from

the first day of handing over of the site, whichever is later.

0.8 Validity of Bids

The tender for the work shall remain open for acceptance for a period of 60 (Sixty) days

from the date of opening of the financial bids. If any tenderer withdraws his tender before

the said period or issue of letter of acceptance/intent, whichever is earlier, or, makes any

modifications in the terms and conditions of the tender which are not acceptable to the

IITH, then the IITH shall, without prejudice to any other right or remedy, be at liberty to

forfeit earnest money as aforesaid.

0.9 Performance Guarantee

The contractor whose tender is accepted shall submit an irrevocable Performance Guar-

antee of 5% (Five per cent) of the contract amount of Part A in addition to other deposits

mentioned elsewhere in the contract for his proper performance of the contract agree-

ment, (not withstanding and/or without prejudice to any other provisions in the contract)

within 15 days of acceptance of tender by IITH. This period can be further extended by

the Engineer-in-Charge up to a maximum period of 30 days on written request of the

contractor stating the reason for delays in procuring the Performance Guarantee, to the

satisfaction of the Engineer-in-Charge. This guarantee shall be in the form of Guarantee

Bonds of any Scheduled Bank in accordance with the form given at Section 7.1

(i) The Performance Guarantee shall be initially valid up to the stipulated date of com-

pletion of Part-A plus 60 days beyond that. In case the time for completion of work

8
 for Part-A gets extended, the contractor shall get the validity of Performance Guaran-

tee extended to cover such enlarged time for completion of work as may be specified

by the Institute.

(ii) The performance guarantee bond will be returned to the contractor after recording

of the completion certificate for the Part A of the contract and upon submission

of another Bank Guarantee equivalent to 5% of contract amount of Part B having

validity of Three (3) years from date of start of Operation & Maintenance period.

(iii) The Performance Guarantee bonds shall not carry any interest. The performance

guarantee submitted against Part B of the contract will be released after handing

over of the plant to IITH in good working condition after completion of the O&M

period and after recording completion certificate for the entire contract comprising of

Parts A and B.

(iv) The Engineer-in-Charge shall not make a claim under the performance guarantee

except for amounts to which the Institute is entitled to under the contract (not with-

standing and/or without prejudice to any other provisions in the contract agreement)

in the event of:

• Failure by the contractor to extend the validity of the Performance Guarantee as

described herein above, in which event the Engineer-in-Charge may claim the

full amount of the Performance Guarantee.

• Failure by the contractor to pay IITH any amount due, either as agreed by the

contractor or determined under any of the Clauses/Conditions of the agreement,

within 30 days of the service of notice to this effect by Engineer-in-Charge.

(v) In the event of the contract being determined or rescinded under provision of any

of the Clause/Condition of the agreement, the performance guarantee shall stand

forfeited in full and shall be absolutely at the disposal of the Director, IITH.

0.10 Language

Language for the bids and communication through out the contract period shall be En-

glish.

0.11 Currency

The tendered amount shall be in Indian National Rupee INR

9
0.12 Security Deposit

The contractor whose tender is accepted will also be required to furnish by way of Security

Deposit for the f ulfilment of his contract, an amount equal to 2.5% of the Contract

amount of the work for Part A. The contractor shall permit IITH at the time of making

any payment to him for work done under the contract to deduct a sum at the rate of

5% of gross amount of each scheduled payment till the sum along- with the sum already

deposited as earnest money, shall amount to security deposit of Part-A. Earnest money

shall be adjusted first in the security deposit and further recovery of security deposit

shall commence only when the up to date amount of security deposit starts exceeding the

earnest money. Such deductions shall be made and withheld by IITH by way of Security

Deposit unless he/they has/have deposited the amount of Security at the rate mentioned

above in form of Guarantee Bond issued by any Scheduled Bank in the prescribed format.

0.13 Award of Work and Signing of the Agreement

The bidder, whose total bid amount for Part A plus Part B is the lowest shall be declared

as the successful bidder. This Notice Inviting Tender shall form a part of the Contract

Document. In accordance with conditions of the contract, the letter of acceptance shall

be issued first in favour of the successful bidder. After submission of the performance

guarantee, the letter of award shall be issued. The contract shall be deemed to have come

into effect on issue of letter of acceptance of the tender. On issue of letter of award, the

successful Tenderer/Contractor shall, within 10 days from such date, formally sign the

agreement consisting of:

• The Notice Inviting Tender

• pre-bid clarifications

• all the documents including additional conditions

• special conditions of contract

• Technical Specifications and drawings, if any, forming part of the bid at the time of

invitation of bid

• the rates quoted at the time of submission of bid and acceptance thereof together

with any correspondence leading thereto.

10
0.14 Form of Agreement
INDIAN INSTITUTE OF TECHNOLOGY HYDERABAD
Kandi 502 285, Sangareddy (District), Telangana,
India Tel: +91 40 2301 7202 Fax: +91 40 23016032 / 23016003

Email: [email protected]

Lump Sum Tender Contract for Works

Tender for the work of:- Design, Supply, Installation, testing and commissioning (DSITC)

of electro-mechanical, instrumentation components pertaining to 650 KLD capacity Sewage

Treatment Plant (STP) at IITH Permanent Campus with GE MBR technology and 3 years of

post- commissioning operation and maintenance of the plant.

(i) To be submitted by 15.00 hours on 22/01/2018 to the Executive Engineer, IIT

Hyderabad.

(ii) technical bids to be opened in presence of tenderers who may be present at 15.30

hours on 22/01/2018 in the office of Executive Engineer, IIT Hyderabad.

Issued to:-.................................................**......................................................................... (Con-

tractor) Signature of officer issuing the documents ...............................**3 .........................................

Designation Executive Engineer, IIT Hyderabad.

Date of Issue: .................**...............

TENDER

I/We have read and examined the notice inviting tender,Specifications applicable ,

Drawings Designs, General Rules and Directions, Conditions of Contract, clauses of

contract, Special conditions, Schedule of Contract Price other documents and Rules re-

ferred to in the condition of contract and all other contents in the tender document for

the work.

I/We hereby tender for the execution of the work specified for IIT Hyderabad within the

time specified in bid document and in accordance in all respects with the specifications,

designs, drawings and instructions in writing referred to in bid documents and with such

materials as are provided for, by, and in respects in accordance with, such conditions so

far as applicable.

We agree to keep the tender open for 60 (sixty) days from the due date of opening of

financial bid thereof and not to make any modification in its terms and conditions.

A sum of Rs. ———————-*4 —————————————————- has been deposited

in the form of bank guarantee of a scheduled bank as earnest money. If I/We, fail to
3 to be filled by EE
4 to be filled by the bidder

11
furnish the prescribed performance guarantee within prescribed period, I/We agree that

the said Director, IIT Hyderabad or his successors in office shall, without prejudice to any

other right or remedy, be at liberty to forfeit the said earnest money absolutely. Further

if I/We fail to commence work as specified, I/We agree that Director, IIT Hyderabad or

his successors in office shall without prejudice to any other right or remedy available in

law be at liberty to forfeit the said earnest money the performance guarantee absolutely,

otherwise the said earnest money shall be retained by him towards security deposit to

execute all the works referred to in the tender documents upon the terms and conditions

contained or referred to therein and to carry out such deviations as may be ordered at the

rates to be determined in accordance with the provision contained in the bid document.

I/We hereby declare that I/We shall treat the tender documents drawings and other

records connected with the work as secret/confidential documents and shall not com-

municate information derived there from to any person other than a person to whom

I/We am/are authorised to communicate the same or use the information in any manner

prejudicial to the safety of the Institute.

Dated Signature of bidder

Postal Address

Witness:

Address:

Occupation:

ACCEPTANCE The above tender (as modified by you as provided in the letters mentioned

hereunder) is accepted by me for and on behalf of the Director, IIT Hyderabad for a sum of

Rs. ..........**..................(Rupees.....................................**......................................................................

The letters referred to below shall form part of this contract Agreement:-

i)

ii) ............**............

iii) For on behalf of the Director, IIT Hyderabad

Signature.................................................

12
Dated ......................

Designation..............

13
0.15 Integrity Pact

INTEGRITY PACT

IIT HYDERABAD is committed to follow the principle of transparency, equity and competi-

tiveness in public procurement.

The subject Notice Inviting Tender (NIT) is an invitation to offer made on the condition that

the Bidder will sign the integrity Agreement, which is an integral part of tender/bid docu-

ments, failing which the tenderer/bidder will stand disqualified from the tendering process

and the bid of the bidder would be summarily rejected.

This declaration shall form part and parcel of the Integrity Agreement and signing of the

same shall be deemed as acceptance and signing of the Integrity Agreement on behalf of

the IIT HYDERABAD.

14
 To be submitted by the bidder on his Letter Head

To

The Executive Engineer,

IIT Hyderabad

Sub: Submission of Tender

Dear Sir,

I/We acknowledge that IIT HYDERABAD is committed to follow the principles thereof as

enumerated in the Integrity Agreement enclosed with the tender/bid document.

I/We agree that the Notice Inviting Tender (NIT) is an invitation to offer made on the con-

dition that I/We will sign the enclosed integrity Agreement, which is an integral part of

tender documents, failing which I/We will stand disqualified from the tendering process.

I/We acknowledge that THE MAKING OF THE BID SHALL BE REGARDED AS AN UN-

CONDITIONAL AND ABSOLUTE ACCEPTANCE of this condition of the NIT.

I/We confirm acceptance and compliance with the Integrity Agreement in letter and spirit

and further agree that execution of the said Integrity Agreement shall be separate and

distinct from the main contract, which will come into existence when tender/bid is finally

accepted by IIT HYDERABAD. I/We acknowledge and accept the duration of the Integrity

Agreement, which shall be in the line with Article 1 of the enclosed Integrity Agreement.

I/We acknowledge that in the event of my/our failure to sign and accept the Integrity

Agreement, while submitting the tender/bid, IIT HYDERABAD shall have unqualified,

absolute and unfettered right to disqualify the tenderer/bidder and reject the tender/bid

is accordance with terms and conditions of the tender/bid.

Yours faithfully

(Duly authorized signatory of the Bidder)

15
 To be signed by the bidder and same signatory competent / authorised to sign the

relevant contract on behalf of IIT Hyderabad.

INTEGRITY AGREEMENT

This Integrity Agreement is made at ........................ on this .............. day of ................ 20.......

BETWEEN

Director, Indian Institute of Technology Hyderabad represented through Executive Engi-

neer, IITH, (Hereinafter referred as the ‘Principal/Owner‘, which expression shall unless

repugnant to the meaning or context hereof include its successors and permitted assigns)

AND

...................................................................................... Represented through ...........................................................

(Hereinafter referred to as the (Details of duly authorized signatory) Bidder/Contractor and

which expression shall unless repugnant to the meaning or context hereof include its suc-

cessors and permitted assigns)

Preamble

WHEREAS the Principal / Owner has floated the Tender No. ........................ (hereinafter

referred to as Tender/Bid) and intends to award, under laid down organizational proce-

dure, contract for .................................................................................... hereinafter referred to

as the Contract.

AND WHEREAS the Principal/Owner values full compliance with all relevant laws of

the land, rules, regulations, economic use of resources and of fairness/ transparency

in its relation with its Bidder(s) and Contractor(s). AND WHEREAS to meet the purpose

aforesaid both the parties have agreed to enter into this Integrity Agreement (hereinafter

referred to as Integrity Pact or Pact), the terms and conditions of which shall also be read

as integral part and parcel of the Tender/Bid documents and Contract between the par-

ties. NOW, THEREFORE, in consideration of mutual covenants contained in this Pact,

the parties hereby agree as follows and this Pact witnesses as under:

Article 1: Commitment of the Principal/Owner

1) The Principal/Owner commits itself to take all measures necessary to prevent cor-

ruption and to observe the following principles:

(a) No employee of the Principal/Owner, personally or through any of his/her family mem-

bers, will in connection with the Tender, or the execution of the Contract, demand, take

16
a promise for or accept, for self or third person, any material or immaterial benefit which

the person is not legally entitled to.

(b) The Principal/Owner will, during the Tender process, treat all Bidder(s) with equity

and reason. The Principal/Owner will, in particular, before and during the Tender pro-

cess, provide to all Bidder(s) the same information and will not provide to any Bidder(s)

confidential / additional information through which the Bidder(s) could obtain an advan-

tage in relation to the Tender process or the Contract execution.

(c) The Principal/Owner shall endeavour to exclude from the Tender process any person,

whose conduct in the past has been of biased nature.

2) If the Principal/Owner obtains information on the conduct of any of its employees

which is a criminal offence under the Indian Penal code (IPC)/Prevention of Corruption

Act, 1988 (PC Act) or is in violation of the principles herein mentioned or if there be a

substantive suspicion in this regard, the Principal/Owner will inform the Chief Vigilance

Officer and in addition can also initiate disciplinary actions as per its internal laid down

policies and procedures.

Article 2: Commitment of the Bidder(s)/Contractor(s) 1) It is required that each Bid-

der/Contractor (including their respective officers, employees and agents) adhere to the

highest ethical standards, and report to the Government / Department all suspected acts

of fraud or corruption or Coercion or Collusion of which it has knowledge or becomes

aware, during the tendering process and throughout the negotiation or award of a con-

tract.

2) The Bidder(s)/Contractor(s) commits himself to take all measures necessary to prevent

corruption. He commits himself to observe the following principles during his participa-

tion in the Tender process and during the Contract execution:

a) The Bidder(s)/Contractor(s) will not, directly or through any other person or firm, offer,

promise or give to any of the Principal/Owners employees involved in the Tender process

or execution of the Contract or to any third person any material or other benefit which

he/she is not legally entitled to, in order to obtain in exchange any advantage of any kind

whatsoever during the Tender process or during the execution of the Contract.

b) The Bidder(s)/Contractor(s) will not enter with other Bidder(s) into any undisclosed

agreement or understanding, whether formal or informal. This applies in particular to

prices, specifications, certifications, subsidiary contracts, submission or non-submission

of bids or any other actions to restrict competitiveness or to cartelize in the bidding pro-

cess.

c) The Bidder(s)/Contractor(s) will not commit any offence under the relevant IPC/PC Act.

Further the Bidder(s)/Contract(s) will not use improperly, (for the purpose of competition

17
or personal gain), or pass on to others, any information or documents provided by the

Principal/Owner as part of the business relationship, regarding plans, technical propos-

als and business details, including information contained or transmitted electronically.

d) The Bidder(s)/Contractor(s) of foreign origin shall disclose the names and addresses

of agents/representatives in India, if any. Similarly Bidder(s)/Contractor(s) of Indian Na-

tionality shall disclose names and addresses of foreign agents/representatives, if any.

Either the Indian agent on behalf of the foreign principal or the foreign principal directly

could bid in a tender but not both. Further, in cases where an agent participate in a ten-

der on behalf of one manufacturer, he shall not be allowed to quote on behalf of another

manufacturer along with the first manufacturer in a subsequent/parallel tender for the

same item.

d) The Bidder(s)/Contractor(s) will, when presenting his bid, disclose (with each tender as

per proforma enclosed ) any and all payments he has made, is committed to or intends to

make to agents, brokers or any other intermediaries in connection with the award of the

Contract.

3) The Bidder(s)/Contractor(s) will not instigate third persons to commit offences outlined

above or be an accessory to such offences.

4) The Bidder(s)/Contractor(s) will not, directly or through any other person or firm in-

dulge in fraudulent practice means a willful misrepresentation or omission of facts or

submission of fake/forged documents in order to induce public official to act in reliance

thereof, with the purpose of obtaining unjust advantage by or causing damage to justified

interest of others and/or to influence the procurement process to the detriment of the

Government interests.

5) The Bidder(s)/Contractor(s) will not, directly or through any other person or firm use

Coercive Practices (means the act of obtaining something, compelling an action or influ-

encing a decision through intimidation, threat or the use of force directly or indirectly,

where potential or actual injury may befall upon a person, his/ her reputation or property

to influence their participation in the tendering process).

Article 3: Consequences of Breach

Without prejudice to any rights that may be available to the Principal/Owner under

law or the Contract or its established policies and laid down procedures, the Princi-

pal/Owner shall have the following rights in case of breach of this Integrity Pact by the

Bidder(s)/Contractor(s) and the Bidder/ Contractor accepts and undertakes to respect

and uphold the Principal/Owners absolute right:

1) If the Bidder(s)/Contractor(s), either before award or during execution of Contract has

committed a transgression through a violation of Article 2 above or in any other form,

18
such as to put his reliability or credibility in question, the Principal/Owner after giving 14

days notice to the contractor shall have powers to disqualify the Bidder(s)/Contractor(s)

from the Tender process or terminate/determine the Contract, if already executed or ex-

clude the Bidder/Contractor from future contract award processes. The imposition and

duration of the exclusion will be determined by the severity of transgression and deter-

mined by the Principal/Owner. Such exclusion may be forever or for a limited period as

decided by the Principal/Owner.

2) Forfeiture of EMD/Performance Guarantee/Security Deposit: If the Principal/Owner

has disqualified the Bidder(s) from the Tender process prior to the award of the Contract

or terminated/determined the Contract or has accrued the right to terminate/determine

the Contract according to Article 3(1), the Principal/Owner apart from exercising any le-

gal rights that may have accrued to the Principal/Owner, may in its considered opinion

forfeit the entire amount of Earnest Money Deposit, Performance Guarantee and Security

Deposit of the Bidder/Contractor.

3) Criminal Liability: If the Principal/Owner obtains knowledge of conduct of a Bidder or

Contractor, or of an employee or a representative or an associate of a Bidder or Contrac-

tor which constitutes corruption within the meaning of IPC Act, or if the Principal/Owner

has substantive suspicion in this regard, the Principal/Owner will inform the same to law

enforcing agencies for further investigation.

Article 4: Previous Transgression

1) The Bidder declares that no previous transgressions occurred in the last 5 years with

any other Company in any country confirming to the anticorruption approach or with

Central Government or State Government or any other Central/State Public Sector En-

terprises in India that could justify his exclusion from the Tender process.

2) If the Bidder makes incorrect statement on this subject, he can be disqualified from the

Tender process or action can be taken for banning of business dealings/ holiday listing

of the Bidder/Contractor as deemed fit by the Principal/ Owner.

3) If the Bidder/Contractor can prove that he has resorted / recouped the damage caused

by him and has installed a suitable corruption prevention system, the Principal/Owner

may, at its own discretion, revoke the exclusion prematurely.

Article 5: Equal Treatment of all Bidders/Contractors/Subcontractors

1) The Bidder(s)/Contractor(s) undertake(s) to demand from all subcontractors a commit-

ment in conformity with this Integrity Pact. The Bidder/Contractor shall be responsible

for any violation(s) of the principles laid down in this agreement/Pact by any of its Sub-

contractors/sub-vendors.

2) The Principal/Owner will enter into Pacts on identical terms as this one with all Bid-

19
ders and Contractors.

3) The Principal/Owner will disqualify Bidders, who do not submit, the duly signed Pact

between the Principal/Owner and the bidder, along with the Tender or violate its provi-

sions at any stage of the Tender process, from the Tender process.

Article 6- Duration of the Pact

This Pact begins when both the parties have legally signed it. It expires for the Con-

tractor/Vendor 12 months after the completion of work under the contract or till the

continuation of defect liability period, whichever is more and for all other bidders, till the

Contract has been awarded.

If any claim is made/lodged during the time, the same shall be binding and continue to be

valid despite the lapse of this Pacts as specified above, unless it is discharged/determined

by the Competent Authority, IIT HYDERABAD.

Article 7- Other Provisions

1) This Pact is subject to Indian Law, place of performance and jurisdiction is the Head

quarters of the IITH of the Principal/Owner, who has floated the Tender.

2) Changes and supplements need to be made in writing. Side agreements have not been

made.

3) If the Contractor is a partnership or a consortium, this Pact must be signed by all the

partners or by one or more partner holding power of attorney signed by all partners and

consortium members. In case of a Company, the Pact must be signed by a representative

duly authorized by board resolution.

4) Should one or several provisions of this Pact turn out to be invalid; the remainder of

this Pact remains valid. In this case, the parties will strive to come to an agreement to

their original intensions.

5) It is agreed term and condition that any dispute or difference arising between the

parties with regard to the terms of this Integrity Agreement / Pact, any action taken by

the Owner/Principal in accordance with this Integrity Agreement/ Pact or interpretation

thereof shall not be subject to arbitration.

Article 8- LEGAL AND PRIOR RIGHTS

All rights and remedies of the parties hereto shall be in addition to all the other legal

rights and remedies belonging to such parties under the Contract and/or law and the

same shall be deemed to be cumulative and not alternative to such legal rights and reme-

dies aforesaid. For the sake of brevity, both the Parties agree that this Integrity Pact will

have precedence over the Tender/Contact documents with regard any of the provisions

covered under this Integrity Pact.

IN WITNESS WHEREOF the parties have signed and executed this Integrity Pact at the

20
place and date first above mentioned in the presence of following witnesses:

..................................................... (For and on behalf of Principal/Owner)

................................................... (For and on behalf of Bidder/Contractor)

WITNESSES:

1. .............................................. (signature, name and address)

2. ............................................... (signature, name and address)

Place:

Dated :

21
Chapter 1

Information and Instructions to

Bidders

1.1 General

(i) Model Letter of transmittal and other forms for deciding eligibility are given in Section

(ii) All information called for in the model forms should be furnished against the relevant

columns in the forms. If for any reason, information is furnished on a separate sheet,

this fact should be mentioned against the relevant column. Even if no information

is to be provided in a column, a nil or No such case entry should be made in that

column. If any particulars/query is not applicable in case of the bidder, it should be

stated as not applicable.

(iii) The bidders are cautioned that not giving complete information called for in the

NIT or not giving it in clear terms or marking any change in the prescribed forms

or deliberately suppressing the information may result in the bid being summarily

disqualified. Bids made by telegram or telex or through other electronic means and

those received late shall not be accepted.

(iv) The bidder should sign on each page of the bid document.

(v) Overwriting should be avoided. Correction, if any, should be made by neatly crossing

out, initialling, dating and rewriting. Pages of the eligibility criteria document are

numbered.

(vi) Additional sheets, if any, added by the contractor, should also be numbered by him.

They should be submitted as a package with signed letter of transmittal.

(vii) References, information and certificates from the respective clients certifying suit-

ability, technical knowledge or capability of the bidder should be signed by an Officer

not below the rank of Executive Engineer or equivalent. In case of certificates from

22
 private organizations, such certificate shall be submitted in original issued by Project

Manager of such organization.

(viii) The bidder may furnish any additional information which he thinks is necessary

to establish his capabilities to successfully complete the envisaged work. He is,

however, advised not to furnish superfluous information. No information shall be

entertained after submission of eligibility criteria document unless it is called for by

the IIT Hyderabad.

1.2 Definitions

In this document, the following words and expressions have the meaning hereby assigned

to them.

(i) Government or IITH or IIT Hyderabad or Institute or Department : Means the Indian

Institute of Technology Hyderabad, Kandi-502285, Sangareddy District, Telangana

State, India acting through the Engineer-in-Charge, IIT Hyderabad.

(ii) Engineer-in-Charge means Engineer-in-Charge of the work, representing Director,

IIT Hyderabad.

(iii) Bidder or tenderer: Means the individual, sole proprietary firm, firm in partnership,

limited company, private or public or corporation.

(iv) Year: Means Financial year unless stated otherwise.

(v) Technology Provider : Means Suez Water Technologies and Solutions (I) Pvt. Ltd.,

formerly GE India Industrial Pvt. Limited

(vi) ”GE” means Suez Water Technologies and Solutions (I) Pvt. Ltd., formerly GE India

Industrial Pvt. Limited

(vii) MoU means Memorandum of Understanding

1.3 Method of application:

(i) If the bidder is an individual, the application shall be signed by him above his full

type written name and current address.

(ii) If the bidder is proprietary firm, the application shall be signed by the proprietor

above his full typewritten name and full name of his firm with its current address.

23
(iii) If the bidder is a firm in partnership, the application shall be signed by all the part-

ners of the firm above their full typewritten names and current addresses, or, al-

ternatively, by a partner holding power of attorney for the firm. In the latter case,

a certified copy of the power of attorney should accompany the application. In both

cases, a certified copy of the partnership deed and current address of all the partners

of the firm should accompany the application.

(iv) If the bidder is a limited company or a corporation, the application shall be signed

by a duly authorized person holding power of attorney for signing the application

accompanied by a copy of the power of attorney. The bidder should also furnish a

copy of the Memorandum of Articles of Association duly attested by a Public Notary.

1.4 Final decision making authority:

IITH reserves the right to accept or reject any bid and to annul the process and reject all

at any time, without assigning any reason or incurring any liability to the bidders bids .

1.5 Particulars provisional

The particulars of the work given in Chapter 4.1 are indicative. They are liable to change

and must be considered only as advance information to assist the bidder.

1.6 Site visit

The bidders are advised to visit the site of work, at his own cost, and examine it and its

surroundings to familiarize himself, collect all information that he considers necessary

for proper assessment of the work and shall quote accordingly.

1.7 Criteria for eligibility

(i) Contractors who fulfill all the initial criteria of qualification for bidding specified in

NIT be eligible to apply.

(ii) The bidder shall be registered with GST council of Govt. of India. A certified copy of

Certificate of Registration for GST shall be enclosed with bid documents as a proof.

(iii) The bidder should own construction equipment required for the proper and timely

execution of the work.

(iv) The bidder should have sufficient number of Technical and Administrative employees

for the proper execution of the contract. The bidder should submit a list of the

24
 personnel to be posted at site of work along with their credentials stating clearly how

they would be involved in this work.

(v) The bidders performance for each work completed in the immediately preceding

seven years and works in hand should be certified by an Officer not below the rank of

Executive Engineer or equivalent. In case of certificates from private organizations,

such certificate shall be submitted in original issued by Project Manager of such

organization.

1.8 Evaluation criteria

The details submitted by the bidders shall be evaluated in the following manner:

(i) The initial criteria of qualification prescribed in Section 0.2 of NIT in respect of ex-

perience of similar works completed, bidding capacity and financial turn over etc.,

shall first be scrutinized and the bidders eligibility for the work be determined.

(ii) The bidders qualifying the initial criteria of qualification as set out in Section 0.2 of

NIT shall be evaluated for following criteria by scoring method on the basis of details

furnished by them:

Table 1.1: Evaluation Break-up

Sl No. Criterion Maximum Marks

(a) Financial strength (Form A & B) 20
(b) Experience in similar works during last seven years (Form C ) 50
(c) Performance on works (Form E) time over run 10
(d) Performance on works (Form E) quality 10
(e) Personal and Establishment (Form F & G) 10
Total 100

(iii) The scoring for evaluation shall be done as per Table 1.2. IITH reserves the right to

restrict the list of such qualified contractors to any number deemed suitable by it.

(iv) IIT Hyderabad will independently verify the credentials submitted by the bidder and

may obtain the Client feedback directly. In case of adverse feedback of the clients,

those bids will be disqualified. The bidders shall give complete contact information

of clients of eligible projects while submitting their credentials. Bids with incomplete

submissions in this context shall be rejected.

1.9 Disqualification

Even though any bidder may satisfy the above requirements, he would be liable to dis-

qualification if he has:

25
 • made misleading or false representation or deliberately suppressed the information

in the forms, statements and enclosures required in the eligibility criteria document.

• record of poor performance such as abandoning work, not properly completing the

contract, or financial failures / weaknesses etc.,

1.10 Financial information

Bidder should furnish the following financial information: Annual financial statement for

the last five years in (Form A) & solvency certificate in (Form B) given at Chapter 7.

1.11 Experience in Similar Works

Bidder shall furnish the following attested credentials in the eligibility document :

(i) List of all works of similar works successfully completed during the last seven years

in (Form C) given at Chapter 7.

(ii) List of the projects under execution or awarded in (Form D)given at Chapter 7.

(iii) Particulars of completed works and performance of the bidder duly authenticated/certified

by an Officer not below the rank of Executive Engineer or equivalent should be fur-

nished separately for each work completed or in progress in (Form E) given at Chap-

ter

7.

In case of projects pertaining to private sector, the bidder shall submit certificates in

ORIGINAL issued by the Project Manager of the Client organization.

(iv) Information in (Form D) should be complete and no work should be left out.

1.12 Organization information

Bidder shall furnish the following self attested documents:

(i) Structure and organization in Form F given at Chapter 7.

(ii) Details of Technical and administrative personnel to be employed for the work in

Form-G given at Chapter 7.

1.13 Construction Plant and Machinery

Bidder shall furnish the following attested documents in the eligibility document:

(i) List of P& M owned

26
 (ii) List of construction plant and machinery likely to be used in carrying out the work

in Form H given at Chapter 7.

1.14 EPF Registration

The Bidder should submit EPF registration Certificate valid as on date of opening of bid.

1.15 Goods and Services Tax (GST )

GST shall be applicable for Works contract as per GST Act amended from time to time.

Quoted rates shall be inclusive of applicable GST. Nothing extra shall be payable.

1.16 Opening of price bid (financial bid) its validity

After evaluation of applications, a list of qualified bidders shall be prepared based on the

minimum cut-off marks obtained. There-after the financial bids of only the qualified and

technically acceptable bidders shall be opened at the notified time, date and place in the

presence of the qualified bidders or their representatives. The bids shall remain valid for

60 days from the date of opening of financial bid.

1.17 Award criteria

IIT Hyderabad reserves the right, without being liable for any damages or obligation to

inform the bidder, to:

(i) Amend the scope and value of contract to the bidder.

(ii) Reject any or all the applications without assigning any reason.

(iii) Any effort on the part of the bidder or his agent to exercise influence or to pressurize

the IIT Hyderabad would result in rejection of his bid. Canvassing of any kind is

prohibited.

1.17.1 Award

The work shall be awarded to the successful bidder who has quoted lowest

tendered amount. For the purpose of reckoning lowest tendered amount, the total

of lump sum amount quoted for Part-A and amount quoted for three years of O&

M of Part-B shall be considered.

27
1.18 Appendix-I

Criteria for evaluation of the performance of bidders for pre-eligibility

Table 1.2: Evaluation Criteria

Sl No Attributes Evaluation
Financial strength : 20 Marks (i) 60% marks for minimum eligibility criteria
1
(i) Average annual turnover (ii) 100% marks for twice the minimum
16 Marks eligibility or more, In between (i) & (ii)
(ii) Solvency Certificate 4 Marks on pro-rata basis

Experience in similar Works– (i) 60% marks for minimum eligibility

(a) 1 # 500 or above KLD or criteria
2 50 Marks
(b) 2# 400 to 499 KLD or (ii) 100% marks for twice the minimum
(c) 3#200 to 399 KLD eligibility criteria or more,
In between (i) & (ii) on pro-rata basis
(i) Without levy of compensation : 10 Marks
Performance on works
3 10 marks (ii) With levy of compensation :,0 Marks
(time over run)
(iii) Compensation not decided : 5 Marks
(i) Very Good :10,
Performance of works (ii) Good :8,
4 10 Marks
(Quality) : (iii) Fair :5,
(iv) Poor :0
(As per Form G):
(i)Graduate Engineer :3 marks for each,
(ii) Diploma Engineer : 2 marks for each
Personnel and
5 10 Marks up to max.4 marks,
Establishment
(iii) Supervisory/Foreman: 1 mark for
each up
to max. 3 marks

28
Chapter 2

Conditions of the Contract

2.1 General Conditions

1. As per the overall master plan of the IIT Hyderabad permanent campus project two

sewage treatment plants are proposed to be constructed. These two sewage treat-

ment plants are designated as STP-I and STP-II. This tender is for STP-I. The Civil

works of STP-I are being constructed by IIT Hyderabad under separate contract.

STP-I is planned to handle 1950 KLD sewage and accordingly civil construction work

is being constructed in modules of 3 trains/streams of 650 KLD each with a com-

mon collection sump to cater to peak demand of 1950 KLD. The present contract is

to bring into operation one 650 KLD (Module No.1) module by installation of electro-

mechanical and instrumentation equipment required for one 650 KLD module and

installation of all common equipment and instrumentation required for overall ca-

pacity of 1950 KLD (3 modules) like screens, centrifuge etc.,

The detailed working drawings of the civil construction works of proposed STP-I

pertaining to Architectural plans, sections, elevations etc. indicating sizes of units,

levels etc. and structural drawings are enclosed with the bid document in pdf for-

mat. Bidders are advised to thoroughly study these drawings specifically, the sizes

of layout of different tanks, their sizes, levels etc. The design of electro-mechanical

equipment of the proposed work shall be in tune with the Civil construction such

that the treatment plant will meet the desired requirements in terms of quantity of

treated sewage/day, quality of treated sewage etc.The following drawings shall form

a part of the tender document:

Architectural Drawings:

• Drawing No.ES-STP-100:Excavation Plan.

• Drawing No. STP-AR-01: Site Plan.

• Drawing No. STP-AR-02: Plans and Sections.

29
 • Drawing No. STP-AR-03: Plans and Sections.

• Drawing No. STP-AR-04: Elevation and other details.

Structural Drawings:

• Drawing No. ES-STP-01: STP foundation layout

• Drawing No. ES-STP-01A: STP foundation details

• Drawing No. ES-STP-02: STP framing plan and slab layout

• Drawing No. ES-STP-03: STP beam details

2. Any clarification or doubt regarding these drawings may be raised by the bidders in

the pre-bid meeting and get clarity before submission of bids. No claims shall be

entertained thereafter.

3. The power supply for the sewage treatment plant shall be made available at the

control panel room. The distribution of power for various units/equipment, switch-

gear/panels/starters/VFDs and cabling including design of cables and switch-gear

shall be within the scope of the contractor.

4. The total electrical load of the plant shall be worked out by the contractor and

accordingly, IITH will arrange power supply cables up to the Control Room.

5. All the equipment like motors, pumps, blowers etc. must be high energy efficient as

per BEE Standards

6. For Operation Maintenance Services, power supply will be arranged free of charge

by IITH.

7. The Institute has appointed Tata Consulting Engineers as Project Management Con-

sultant (PMC) and Bharat Sanchar Nigam Limited as Project Certification Agency

(PCA) for this work. The successful bidder shall execute the work in co-ordination

with these two agencies. The role of PMC and PCA shall cease after closure of orig-

inal Agreement. Representatives from both these agencies shall inspect all aspects

of the work like conformance of material, processes, safety issues, attend factory

inspections, if any, witness tests , scrutinize the Running Bill payment bills raised

by the contractor and recommend the same to IITH for payment etc.

8. The PMC and PCA shall satisfy themselves that the work has been done in each stage

in conformity to the approved drawings and specifications contained in the tender

documents and certify the same before recommending to the Engineer-in-Charge,

IITH for the release of the scheduled payment.

9. The work shall be carried out as per the drawings vetted by the Technology Provider

and approved by the Engineer-in-Charge adhering to Technical Specification of con-

30
 tract for Electro-Mechanical equipment, Membranes, Instrumentation, automation

,electrical works, piping etc. as per Chapter 4. All allied civil works required for

equipment foundation, platforms etc,. shall be executed as per CPWD Specification

2009 volume I and II.

10. The list of approved makes or brands are mentioned against each of the electro-

mechanical, instrumentation, membranes and other items required for completion

of work. The contractor shall procure any one of the approved makes conforming to

the required specifications. The brand,make and model of equipment being procured

shall be intimated in advance to Engineer-in-Charge before their procurement.

11. In case make/brand is not specified for any of the item required for the plant and

not included in the list, contractor may propose any one of the reputed brands for

such items for approval of Engineer-in-Charge. Procurement of such items shall be

done only after obtaining written approval of Engineer-in-Charge.

12. The contractor shall make his own arrangements at site for proper storing of GE

membranes as per the recommendations of the Technology Provider until installa-

tion of the membranes.

13. All electro-mechanical, instrumentation equipment shall be properly stored under

protected environment at site until they are installed in their designated locations.

14. The testing charges for conducting the tests on influent sewage or treated water at

third party laboratories as and when intended by the Engineer-in-Charge, shall be

reimbursed. The reimbursement such third party test charges can be claimed along

with the monthly O& M bills. Third party tests shall be done at the labs approved

by the Institute.

15. The contractor shall arrange at site control room one desktop computer system

loaded with required licensed software for monitoring the operations of the plant

and for storing and retrieval of data along with one laser printer. The computer and

printer shall be properly maintained at control room.

16. During the O& M period, the contractor shall maintain at site sufficient numbers of

all equipment required for O& M like wheel borrows, spades, pans, safety equipment,

all tools and tackles required for day to day operations and troubleshooting.

17. The contractor shall carry-out safety audit of the plant on quarterly basis and report

there-of shall be furnished to Engineer-in-Charge. First safety audit shall be carried

out after three months of commencement of O& M period.

18. All near misses, accidents in the premises of STP shall be reported to the Engineer-

in-Charge as and when they occur. Process improvement to avoid such incidents in

31
 future shall also be undertaken under intimation to the Engineer-in-Charge.

19. Housekeeping of the STP premises shall be the responsibility of the contractor until

the end of O& M period. The entire external and internal premises of STP shall be

maintained properly all the time including the janitorial services.

20. Air conditioning Equipment: Wall mounted split type air conditioners of 2 TR capacity

shall be provided for the control room. Outdoor condensing unit shall be located on

the roof of the building or grouted on the external side of the wall with suitable

brackets.

One more set of 2 TR split ACs (2x2TR) shall be provided in the laboratory. Cost of

these ACs is deemed to be included in the quoted lump sum amount.

The ACs shall be properly maintained during the O&M Period by the contractor.

21. IITH shall not ensure inflow of a 650 KLD sewage for treatment all along the contract

period. There can be periods of low flow at regular intervals. The successful bidder

shall design most appropriate design based on the GE MBR technology treatment

process to ensure the treated sewage quality meets the standards specified in this

document and shall simultaneously meet disposal standards as prescribed by the

Central Pollution Control Board / Telangana State Pollution Control Board as may

be applicable as per the law.

22. The contractor shall not assign or sublet any part or whole of the contract under

any circumstances.

23. Rights on treated water: IITH shall have full rights on treated water including the

softened water. Through a network of separate pipe lines , IITH will utilize the treated

water for internal purposes like flushing, gardening and make-up water for HVAC

systems on daily basis. Contractor shall not have any rights on the treated water.

24. Running account bills and Final bills for the work: The contractor shall submit all

the running account bills in the proforma CPWA-27A and the final bill in proforma

CPWA-27B. Payment under Schedule 6 of Payment Terms shall be treated as pro-

visional final bill of Original Agreement(Part-A) for DSITC Works. The final bill of

entire contract shall be payable on completion of Supplementary Agreement (Part-B)

for O & M services and issue of completion certificate for entire work by Engineer-

in-Charge.

2.2 Tender Rates

(i) The tenderer shall study carefully, the drawings, specifications, schedule of contract

price and all other conditions to fully understand the scope of work before quoting

32
 his rates.

(ii) The rates and amount for which the tender is approved shall be inclusive of all

expenses for the proper and entire completion of the work and shall be inclusive

of all taxes, duties and levies including GST, Import duties, labour cess, municipal

taxes local taxes, all royalties, patent rights, other incidental charges etc. The Lump

sum amount offered shall be final and no claim whatsoever on any account shall be

entertained.

(iii) Under Part-A of the contract, bidder shall quote lump sum amount for designing,

supplying, installation, testing and commissioning of all electro-mechanical equip-

ment, instrumentation, piping and allied civil works like equipment foundations,

painting, electrical wiring, panels etc. The indicative list of electro-mechanical equip-

ment, instrumentation, piping, automation etc., is given in Chapter 4. The bidder is

required to quote a single lump sum amount including the GST (i.e., GST for all com-

ponents as well as GST on works contract) for the total contract for Part-A. It may be

noted that the list is indicative only and not exhaustive and hence quoted lump sum

amount for Part-A shall include cost of all items required for supply, installation,

trial run and successful commissioning of the plant as per approved design, draw-

ings and specifications and nothing extra shall be paid over and above the quoted

amount against Part-A of the contract.

(iv) Under Part B of the Contract, contractor shall be responsible for operation and main-

tenance of the plant for three years. Bidder shall quote monthly charges inclusive of

all taxes as per the Schedule of Contract price.

2.3 Specialized Work

Plant automation is considered to be specialized component of the Contract. The bidder

shall propose such agency who fulfills the requirements specified in Section 5.50.

2.4 Taxes

(i) The Tendered amount for both Part-A and Part-B shall be inclusive of applicable Works

Contract Tax under GST.

(ii) Other Taxes: Income tax/surcharge/cess or any other tax as applicable on the

amounts paid by IIT Hyderabad shall be recovered at source at applicable rates as notified

by Government of India and a certificate to this extent shall be issued to the contractor.

33
2.5 Mobilization Advance

(i) Mobilization advance of 10% of contract amount for Part-A may be payable to the

contractor after award of work against bank guarantee bond (BG) of any scheduled

bank of 110% of the advance amount. The BG shall be submitted in the prescribed

proforma as given in Section 7 and shall be valid for one year from the date of

submission or as specified by the Institute. If the commissioning of the plant is

delayed due to any reasons, the Contractor shall arrange for extension of validity of

the BG to such period as specified by the Institute.

(ii) Mobilization advance as stated above may be given, if requested by the contractor in

writing within one month of the order to commence the work. Such advance shall

be paid in one or more instalments to be determined by the Engineer-in-Charge at

his sole discretion. The first instalment of such advance shall be released by the

Engineer-in-Charge to the contractor on a request made by the contractor to the

Engineer- in-Charge. The second and subsequent instalments shall be released by

the Engineer- in- Charge only after the contractor furnishes a proof of the satis-

factory utilization of the earlier instalment of the mobilization advance to the entire

satisfaction of the Engineer-in-Charge.

If the circumstances are considered reasonable by the Engineer-in-Charge, the pe-

riod mentioned above for request by the contractor in writing for grant of mobilization

advance may be extended at the discretion of the Engineer-in-Charge.

2.5.1 Interest on Mobilization Advance

The mobilization advance shall bear a simple interest at the rate of 10 per cent per annum

and shall be calculated from the date of payment to the date of recovery, both days

inclusive, on the outstanding amount of advance.

2.5.2 Recovery of Mobilization Advance

Recovery of such sums advanced together with interest due on the entire outstanding

amount up to the date of recovery of the instalment shall be made by the deduction from

the contractors scheduled payments as follows:

(a) 60% of mobilization advance from payments under Schedule 2 (on pro rata basis from

each segment of schedule 2 payments.)

(b) 80% of mobilization advance from payments under Schedule 3 less already recovered

amount of mobilization advance.

34
(c) 100% of mobilization advance from payments under Schedule 4 less already recovered

amount of mobilization advance.

(d) Above recoveries will be made along with applicable interest amount corresponding to

that period.

2.6 Payment for additions and deductions for Omissions

(i) Authorized variations shall not vitiate the contract but additions and omissions shall

be measured up and paid. The rates for extra or reduction and deduction items shall

be worked out as per prevailing market rates. The rates finalized by the Engineer-in-

Charge shall be final and binding. The coefficients for materials and labour for analysing

the rates shall be as specified in the latest Delhi Analysis of Rates published by CPWD.

Where, such coefficients are not available, the actual observed values will be adopted.

(ii) The execution of any items of work where any incidental work is actually required but

not specifically stated in the tender, it is to be understood that the amount quoted by the

contractor shall cover such charges also and nothing extra on account of such incidental

charges, if any, shall be paid.

2.7 No Payment for Unsanctioned Extras

It shall be distinctly understood that no payment whatever will be made to the contractor

for variations by way of extras in cases where such variations have been made without

the written sanction of the Engineer-in-Charge.

2.8 Penalty for not fulfilling Effluent Characteristics

In case if the contractor fails to meet specified parameters of the quality of the treated

sewage, the contractor shall pay to the IITH liquidated damages amounting to Rs 2,000.00

(Rupees two thousand only) per day of occurrence, over and above the costs and com-

pensation that might be required by the IITH to pay to the affected people and parties ,if

any.

2.9 Defect Liability Period

The defect liability period for this contract shall be for a period of two (2) years from the

date of completion of Part-A.

The defects, if any, during the defect liability period shall be rectified free of charge by

arranging free replacement wherever necessary as specified in the contract. All expenses

35
including statutory levies on account of such replacement shall be borne by the contrac-

tor.

2.10 Record of Completion

The Part-A of contract shall be deemed to be completed on issue of completion certificate

by Engineer-in-Charge. The period of three years for Part-B of the contract shall com-

mence only after the date of completion of Part-A. The whole contract shall be deemed to

be completed on successful completion of both Part-A and Part-B components.

2.11 Warranty

All electro-mechanical equipment, instrumentation and ultra-filtration membranes shall

have warranty till end of the total contract period for Part A and Part B. Even in case

warranty of this period is not extended by any Original Equipment Manufacturer (OEM),

it shall be the responsibility of the contractor to maintain the plant trouble free.

2.12 Disputes and Arbitration

(a) Unless otherwise specified, in all cases of disputes which cannot be settled by mu-

tual negotiations, the disputes or differences shall be referred to a Dispute Redressal

Committee (DRC) to be constituted by the Director, IIT Hyderabad at the request of the

contractor. In case the decision of the DRC is not acceptable to the parties, those disputes

shall finally be settled and binding on both parties by arbitration in conformity with the

rules of Indian Arbitration and Conciliation Act 1996 as amended from time to time. All

disputes or differences whatsoever arising between the parties out of relating to the con-

struction, meaning and operation or effect of the general terms and conditions included

in the agreement or the breach thereof shall be binding on the parties.

b) Performance of the Agreement conditions shall continue during arbitration and any

subsequent proceedings.

c) The jurisdiction and seat of arbitration shall be Hyderabad. The Arbitrator shall be

appointed by the Director, IITH.

d) All legal matters are subjected to within the jurisdiction of High Court (AP & Telan-

gana), Hyderabad.

2.13 Force Majeure

In this Clause, Force Majeure means an exceptional event or circumstance:

(a) which is beyond a Partys control,

36
(b) which such Party could not reasonably have provided against before entering into the

Contract,

(c) which, having arisen, such Party could not reasonably have avoided or overcome, and

(d) which is not substantially attributable to the other Party.

Force Majeure may include, but is not limited to, exceptional events or circumstances

of the kind listed below, so long as conditions (a) to (d) above are satisfied:

(i) war, hostilities (whether war be declared or not), invasion, act of foreign enemies,

(ii) rebellion, terrorism, sabotage by persons other than the Contractors Personnel, revo-

lution, insurrection, military or usurped power, or civil war,

(iii) riot, commotion, disorder, strike or lockout by persons other than the Contractors

Personnel,

(iv) munitions of war, explosive materials, ionising radiation or contamination by radio-

activity, except as may be attributable to the Contractors use of such munitions, explo-

sives, radiation or radio-activity, and

(v) natural catastrophes such as earthquake, hurricane, typhoon or volcanic activity.

If a Party is or will be prevented from performing its substantial obligations under

the Contract by Force Majeure, then it shall give notice to the other Party of the event

or circumstances constituting the Force Majeure and shall specify the obligations, the

performance of which is or will be prevented. The notice shall be given within 14 days

after the Party became aware, or should have become aware, of the relevant event or

circumstance constituting Force Majeure.

The Party shall, having given notice, be excused performance of its obligations for so

long as such Force Majeure prevents it from performing them.

Notwithstanding any other provision of this Clause, Force Majeure shall not apply to

obligations of either Party to make payments to the other Party under the Contract.

2.14 Price Escalation

The lump sum contract amount shall be final and Price Escalation shall not be applicable.

2.15 Time Extension of Contract Period

(i) The time allowed for execution of the Part-A of contract as specified in NIT or the ex-

tended time in accordance with these conditions shall be the essence of the Contract.

The execution of the works shall commence from such time period as mentioned in

award letter or from the date of handing over of the site whichever is later. If the Con-

tractor commits default in commencing the execution of the work as aforesaid, IITH

37
 shall without prejudice to any other right or remedy available in law, be at liberty to

forfeit the earnest money performance guarantee absolutely.

(ii) As soon as possible after the Contract is concluded, the Contractor shall submit

a Time and Progress Chart for each mile stone of Part-A and get it approved by

the Engineer-in-Charge. The Chart shall be prepared in direct relation to the time

stated in the Contract documents for completion of components of the Part-A. It

shall indicate the forecast of the dates of commencement and completion of various

components of the work and may be amended as necessary by agreement between

the Engineer-in-Charge and the Contractor within the limitations of time imposed in

the Contract documents .

(iii) the work(s) be delayed by:

(a) force majeure, or

(b) abnormally bad weather, or

(c) serious loss or damage by fire, or

(d) civil commotion, local commotion of workmen, strike or lockout, affecting any of

the trades employed on the work, or

(e) delay on the part of other contractors or tradesmen engaged by Engineer-in-

Charge in executing work not forming part of the Contract, or

(f) non-availability of stores, which are the responsibility of IITH to supply if any or

(g) non- availability or break down of tools and plant to be supplied or supplied by

IITH if any or

(h) any other cause which, in the absolute discretion of the Engineer-in-Charge is

beyond the Contractors control,

then upon the happening of any such event causing delay, the Contractor shall

immediately give notice thereof in writing to the Engineer-in-Charge IITH but shall

nevertheless use constantly his best endeavours to prevent or make good the delay

and shall do all that may be reasonably required to the satisfaction of the Engineer-

in-Charge to proceed with the works.

(iv) Request for rescheduling of Mile stones and extension of time, to be eligible for con-

sideration, shall be made by the Contractor in writing within fourteen days of the

happening of the event causing delay on the prescribed form to the Engineer-in-

Charge. The Contractor may also, if practicable, indicate in such a request the

period for which extension is desired.

(v) In any such case the Engineer-in-Charge may give a fair and reasonable extension

38
 of time and reschedule the mile stones for completion of Part-A of contract. Such

extension shall be communicated to the Contractor by the Engineer-in-Charge in

writing, within 3 months of the date of receipt of such request. Non application by

the contractor for extension of time shall not be a bar for giving a fair and reasonable

extension by the Authority and this shall be binding on the contractor.

2.16 Safety Requirements

(i) The contractor shall take all necessary measures for the safety of traffic and workers

during construction and provide, erect and maintain such barricade including signs,

markings, lights etc. necessary all around the construction site and offices, workshop,

storage yards etc. The manner and the position of boundary where barricading is to be

provided shall be decided by the Engineer-in-Charge whose decision shall be final and

binding. Nothing Extra shall be paid for the same.

(ii) The painting of barricades in a suitable retro reflective paint shall be regularly done

as decided by Engineer-in-Charge but not take more than the 3 months intervals. He

should also deploy necessary watch and ward and signages to keep the public away from

the construction site. During execution of work there may be requirement of dismantling

and re-erecting of barricades at certain locations. The contractor shall have to do the

same as per requirement of site and direction of Engineer-in-Charge. Nothing extra shall

be payable due to this.

(iii) The contractor shall make arrangement for Helmets and leather shoes (meant of

construction work at sites) for the labour and technical staff of the contractor during the

entire period of construction for safety reasons.

(iv) Existing drains, pipes, cables, overhead wires, sewer lines, water lines and other

services proposed to be retained, but encountered in the course of the execution of the

work shall be protected against the damage by the contractor at his own expense. The

contractor shall not store materials or otherwise occupy any part of the site in a manner

likely to hinder the operation of such services.

(v) The contractor shall conduct his work, so as not to interfere with or hinder the

progress or completion of the work being performed by other contractor (s) or by the

Engineer-in-Charge and shall as far as possible arrange his work and shall place and

dispose off the materials being used or removed, so as not to interfere with the operations

of other contractors, or he shall arrange his work with that of the others in an accept-

able and coordinated manner and shall perform it in proper sequence to the complete

satisfaction of Engineer-in-Charge.

39
2.17 Foreign Exchange

No foreign exchange shall be made available by the department for the purchase of equip-

ment, plants, machinery, materials of any kind or any other items required to be carried

out in execution of work. Foreign exchange required for the work shall be arranged by

the contractor at his own cost.

2.18 Compensation for Delay

If the contractor fails to maintain the required progress in terms of Section 2.19 or to

complete the work on or before the contract or extended date of completion, he shall,

without prejudice to any other right or remedy available under the law pay to the IITH

on account of such breach, the amount calculated at the rates stipulated below as the

Director, IITH (whose decision in writing shall be final and binding) may decide on the

contract amount of Part-A of the work for every completed day/month (as applicable)

that the progress remains below that specified in Table 2.1 or that the work remains

incomplete.

(i) Compensation for delay of work : @ 1.00 % per month of delay to be computed on

per day basis

Provided always that the total amount of compensation for delay to be paid under this

Condition shall not exceed 5% Contract Amount of Part-A of the contract.

The amount of compensation may be adjusted or set-off against any sum payable to

the Contractor under this or any other contract with the IITH.

2.19 Milestones of the Contract

The milestones of the contract are given in the table below. The Contractor shall achieve

progress of the work in accordance with the set milestones. In case, the contractor does

not achieve a particular milestone mentioned in the contract, and does not reach the last

milestone within the specified period, the condition of penalty as stipulated under Section

2.18 will automatically be applied. Penalty in such case shall be automatic without any

notice to the contractor.

40
 Table 2.1: Table of Milestones

Sl No Milestone Time Period

Submission of final design documents
1 One (1 ) Month
& drawings duly vetted by Technology Provider
Supply of all electro-mechanical
2 Four (4) Months
Instrumentation equipment to site
Supply of GE Membranes/
3 Five(5) Months
Cassette to site
Completion of Installation of
4 Seven (7) Months
electro-mechanical, electrical, piping,
Supply, installation and commissioning
5 Eight (8) Months
of Plant Automation.
Completion of Part-A
5 Nine (9) Months
(Trial run and Successful Commissioning of plant)

*Time periods shown above table shall be reckoned from date of commencement.

2.20 Documents to be submitted to IITH

The Contractor on completion of the work shall submit the documents as listed below:

Documents related to equipment should be submitted to IITH as soon as they are avail-

able:

• Certificate of Origin 2 copies

• A set of shipping documents

• Import shipment/Airway bill/Bill of Lading copy at the time of delivery of the item

at site

• Packing list original with 2 spare copies.

• Warranty Certificate with 2 spare copies.

• Manufacturers Test Certificate (MTC) of all equipment

• OEM manuals

Apart from the above, the Engineer-in-Charge is empowered to seek any documents,

including priced invoices of materials and equipment related to execution of the works

from the contractor.

2.21 Labour huts, watch and ward, storage of equipment

(i) IIT Hyderabad shall not allow the contractor to set up the labour camp inside its

premises. The contractor shall make his own arrangements for labour camp outside the

campus. (ii) The Contractor shall be responsible for watch and ward and for safe custody

of his materials and equipment. IITH shall not assume any responsibility.

41
2.22 Transfer of Ownership

(i) Ownership of the Plant and Equipment (including spare parts) to be imported or

procured from within the country shall automatically deemed to be transferred to

the Institute upon release of scheduled payment to the contractor.

(ii) Notwithstanding the transfer of ownership of the Plant and Equipment, the respon-

sibility for care and custody thereof together with the risk of loss or damage thereto

shall remain with the Contractor until Completion of the stipulated O&M period, in

which such Civil Construction, Plant and Equipment are incorporated.

(iii) The Contractor shall be liable for any loss of or damage to any of the plant and

equipment, or any other property used for purposes of the plant.

(iv) The Contractor shall not be allowed to take back any items, equipment, loose fur-

niture, computers & peripherals, tools and plants other than those issued by con-

tractor to his workmen after the completion of OM period or at any point of time of

operations. All the equipment installed and procured as a part of this contract shall

remain the absolute property of IIT Hyderabad.

(v) After completion of the O&M period, the contractor may take back tools and tackles,

PPE issued to his workers, wheel borrows, spades, pans, unused chemicals, un-

used spare parts, unused registers/ stationary and other tools used for day to day

operations.

42
2.23 Abbreviations

Table 2.2: Abbreviations

BIS/IS Bureau of Indian Standards

BOD Biological Oxygen Demand
BS British Standards
CI Cast Iron
COD Chemical Oxygen Demand
DI Ductile Iron
DSITC Design, Supply, Installation, Testing and Commis-
sioning
EIC Engineer-in-Charge
GI Galvanized Iron
GST Goods and Services Tax
HMI Human Machine Interface
HRT Hydraulic Retention Time
I/O Input/Output
IS/BIS Indian Standards / Bureau of Indian Standard
KLD Kilo Litres Per Day
LPH Litre Per Hour
MBR Membrane Bioreactors
MLSS Mixed Liquor Suspended Solids
MLVSS Mixed Liquor Volatile Suspended Solids
MoC Material of Construction
MS Mild Steel
MWC Meter Water Column
N m3/hr Normal Meter Cube Per Hour
NaOCl Sodium Hypochlorite
NB Nominal Bore
O&M Operation and Maintenance
P&ID Process and Instrumentation Diagram
PLC Programmable Logic Controllers
SCADA Supervisory Control and Data Acquisition
SHT Sludge Holding Tank
SI System Integrator
SRT Solid Retention Time
SS Stainless Steel
SWD Side Water Depth
TDH Total Dynamic Head
TMP Trans Membrane Pressure
TSS Total Suspended Solids
UF Ultra Filtration
UPVC Un Plasticized Vinyl Chloride
VFD Variable Frequency Drive CSS
Common Collection
Sump
SHT Sludge Holding Tank

2.23.1 Abbreviations-Electrical

In this document, the following abbreviations of electrical terms have been used.

R - red phase

Y - yellow phase

B - blue phase ac - alternating current

dc - direct current

43
A - ampere

mA - milliampere

V - volt

kV - kilovolt

kW - kilowatt

kVA - kilovolt ampere

kWh - kilowatt hour

MVA - megavolt ampere

Hz - hertz (cycles per second)

HV - high voltage

IEC - International Electro Technical Commission

IS - Indian Standard

LV - low voltage

SP - single pole

SPN - single pole and neutral

DP - double pole

TP - triple pole

TPN - triple pole and neutral

HRC - high rupturing Capacity

MCB - miniature circuit breaker

MCC - Motor control centre

MCCB - moulded case circuit breaker

OEM - original equipment manufacturer

PCC - power control centre

PMCC - power and motor control centre

RCD - residual current device

ACB - air circuit breaker

VCB - vacuum circuit breaker

44
Chapter 3

Special Conditions of Contract

3.1 Special Conditions of Contract (SCC)-Part A

3.1.1 General

Description of DSITC1 Works

(i) The Contractor shall carry out and be responsible for the design and installation of

the 650 KLD capacity Sewage Treatment Plant. The Contractors work and services

as part of the “DSITC Works“shall cover necessary design and installation of the STP

and all allied works in accordance with and as contemplated by the Design-Build

Documents and the Technical Standards including the design services in respect

of the 650 KLD STP with tertiary treatment process and all allied works including

treatment process, hydraulic, electro-mechanical ,electrical, instrumentation, pip-

ing, automation etc, Complete.

(ii) Supplementing the General Conditions

The provisions contained in this DSITC Works section are to be read in conjunction

with the General Conditions of Contract and Special Conditions of Contract (SCC) as

contained in this bid document for the purpose of providing greater specificity of the

DSITC Works that the Contractor shall perform.

3.1.2 Design Services

(i) Design and Engineering

The Contractor shall execute the detailed design of 650 KLD STP and its execu-

tion in compliance with the technical specifications and requirements contained

in the contract, codes of practices as published by the Bureau of Indian Standard

(BIS) or its equivalent International Standards as well as “Manual on Sewerage and

Sewage Treatment“ as published by the Central Public Health Engineering Organi-

zation (CPHEO) of the Ministry of Urban Development, Government of India, New

1 Design, Supply, Installation, Testing and Commissioning of 650 kLD STP1

45
 Delhi. Wherever, the codes, standards and manual do not provide for the design and

execution of some component i.e., required to be designed and executed, the Con-

tractor shall follow the standard engineering practices. In case of any contradiction

on a particular provision between various standards, the decision of IITH on that

provision shall be final and binding.

(ii) The designs and drawings as formulated by the Contractor shall be vetted by the

Technology Provider and shall be approved by the Engineer in-Charge before com-

mencement work at site.

(iii) The Contractor shall be responsible for any discrepancies, errors or omissions in the

specifications, drawings and other technical documents, desired output / perfor-

mance of the STP, whether specifications, drawings and other documents have been

approved by the Engineer-in-Charge or not, provided that such discrepancies, errors

or omissions are not because of inaccurate information furnished in writing to the

Contractor by Engineer-in-Charge.

(iv) Codes and Standards

Wherever references are made in the Contract to codes and standards, in accordance

with which the Contract shall be executed, the edition or the latest version of such

codes and standards shall apply unless otherwise specified. During Contract exe-

cution, any changes in such codes and standards shall be applied after approval by

Engineer-in-Charge.

(v) Design Responsibilities

The Contractors design and design-related services shall include, but not limited to

the following:

(i) Acquisition of all data and information necessary to prepare the design and that

are required to demonstrate that the 650 KLD STP meets or exceeds the required

Effluent Quality Parameters specified in the bid document keeping in view the civil

construction work already carried out by IITH

(ii) Preparation of Hydraulic Flow Diagram (HFD)/schematic/preliminary design doc-

uments to illustrate the scale and character of the DSITC Works and how the units

of the process-adopted functionally relate to each other.

(iii) preparation of design development documents, based on the schematic design

documents , consisting of drawings and other documents appropriate to the size of

the 650 KLD STP to describe the units and character of the entire electro- mechanical

46
 works, instrumentation ,control and electrical systems, materials, operations and

such other elements as may be appropriate.

(v) Assisting IIT Hyderabad in obtaining all approvals, permits, including licences for

the execution of this contract, and necessary compliance with occupational health

and safety requirements, under the Applicable Laws of Central and or State Govern-

ment Authorities, local Municipal Authorities etc., including all documentation for

obtaining such approval, permits or licences.

(vi) the coordination required to integrate all parts of the DSITC Works;

(vii) Vetting of hydraulic design, P&ID drawings and other documents by Technology

Provider.

3.1.3 Design-Build Documents

The Contractor shall prepare all of the basic and detail engineering Design-Build Docu-

ments including, but not limited to:

(i) Documents shall include the designs, drawings, as-built documents, operations

manuals, schematic design documents, design development documents, and all

modifications thereto required in order to properly and fully design and build the

STP and all allied works as contemplated as per the Technical Specification and the

remaining provisions of the Contract.

(ii) The Contractor shall prepare any other document, as may be requested by the

Engineer-in-Charge, necessary to monitor the progress of the DSITC Works and as-

sess the Contractors compliance with the Contract.

(iii) The Contractor shall provide IITH with three sets of all of the Design-Build Docu-

ments duly vetted by the Technology Provider in reproducible form and shall modify

them to keep them up-to-date as requested by IITH . The Design-Build Documents,

with the exception of the as-built documents, shall be subject to the review and ap-

proval of the Engineer-in-Charge prior to performing any of the services set out in

this Section in respect of any Design-Build Document.

(iv) After completion of DSITC Works, the Contractor shall provide to IITH two sets of

the as built Designs, Drawings/Documents in hard form one one set in soft form

showing the exact as built locations, sizes and details of the STP and the DSITC

Works as executed. The STP shall not be considered to have reached Completion

until as built drawings have been submitted to IITH. The Contractor shall update

the as built Designs, Build Drawings/Documents as necessary for the correction of

defects or deficiencies contemplated by contract.

47
3.1.4 Design Considerations

In preparing the electro-mechanical design for the 650 KLD Capacity STP and all allied

works and the Design-Build Documents, the Contractor shall,

• Protect public health and safety,

• Achieve required effluent quality parameters

• Ensure the STP and all allied works has the capacity to accommodate the anticipated

sewage

3.1.5 Design Responsibilities On Site Issues

In preparing the electro-mechanical design for the STP and the Design-Build Documents,

the Contractor shall ensure that the design of allied works like control valves chambers,

anchor /thrust /pedestal blocks etc.,

3.1.6 Sewerage Treatment Plant Layout and operation sequence

The layout of the plant is shown in the architectural drawings provided with the bid

document .Further,

(a) The STP shall comprise treatment process leading to the minimum effluent quality pa-

rameters as specified in Contract. For achieving the desired treated sewage discharge

quality standards and keeping in view the Civil construction work already carried out

by IITH, the Contractor shall design most efficient system for primary, secondary and

tertiary treatment systems using GE MBR Technology.

(b) Plans for submission of process design and hydraulic design calculations, equipment

lay out and hydraulic flow diagram (Process Instrumentation diagram), preparation

submission of electrical & mechanical equipment drawings including equipment in-

stallation drawings, supporting calculations technical information, instrumentation

control system and all allied /ancillary works of required capacity including, disin-

fection requirement, sludge disposal arrangements, as per approved designs, testing,

commissioning. The testing shall be carried out by performing trial run of the plant for

one month. Maintaining required MLSS during the trial run shall be the responsibility

of the Contractor.

(c) Scope of contractor also includes establishing office including store house for tools

and spares, O& M manual and as-built drawings for all electrical mechanical works.

The building construction is in progress and IITH will hand over the same to the

contractor.

48
(d) Supply and providing safety equipment namely gas mask, breathing apparatus, Air

hose respirator, portable lighting equipment, non -sparking lighting equipment, portable

air blowers, safety belts, inhalators and diver suit at the commencement of O & M and

maintain them at plant for entire duration of O& M period.

(e) Training IITH staff after commissioning of the plant.

(f) Handing over of the Plant in good working condition with all relevant documents such

as as-built drawings, physical operational condition of the assets, rights on pro-

prietary technologies, software, systems, AMC documents, O& M manual, periodical

reports along with soft copy to IITH.

(g) Design shall be such that the plant requires minimum energy and less manpower

requirement with full automation for its sustainable and efficient operation mainte-

nance.

3.1.7 Influent Quality

The electro-mechanical design of the plant shall be based on the values of raw sewage as

presented in Table: 3.1. The values indicated in the table are indicative and the system

designed should be able to absorb variations by equalization of feed. All concentrations

refer to maximum concentrations to be used for the systems design. Fluctuations in

feed composition and hydraulics shall be appropriately equalized to allow for optimum

biological treatment.

Table 3.1: Influent Parameters

Design
Parameter Unit
Criteria
pH No Unit 6 to 8
Oil & Grease mg/l 10-50
Chemical Oxygen Demand (COD) mg/l 350 to 400
Biological Oxygen Demand 5-day (BOD5) mg/l 200 to 250
Total Suspended Solids mg/l 250-350
Total dissolved solids mg/l 230-280
Ammonia, as NH3 mg/l <35
TKN, as N mg/l <45
Total Alkalinity as CaCO3 mg/l 150
Total Nitrogen mg/l 70
Hardness as CaCO3 mg/l 160-200
Phosphates mg/l 2.1-2.3
Sulphates mg/l 7.4-8.2

3.1.8 Influent Flow Data

Flow rate at the inlet to the proposed MBR as well as the resulting indicative bioreactor

temperature is shown in Table 3.2

49
 Table 3.2: Influent Flow Data

Parameter Unit Design

Max. Influent flow rate KLD 650
◦
Assumed Feed Temperature C 20-37
Peak Factor 2
Peak flow duration Hour 3
◦ 30
Design Bioreactor Temperature C
(See Note 2)

Note (1): The feed flow to be properly equalized.

Note:(2): If flow is less than 50% of the designed flow then the number of hours of opera-

tion of the MBR permeate pump shall be reduced accordingly. System should be able to

function at Minimum flow of 30% of the designed capacity.

Note (3): Biological and membrane process shall be designed for a Sewage Water temper-

ature operating range of 25 to 35 ◦ C. Higher temperatures >38◦ C have to be avoided as

they exceed the tolerance for the biology and membranes; otherwise appropriate cooling

arrangements shall be made by contractor.

3.1.9 Operation Basis

The STP shall be operational 24 hrs and 365 days of the year. Operations shall be so

planned to consider Maintenance/Recovery Clean Time.

The permeate Pump shall operate for approximately 22 hours per day to treat the

average daily flow of 650 KLD, remaining time shall be used for back wash cleaning

purposes. This shall be pre-programed in the PLC.

3.1.10 Required Effluent Quality

Table below shows the expected effluent quality upon equipment start-up and running of

of the plant.

Table 3.3: Required Effluent Quality Parameters

Parameter Unit Required

Biological Oxygen Demand 5-day (BOD5) mg/l <5
Total Suspended Solids mg/l <5
Turbidity NTU <1
Hardness of softened water mg/l <50
Total coliform MPN/100 ml, max <100
Oil and grease Not detectable
Colour and Odour Clear and Not objectionable
Chlorine mg/l >1 ppm as total Cl.

*Note : The test results of treated effluent shall conform to the above parameters within

the permissible variation up to 5%. In case the results vary beyond the permissible limit,

50
the Contractor shall call the Technology Provider and take corrective action at his own

cost.

3.1.11 Site Administrative Facility

The Contractor shall be responsible for the administration of the STP and all allied works

during the Design-Build Period and the Contractor shall arrange at his own cost

(i) temporary office facilities for use by the Contractor and his specialized agencies dur-

ing the administration and execution of the DSITC Works;

(ii) appropriate signage for the Site and the STP, including signs that:

• identify the STP and its units;

• provide warning and hazard notification in designated areas where warranted;

and

• identify areas of the STP that are restricted to visitors and are accessible to only

designated employees of the Contractor;

3.1.12 Equipment Installation Services

(i) The Contractor shall carry out all equipment installation in all units of STP designed

pursuant to DSITC Works of the Contract.

(ii) The Contractor shall have total control of the installation services and shall effectively

direct and supervise the installation services so as to ensure conformity with the

Design-Build Documents.

(iii) The Contractor shall be solely responsible for installation means, methods, tech-

niques, sequences, and procedures and for coordinating the various parts of the

DSITC Works under the Contract.

3.1.13 Procurement and Transportation

(i) The Contractors shall at his own risk and expense transport all equipment and ma-

terials to the site for execution of the contract.

(ii) The Contractor shall be responsible for obtaining, if necessary, approvals from the

authorities for transportation of Equipment and materials to the Site. The Contractor

shall indemnify and hold harmless the IITH from and against any claim for damage

to roads, bridges or any other traffic facilities or individuals that may be caused by

the transport of the to the Site.

51
3.1.14 Temporary Supports, Structures and Utility Services

(i) Contractor shall have the sole responsibility for the design, erection, operation, main-

tenance, and removal of temporary supports, structures and utility services and the

design and execution of construction methods required in their use.

(ii) The Contractor shall engage and pay for registered professional engineering person-

nel skilled in the appropriate disciplines to perform those functions required by law

or by the Design- Build Documents and in all cases where such temporary supports,

structures and utility services and their designs and method of construction are of

such a nature that professional engineering skill is required to produce safe and

satisfactory results

3.1.15 Document Review

The Contractor shall review the approved documents and shall report promptly to IITH

any error, inconsistency or omission the Contractor may discover. If the Contractor does

discover any error, inconsistency or omission in the documents, the Contractor shall

not proceed with the work affected until the Contractor has corrected any such errors

or inconsistency or supplied any missing information and these corrections have been

approved in writing by IITH.

3.1.16 Plant and Equipment

(i) The Contractor shall provide and pay for labour, Plant and Equipment, tools, construc-

tion machinery and equipment, materials and supplies, transportation, and all other fa-

cilities and services necessary for the performance of the DSITC Works in accordance

with the Tender Documents.

(ii) The Contractor shall ensure that all Plant and Equipment provided are in good working

condition. Plant and Equipment which are not specified shall be of a quality consistent

with those specified and their use shall be acceptable to IITH.

3.1.17 Documents at the Site

The Contractor shall keep one copy of all approved Documents as up-dated, submittals,

reports and records of meetings at the Site, in good order and shall make them available

to IITH upon request and at any reasonable time.

3.1.18 Use of the STP site

(i) The Contractor shall confine construction machinery and equipment, storage of Plant

and Equipment, Contractors Equipment (Design-Build) and Contractors Equipment (Op-

52
erations), and operations of Contractors Personnel to limits indicated and shall not unrea-

sonably encumber the Site with Plant and Equipment, Contractors Equipment (Design-

Build) or Contractors Equipment (Operations).

(ii) The Contractor shall not store Plant and Equipment, Contractors Equipment (Design-

Build) or Contractors Equipment (Operations) at the Site which are not necessary for the

construction of the STP.

3.1.19 Setting Out

If, at any time during the construction of the Plant, any error shall appear in the position,

level or alignment of the plant, the Contractor shall forthwith notify IITH of such error

and, at his own expense, immediately rectify such error to the reasonable satisfaction

of IITH. Similar action shall be taken if any error, mistake, bad work is notified to the

contractor by the Institute.

3.1.20 Quality Assurance

(i) The Contractor shall institute a quality assurance system to ensure compliance with

the requirements of the Design-Build Documents. Compliance with the quality as-

surance system shall not relieve the Contractor of its duties, obligations or responsi-

bilities.

(ii) The Contractor shall submit for approval details of all quality assurance procedures

and documents relating to Contractors compliance with the quality assurance sys-

tem to IITH before each stage of the DSITC Works is commenced as set out in the

Time Schedule. When any document is issued to IITH , it shall be accompanied by

the signed quality statements for such document, if any. IITH may audit any aspect

of the quality assurance system and the Contractor shall take any corrective action

as IITH may deem appropriate.

(iii) Contractor shall maintain at site all records of material brought to site, material tests

conducted and test results there-of, in approved formats registers

3.1.21 Site Regulations and Safety

(i) The Contractor shall establish Site regulations setting out the rules to be observed

in the execution of the Contract at the Site and shall comply therewith. He shall

prepare and submit to IITH , proposed Site regulations for the IITH s approval, which

approval shall not be unreasonably withheld. Such Site regulations shall include

rules in respect of security, safety of Plant, gate control, sanitation, medical care,

53
 emergency preparedness, emergency response, on-site safety training of employees

and fire prevention.

(ii) The Contractor shall comply with all applicable safety regulations in providing the

DSITC Works and in occupying any part of the Site. Unless otherwise stated in

the Design-Build Documents, the Contractor shall, during the Design- Build Period,

carry out safety briefings of applicable site regulations to all employees, Specialized

agencies, IITH representatives and visitors to the Site prior to permitting first access

of the applicable person to the and at regular intervals thereafter.

(iii) During the Design-Build Period, the Contractor shall develop and implement a com-

prehensive occupational health and safety program for the protection of the Contrac-

tors Personnel and all other persons who may attend at the STP site. The program

shall include a description of how the Contractor shall,

(a) carry out all occupational health and safety responsibilities in respect of the STP

site as required under the Applicable Law;

(b) develop and manage all required occupational health and safety reporting proce-

dures; and

(c) manage all occupational health and safety claims.

3.1.22 Contractor‘s Equipment (Design-Build) and Site Clearance

(i) All Contractors Equipment (Design-Build) brought by the Contractor onto the Site

shall be deemed to be intended to be used exclusively for the execution of the Con-

tract. The Contractor shall not remove the same from the Site without IITH‘s consent

that such Contractors Equipment (Design-Build) is no longer required for the execu-

tion of the Contract.

(ii) The Contractor shall maintain the STP site in a tidy condition and free from the

accumulation of waste products and debris. The Contractor shall remove waste

products and debris resulting from the Site and shall leave the Facility clean and

suitable for occupancy and performance of the Operations and Maintenance Services

before declaration of completion of Part-A of contract. The Contractor shall remove

products, tools, construction machinery, and equipment, including the Contractor‘s

Equipment, not required for the performance of the remaining ,if any,DSITC Works.

(iii) Upon successful commissioning of plant, the Contractor shall remove products,

tools, construction machinery and equipment, and waste products and debris, in-

cluding the Contractor‘s Equipment (Design-Build).

54
(iv) Upon the issue of Part-A Completion Certificate, the Contractor shall clear away

and remove, from the STP site, all Contractor‘s Equipment (Design-Build), surplus

material, wreckage, rubbish and temporary work or structures. The Contractor shall

ensure that the STP site is in a clean and safe condition to the satisfaction of IITH .

(v) If the Contractor fails to remove, no later than 30 days after the issue of the Com-

pletion Certificate, any remaining Contractor‘s Equipment (Design-Build), surplus

material, wreckage, rubbish and temporary work or structures, IITH may sell or oth-

erwise dispose of such items. IITH shall be entitled to retain, from the proceeds of

such sale, a sum sufficient to meet the costs incurred in connection with the sale or

disposal, and in restoring the STP site. Any balance of the proceeds shall be paid to

the Contractor. If the proceeds of the sale are insufficient to meet IITH‘s costs, the

outstanding balance shall be recoverable from the Contractor by IITH.

3.1.23 Protection of the Environment

(i) The Contractor shall take all reasonable steps to protect the environment, both on

and off the Site, and to limit damage and nuisance to people and property resulting

from pollution, noise, dust and other results of its Services, including,

(a) adopting working practices that prevent or minimize the transfer of any pollutant

off-site;

(b) maintaining the access roads in good repair;

(c) using appropriate dust suppressant methods;

(d) restricting trucking and loud machinery and equipment use to daylight hours;

(e) using mufflers, silencers and other appropriate methods to minimize the noise of

the construction;

(f) maintaining a clean STP site, that are free of garbage.

(ii) The Contractor shall, at all times during installation/ testing/ commissioning and

O& M period ensure that the Environmental Management Plan is followed.

3.1.24 Security of the STP site

Unless otherwise stated in the Design-Build Documents:

(a) the Contractor shall be responsible for keeping unauthorised persons off the Site

from STP,

(b) the Contractor shall maintain detailed record of all persons that enter the STP site;

and

55
 (c) the Contractor shall ensure that authorised persons shall be limited to the Con-

tractors Personnel, representatives of the Institute, employees of Specialized agencies and

persons authorised by IITH.

3.1.25 Emergency Work

If, by reason of an emergency arising in connection with and during the execution of the

DSITC Works, any protective or remedial work is necessary as a matter of urgency to

prevent damage to the STP site, the Contractor shall immediately carry out such work.

If the Contractor is unable or unwilling to do such work immediately, IITH may do

or cause such work to be done as IITH may determine is necessary in order to prevent

damage to the Site of the STP. In such event IITH shall, as soon as practicable after the

occurrence of any such emergency, notify the Contractor in writing of such emergency,

the work done and the reasons therefore. by IITH is work that the Contractor was liable

to do at its own expense under the Contract, the reasonable costs incurred by IITH in

connection therewith shall be paid by the Contractor to IITH .

3.1.26 Tests and Inspection

(i) The Contractor shall at its own expense carry out at the place of manufacture or on

the Site all such tests and inspections of the Plant Equipment. The Contractor shall,

in addition to those tests and inspections set out in the Contract, develop a plan for

all testing and inspection of the equipment that is required in order to complete the

STP in accordance with the Technical Specifications and as required by the Institute.

(ii) The Engineer-in-Charge or his designated representatives shall be entitled to attend

any test or inspection. The contractor shall make travel arrangements by approved

mode of transport to the representatives of the IITH to attend inspection tests. Reim-

bursement of the expenses incurred on such travel arrangements shall be claimed

in the running account bills of work.

(iii) Whenever the Contractor is ready to carry out any test or inspection, the Contractor

shall give a reasonable advance notice of such test or inspection and of the place

and time thereof to IITH . The Contractor shall obtain from any relevant third party

or manufacturer any necessary permission or consent to enable the Engineer-in-

Charge or his designated representatives to attend the test or inspection.

(iv) The Contractor shall provide IITH with a certified report of the results of tests or

inspection carried out on plant and equipment.

56
 (v) If IITH , or their designated representatives, fails to attend the test or inspection,

or if it is agreed between the Parties that such persons shall not do so, then the

Contractor may proceed with the test or inspection in the absence of such persons,

and shall provide IITH with a certified report of the results thereof.

(vi) If any Plant and Equipment or any part of the STP fails to pass any test or inspection,

the Contractor shall either rectify or replace such Plant and Equipment or part of the

STP and shall repeat the test or inspection upon giving a notice the Engineer-in-

Charge.

(vii) The Contractor shall give IITH access at any reasonable time to any part of the STP

or any place where the Plant and Equipment are being manufactured or installed in

the STP, in order to inspect the progress of the work and the manner of manufacture

or installation.

(viii) The Contractor agrees that neither the execution of a test or inspection of Plant

and Equipment or any part of the Site and the STP , nor the attendance by IITH

, nor the issue of any test certificate shall release the Contractor from any other

responsibilities under the Contract.

(ix) No part of the plant or foundations shall be covered up on the Site without the

Contractor carrying out any test or inspection required under the Contract. The

Contractor shall give a reasonable notice to IITH whenever any such part of the plant

or foundations is ready or about to be ready for test or inspection; such test or

inspection and notice thereof shall be subject to the requirements of the Contract.

3.1.27 Start-Up and Commissioning

• Flushing and disinfection of all piping and tanks (including process equipment

tanks) and verification of removal of all residual debris from construction.

• Alignment required materials for rotating equipment

• MEG testing of all field motor power wiring (as required);

• Continuity checks for all electrical field wiring per Installation Checklist.

• Hydro-testing of all field installed piping

• Supply raw materials, oils/lubricants chemicals and utilities during start-up and

operation.

• Operating and maintenance personnel during equipment checkout, start-up and

operation.

57
 • Process or biological start up and commissioning of the plant shall be completed by

the contractor prior to membrane equipment start up.

• Commissioning plan shall include at least 10 hours of site safety training to all

stakeholders.

3.1.28 Tests on Commissioning

(i) The Performance Tests on Commissioning as set out in in the Contract and repeats

thereof, shall be conducted by the Contractor during Commissioning of the STP and

all allied works to ascertain whether the STP or the relevant part can attain the tech-

nical standards as required in the contract. The Contractors, Technology Providers

and IITHs representatives shall attend the Tests on Commissioning, and shall advise

and assist IITH . IITH shall promptly provide the Contractor with such information

as the Contractor may reasonably require in relation to the conduct and results of

the Tests on Commissioning, and any repeats thereof.

(ii) Performance test is carried out for 72 hours / 3 days continuous operating run

without intervention. During this period analysis of influent and effluent shall be

performed by the Contractor. The field/laboratory tests carried out during the per-

formance tests shall be witnessed by representatives of all stakeholders and docu-

mented within thirty (30) days of completion of commissioning of the system, the

Contractor and Technology Provider shall start-up the Equipment. Thereafter, the

Contractor shall maintain continuous and stable operation of the system until end

of operation and maintenance services period of three years under this contract has

been discharged.

(iii) The Performance Test shall be conducted by the Contractor in accordance stan-

dard techniques and operating procedures specified in the Operating and Mainte-

nance Manual approved by IITH. Compliance with the performance guarantee shall

be demonstrated by successfully completing a three (3) day performance test. 24-h-

composite samples of raw waste water and permeate shall be collected and analyzed

each day during the performance test period. Compliance with the performance

guarantee shall be determined by computing the arithmetic average of the effluent

concentrations over the three (3) day period. If the calculated averages meet or sur-

pass the guaranteed effluent parameters , the test is deemed successful.

(iv) On-line instrumentation provided and grab sample testing performed is included as

indications of the performance of the plant and to assist in the proper operation

and control of the system. These results may include values beyond the stated

58
 warranty values (during process upsets or if instrument poorly/not calibrated, etc.)

and additional composite testing as above must be performed to establish that the

plant is meeting performance requirements. All analytical work shall be carried out

by the Contractor.

(v) During the Performance Test, the MBR system operation should be according to the

GE Operations Manual duly approved by IITH and the operating parameters specified

in this section.

(vi) In the event of an interruption during the Performance Test due to any of the follow-

ing events, the test shall be extended by the period of the interruption plus the time

required to re-attain operating conditions in effect at the time of the interruption and

data recorded during that period shall not be included:

a. Power interruption in excess of sixty (60) minutes per day.

b. Mechanical failure of the system.

c. Any influent or operating parameter outside the accepted operating ranges defined

in this section.

(vii) If, after the system has been operated pursuant to the conditions herein above set

forth, it becomes reasonably apparent, based on the results obtained at the comple-

tion of the Performance Test, that the system performance is short of the guaranteed

performance, then additional Performance Tests of the system shall be conducted by

the Contractor/Technology Provider. In such event, Contractor/Technology Provider

shall be responsible to undertake all necessary reasonable corrective measures in an

effort to bring the system up to the guaranteed performance levels.

3.1.29 Review of Works and Monthly Progress Report (Part-A)

(i) The Contractor shall submit to IITH after the end of each month three copies, each

signed by the Contractors Representative , a notice (the Monthly Progress Report)

in such form as IITH may from time to time prescribe, showing the percentage of

completion that the Contractor considers it has effected in the preceding month, in

respect of the DSITC Works.

(ii) The Contractor shall prepare monthly progress reports of the DSITC Works during

the execution Period and submit hard and soft copies of the reports to IITH before

7th of succeeding calendar month.

(iii) The DSITC Works monthly reports shall include the following information:

59
 • photographs and detailed descriptions of progress, including each stage of de-

sign, procurement, manufacture, delivery to the STP site, erection, testing and

commissioning;

• charts showing the status of DSITC Documents, purchase orders, manufacture

and construction;

• for the manufacture of each main item, equipment, machinery, floor or compo-

nent of the STP , the name of manufacturer, manufacture location, percentage

progress, and the actual or expected dates of commencement of manufacture,

Contractors inspections, tests and delivery relating thereto;

• detailed records of the Contractors Personnel and Contractors Equipment (Design-

Build) on the STP site and the actual usage of the Contractors Equipment

(Design- Build) during the reporting period and the tasks performed by the Con-

tractors Personnel;

• copies of quality assurance documents, test results and certificates of the Plant

and equipment;

• all monitoring results;

• safety statistics, including details of any hazardous incidents and activities re-

lating to environmental aspects and public relations;

• percentage completion achieved compared with the planned percentage comple-

tion for each activity; and

• where any activity is behind in the scheduled completion, comments and likely

consequences and a description of the corrective action being taken.

(iv) site co-ordination meeting of all stakeholders shall be held every fortnight to review

the progress of the work and plan for future course of action. From contractors side,

their Management Representative shall attend the such meetings.

3.1.30 Issue of Completion Certificate for Part-A of Contract

(i) The Part-A component of the work is deemed to be completed only after issue of

completion certificate by the Engineer-in-Charge upon successful completion of the

commissioning of the plant .The commissioning is deemed to be successful only upon

achieving the desired quality of effluent during the Performance Test.

(ii) As soon as the commissioning of plant, in the opinion of the Contractor, been com-

pleted in accordance with the Specified Technical Standards, has satisfactorily passed

all Tests on Completion , the Contractor shall so notify IITH in writing (the Notice of

Completion of Part-A) and provide the as-built Design-Build Documents.

60
(iii) Before notifying the IIT Hyderabad about the completion of Part-A, the Contractor

shall complete all outstanding minor items so that the STP site are fully in accor-

dance with the requirements of the Contract, failing which IITH shall undertake such

completion and deduct the costs thereof from any monies owing to the Contractor

(iv) IITH shall, no later than 30 days after receipt of the Contractors notice either issue a

Completion Certificate stating that the STP has reached Completion as of the date of

the Contractors notice of completion or notify the Contractor in writing of any defects

or deficiencies or both.

(v) If IITH is not satisfied that the DSITC Works are complete, IITH shall notify the

Contractor in writing of any defects or deficiencies no later than 7 days after receipt

of the Notice of Completion.

(vi) If IITH notifies the Contractor of any defects or deficiencies or both, the Contractor

shall then correct such defects or deficiencies, and shall repeat the procedure (5) If

IITH is satisfied that the DSITC Works have reached Completion, IITH shall, no later

than 7 days after receipt of the Contractors repeated Notice of Completion, issue a

Completion Certificate stating that the DSITC Works have reached Completion as of

the date of the Contractors repeated Notice of Completion.

3.1.31 Key Staff to be deployed at site

Minimum Staff to be deployed at site by the Contractor during the DSITC execution

period.

Table 3.4: Key Technical Staff

S.No Staff No Minimum Qualifications

Graduate in Electrical/ Mechanical Engineering
with not less than 10 years experience
1 Project Engineer 1
in construction of Sewage
Treatment Plant.
Graduate Engineer (Electrical or Mechanical engineering)
with not less than ten years experience
2 E & M Engineer 1
in construction of
similar engineering works

CVs of key staff shall be submitted along with the bid and shall be subject to approval

of IITH . During execution period, if any staff is to be replaced by the Contractor, suitable

CV shall be submitted against the Key persons and to be got approved by IITH.

61
3.2 Special Conditions of Contract(SCC)-Part:B
3.2.1 Introduction

The contractor shall ensure the Operation and Maintenance of the Sewage Treatment

Plant (STP) in compliance to the guidelines contained in the latest edition of of the Man-

ual on Sewerage Sewage Treatment Systems Part-B, Operations and Maintenance, pub-

lished by the Central Public Health Environmental Engineering Organization (CPHEEO),

Ministry of Urban Development, Government of India, New Delhi. Notwithstanding any-

thing contained in the said manual, conditions laid down here under in the foregoing

sections shall also apply.

3.3 Effective date of commencement of Part B

The effective date of commencement of Part B of the contract shall be reckoned from the

next day of declaration of completion of Part A of the contract by the Engineer-in-Charge.

The Contractor shall be prepared to take up the maintenance activities from this day on

wards.

3.4 Scope of Operation and Maintenance Services

After the trial run and commissioning of the plant, the Contractor shall operate and

maintain the Sewage Treatment Plant under this contract for a total period of three (3)

years .The break-up of this three year period is given here-under:

A) For first two (2) years w.e.f commencement of the defect liability period of STP

B) For next one (1) year w.e.f completion of defect liability period of STP

Part-B component of contract shall be executed complying the following conditions :

1. After Commissioning of STP, during the first Two(2 ) years of the O M period running

concurrently with defects liability period (DLP), the Contractor shall operate and

maintain the plant as per approved OM Manual and maintain the quality of the

treated effluent as prescribed in the contract document.

2. After completion of DLP of STP, the Contractor shall Operate and maintain the

sewage treatment plant, all instruments and mechanical, electrical equipment in

accordance with the quantity and quality parameters specified in DSITC Works for a

further period of One year as stated above. At the discretion of the Institute, the con-

tractor shall provide the O&M services for further three months period beyond the

three years at the same quoted rates applicable for the third year.The plant equip-

ment covered under the above contract shall be totally attended to, by the Contractor

62
 including any Troubleshooting to ensure smooth and trouble free operation.

3. The Equipment is operated and maintained at all times in accordance with the Op-

erations and Maintenance manual duly approved by IITH issued to the contractor

after plant commissioning.

4. The plant is operated within the mixed liquor characteristics defined in the contract

5. The Contractor shall monitor the performance of the sewage treatment plant; con-

duct the analysis of the inlet sewage and effluent quality after treatment. Contractor

shall initiate and take adequate actions to ensure smooth and satisfactory perfor-

mance / running of the plant.

6. The Contractor shall prepare and implement an effective plant maintenance pro-

gramme in consultation with IITH. It is an absolutely Contractors responsibility to

look after all sorts of maintenance whether preventive, Minor, Major, or break-down.

7. The Contractor shall determine operating parameters, select settling (Chemical doses

etc.) and generally optimize the process, and working of the treatment plant meeting

the required quality parameters.

8. The Contractor should plan & procure all spares, Polyelectrolyte and all consum-

ables including chemicals, grease, lubricating oil, cleaning agents, laboratory reagents

etc.

9. The Contractor shall be responsible for keeping up-to-date record of documents

including History Card for equipment and maintaining every day log book relating

to various analyses performed.

10. The Contractor shall maintain and update logbook, in which details of operational

parameters are recorded every day and at regular interval say hourly or as decided

mutually.

11. The Contractor shall prepare and submit a weekly report of plant performance

records.

12. The Contractor shall be responsible to carry out day to day periodic maintenance,

necessary to ensure to smooth and efficient performance / running of all equipment

/ instruments comprising the sewage treatment plant and maintaining the record of

the same.

13. The Contractor shall have to issue identity cards with photographs to all the staff

employed for Operation and Maintenance. The list of the same shall be submitted

to IITH mentioning qualification & experience.

63
14. The Contractor shall employ staff for operation and maintenance of the Plant as per

the minimum specified here-in for entire duration of O& M Services period of Three

(3) years.

15. The above staff shall be distributed in three shifts and at no point of time the plant

shall remain unattended. As per agreement the number of staff in each shift should

always remain present otherwise penalty towards absence of any staff shall be re-

covered from the Contractor. The Contractor shall make the arrangement of reliever

for weekly-off/holiday etc.Absence on any ground like weekly off or holiday shall

not be considered. The presence of staff in each shift should be marked in muster

(muster shall be in electronic form by use of biometric machines logged to the com-

puter system installed in the plant) to be maintained at office of shift-in-charge at

Sewage Treatment Plant that shall be considered as final. The Contractors staff

must mark their presence in this muster. The Contractor may maintain a separate

register for his own purpose. Copy of muster shall be enclosed with every monthly

bill.

16. The staff of Contractor shall always remain in contact with the Engineer-in-Charge

or his authorized representative deployed by IITH and follow their instruction.

17. Unsatisfactory and inefficient running of the plant and unnecessary and excessive

usage of spare, consumable, etc. supported by the reasons which are under control

of Contractor shall be highly objected. In such cases IITH s decision shall be final

and binding to the Contractor.

18. It is required that at least once in every one month a technical expert of contrac-

tor other than the Staff of the Contractor shall visit and audit the functionality of

the plant and systems and shall suggest, if required, to improve the efficiency and

working of the plant etc. No separate payment shall be made for such visits. The

visit must be recorded and outcome of the visit/minutes of the meeting should be

got signed by IITH authorities without which the visit shall not be considered.

19. In addition to the contractors technical expert visit, the contractor shall arrange a

visit to the plant by representative of Technology Provider (GE) once in every six

months. The Technology Provider shall study the functioning of the plant, conduct

tests on in-coming sewage and treated sewage, compare the results with the spec-

ified parameters of effluent. The Technology Provider shall submit the inspection

report commenting on the state of affairs of the plant, maintenance and up-keep

of equipment, house-keeping, safety and environmental issues including the test

64
 results. The report shall also include suggestions for the reasons and corrective ac-

tions needed if the test results are not satisfactory and improvement of systems, in

general.

20. Compliance on the issues mentioned in the inspection report of Technology Provider

shall invariably be furnished by the contractor to the Engineer-in-Charge with-in

one month of date of issue of inspection report. Documentary evidence shall be

furnished along with compliance report substantiating the corrective action taken

and the subsequent test results meeting the requirements of contract.

21. The first inspection of plant by Technology provider shall be carried out within the

first six months ( preferably at the end of first three months) of O& M period and

subsequent visits shall be planned once in every three months until completion of

total three years O& M period.

22. All expenses for arranging visits of Technology Provider shall be borne by the Con-

tractor and hence the contract price for O& M Services are deemed to be inclusive of

the same. Nothing extra shall be paid by IITH on this account. In case, the visit of

Technology Provider is not arranged by the contractor within fifteen(15) days from

the due date of visit, IITH shall arrange such visit by the Technology Provider at the

risk and cost of the Contractor. All expenses incurred by IITH towards arranging

the visit of Technology Provider for inspection of plant will be recovered from the

ensuing bill of the contractor in addition to a penalty amount of Rs 10,000.00 for

every such default on part of contractor.

23. Contractor shall comply with all safety rules and regulations mentioned in O& M

manual. IITH shall not be responsible for any accident /injury to the staff of the

Contractor. Further the IITH shall not provide any insurance or medical facility to

the staff of Contractor. The responsibility lies with the Contractor.

24. All Central/State Government / Semi-Government / Local Bodys Rules and Regu-

lations pertaining to this contract shall be followed and observed by the Contractor

without any extra cost to IITH.

25. No accommodation / guesthouse / transportation facility shall be provided by IITH

to the Contractor or his representatives. Operation & maintenance staff shall not be

given any accommodation facility inside the plant (IITH) premises.

26. The Contractor should employ all the staff within seven days of successful commis-

sioning of plant.

65
27. The Contractor shall provide the necessary tools and tackles required for day-to-day

maintenance during O& M period.

28. The scope of work also includes up-keep of complete plant area premises, including

floor, toilet block, railing, door, windows, light fixtures and ceiling etc. The entire

premises of the plant area shall also be cleaned and maintain by the Contractor

regularly.

29. The work shall be done as per specified standard practices and by following labour,

factory, electrical, TSPCB and all statutory rules and regulations as applied of Local,

State and Central Government of India etc. .

30. Right is reserved by IITH for suspension, dismissal, termination of any staff em-

ployed by Contractor who are found to be indulging in unlawful, unethical activities.

31. Monitoring of proper functioning of plant shall be done as per approved O& M man-

ual. Contractor has to maintain all quality parameters of effluent within stipulated

limit or he shall be penalized for not maintaining the parameters specified in the

contract. All expenditure incurred for the same like, suit fee, court fee, case fee, or

the penalty as decided by Engineer-in-Charge and penalty charged by TSPCB or any

other statutory body shall be charged to Contractor and deducted from his security

deposit, bills, etc.

32. Contractor shall have to test the effluent / influent at his own cost at the plant

laboratory on daily basis. The same will be verified by and checked by IITH whenever

required.

33. No equipment shall remain ideal or un-attended or damaged for the period of 3

days. If any equipment is not repaired, rectified and or replaced within 3 days, the

Contractor shall be penalized with no limit at the rate of Rs. 2000/- per day delay

per each individual equipment of the plant. In case, the contractors fails to attend

the faults within 3 days, the same shall be attended by IITH at the risk and cost of

the contractor

34. During Operation & Maintenance period, Contractor has to supply all the spares, at

his cost during preventive, major-minor breakdown, replacement and maintenance

work. No extra payment shall be made for such maintenance on any ground. No

separate payment for the same shall be made by the IITH irrespective of the number

of such break down / minor, major repairs replacements. After completion of DLP

of two years, the Contractor may enter into annual maintenance agreement

66
 (AMC) with concerned original equipment manufacturers (OEM) for equipment

of plant so that the plant is operated trouble free.

35. Copies of such AMC agreements may be submitted to IITH for record. The AMC may

be renewed every year before due date. At the time of handing over of the plant to

IITH after the end of O& M period, all equipment of plant shall be in good workin

condition.

36. Operation and maintenance of PLC based automation system and all instruments

installed in the STP shall be the responsibility of the Contractor. All repairs, replace-

ments towards the entire instrumentation works during the O& M period shall be in

the scope of Contractor.

37. The Contractor shall also dispose off the sludge, screenings, grit and any other

material to the satisfaction of IITH at his own cost .However, IITH shall have full

rights on the dried sludge for using for its internal purposes.

38. At the time of handing over of the plant on completion of O&M period, the con-

tractor shall handover all records pertaining to the plant like Operating Manuals,

Warranty Certificates, AMC copies, registers of Tests/flow particulars, charts, third

party reports etc. to IITH.

39. output and Operational Guarantees: The Contractor is fully responsible for treat-

ing all the Sewage reaching at the Common Collection Sump. The performance of

the Contractor shall be treated as unsatisfactory if he fails to treat the complete

sewage or does not maintain the guarantees mentioned in the contract excepting in

force majeure condition or fails to fulfill other conditions of the contract.

40. Treated Effluent Quality: The Contractor shall operate the Sewage Treatment Plant

in such a way that the treated effluent quality attains parameters as prescribed in

this contract document.

41. The scope of O&M Services includes softening of the treated sewage water after the

process of Ultra filtration of MBR. The quantity of effluent to be softened per day

shall be a minimum of 2,50,000 litres. The hardness of the softened water shall be

less than 50 mg/l. The softened water shall be made available in the soft water tank.

All equipment, consumables required for softening of the effluent shall be borne by

the contractor and nothing extra shall be payable on this count. IITH will utilize this

soft water for make-up water of HVAC system.

67
42. Chemical Requirements: All chemicals and other consumables consumed to op-

erate the Sewage Treatment Plant and other facilities under this contract shall be

borne by the Contractor.

43. Adverse Operating Condition: During which the raw sewage quality deteriorates

beyond the Specifications contained in contract, the following provisions shall be

applicable:

a) If the raw sewage can still be treated to meet the Output Standards, the Contractor

shall comply with such specifications.

b) In the event it is not possible to meet the Output Standards, the Contractor shall

immediately inform IITH and take all corrective measures at his own cost and risk

to ensure that the prescribed output standards are achieved.

44. Test to be carried during O & M period: Sampling and testing to be carried out for

the parameters given below: This schedule shall also be maintained during the O&

M period. Sampling shall be done in accordance with BIS 3025.

(i) Inlet chamber at sewage treatment plant for flow, BOD, pH, suspended solids(SS),

temperature, COD , oil & grease, TDS ; Outlet of the sedimentation units for

BOD, suspended solids, pH, COD and oil grease, TDS.

(ii) Inlet of the reactor unit for MLSS, Dissolved Oxygen pH.

(iii) Outlet of the reactor unit for Dissolved Oxygen, Sludge volume Index pH.

(iv) Outlet of the secondary treatment units for BOD, Suspended solids, pH, COD

and oil grease

(v) Outlet of the chlorination units for BOD, Suspended solids, pH

(vi) Excess sludge for Volatile suspended solids, total solids, specific gravity

(vii) Various parameters to be tested by online monitoring system at these locations

as per specific requirements of Instrumentation.

(viii) Residual Free Chlorine after Chlorination.

(ix) Hardness of softened water

(x) Total Coliform

45. The Contractor shall get analysed the untreated as well as treated sewage samples

once in every three months from TSPCB or any other lab approved by the Engineer-

in-Charge for all parameters mentioned in Table 3.1 and Table 3.3 specifying the

characteristics of treated sewage. The necessary lab testing charges will be reim-

bursed by the Institute on actuals. The TSPCB Vigilance testing charges for samples

68
 directly collected by TSPCB are also reimbursable to the Contractor. The Contractor

shall ensure adherence to standard protocols of collection and storage of samples.

3.4.1 Calibration of Instruments

All the measuring instruments and other devices shall be calibrated regularly as men-

tioned below:

(i) The instruments and devices shall be calibrated by the plant Manager or any autho-

rized specialized staff of the Contractor once in every two months.

(ii) All such instruments shall be calibrated once in every twelve months by approved

third party specialized agency.

(iii) Immediately after calibration, the results/ reports shall be submitted to IITH. (iv) First

calibration by approved third party specialized agency shall be done after twelve months

of commencement of O& M period.

3.4.2 Contractors staff during OM period

(i) Key Staff:

The minimum key staff required for O & M Services shall be as given below. Non-

deployment of the personnel during O&M as per the contract shall lead to imposition

of penalty as mentioned in Contract.

(a) One Electro-Mechanical Engineer (Plant Engineer)

Degree in Mechanical or Electrical Engineering from a recognized university/ Insti-

tute with minimum 10 years experience in Operating /Maintaining any STP.

(b) Plant Operator: One per each shift

with minimum 7 years experience in managing STP

CVs of key staff shall be submitted at the commencement of of O & M period and

shall be subject to approval of IITH.

(ii) Non Key Staff : The contractor must deploy adequate number of non -key staff

comprising of operators, skilled technicians, semiskilled and unskilled labourers to

discharge the contractual liabilities of operation and maintenance and other essential

activities of upkeep of the plant.

(iii) Institute shall monitor the presence and availability of such key and non-key staff.

As specified elsewhere in the contract document, the contractor shall maintain the

attendance in biometric form for all the staff so deployed.

(iv) No labour below the age to 18 years shall be employed on the work. List of staff

is to be given by the contractor to IITH and advance intimation to be given before

69
 deputing/removing any staff from site during the period of contract. Not more than

one of the Contractor’s key staff shall be absent from the Plant premises at any given

time. In case it is necessary for more than one of the key personnel to be absent

at a given time, the Contractor shall provide replacement of equivalent or better

qualifications. The CVs of such key staff replacements shall be got approved from

IITH in advance.

(v) Engineer-in-Charge shall be empowered to direct the Contractor to remove any or all

staff employed on OM of the plant if in his opinion continued presence of such staff

is detrimental to safety or proper OM of the plant. Whenever the Engineer-in-Charge

informs the Contractor in writing that any person on the work is in his opinion

unsatisfactory or/incompetent or unfaithful or dishonest, untruthful or disorderly

or to be otherwise unsuitable, such person shall be discharged by the Contractor

from the work and shall not be employed again on it. The Contractor shall comply

with such directions and immediately deploy suitable substitute(s) thereof.

3.4.3 Safety and Security

The Contractor shall take all safety precautions under various Acts/Rules under cen-

tral/State Govt. from time to time and he shall be responsible for safety of its staff

and the consequences thereof. IITH shall deploy round the clock security personnel at

entrance of plants premises. The Contractror shall be responsible for the safety of the

plant, equipment and personnel during O&M period.

3.4.4 Responsibility for damages

(a) Safety of the whole of the plant shall remain with the Contractor who shall be responsi-

ble for all accidents or damages from whatever cause arising and chargeable for anything

that may be stolen, removed, destroyed or damaged to whomsoever belonging and also

for making good all defects and damages to the said works or to any property adjoining or

any cause whatever, whether such damage or defects were occasioned by the negligence

of the Contractor or not or may be or might have been discovered during the progress

to be known after the completion whereof or whether payment may wholly or partially

have been made or the works approved as supposed to have been properly done and no

certificate of approval of any works by any statutory bodies shall affect or prejudice the

right of IITH against the Contractor or be considered or held as at all conclusive as to the

sufficiency of any work materials.

(b) Adequate safety precautions against fire, flooding, lightening, electrical shocks, ac-

cident due to moving/non-moving heavy/light equipment shall be strictly taken up by the

70
Contractor at his own cost. Suitable safety measures like gumboots, gloves, safety belts,

ladders, safety lamps, gas masks, Oxygen apparatus, insulated tools, alarms etc. shall

be provided by the Contractor. Necessary medical first aid kit shall be made available all

the time. In absence of observance of above safety precautions, the Contractor shall be

responsible for any unforeseen loss of the equipment or persons dealing with it. Special

care shall be taken by the Contractor while carrying out the work in sewage gas zone.

Any incidence of human life or accident shall be totally Contractor’s responsibility.

(c) The Contractor shall ensure that the staff employed are adequately skilled and

trained and takes all necessary precautions while carrying out the work as per Indian

Electricity Rules/Factory Act/CPHEEO Manual/Approved Operation Manual or manu-

facturer’s special instruction for safety / gas handling. The staff should use all protective

and safety equipment which should be provided by the contractor during operations.

(d) In the event of any accident on or off site, in which the Contractor or his personnel

are involved, in which an injury occurs to any person whether directly concerned with the

project or a third party, the Contractor shall inform IITH within 24 hours of the occur-

rence of the event. The plant shall be open to local/state/central agencies for verification

of safety/emission/acts compliance.

(e) During night hours, the main gate should be locked. However, shift duty staff

should be alert and open the gate during surprise checking of IITH staff or any other

Government Authorities or his nominee without any wait. Only bona-fide persons shall

be allowed in the plant premises being a prohibited area. Smoking and drinking liquor

are prohibited in the plant. The staff engaged shall wear common uniform with name

plate indicating name and designation during duty hours.

(f) All staff of the contractor deployed on the plant for OM shall carry valid identity

cards issued by Contractor and duly counter-signed by Engineer-in-Charge.

3.4.5 Reporting

The Contractor shall prepare daily and monthly reports (in approved formats) of pump-

ing/treatment and project performance and submit to IITH and shall assist IITH in

preparing the necessary documents for their purpose and record as per Performa given

from time to time. The reports shall contain the following:

• Raw Sewage quantity, quality and effluent quality as per the on-line monitoring

programme and other tests as specified in this section and print outs of online

monitoring shall be submitted to Engineer-in-Charge.

• A description of the maintenance work carried out in the reporting period. A report

on major failures, if any, their causes and remedial actions taken.

71
 • Sludge quality and quantity (daily basis) in the reporting period.

• Power and chemicals consumed in the reporting period.

• An inventory of the chemicals and spare parts available at the end of the reporting

period.

• O&M staff deployed by the Contractor during the reporting period.

• Major repair works carried out, if any

• . Near misses and other accidents happened during period under report.

3.4.6 Record Keeping

Contractor is required to maintain separate register as well as computerized records at

STP of following information:

• Pumping register

• Quantity of sewage treatment and performance register

• Working hours register

• Electricity break down register

• Maintenance register

• Staff attendance register in the form of computer generated log sheets of biometric

attendance.

• Monthly Electricity consumption register

• AMC with OEM register

• Equipment breakdown, repair record and extent of repair

• Chlorination equipment and chlorine toner operating and using register

• Soft water quantity register

• Any other registers/ records as may be required by the Engineer-in-Charge.

• In addition to the above, the contractor shall also submit two sets of asset registers

containing details of:

all major electro-mechanical equipment ,instrumentation like various operating ma-

chines such as Manual and Mechanical Screens, Mechanical Grit Removers, Pumps,

72
 Motors, Scrapers, Air Blowers, Centrifuge , all equipment related to PLC and Au-

tomation, etc. . The information shall include the make, model number, serial

number, book value, warranty, particulars of OEM etc.,

One set of the assets register shall be kept in the control room and maintained by

the Plant Engineer.

• Records of effluent quality and other laboratory tests are kept in the laboratory as

per testing schedules.

• The record with respect to flow shall be maintained by Contractors as per Table

below. The concerned staff passes the daily log sheet to the plant Manager on the

subsequent day duly signed. The plant Manager shall verify the daily record as well

as the calculations and shall be responsible to generate further data using these.

Table 3.5: Hourly Record of Flow

Head Over Notch Rate of Average Rate of Flow

Date/Time
/Weir / Meter Flow Flow in past Hour Quantity
0600
0700
0800
0900
–
–
1400
1500
1600
–
–
0000
0100
–
–

3.4.7 Site Order Book

A Site order Book shall be kept by the Engineer -in-charge at the plant site. Orders

entered in this Book by the Engineer-in-Charge or his authorized representative shall be

held to have been formally communicated to the Contractor. The Engineer-in- Charge or

his authorized representative shall sign each order as it is entered and shall hand over

the duplicate to the Contractor or his staff, who shall sign the original in acknowledgment

of having received the order.

3.4.8 Operations

(a) In case, the motor or any other equipment is burnt or damaged due to negligence of

the Contractor or due to faulty operation it shall be sole responsibility of the Contractor

73
to rewind/replace/repair it as per standards of the equipment free of cost. In case of

any fault in operation and performance of the plant, Contractor or his staff at duty shall

immediately report to IITH about it.

(b) The Contractor shall run the plant after ensuring proper voltage. He shall also

record all the power failures and voltage, current, power, KWH in daily log sheet. He shall

bring it to the notice of Engineer-in-Charge about the breakdown/power failure. He shall

also get the electricity restored simultaneously.

(c) Any dispute with the workmen shall be Contractors responsibility as per Labour

Laws/Govt. Rules and Regulations. In no way IITH shall be responsible for the disputes

between them. The Contractor shall follow the rules and regulations as per rules of the

Government and applicable laws.

(d) The Contractor shall arrange all necessary required tools, tackles and instruments

in advance for proper operation and maintenance of the entire plant. The Contractor

shall operate and maintain all (E&M) equipment as per the recommendations of the re-

spective equipment manufacturer. He shall further maintain and operate the plant, as per

CPHEEO manual to obtain the treated effluent results as per approved norms specified

in this document elsewhere.

(e) The floating material/scum,if any, should be collected in bins and dispose the same

in open pits away from the plant & machinery which should be dried and disposed off

regularly at a location outside the plant and approved by statutory authority. During

rainy season, this should be buried after using lime.

(f) The screened material, grit and the dried sludge cake from the centrifuge should be

collected in tractor or by appropriate means and the same shall be disposed off at site

/yard within the battery limits ,away from the plant.The screened material, grit and any

other non-useful material so collected and accumulated over a period of time shall be

removed at regular intervals from the STP and IITH premises by transporting the same

using mechanical means to approved municipal dumping ground.

3.4.9 Maintenance

1. The work shall be carried out and completed under the exclusive control direction

and supervision and to the satisfaction of Engineer-in-Charge. Engineer-in-Charge

shall likewise have full power to reject or condemn any work or material that he may

deem unsuitable. In case of any work or material being rejected by the Engineer

in-charge, the Contractor shall immediately remove and replace the same to the

satisfaction of Engineer-in-Charge or Engineer-in-Charge shall have full powers to

get the same removed and replaced and deduct the expenditure incurred in the

74
 process from any amount due or that may become due to the Contractor.

2. The Contractor shall use only the original and genuine spares of the original equip-

ment as per recommendations given in the maintenance booklet of the manufac-

tures/as per directions of Engineer-in-Charge . Adequate stock of such spares is

to be maintained by the Contractor. Test certificate of manufacturer is required

for bearings along with supplies. Test certificate of all major equipment shall be

submitted from the manufacturer.

3. If any material brought to the site , be in the judgment of the Engineer-in-Charge,

found inferior or improper & not as per described standards, the said materials

or workmanship shall, where required by Engineer-in-Charge, shall be removed or

amended by the Contractor forthwith.

4. The Engineer-in-Charge is authorized to remove or cause to be removed the materi-

als and workmanship so objected to or any part thereof and replace the same with

such other materials and workmanship as shall be satisfactory to him and there

upon the Contractor shall on demand repay to IITH the expenses incurred there by

or to which the IITH may be put or be liable in connection therewith, the amount

thereof to be certified by the Engineer-in-Charge whose certificate shall be final.

5. The Contractor shall also be responsible to maintain cleanliness in around the plant

including electro-mechanical equipment, disposal of floating amterial removed from

the bar screens etc., Grit and other unwanted material and keep the premises in a

tidy condition. The terraces of the STP building shall be always kept free of debris,

junk, waste material, vegetation etc.

6. All leakages should be attended promptly to avoid unhygienic conditions, deteriora-

tion of plant and building. Chokages of Electro-Mechanical equipment, sewer lines

of STP building, rain water pipes, storm water drains should be removed at once.

All the valves/gates which are not used regularly should be operated at least once a

week and make sure that they are properly lubricated /greased.

7. All safety valves should be checked daily and ensure that they are working properly.

In case of any fault the same should be attended immediately without any wait. The

maintenance of the plant shall be as per maintenance manuals of the manufacturer

for all equipments. Contractor shall keep all the safety devices in working order.

8. The Contractor should make sure that no unwanted material should float/grow in

and around different units. In case it is found the same shall be removed /cleaned

75
 immediately. He shall also be responsible for cleaning/sweeping the plant buildings

inside and outside, roads, foot path etc.

9. Weirs of reactors etc shall be maintained clean round the clock. During preven-

tive/ breakdown maintenance, the Contractor shall visit the unit/units as and when

needed. The pumping units or any other machinery required ,if any, shall be ar-

ranged by the Contractor at his own cost for completing the preventive maintenance

work. In case of battery operated auto system panels, system alarm etc., batteries

are required to be maintained and replaced as and when needed by the Contractor.

10. The Contractor shall provide necessary protection systems wherever necessary in-

cluding alarms. Cautionary Sign boards shall be placed at appropriate locations

11. The Contractor shall maintain the Supervision Control and Data Acquisition System

(SCADA) in working condition for the 3 years of O & M period. The Contractor

shall not remove/shift any equipment/machinery even temporarily without written

permission of Engineer-in-Charge.

12. POL (Petrol/Diesel Oil & Lubricants) has to be arranged by the Contractor as and

when needed as per manufactures recommendations for periodical maintenance of

entire plant. IITH shall not provide such items.

13. The Contractor shall have to carry out periodical testing of the installations/equipment

as per CPHEEO manual and Indian Electricity Rules as amended up to date and

shall have to maintain complete record in the maintenance register.

14. IITH shall be at liberty to post its staff for surveillance/ inspection at the plant

with access to all units, control room and records, log books, MIS (Management

Information system), data etc. round the clock as required. The logbooks will be

attested by the authorized IITH Officials and this record shall be open for further

inspection/checking by IITH and all other Government Agencies CPCB/TSPCB etc.

for further action/improvements/rectifications.

15. In case of major repair due to normal wear and tear/break down, the Contractor

should bring the same to the notice of IITH immediately and necessary measures for

its repair/replacement should be taken simultaneously. Breakdown, all repairs of

any kind are to be attended by the Contractor. Any unit/equipment being irrepara-

ble in the opinion of IITH shall be replaced by the Contractor at no cost to IITH

16. The Contractor shall give his telephone no., contact addresses, etc. to Engineer-in-

Charge as well as shift duty shift staff to contact him/them during emergency/odd

76
 hours etc. The mobile number of the authorized representative of the contractor

and that of plant manager shall be displayed on notice board placed at a prominent

location in the STP building.

17. The contractor shall arrange a white notice board in the control room of STP and all

details like sewage volume handled/treated , treated water volume, test results etc,

shall be displayed on daily basis.

18. The contractor shall display in the control room a schematic flow diagram and the

layout of the plant and equipment.

3.4.10 Routine, Preventive, Minor & Major maintenance

Routine, Preventive, Minor & Major maintenance of all Electrical, Mechanical, hydraulic

machines & Equipment of the plant as listed below shall be the responsibility of the

contractor.

(i) Routine & preventive maintenance of electrical /Mechanical/ hydraulic/ machines

equipment is to be carried out as per the approved operation & maintenance manual.

Minimum oil & grease requirement for one year Operation & maintenance of the Plant

to be procured by the Contractor well in advance.

(ii) The Contractor should prepare schedule of daily maintenance preventive mainte-

nance of all the equipment & machinery operated & run by him in the premises of

the plant. The schedule should be as per the guidelines mentioned in the contract

& as per the approved O & M manual. The scope covers Routine, Preventive, Mi-

nor & Major maintenance of all major minor equipments, and machines in the Plant

like Submersible pumps, blowers, Coarse & Fine screens, Grit Removal Mechanism,

Channel gates, Decanters, Sludge pumps, Centrifuge feed pumps, Centrifuges, hol-

low fibre membranes etc. All dosing systems including Chlorine Dosing equipment,

etc.

(iii) The scope also covers Routine, Preventive, Minor & Major maintenance of all the

instrumentation system installed like PLC, Actuators, Flow meters level indicators

etc. The Contractor should also carry out Routine, Preventive, Minor & Major main-

tenance of all major minor electrical equipment like Electrical Panels, Switch Gears,

Power Cables, Control cables, Changeover switches etc. so as to ensure uninter-

rupted round the clock operation of the Plant.

(iv) The Contractor should maintain all civil structures including office/ Store room,

Storm water drains, fencing etc in a neat manner. He should maintain all civil struc-

tures of the plant sturdy to complete the natural/designed lifetime. The Contractor

77
 should carry out the safety audit of the plant & necessary certificate from the com-

petent authorities must be obtained .

(v) The Contractor should procure and keep stock all the spares required for all types of

maintenance in advance in sufficient quantity. The brand/make of the part/equipment/machine

to be repaired /replaced should be as per IITH approved list & as per the approved

O & M manual or as per the existing manufacturers brand.

3.4.11 Release of Hazardous Substances or waste, if any

(a) The Contractor, after first notifying the IITH/TSPCB shall be responsible for fulfilling

all requirements associated with any release of any substance into the environment as

required by Applicable law or by any Legal Entitlement including but not limit to the

notification or reporting of releases / Hazardous substances or Hazardous Waste. The

Contractor shall prepare a memorandum evidence such notification or reporting and pro-

vide copies thereof to IITH , along with any documents provided to the relevant regulatory

agency regarding such release.

(b) The Contractor shall assist IITH in the process of obtaining clearances of all such

agencies as required for the purpose, including all clearances during O&M period. He

shall be fully responsible to comply with all requirements of Laws including hazardous

substances, emission standards for air, discharge standards for effluent oil, sub-soil

pollution. The Contractor shall not release any hazardous/toxic materials inside the

premises.

3.4.12 Technical Audit

Engineer-in-Charge has the right to conduct a technical audit of the plant and to perform

any analysis or inspection he deems necessary. The Contractor shall at his cost provide

all assistance IITH requires to complete these inspections. Such audits may cover all or

any of the obligations of the Contractor, including without limitation:

(a) Verification of the system capacity with due allowance for normal wear and tear

during the O&M Period.

(b) Verification of the performance standards and useful life of the individual assets of

the Facility, with due allowance for normal wear and tear during the O&M Period.

(c) Verification of the capacity of the Facility to meet Output Standards during the

residual life of the Facility with due allowance for normal deterioration expected during

such residual life.

(d) Sampling, testing and verification of the Output Standards for treated sewage,

sewage losses.

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3.4.13 Inspection

(a) At any time or at the end of each twelve month period, or at the initiative of the TSPCB,

a visit shall be organized so that both parties can check the condition of the installations

at the facility.

(b) A report shall be drawn up to record the opinions of the both parties. IITH/TSPCB

reserves the right to call the Technology Provider, equipment manufacturers or specialized

technicians for these visits.

3.4.14 Taking Over of Plant after Completion of O & M Period

The plant shall be taken over by IITH on satisfactory completion of the Operation &

Maintenance of the plant provided:

(i) The plant /equipment are in good, smooth running condition. The results of the

treated waste water quality for the preceding three months of operation of the plant

are within the limits specified.

(ii) In case of major repairs /replacement of equipment, the performance guarantee for

such unit/equipment shall be extended by six months from the date of putting back

in to satisfactory operation of such unit/equipment ,in case such putting back is

within last three months of the end of completion of operation & maintenance period.

(iii) All records of operation & maintenance are handed over to IITH in proper condition.

(iv) In case taking over of the STP is delayed on account of Contractor’s failure, the oper-

ation & maintenance period shall be extended further till he meets the requirement

without any extra cost to IITH .

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Chapter 4

Scope of Work and Services

4.1 Scope of Part-A of the Contract

(i) Unless otherwise expressly limited in the Contract the Contractors obligations cover

the provision of all Plant and Equipment , Installation Services required for the de-

sign, procurement, quality assurance, installation, associated civil works which are

not explicitly excluded, trial run, commissioning and delivery of the Plant and Equip-

ment and completion of the facilities in accordance with the plans, procedures, spec-

ifications, drawings, codes and any other documents as specified in the Contract in-

cluding ,but are not limited to, the provision of supervision and engineering services,

the supply of labour, materials, equipment, spare parts and accessories, Contractors

tools & plants and other machinery; construction utilities and supplies, temporary

materials, structures and facilities, transportation (including, without limitation, un-

loading and hauling to, from and at the Site) and storage.

(ii) The Contractor shall, unless specifically excluded in the Contract, perform all such

work and/or supply all such items and materials not specifically mentioned in the

Contract but that can be reasonably inferred from the Contract as being required for

fulfilling the contractual requirements as if such work and/or items and materials

were expressly mentioned in the Contract.

(iii) Indicative details of scope of the work for which bids are invited are as under :

Civil Construction by IITH: IITH shall make available the following Civil structures

required for execution of contract:

• Common collection sump

• Equalization Tank

• Anoxic Tank

• Aeration Tank

• Membrane Tank

80
 • Treated water storage sump

• Pump room

• MCC and Panel room

• Store Room

• Through a network of sewer pipes already laid or by other means, the raw sewage

will be made available by IITH in the common collection sump of the STP.

(iv) The DSITC Services under the Part-A of contract includes the following components

of the work :

(a) Design of electro-mechanical, instrumentation, piping, automation components

of the plant to meet the specified performance requirements (b) Supply, installation,

testing and commissioning of electro-mechanical equipment/components including

GE MBR membranes Supply, installation and commissioning of all instrumentation,

piping ,automation and electrical works of plant ( the scope of IITH is confined to

construction of all tanks, office building with basic electrical services )

(c) Complete allied works like valve chambers, thrust blocks, anchor blocks, etc.,

(v) The OM services under the Part-B of contract includes Operation and Maintenance

of the plant for 3 years from the date of commissioning.

4.1.1 Contractor‘s Responsibilities

The Contractor shall design, supply, install, test, commission and run the STP with due

care and diligence in accordance with the Contract.

The Contractor confirms that he has entered into this Contract on the basis of a

proper examination of the data relating to the site and facilities provided by the IITH,

and on the basis of information that the Contractor could have obtained from a visual

inspection of the Site and of other data readily available to him relating to the Facilities

.The Contractor acknowledges that any failure to acquaint himself with all such data and

information shall not relieve his responsibility for properly estimating the difficulty or

cost of successful performance of the plant.

4.2 Details of Equipment

Indicative details of equipment which will be a part of Scope of Part-A of Contract: The

table 4.1 shows the list of equipment for the proposed UF MBR System and the contrac-

tors scope of supply. The indicative quantity and capacity of these equipment shall be as

mentioned in the Schedule of Contract Price of the bid document. The symbol ”Y” in the

81
table indicates with whom (Contractor or IITH) the scope of the equipment/item lies. The

list is only indicative. The Contractor shall provide any other equipment not mentioned

in the table below, required for commissioning of the plant.

Table 4.1: Indicative details of equipment which will be a part of Scope of Part-A of
Contract

Scope of Scope of
Common Collection Sump and associated equipment
Contractor IITH
RCC Common Collection Sump Y
Coarse screen,16 mm Y
C I Sluice Gates Y
Manual Fine screen,6mm Y
Mechanical Fine screen,6mm Y
Grit removal system Y
Oil and grease removal system Y
Drain valve for oil and grease Y
Level Switch Y
Coarse bubble diffusers
(10 Nos, approx) Y

Scope of Scope of
Equalization Tank and associated equipment
Contractor IITH
RCC Equalization Tank Y
Bioreactor Feed Pump Y
Discharge Check Valve Y
Pressure Gauge Isolation Valve Y
Pressure Gauge Y
Discharge Isolation Valve Y
Pump discharge to tank return Isolation Valve Y
Mechanical screen (2 mm punched hole Type) Y
Mechanical screen Isolation Valve Y
Flow Transmitter Y
Coarse bubble diffusers in equalization tank Y
Other piping, valves & other items as denoted in P&ID Y

Mixing Blowers and associated equipment for CCS, Equalization Tank and SH Tank

Scope of Scope of
Mixing Blowers and associated equipment
Contractor IITH
Inlet/Discharge,Filter-Silencers Y
Mixing,Blower with Acoustic hood Y
Pressure,Safety Valves (integral to blower package) Y
Discharge,Pressure Gauge c/w Isolation Valve Y
Discharge,Check Valves Y
Discharge,Isolation Valves Y
Other,piping, valves & other items as denoted in P&ID Y

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 Membrane Aeration Blowers and Associated Equipment

Membrane Aeration Blowers and Scope of Scope of

associated equipment Contractor IITH
Inlet/Discharge Filter-Silencers Y
Mixing Blower with Acoustic hood Y
Pressure Safety Valves (integral to blower package) Y
Discharge Pressure Gauge c/w Isolation Valve Y
Discharge Check Valves Y
Discharge Isolation Valves Y
Blower Discharge Low Flow Switch Y
Other,piping, valves & other items as denoted in P&ID Y

Process Aeration Blowers and Associated Equipment

Process Aeration Blowers and Scope of Scope of

Associated Equipment Contractor IITH
Inlet/Discharge Filter-Silencers Y
Process Air Blower with acoustic hood and VFD Y
Pressure Safety Valves (integral to blower package) Y
Discharge Pressure Gauge c/w Isolation Valve Y
Discharge Check Valves Y
Discharge Isolation Valves Y
Blower Discharge Low Flow Switch Y
Other,piping, valves & other items as denoted in P&ID Y

Anoxic tank and Associated Equipment

Scope of Scope of
Anoxic tank and Associated Equipment
Contractor IITH
RCC Bio Reactor Splitter Channel
Y
(applicable for multiple trains)
RCC Anoxic Tank Y
Anoxic Tank Mixer (Submersible type) 1set Y
Inlet Sluice Gate/ isolation valve
Y
(applicable for multiple trains)
Outlet Sluice Gate/isolation valve
Y
(applicable for multiple trains)
Other Piping, valves and other items as
Y
denoted in P&ID

Membrane Bio-reactor and Associated Equipment

Membrane Bio-reactor and Scope of Scope of

Associated Equipment Contractor IITH
RCC Aerobic Tank Y
RCC Membrane tank distribution channel
Y
(applicable for multiple trains)
Aerobic Tank Fine Bubble Diffuser Y
Dissolved Oxygen Transmitter Y
Outlet Sluice Gate/isolation valve
Y
(applicable for multiple trains)
Aerobic Tank Level Switch Y
Air Inlet Isolation Valves Y
Air Drop Pipe from Tank top to bottom Y
Other Piping, valves and other items as denoted in P&ID Y

83
 Membrane Tank and Associated Equipment

Membrane Tank and Scope of Scope of

Associated Equipment Contractor IITH
Feed Water Sluice Gate/ Isolation valve
Y
(applicable for multiple trains)
RCC Membrane Tank Y
ZeeWeed,Membrane Cassette SS 304 Y
ZeeWeed 500D, 370 sqft Membrane,30 no. of modules
Y
fixed in one cassette of 48 module capacity
Permeate Collection Headers SS304L Y
Membrane Air Scour Header Pipes SS304L/PVC Y
Straub couplings- Air header Y
Air Header Cassette Isolation Valve Y
Permeate header cassette isolation valve Y
Cassettes pins, brackets, hangers, beams Y
SS304L Fasteners for SUEZ/GE supplied header piping Y
Deflector Plate for Membrane Tanks Y
Cyclic Air Valve (if applicable as per P&ID) Y
Membrane Tank Level Transmitter Y
Isolation Flow ValveAutomatic/manual
Y
as shown in P&ID (Drain)
Isolation,Flow Valve Automatic/manual
Y
as shown in P&ID (RAS inlet header)
Other Piping, valves and other items as denoted in P&ID Y

Permeate Pump and Associated Equipment

Permeate Pump and Scope of Scope of

Associated Equipment Contractor IITH
TMP Pressure Transmitter Y
Pressure Switch Y
Permeate Isolation Valve (Automatic) Y
Pump Suction Pressure Gauges Y
Pump Suction Drain Valve Y
Permeate /Back-pulse Pump Y
Permeate /Back-pulse Pump VFDs Y
Pump Discharge Pressure Gauges & Gauge Cock Y
Pump Discharge Drain Valve Y
Pump Discharge Check Valve Y
Permeate Discharge Isolation Valve Automatic Y
Permeate Flow Meter Y
Back-pulse Water Isolation Valves Automatic Y
Back-pulse recirculation valves- Automatic Y
Online Turbidity meter Y
Other Piping, valves and items generally as denoted in P&ID Y

84
 Back pulse tank and Associated Equipment

Scope of Scope of
Back pulse tank and Associated Equipment
Contractor IITH
FRP Back Pulse Tank Y
Back Pulse Tank Header inlet valve- Automatic Y
Sodium Hypochlorite Solution Injection Valves
(Ball check and ball valve) for Recovery/ Y
Maintenance cleans
Citric Acid Solution Injection Valves for
Y
Recovery cleans (Ball check and ball valve)
Level switch Y
LIT Isolation Valve Y
Back Pulse Tank Drain Valve Y
Other Piping, valves & items generally as denoted in P&ID Y

Permeate pump priming system and Associated Equipment

Permeate pump priming system Scope of Scope of

and Associated Equipment Contractor IITH
Pump Suction Ejector Inlet Isolation Valve Y
Pump Suction Ejector Angle Seat Valve Y
Pump Suction Ejector Pressure Gauge Y
Permeate Pump Ejector Y
Solenoid Valve Y
Filter Y
Isolation Valve Y
Other Piping, valves & items generally as denoted in P&ID Y

RAS pump priming system and Associated Equipment

RAS pump priming system Scope of Scope of

and Associated Equipment Contractor IITH
Pump Suction Isolation Valves Y
Pump Suction Pressure Gauges/Valves Y
Pump Suction Piping Drain Valves Y
RAS Pump Y
Pump Discharge Pressure Gauges/Valves Y
Pump Discharge Check Valves Y
Pump Discharge Piping Drain Valves Y
Pump Discharge Isolation Valves Y
Other Piping, valves & items generally as denoted in P&ID Y

Chemical cleaning system NaOCl dosing system (M)

Chemical cleaning system NaOCl dosing system Scope of Scope of

for maintenance clean Contractor IITH
Pump Inlet Isolation Valves Y
Pump Discharge Valve Y
Sodium Hypochlorite Pump Y
Tank Level Switch Y
Pump Pressure Safety Valves Y
Discharge flow indicator Y
Pump discharge Isolation Valve Y
Pump Suction Foot Valve/Check Valve Y
Other piping, valves, chemical and items
Y
generally as denoted in P&ID

85
 Chemical cleaning system NaOCl dosing system (R)

Chemical cleaning system NaOCl dosing Scope of Scope of

system for Recovery clean Contractor IITH
Pump Inlet Isolation Valves Y
Tank Y
Pump Discharge Valve Y
Sodium Hypochlorite Pump Y
Tank Level Switch Y
Pump Pressure Safety Valves Y
Discharge flow indicator Y
Pump discharge Isolation Valve Y
Pump Suction Foot Valve/Check Valve Y
Other piping, valves, chemical and items
Y
generally as denoted in P&ID

Chemical cleaning system

Chemical cleaning system Citric dosing system Scope of Scope of

for recovery and maintenance clean Contractor IITH
Pump Inlet Isolation Valves Y
Tank Y
Pump Discharge Valve Y
Citric Acid dosing Pump Y
Tank Level Switch Y
Pump Pressure Safety Valves Y
Discharge flow indicator Y
Pump discharge Isolation Valve Y
Pump Suction Foot Valve/Check Valve Y
Other valves and items piping, chemical,controls
Y
generally as denoted in P&ID

Air Compressor system

Scope of Scope of
Air Compressor system
Contractor IITH
Air Compressor with Vertical Receiver Tank Y
Receiver Tank Pressure Gauge Y
Receiver Tank Pressure Switch Y
Receiver Tank Pressure Relief Valve Y
Receiver Tank Drain Valve Y
Receiver Tank Isolation Valve Y
Refrigerated Air Dryer Y
Refrigerated Isolation Valves Y
Inlet Filter Y
Primary Coalescing Filter
Y
Isolation Valves
Primary Coalescing Filter Bypass Valve Y
Pressure Regulator Valve Y
Discharge Pressure Indicator Y
Other Piping, valves & items generally
Y
as denoted in P&ID

86
 Plant Automation*

Scope of Scope of
Plant Automation Component
Contractor IITH
PLC panel with required I/O,16 HMI interface :HMI Panel to comprise
standard PC with
CPU, 22 LED monitor, Laser printer, SCADA software.
The automation shall include designing
automation, system integration job and all hardware/software/ Y
instruments/sensors/ transducers/ equipment/
panels/electrical components etc.
Complete, as per scope mentioned in Technical Specifications
of the contract.
* For detailed information and scope of work, Specifications under sections 5.48 and
5.49 shall be referred to.

Mono Rail Arrangement

Scope of Scope of
Monorail and hoist
Contractor IITH
Hot dipped galvanized mild steel Monorail and hoist for
membrane installation & maintenance across Y
all three trains and membrane lay down area

Sludge de-watering & Softening Systems

Sludge de-watering and Scope of Scope of

Softening systems Contractor IITH
Coarse Bubble diffuser for Sludge holding tank
(3 Nos, approx) Y
RCC Sludge Holding tank Y
Feed Pump isolation Valve Y
Sludge transfer pump Y
Pressure Indicator Y
Check Valve Y
Discharge Isolation Valve Y
Centrifuge Y
Polymer Dosing Pump Y
Polymer Dosing Pump Isolation Valves Y
Polymer Check Valves Y
Level Switch Y
Polymer Dosing Tank Y
Softener System Y
Softener feed pump Y
Softener vessel with Resin Y
Softener internal piping with valves Y
*Instruments set Y
Other Piping, valves & items generally as
Y
denoted in P&ID
* Contractor shall install all required instruments and equipment to fulfill the specified
effluent characteristics in terms of quantity and quality.

Instrumentation in treated water tank & Soft water tank

Sludge de-watering and Scope of Scope of

Softening systems Contractor IITH
Complete Instrumentation in these tanks Y

87
4.3 Works in the scope of IITH

In addition to the information provided in 4.2, the following works are within the scope of

the institute.

Civil Works

• Civil works for Pre-treatment system such as screen chamber, grit chamber.

• Civil tanks such as Equalization tank, Bioreactor, Membrane tank etc.

• Treated water storage and Sludge holding tank as shown in relevant drawings.

• Water proofing treatment of all RCC tanks

• All access platforms on tanks

• Pavement around the treatment plant

• Internal pathways

• Walkways over treatment tanks including railing

• Fencing with gate all-round the plant

• Membrane tank coating as required

Electrical Works

• Incoming three phase power supply cable

• * general lighting, fans and general power wiring

• * Extending of Body earthing GI strips near the incoming power cable

• *Street lighting

Table 4.2: Other Equipment

Other Equipment
Scope of Scope of
Description
Contractor IITH
All Civil Works listed below:

Civil works for Pre-treatment system such

Y
as screen chamber, grit chamber

Civil tanks such as Equalization tank,

Y
Bioreactor, , Membrane tank & etc.

88
Treated water storage and Sludge holding
Y
tank as shown in Civil drawings

Water proofing treatment of all RCC tanks Y

All access platforms on tanks Y

Pavement around the treatment plant Y

Internal pathways Y

Walkways over treatment tanks including railing Y

Fencing with gate all-round the plant Y

All Electrical Works listed below: Y

Incoming three phase power supply cable Y

*. general lighting, fans and general power wiring Y

*. Extending of Body earthing GI strips

Y
near the incoming power cable

*Street lighting Y

– Equipment Foundation civil work, full floor

Y
coverage equipment contact pads, etc.

– Process and utilities piping, pipe supports,

Y
hangers, valves, etc. including but not limited to:

Piping, painting to pipes ,pipe supports and valves between

plant process equipment Y

– All other equipment as required for

completion of MBR System as per P&ID Y

– All Electrical wiring, conduit and other appurtenances

required to provide power connections as required from

Y
the control panel to all electrical equipment,

pump motors and instruments, sensors.

– All weather protection as required for process equipment

skids and control equipment. Skids and electrical panels

Y
are designed for indoor operation and shall need shelter

from the natural elements.

–Raw materials, chemicals, and utilities during equipment

Y
start-up and operation

– Equipment lifting davit arm with lifting cables Y

– Motor Control Centre Y

– Membrane tank coating as required Y

89
 – Laboratory Assistance during trial run and commissioning
Y
of STP plant as required.

– Disposal of Initial Start-up wast ewater and associated Y

chemicals

– Receiving, unloading and safe storage of

Y
equipment at site until ready for installation;

– Erection and Installation (equipment,

Y
instrumentation & piping ) & commissioning

– Erection installation of electrical panel and cabling works ,

required earthing, non-skid type electric insulated Y

rubber mats

– Fire Fighting Systems and fire extinguishers Y

– Any other equipment/ item/work not included above

Y
and is required for completion of the STP

– Working platforms in the laboratory Y

4.4 Contractors Scope of supply for Design and Detail

Engineering

The scope of the contractor includes design of the treatment process adopting hollow fi-

bre UF MBR technology of Suez Water Technologies & Solutions (I) Pvt. Ltd., with due

consideration to the layout and hydraulic volumes of various treatment tanks already

constructed by IITH. The Contractor shall submit detailed design calculations with refer-

ences to Codes, Manuals etc.,. The design calculations and drawings shall be vetted by

the Technology Provider. Tentative list of drawings/documents which shall be submitted

to IITH for approval of design shall include the all the drawings listed herein under Table

4.3:

Table 4.3: Drawings and Submittals

PURPOSE
DRAWING / DRAWING /
Sl.No I For information;
DOCUMENT NO DOCUMENT TITLE
A- For approval
BASIC ENGINEERING PACKAGE

1 XXXXXX-AM-01 Process Flow Diagram A

2 XXXXXX-AP-01 P & I Diagram A

3 XXXXXX-AG-01 Equipment Layout A

90
 Table 4.3: Drawings and Submittals

PURPOSE
DRAWING / DRAWING /
Sl.No I For information;
DOCUMENT NO DOCUMENT TITLE
A- For approval
4 XXXXXX-AE-01 Equipment List A

CIVIL DESIGN INPUT DRAWINGS

5 XXXXXX-PG-02 GA for Bioreactor tank A

6 XXXXXX-PG-03 GA for Membrane tank A

7 XXXXXX-CA-01 Equipment Foundation Layout A

8 XXXXXX-PG-05 GA of MCC/Control Building A

GA for Diffuser Arrangement

9 XXXXXX-PG-08 A
Bioreactor tank

10 XXXXXX-SA-07 Fabrication drawing for Baffle Plate A

11 XXXXXX-SA-011 Puddle Pipe Drawings ( if applicable) A

DETAIL ENGINEERING PACKAGE (Mechanical)

1 XXXXXX-KG-01 Data sheet for Screens I

2 XXXXXX-KG-02 Data sheet for Process Air Blowers I

3 XXXXXX-KG-03 Data sheet for Membrane Air Blowers I

4 XXXXXX-KG-04 Data sheet for UF Membrane I

5 XXXXXX-KG-05 Data sheet for Bioreactor feed pumps I

6 XXXXXX-KG-06 Data sheet for RAS pumps I

Data sheet for Permeate cum

7 XXXXXX-KG-07 I
Back-pulse Pumps

8 XXXXXX-KG-08 Data sheet for NaOCL Dosing Pump I

9 XXXXXX-KG-09 Data sheet for nutrient dosing pump I

Data sheet for Citric Acid Dosing

10 XXXXXX-KG-10 I
Pump & agitator

11 XXXXXX-KG-11 Data sheet for NaOCL Dosing Pump I

12 XXXXXX-KG-12 Data sheet for Manual butterfly valves I

13 XXXXXX-KG-13 Data sheet for actuated butterfly valves I

14 XXXXXX-KG-14 Data sheet for ball valves I

15 XXXXXX-KG-15 Data sheet for wafer check valves I

16 XXXXXX-PC-03 Piping Routing drawing A

17 XXXXXX-PG-05 GA for Nutrient dosing tank I

18 XXXXXX-PG-06 GA for Citric acid Dosing tank I

19 XXXXXX-PG-07 GA for NaOCl dosing tank I

91
 Table 4.3: Drawings and Submittals

PURPOSE
DRAWING / DRAWING /
Sl.No I For information;
DOCUMENT NO DOCUMENT TITLE
A- For approval
20 XXXXXX-PG-08 GA of Back-pulse Tank I

21 XXXXXX-PK-01 Valve schedule A

DETAIL ENGINEERING PACKAGE (E&I)

1 XXXXXX-EO-01 Electrical Load list A

2 XXXXXX-IK-01 Instrument Schedule A

3 XXXXXX-JH-01 PLC I/O List A

4 XXXXXX-IE-01 PLC Panel GA & Wiring Drawing A

5 XXXXXX-JA-01 Control Narrative A

6 XXXXXX-JB-01 Operating Sequence Chart A

7 XXXXXX-JC-01 Control Logic Summary Chart A

8 XXXXXX-ID-01 Data sheet for Pressure Gauges I

9 XXXXXX-ID-02 Data sheet for Pressure Switch I

10 XXXXXX-ID-03 Data sheet for Level Switch I

11 XXXXXX-ID-04 Data sheet for Pressure Transmitter I

12 XXXXXX-ID-05 Data sheet for Level Transmitter I

13 XXXXXX-ID-06 Data sheet for Flow Transmitter I

14 XXXXXX-ID-07 Data sheet for Temperature Transmitter I

15 XXXXXX-ID-08 Data sheet for pH Transmitter I

16 XXXXXX-ID-09 Data sheet for Turbidity Analysers I

17 XXXXXX-ID-10 Data sheet for DO Analysers I

18 XXXXXX-ID-11 Data sheet for FLOW Switch I

19 XXXXXX-ID-12 Data sheet for Junction boxes I

20 Cable Termination details I

GENERAL

1 XXXXXX-UA-01 Operation and Maintenance Manual A

Master Construction Schedule

2 XXXXXX-WF-01 A
conforming to Milestones of contract

3 XXXXXX-YC-01 Inspection Test Plan A

4 XXXXXX-TB-01 Pre-commissioning Procedures A

5 XXXXXX-TB-03 Drawing Document List A

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4.5 Scope of Technology Provider

The Contractor shall arrange required technical services by the Technology Provider as

specified in the MoU document between the Contractor and Technology Provider Suez

Water Technologies & Solutions (I) Pvt. Ltd.,. The costs incurred by the contractor for

arranging the technical services by the Technology Provider are deemed to be included

in the Contract Price for Part-A and Part-B of the Schedule of Contract Price for DSITC

Services and O&M Services. Nothing extra shall be payable on this account. All incidental

expenses like travelling, lodging and boarding arrangements for the representative(s) of

Technology Provider shall be borne by Contractor during entire period of this Contract.

The following are the technical services to be rendered by the Technology Provider:

4.5.1 Technical Advisory Services during Pre-Construction

The Contractor shall undertake the design of the proposed sewage treatment plant in con-

sultation with the Technology Provider. Technology provider shall scrutinize the design

calculations of all electro-mechanical, instrumentation, piping, electrical and automation

of control systems and vet the same. Similarly, all deliverable drawings/documents in-

cluding Maintenance Manual shall be vetted by the Technology Provider duly affixing the

signature of authorized signatory along with seal of Suez Water Technologies & Solutions

(I) Pvt. Ltd., .

4.5.2 Technical Advisory Services during Equipment Installation

In support of unloading the equipment, rigging the equipment into place, installing in-

terconnecting piping, installing interconnecting wiring, installing power wiring, installing

pneumatic lines, verifying adequate drainage, testing for adequate water and air pressure,

testing power supply and testing interconnecting wire circuitry.

4.5.3 Technical Advisory Services during Post-Installation

Inspection of installation work, address questions, develop punch list of completion items

necessary prior to next visit including technical advisory services in support of loading

membrane elements / cassettes (if not loaded in factory)

4.5.4 Technical Advisory Services during Equipment trial run

Includes technical advisory services in preparing the equipment to operate I/O verifica-

tion, support for flushing & back washing system, operating the equipment manually,

I/O verification, operating the equipment automatically, testing control system, techni-

cal advisory services in support of membrane loading, flushing preservative, and system

93
sanitization

4.5.5 Technical Advisory Services during Commissioning of plant

(Performance Test)

Includes technical advisory services in support of set-up of and witness performance

test of 72 hours / 3 days continuous operating run without intervention beyond normal

operational activities.

4.5.6 Formal Training

This shall include formal on-site training to staff of Contractor and IITH that typically

takes place after the commissioning of the plant. This does not include informal training

that takes place with an operator being present and assisting the technicians performing

start-up. The on-site training program shall also include site safety training. The training

program shall be properly documented and a report shall be submitted to IITH.

4.5.7 Other Services

The technical services listed above shall include at least 4 trips to site with total 20

working days on-site availability for above mentioned services. Travel time to and from

the job site for Technology Provider‘s Field Service personnel is not included in the 20

days period.

In addition to above technical services, the contractor shall arrange representative of

Technology Provider at kick-off meeting to be held at site after award of work.

As specified in the Conditions for O&M Services, the contractor shall arrange visits of

the Technology provider to the plant once in every three months for complete performance

audit of the plant and submit such audit report to the Institute.

4.5.8 Performance Guarantee

As specified in the bid document the Technology Provider shall submit performance guar-

antee bond for the quality of treated sewage by furnishing to IITH a joint undertaking with

Contractor to this effect.

4.6 Scope of Part-B of the Contract

Scope of work under Part B of the contract i.e, Operation and Maintenance services is

given in the Special Conditions of the Contract.

94
4.7 Schematic P&ID

For understanding of the bidder, a schematic of the plant is given in this section. The P&I

diagram is only indicative. On award of the work, the Contractor shall prepare schemat-

ics, detailed processes, P&ID and good for construction drawings incorporating all work-

ing details for approval of the institute after due vetting by the Technology Provider.

95
INDICATIVE P&ID FOR PROPOSED
SEWAGE TREATMENT PLANT
AT IIT HYDERABAD

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Chapter 5

Technical Specifications

Technical Specifications of Membrane, Electro-Mechanical, Instrumentation and

other items of STP work

5.1 General Requirements

This part of the IITH requirements sets out the general standards for Membranes/Electro-

Mechanical equipment/Instrumentation/Automation/Piping etc. to be used by the Con-

tractor for the works. All equipment used for the works shall, unless otherwise specified,

comply with the provisions of this Technical Specification.

5.1.1 Material

All materials incorporated in the work shall be the most suitable for the service conditions

and duty concerned. They shall be new and of approved make / approved quality, free

from imperfections and selected for long life and minimum maintenance. Nondestructive

tests, if called for in the Specification, shall be carried out. All submerged moving parts of

the Plant, or shafts and spindles or faces etc. in contact with them shall be of corrosion

resistant materials. All parts in direct contact with various chemicals, shall be completely

resistant to corrosion, or abrasion by these chemicals, and shall maintain their properties

without aging due to the passages of time, exposure to light or any other cause. All

materials shall conform to the material standards as per BIS or any equivalent standard.

All stainless steel materials used shall be of SS 304/304L as specified.

5.1.2 Workmanship

Workmanship and general finish shall be of first class quality and in accordance with best

workshop practice. All welds shall be as per BIS standards. All tolerances and clearances

shall be as per good and sound Engineering practices. Should the Engineer-in-Charge

not consider any material acceptable, it shall be replaced.

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5.1.3 Design Features

As far as practicable, all designs shall be as per latest concept and practices. The equip-

ment shall be new, of robust design for a long reliable operating life. These shall be ca-

pable of 24 hours per day continuous operation for prolonged period in the climatic and

working conditions prevailing at the site and with a minimum of maintenance. Particular

attention shall be given to extra temperature and the rating of electrical and mechanical

equipment, membranes ,cooling systems and the choice of lubricants shall be for the

temperatures as specified.

The equipment shall be designed to provide easy access to and replacement of com-

ponent parts which are subject to wear without the need to replace whole units. Design

features shall include the protection of equipment against damage caused by vermin, dirt,

dust and dampness and to reduce risk of fire. Equipment shall operate without undue

vibration.

The noise level produced by any equipment like pump sets, compressor sets and

blower sets shall not exceed 85 dBA measured at a distance of 3 m from the outer surface

of the equipment. At the time of operation, the mechanical vibration shall not exceed the

limits given below, at recommended points of measurement as per ISO 10816:1995.

Parts shall be designed to withstand the maximum stresses under the most severe

conditions of normal service. All rotating elements shall be dynamically and statically

balanced.

Table 5.1: Equipment Velocity of Vibration

Velocity of
S. No EQUIPMENT
Vibration (mm/sec)
All rotating equipment not having reciprocating
1 1.12
parts with motor KW less than or equal to 15 KW
All rotating equipment not having reciprocating parts
2 1.8
with motor KW more than 15 KW and less than or equal to 75 KW
All rotating equipment not having reciprocating parts
3 2.8
with motor KW greater than 75 KW

5.1.4 Lubrication

The equipment shall be lubricated by long life lubricants such that working life is not less

than 3000 operation hours or as recommended by equipment manufacturer. A complete

schedule of recommended oils and other lubricants shall be furnished by the Contractor.

The number of different types of lubricants shall be kept to a minimum. The schedule

and the name of the supplier of the lubricants shall be submitted to the IITH for approval.

Lubricants shall be oil and grease. The Contractor shall indicate indigenous available

equivalent lubricants, with complete specification. Where the lubricant is grease, prefer-

111
ence shall be given to a pressure system which does not require frequent adjustment or

recharging. Preferably, life lubricated grease packed bearings shall be used. Where more

than one special grease is required, a grease gun for each special type shall be supplied

and permanently labeled.

5.1.5 Name Plates

Each equipment of the plant shall have permanently attached to it a name plate and

rating plate in a conspicuous position, Upon these shall be engraved or stamped, the

manufacturers name, type and serial number of the equipment, details of the loading

and duty at which the equipment has been designed to operate, and such diagrams as

may be required by the IITH . All indicating and operating devices shall have securely

attached to them or marked upon them designations as to their functions and proper

manner of use.

5.1.6 Painting

(i) At Manufacturers Works

The Contractor shall be responsible for the cleaning, preparation for painting, and

priming or otherwise protecting, as specified, all parts of the Plant/ Equipment at

the place of manufacture prior to packing.

Parts may be cleaned but surface defects may not be filled in before testing at the

manufacturers works. Parts subject to hydraulic test shall be tested before any sur-

face treatment. After testing, all surfaces shall be thoroughly cleaned and dried out,

if necessary by washing with an approved de- watering fluid prior to surface treat-

ment. Except where the specification provides to the contrary, all painting materials

shall be applied in strict accordance with the paint manufacturers instructions.

A primer coat of a zinc rich epoxy resin based coating with at least 75 microns dry

film thickness is to be provided. In addition, the parts for wet duty are to be provided

with an adequate number of coats of coal tar epoxy polyamine coating to a dry film

thickness of 175 microns excluding primer coating.

(ii) At Site

Immediately on arrival at the site, all items of Plant shall be examined for damage to

the paint coat applied at the manufacturers works. Any damaged portions shall be

cleaned down to the bare metal, all rust removed, and the paint coat made good with

similar paint. After erection, such equipment/ items which are not finish painted

shall be done so. Items that have been finish painted at the manufacturers works

shall be touched up for any damaged paint work.

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 For finish painting, two coats of synthetic enamel conforming to IS: 2932 shall be

applied. Dry film thickness of each coat shall be at least 25 microns. The dry paint

film thickness shall be measured by Elcometer or other instruments approved by the

IITH. In order to obtain the dry film thickness specified, the Contractor shall ensure

that the coverage rate given by the paint manufacturer will enable this thickness to

be obtained.

Painted fabricated steel work which is to be stored prior to erection shall be kept

clear of the ground and shall be laid out or stacked in an orderly manner that will

ensure that no water or dirt can accumulate on the surface. Suitable packing shall

be laid between the stacked materials. Where cover is provided, it shall be ventilated.

(iii) Galvanizing

Wherever galvanizing has been specified, the hot dip process shall be used . The

galvanized coating shall be of uniform thickness. Weight of zinc coatings for various

applications shall not be less than those indicated below:

a) Fabricated steel : 460 g/sq. m

b) Fasteners : 300 g/ sq. m

Galvanising shall be carried out, after all drilling, punching, cutting, bending and

welding operations have been carried out. Burrs shall be removed before galvanizing.

Any site modification of galvanized parts should be covered well by zinc rich primer

and aluminum paint.

5.1.7 Supports for Pipe Work Valves

All necessary supports, saddles, slings, fixing bolts foundation bolts shall be provided

to support the pipe work. Valve and other equipment mounted in the pipe work shall be

supported independently of the pipes to which they connect.

All valves to be installed in straight lines shall be installed between the flanges with a

dismantling joint or SS expansion bellow at one side of the valve. The dismantling joint

must allow a minimum clearance of 20 mm. The pressure rating of the dismantling joint

/expansion below shall be same as that of the valve.

5.2 Indicative Ultra Filtration Membrane System Design

General Process Overview

The hydraulic, biological and membrane design shall be based on the sewage charac-

teristics described in the contract.

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 Domestic sewage from the IIT Campus is collected in the common collection sump of

the STP. Then the sewage shall flow through Bar Screens, oil Skimmer and collected in

equalization tank.

The homogenized and mixed waste water in the equalization tank shall be pumped

through fine screening before entering the MBR.

An internally-fed screen with punched-hole openings less than or equal to 2 mm in di-

ameter with no possibility of bypass or carryover is absolutely required to maintain both

membrane protection and optimal MBR operation.

Effluent from the Equalization tank and Return Activated Sludge (RAS) being pumped

from the membrane tank must be mixed and fed into the bioreactor tank.

Biological trains shall be equally divided into single/multiple trains on hydraulic loading

and shall be operated in parallel. Each train shall comprise of an aerobic tank. The

present scope of work includes single train/stream only.

Influent wastewater and re-circulated sludge shall be divided between all the biological

trains as it enters each aerobic tank whereever required.

Biological process blowers and fine bubble diffusers in the aerobic tanks shall provide the

oxygen required for the biological process as well as the mixing energy required to keep

the mixed liquor in suspension. Dissolved oxygen shall be monitored in each aerobic tank

to achieve a desired set point of 2 mg/L.

The mixed liquor overflows by gravity from the biological tanks to the membrane tanks

where the solid/liquid separation takes place by means of the vacuum created by the

process pumps. The permeate is stored in the permeate storage tank.

The mixed liquor from the end of the bioreactor aerobic zone shall proceed by gravity

to the membrane filtration basins. At the outlet of each aerobic tank and inlet of each

filtration basin there shall be isolation valve. Flow shall proceed by gravity through the

valve. The sluice gate valve can be used to either isolate the membrane tank (i.e. during

cleans). Plant demand shall be controlled by the feed flow into the system and can be

trimmed by the level in the bioreactor/membrane tank.

One permeate pump per membrane train/stream is employed to draw water through the

membranes. Treated water flows from the permeate pump to the treated water sump.

Under normal operation and average day flow conditions, permeation is stopped for a

specific period of time at regular intervals. This membrane relaxation period, combined

with air scouring, effectively removes solids that have accumulated on the membrane

surface or within the fibers and reduces electrical costs.

Same permeate pump with valving arrangement are provided for backpulsing the mem-

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branes.

From membrane tanks, Permeate pump draws treated effluent through the pores of the

membrane fibers and into the backpulse tank. Once full, the treated effluent is auto-

matically diverted away from the backpulse tank to a final disposal point. Clean water

(permeate) is suctioned through ZW500D membranes by centrifugal permeate pumps.

The membranes are air scoured with required capacity of membrane aeration blowers

fitted with Mechanical Variable speed drives.

Waste activated sludge (WAS), shall be removed to the sludge handling facilities via a side

stream on the discharge from the membrane tank by pumping in a controlled manner.

Further details of the system design are provided below in the following sections.

5.2.1 Major Process Components for MBR system

(i) The plant shall comprise of the following major components (not limited to):

• Coarse and fine Bar screens, Oil and Grease Removal system

• Equalization tank, Mixing system

During recovery clean, no permeate water shall be generated from the membrane

train.Hence the equalization tank shall be able to take care of the variable flow

rates.

• Bioreactor/Aeration feed pump

• Mechanical Fine Screen 2 mm (Punched Hole configuration)

(ii) The following screening requirements shall be met: Screen raw wastewater with 2

mm punch hole mini screen type Design notes:

(iii) All screen openings are punch hole (dimensions in two directions). Bar or wedge wire

fine screens are not acceptable.

• Bioreactor tank

• Fine bubble diffusers for aerobic tanks

• Biological process blowers

• Biological process chemical feed system

• Membrane tank with accessories for installing UF membrane

(iv) A membrane train is a treatment unit consisting of a single or multiple cassettes

that are manifolded together, installed in an RCC tank (i.e. membrane tank) and

connected to a common permeate pump.

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 (v) Within each membrane tank, the cassettes are connected to permeate header and

air supply header(s). The permeate header conveys permeate from the cassettes to

the permeate pump suction and also delivers cleaning solutions to the membranes.

The air headers deliver air to cassette aerators for air scouring to prevent solids

accumulation on the membrane surface Design notes:

(vi) Puddle pipes inside membrane tank to be SS 304 or FRP. Mild Steel is not acceptable.

(vii) UF membrane The hollow fiber membranes shall be ZeeWeed500D membrane mod-

ules and cassettes. In the ZeeWeed MBR process, the membrane cassettes are im-

mersed directly in the mixed liquor in the membrane tanks.

Figure 5.1: MBR System

5.2.2 Permeate pumps/back pulse pumps (process pumps) with VFD

The membrane cassettes in membrane tank are connected to a permeate header, which

in turn is connected to the suction of a Permeate/Back-pulse Pump. This set of cassettes,

the piping, and the pump is referred to as a membrane train. The vacuum generated by

the Permeate Pump draws permeate from the outside in through the membrane fibers. All

Permeate/Back-pulse pumps discharge into a common permeate collection header. The

train in the plant is operated with a repeating filtration cycle. It consists of two phases:

permeation (drawing) of water through the membranes followed by a short period of re-

verse flow (back-pulsing) or relaxation (no flow). For the proposed membrane filtration

system the same pump shall be used for permeate and back-pulse with necessary valving

arrangement

Pump parts and MOC:

Casing : CI

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Impeller : SS316

5.2.3 Permeate Pump Priming system -Ejector system

After extended standby periods or when a train is first placed into automatic control,

an automated valve which connects the top of the membrane train permeate header to

an ejector (shown below) and an automated valve which connects the ejector to the Air

Compressor opens. The compressed air drives the ejector to create a vacuum that draws

air out of the train, pulling water through the membranes until water in the header hits a

level switch. This indicates that both valves can be closed to ensure the system is primed

and can be placed in operation. To simplify system control the ejector configuration

consists of one unit per train and is controlled by PLC. Make of ejector shall be VACCON/

PIAB only.

5.2.4 Air Scour Blowers for Membrane Aeration

Whenever a membrane train is in production, membrane aeration blowers shall produce

the air scour required to remove solids from the membrane surface and maintain mem-

brane permeability. A specially designed and highly efficient aeration system shall be

used to scour the outside surface of the membrane and move mixed liquor solids away

from the membrane fibres. This shall be accomplished by a SUEZ/ GE patented aeration

system that uses a factory installed aeration grid, which is integrated into the base of

each ZeeWeed500D cassette. The integration of diffusers within the cassette simplifies

the installation of diffusers and enhances the operation of the membrane unit.

The blowers discharge into the membrane aeration manifolds. This manifold delivers air

to the membrane distribution air headers installed above each membrane tank (train).

5.2.5 Conventional Cyclic aeration

For optimal balance between the energy requirements of the membrane aeration blowers

and the amount of air scouring provided at the membranes, the system shall be designed

to cycle air within each membrane cassette (10:10 mode or 10:30 mode). Each cassette

is equipped with two air connections; one air connection from each cassette is connected

to one of two air headers at each membrane tank, using a flexible hose. Airflow is cycled

from one train header to the other (using pneumatic valves) so that half of each cassette

is aerated at a time.

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5.2.6 Recirculation Pump (RAS pumps) & Membrane tank Drain pump

The membrane tanks need to be drained for recovery chemical cleaning or other main-

tenance procedures. This can be achieved by using the above mentioned mixed liquor re

circulation pumps( RAS Pumps).

5.3 Membrane system operation modes & Cleaning pro-

cesses

Operation modes

The sections below highlight the main operational, control aspects and cleaning pro-

cesses of the membrane system. Off, Permeation and Stand-by Modes Off Mode

In OFF mode, devices are off. However, for membrane protection, to ensure the mem-

branes are submerged the feed valves are opened. When the water level is above the

membranes the feed valves are closed.

Filtration/Production/Permeation Mode

Filtration, or permeation, consists of drawing clean water from the mixed liquor through

the membrane fibers via the permeate pump.

Water is produced from each train during the filtration period for duration of 11 min-

utes, followed by a 30 second relaxation. There is permeate/process pump per train

with 50% standby pump for filtration purposes. The vacuum generated by the permeate

pump draws permeate from the outside-in through the membranes and discharges it to

the Permeate Storage Tank. The variable speed pumps are controlled by PLC to maintain

the permeate-flow demand. The PLC continuously runs a PID loop for Trans Membrane

Pressure (TMP) while in production. The PLC uses the lower of the control outputs from

the flow loop and TMP loop. All the permeate pumps are controlled at the same flow set

points and are complete with premium efficiency VFD rated motors and discharge flow

meter. Maximum pump capacity for permeation is achieved at the highest design level

in the process tanks. All pump speeds shall gradually decrease as the liquid level in the

process tanks decreases. If during low flow conditions this level drops below the design

minimum, and the pumps cannot be slowed down any further, one or more trains shall

automatically go into standby mode.

During or below average day flow conditions, all trains shall be in operation provided any

trains are not required to go into stand-by mode. All permeate pumps and Mixed Liquor

118
RAS pumps shall be operating.

All permeate pumps shall discharge into a common permeate collection header. The Per-

meate Storage Tank and the Back-pulse Tank are both fed from the common permeate

header. Cleaning and Maintenance Procedures

As the feed is drawn through the membranes during filtration, solids are removed which

accumulate on the membrane surface. As the solids accumulate, they restrict the flow

through the membranes and eventually membrane cleaning is required in order to main-

tain the filtered water flow rate.

Membrane cleaning is absolutely critical to ensure sustainable operation over the life of

the plant regardless of membrane type. Membrane cleaning features shall include the

following: Membrane Air Scouring: used as a mechanical cleaning action, and shall be

the most energy efficient membrane air scouring method in the industry.

Relax mode Back-pulse Ability: The ability to ensure an even distribution of chemi-

cals across the fibers through back-pulsing under pressure. This reduces the potential

for preferential flow of cleaning chemicals.

Cleaning: The ability to clean not only the inside of the membrane surface with mainte-

nance cleaning, but also the outside of the surface with recovery cleaning.

Ability to clean quickly and easily through fully automated processes such as relaxation,

back-pulsing, maintenance and recovery cleaning.

5.4 Membrane Performance

The multi-level approach to maintaining membrane performance is summarized in the

following sections.

Membrane Scouring by Aeration Whenever a membrane train is in production, membrane

scour aeration is required to maintain consistent permeability of the membrane.

Specially designed highly efficient coarse bubble aeration is used to scour the outside

surface of the membrane and move mixed liquor solids away from the membrane fibers.

This is accomplished by a SUEZ/ GE patented aeration system that uses a factory in-

stalled coarse bubble aeration grid which is integrated into the base of each ZeeWeed

500D cassette.

119
 Figure 5.2: Schematic Representation of Aeration

The membrane cassette is aerated to provide a mechanical cleaning action. This air

scour removes foulants that may deposit on the outside of the fiber, maintaining mem-

brane permeability. The aeration also minimizes the effect of concentration polarization

which is recognized as a significant membrane fouling mechanism.

Figure 5.3: Schematic Representation of Air scour

The system shall be designed to supply Air to each air header of a membrane train at

10 seconds ON and 10 seconds OFF (10:10) aeration mode. A 10 to 30 seconds aeration

mode shall be operated during normal operation of the plant resulting in overall decreased

aeration energy consumption. The process shall be PLC-automated and provide among

the lowest MBR energy consumption without sacrificing any performance.

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Relaxation

Relaxation mode combined with air scouring is the routine cleaning mode during nor-

mal production. The combined stoppage of permeation and air scouring effectively re-

moves solids that have accumulated on the membrane surface or within the fibers and

reduces electrical costs.

Figure 5.4: Schematic of Process Flow

While operating in relaxation mode, permeation for each train is stopped sequentially

for a short period of time (30-60 sec) every 10-12 minutes to allow air scouring of the

membranes without permeation. No chemical or permeate is used during relaxation

mode. This is the normal operating mode of ZeeWeed MBR systems. The relaxation func-

tion shall be fully automated by the PLC with no contractor intervention.

Back-pulse or Backwash Back-pulsing is a cleaning tool which allows for reliable system

performance during unexpected influent or process operating scenarios. Back-pulsing

involves reversing the flow through the membranes to dislodge any particles that may

have adhered to the membrane surface. As with relaxation, the back-pulse functionality

is fully automated by the PLC with no need for contractor intervention.

121
 Figure 5.5: Schematic of Back Wash

The back-pulse system has also been incorporated into the automated membrane

cleaning systems included in the proposed design. Back-pulsing is particularly critical

for efficient membrane cleanings. Without back-pulse, deep chemical cleaning of mem-

brane pores is impossible for any type of membrane, and can run the risk of membranes

becoming deeply and irreversibly fouled with organic matter.

The back-pulse tank is automatically filled with permeate which is used for the back-

pulse process. If required, hypochlorite may be added to the back-pulse tank to maintain

a concentration of ¡ 5.0 mg/L to prevent bacterial growth.

Maintenance Clean Over time, the membranes can experience fouling caused by accu-

mulation of organic matter or crystallized salts within the membrane fiber pores. Clean-

ing of the membranes in this circumstance to restore the permeability requires use of a

Clean-In-Place system.

Clean-In-Place (CIP) membrane cleaning is a standard operational procedure for most

membrane systems including the ZeeWeed system.

A maintenance clean is a regularly scheduled, fully automated cleaning that involves an

extended back-pulse combined with low concentration of chemical addition. Maintenance

cleans are intended to maintain membrane permeability and extend the time between re-

covery cleans.

The maintenance cleaning procedure is entirely automated and shall be scheduled to oc-

cur during off-peak hours of the day. The ZeeWeed membrane filtration system includes

the capability to perform maintenance cleans using sodium hypochlorite (NaOCl) and cit-

ric acid to target organic and inorganic foulants respectively.

The maintenance cleaning procedure shall incorporate the following features:

Fully automated;

122
Performed without draining the membrane tank;

Low chemical concentration.

A maintenance clean consists of a series of short back-pulses with chemical solution,

followed by a back-pulse with only permeate to flush the headers and membranes.

Figure 5.6: Schematic of Maintenance Clean

Recovery Clean:

Recovery cleaning is required to restore the permeability of the membrane once the mem-

brane becomes fouled. The recovery cleaning procedure consists of a chemical back-pulse

sequence, followed by a chemical soak period.

Key features of the recovery cleaning procedure for ZeeWeed MBR shall be:

–Fully automated once initiated by the contractor;

–Cleans all membrane cassettes in a train at the same time;

–Requires moderate chemical concentration

–Thoroughly cleans the surface of the membrane

123
 Figure 5.7: Schematic of Recovery Clean

5.5 System Design Details

The proposed MBR system shall be designed based on the design criteria and assump-

tions summarized in the previous sections above in consultation with Technology Provider.

Biological Process Design

Criteria for biological design based on the design flow and loading conditions shall be as

mentioned in below table. Based on the influent characteristics, process configuration

shall be selected .

Table 5.2: Biological Process Design Overview for STP

Train -1
Parameter Units
(650 KLD)
Flow Basis of Biological Design 650 KLD
No of Biological train(s) 1 No(s)
*Anoxic Working Tank Volume 91 Cum
*Aerobic working Tank volume 202 Cum
*Total Biological Tank volume 293 Cum
*The volumes mentioned above are hydraulic volumes

The table below lists the indicative main design assumptions and outputs at the design

temperature for the average day flows for 1 train of 650 KLD.

124
 Table 5.3: Biological Process Design Details for 650 KLD (Typical)

Parameter Average Day Units

Temperature 25 C
Design Bioreactor MLSS 1 8000 g/L
Design Bioreactor MLVSS/MLSS 2 45.3 %
Total HRT (Including Membrane Tank) 12.04 Hours
Total SRT 18.56 Days
Approx. sludge waste rates(from membrane tank) 14.3 Cum/day
Total Oxygen requirement for Aerobic Zone / bioreactor 270 kg/day

Notes:

1. Bioreactor MLSS refers to the MLSS in the aerobic zones.

2. MLVSS/MLSS ratio values obtained based on assumptions made by Technology

Provider

The design shall be based on inlet BOD value for STP mentioned.

The sludge waste rates etc. are based on sludge yields assumed by Technogy Provider

and have to be verified during detail engineering.

5.6 Ultrafiltration System Design

The membrane ultrafiltration system shall be designed to treat the design flows at the

minimum mixed liquor temperature. The membrane system is designed to treat all flow

with one train in operation with individual membrane modules assembled in cassettes

and cassettes are installed in RCC membrane tank. Please refer to table below for details

of the membrane system.

Table 5.4: Membrane System

Parameter Phase -1 Units

Type of Membrane ZeeWeed 500D -
Surface area of each Module 370 (34.37) ft2 (m2)
Number of membrane Tanks 1 nos. for 650KLD each Nos.
Number of 48Module cassette
1 Nos Nos.
installed per train
Number of modules required 30 nos Modules Filled in 48 Module
Nos.
per cassette capacity Cassette for 650KLD
Net flux (max) 30 Lmh (Litre/sqm/hour)

5.7 Control Narrative

5.7.1 Coagulant, Acetic Acid Dosing Control
5.7.1.1 Coagulant Dosing

Coagulant is dosed for phosphorus removal. There are two Coagulant dosing pumps one

Working and one Standby. The pumps rotate on the duty cycle timer. The duty cycle of

125
the pumps can be set on the HMI. The stroke adjustment on the pumps is manual; it will

be set during the commissioning. Further optimization of the pump stroke can be done

during plant operation.

The PLC will request a coagulant dosing pump if one of the bioreactor feed Pump is

running. If the running bioreactor feed pump stops, coagulant dosing pump will continue

to run for 5 minutes and stop. It will start back again if one of the bioreactor feed pump

starts running.

There is low level switch in the dosing tank, to provide feedback to the PLC for alarm-

ing on the HMI. The operator can take necessary action of loading the chemical in the

tank. The pump running is interlock with the low switch. If the level low alarm is active

the pump will stop.

5.7.1.2 Acetic Acid Dosing

Acetic Acid is dosed in the post-anoxic tank as a carbon source. There are two acetic

acid dosing pumps one Working and one Standby. The pumps rotate on the duty cycle

timer. The duty cycle of the pumps can be set on the HMI. The stroke adjustment on the

pumps is manual; it will be set during the commissioning. Further optimization of the

pump stroke can be done during plant operation.

The PLC will request an acetic acid dosing pump if one of the bioreactor feed Pump

is running. If the running bioreactor feed pump stops, acetic acid dosing pump will con-

tinue to run for 5 minutes and stop. It will start back again if one of the bioreactor feed

pump starts running.

There is low level switch in the dosing tank, to provide feedback to the PLC for alarm-

ing on the HMI. The operator can take necessary action of loading the chemical in the

tank. The pump running is interlock with the low switch. If the level low alarm is active

the pump will stop.

5.7.2 ZeeWeed UF Train Modes States of Operation

A UF train is functionally described as a group of ZeeWeed modules and cassettes con-

nected by a common permeate collection header.

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 Each UF Train is sequenced by the PLC. The sequencing of each Train can be de-

scribed by the mode and state of the Train. Each Train is in one and only one mode and

one and only one state at any given time.

Buttons displayed on the HMI screen that the operator can press to initiate a mode

or state or other operation are shown with the first letter capitalized. For example, one

button that is used to put a train to the OFF mode is the Off button.

The specific sequencing of Modes and States and the steps involved are detailed in the

OSC

5.7.3 Production Cycle

The Production Cycle is the alternation of the trains states between PRODUCTION and

BACKPULSE.

This alternation is controlled by a timer.

5.7.4 ZeeWeed UF Train Modes

Modes define how the transitions occur for a Train from one operating state to another.

A specific mode discussed in this document is shown in capital letters, such as AUTO.

Modes can only be selected by the operator, using pushbuttons on the HMI. The mode

button Semi-Auto is available in all states. The Off mode button is available in all states

except OFF. The Auto mode button is available in all states except MAINTENANCE RE-

COVERY CLEANs. The modes of each UF Train are described in the following sections.

5.7.4.1 AUTO Mode

This is the normal mode of operation for a UF Train for production of clean water.

For the train equipment to operate automatically, the operator needs to have all related

devices set to AUTO and the train set to AUTO. The operation of the train is automatic

when in AUTO, and there is minimal operator attention required unless an alarm is

activated.

In AUTO mode, the train changes state between the Production Cycle and STANDBY

according to train start stop triggers, which are based on the membrane tank operating

level. Please refer CLC for the membrane operating level.

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5.7.4.2 OFF Mode

This mode immediately places the Train to OFF state and prevents the operator from

manually selecting other states until the Train is placed in another mode.

The operator may turn a train OFF at any time. Pressing the Off button places the

train into OFF mode and OFF state. It is the responsibility of the operator to ensure that

if the Off button is pressed when a train is in a clean, the tanks contents are suitable for

a train to proceed to another mode.

5.7.4.3 SEMI-AUTO Mode

This mode safely places the Train to OFF state, but permits the operator to manually

select other sequences such as a Backpulse, Maintenance Clean, and Recovery Clean.

Upon completion of a sequence, the Train will return to the OFF state and wait for further

operator selection.

5.7.5 UF Train States

States are a series of steps the train follows to perform various operations, such as pro-

ducing water. A specific state discussed in this document is shown in capital letters,

such as PRODUCTION. The states available to each train are: OFF, PRIME, STANDBY,

PRODUCTION, BACKPULSE, MAINTENANCE CLEAN, and RECOVERY CLEAN. Each of

these states is discussed further in the following sections of the Control Narrative and

detailed sequencing information is available in the OSC.

5.7.5.1 State Interlocks

The train proceeds to the selected state once the resources are available. There are

interlocks preventing more than one train from entering the same state at the same time.

The state interlocks are:

Only one train can be in Prime at a time;

Only one train can be in Backpulse at a time;

Only one train can be in MAINTENANCE CLEAN, RECOVERY CLEAN at a time.

5.7.6 Priming System Control

Each train is provided with an ejector, which uses compressed air to operate and primes

the permeate piping in PRIME and at the beginning of STANDBY, BACKPULSE, MAINTE-

NANCE CLEAN, RECOVERY CLEAN.

The trains ejector compressed air valve opens which also opens the permeate header

isolation valve. During this time, air in the permeate header is pulled up and out through

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the ejector, which also pulls water into the membranes and Permeate pump suction. Any

water that is drawn into the ejector drains out by gravity.

The PRIME state is used to remove air from the suction of the Permeate pump. A train

proceeds to PRIME after the Auto button is pressed in the OFF state. The ejector operates

for typically 60 seconds, a longer duration than what is used for intermittent operation,

and the duration is adjustable at the HMI.

Trains are intermittently primed in STANDBY for an adjustable duration default is 15

seconds. The duration of the Master Ejector Cycle timer is adjustable and the default

time is 8 minutes. The Master Ejector Cycle timer operates as long as there is at least

one train in STANDBY, with a time assigned for each train when the ejector operates,

provided the train is in STANDBY.

The operator can manually initiate PRIME by pressing the Prime button at the HMI.

The Prime button is available in SEMI AUTO and the state OFF.

5.7.7 Standby and the Production Cycle

The UF trains switch between Standby and the Production Cycle based on Start Stop

Train Triggers.

The Start trigger is based on the membrane tank operating level.

5.7.7.1 Standby

The steps for the STANDBY are:

1. Fills the membrane tank to a level above the membranes;

2. While a train is in Standby intermittently the ejector runs based on priming timers;

the membranes are aerated based on the frequency and duration aeration timers. The

train remains in this step until one of the following is active:

– a start trigger;

– maintenance clean request;

– backpulse button is selected;

– Prime button is selected.

5.7.7.2 Production

In Production, the train is producing permeate. The steps for the PRODUCTION are:

(a) Align the valves;

(b) The Permeate/Backpulse starts and runs until the production cycle timer triggers

one of the following: BACKPULSE can be triggered by either the pushbutton or a sched-

uled time.

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5.7.7.3 Backpulse

Treated water is periodically reversed back through the membranes to maintain stable

transmembrane pressures.

The steps for the BACKPULSE are:

1. Stops the permeate/backpulse pump;

2. Align the valves;

3. Starts the permeate/backpulse pump and it runs for the backpulse duration time.

The water is drawn from the backpulse tank and pumped through the membranes into

the membrane tank.

4. Stops the permeate/backpulse pump;

5. After the BACKPULSE is complete and if the membrane tank level is ok for the

Production the train proceeds to PRODUCTION. After the BACKPULSE is complete and if

the membrane tank level is below operating setpoint the train proceeds to STANDBY.

The PLC controls the permeate/backpulse pump speed to backpulse the trains at a

set flow rate per train up to a maximum TMP. A transmitter on the membrane header

is used to calculate the BACKPULSE TMP. This TMP limit provides membrane protection

against over-pressurization. If the TMP is too high, the TMP high trigger is active and the

flow control PID loop output is captured. This value becomes the maximum value for the

output of the flow control PID loop.

When the TMP high trigger becomes active, the PLC gradually reduces the maximum

for the flow PID loop output until the TMP high trigger is not active, (i.e., TMP is less

positive). At the moment when the TMP high trigger becomes inactive, the maximum

value is then gradually increased until the TMP high trigger is active again, or continues

to increase until the maximum value for the flow control PID loop output equals 100%.

This control strategy allows the PLC to vary the pump speed to maximize flow while

avoiding excessive TMP across the membranes.

The Operator can enable or disable the TMP limiting function from the HMI. If the TMP

limiting function is disabled the PID Output wont be limited. It will vary from 0-100

The backpulse duration, production cycle duration, TMP setpoint and flow setpoint for

all UF trains can be set through the HMI. All UF trains in the plant share the backpulse

duration, production cycle duration, TMP setpoint and flow setpoint.

The operator can initiate a BACKPULSE from the HMI for any UF train by pressing the

Backpulse button. This button is disabled if any other train is in BACKPULSE.

Low and High Level switch is located in Back pulse tank to provide the level feedback

to PLC. If the Level switch 20-LS-601 Low is active during backpulse the Process pump

stops and the ZeeWeed continues without any back pulse. Refer CLC for further details.

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 High Level switch controls the opening of the Valve 20-FV-601. 20-FV-601 will open if

the backpulse level high alarm is not active.

5.7.8 Membrane Tanks Level Permeate Flow Control

Flow set point will be entered for the ZeeWeed manually. The supervisor can do this by

setting the production flow rate of the ZeeWeed on the HMI. The system will maintain the

entered production flow rate up to a maximum Trans Membrane Pressure (TMP) or an

operating membrane tank level.

Figure 5.8: Schematic of Recovery Clean

5.7.9 Production Trans Membrane Pressure (TMP)

Trans Membrane Pressure is the differential pressure across the membranes as measured

by the level transmitter in the membrane tank and pressure transmitter on the permeate

header. In PRODUCTION, the process pump draws the water through the membranes

so the pressure in the permeate header is lower than on the outside of the membranes

resulting in a negative value for TMP. During BACKPULSE and backpulsing steps in CIP

the water is flowing in the opposite direction so the pressure in the permeate header is

higher than the outside of the membranes resulting in a positive value for TMP.

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5.7.9.1 TransMembrane Pressure (TMP) Calculation

TMP is calculated by using the equation below. During PRODUCTION the value is nega-

tive, for backpulses and CIP, it is positive.

TMP = Header Pressure + C x (A + B - Membrane Tank Level)

Where:

A is the height of the pressure transmitter above the top of the membranes.

B is the height to the top of membranes in the membrane tank.

C is a conversion factor (water depth to pressure); consult the CLC for the value.

In PRODUCTION, an increased TMP value means a larger pressure differential be-

cause the pressure inside the membranes is lower than outside the membranes. This

corresponds to a lower number as expressed in engineering units. Therefore a high pro-

duction TMP is actually expressed as a Pressure Differential Alarm Low Low.

Figure 5.9: TMP Flow Chart

5.7.9.2 TMP Limiting the Permeate/Backpulse Pump Speed

The PLC continuously calculates the TMP value while in PRODUCTION. If the TMP is too

low, (i.e., too negative) the TMP low trigger is active and the flow control PID loop output

is captured. This value becomes the maximum value for the flow control PID loop output.

When the TMP low trigger becomes active, the PLC gradually reduces the maximum for

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the flow PID loop output until the TMP low trigger is not active, (i.e., TMP is less negative).

At the moment when the TMP low trigger becomes inactive, the maximum value is then

gradually increased until the TMP low trigger is active again, or continues to increase

until the maximum value for the flow control PID loop output equals 100%. This control

strategy allows the PLC to vary the pump speed to maximize flow while avoiding excessive

TMP across the membranes.

The Operator can enable or disable the TMP limiting function from the HMI. If the TMP

limiting function is disabled the PID Output wont be limited. It will vary from 0-100

5.7.10 Start Stop Train Triggers

The trains in operation at any given time varies depends on a Start, Stop train trig-

ger. When Start trigger is active, a train switches from STANDBY to PRODUCTION.

When a Stop train trigger is active, a train switches from PRODUCTION to STANDBY.

The Start,Stop trigger is based on the operating tank level in the membrane tank . The

setpoint values for these triggers are defined in the CLC.

5.7.11 Permeate/Back pulse Pump

There are two Permeate/Backpulse Pump two working one dedicated pump for each train

and one store standby. Each working Pump has a dedicated VFD for Flow Control. There

are two set point entered by the operator one for Permeating and one for Backpulse. The

PLC will start and stop Pumps as necessary based the OSC. The Permeate/Backpulse

pump is interlocked by low level alarm in Membrane Tank during PRODUCTION or low

level alarm in backpulse tank during back pulse.

Discharge of the Permeate/Backpulse pump is equipped with the flow transmitter.

There will be three totalizer derived from the transmitter operator resettable Net totalizer,

daily totalizer and non-resettable totalizer

5.7.12 Sodium Hypochlorite Dosing Permeate Line

Sodium hypochlorite is dosed in the permeate line for organic removal. There are two

Hypo dosing pumps one Working and one Standby. The pumps rotate on the duty cycle

timer. The duty cycle of the pumps can be set on the HMI. The stroke adjustment on the

pumps is manual; it will be set during the commissioning. Further optimization of the

pump stroke can be done during plant operation.

The PLC will request a Hypo dosing pump if one of the UF is in production.

There is low level switch in the dosing tank, to provide feedback to the PLC for alarming

on the HMI. The operator can take necessary action of loading the chemical in the tank.

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The pump running is interlock with the low switch. If the level low alarm is active the

pump will stop.

5.7.13 Membrane Aeration Control

There are three membrane aeration blower two working and one selectable standby

blower. The standby selection of the standby blower i.e. 20-B-200-2 is done at the HMI.

The blower will start stop as required per the OSC.

A low air flow switch is located on the discharge of each blower, for blower protection.

If the switch is active, an alarm occurs and the PLC changes the lead to the next available

blower. If there is no other blower available, a different alarm occurs and the PLC shuts

down the respective train.

There are selection button available on the HMI for selectin the standby blower. Blower

2 can be only be standby for Blower 1 or Blower 3 which is operator selectable on the HMI.

Every time the selection is changed there will be pop up on the HMI for valve confirmation

by the operator.

Post Anoxic tank is also aerated using the membrane blower. This can be achieved by

opening either respective manual valve.

5.7.14 Turbidity

Integrity of the ZeeWeed is monitored with on-line turbidity meter when it is in PRODUC-

TION.

There are three manual valve one for each ZeeWeed permeate line and one for common

header.

Depending upon the valve opening the analyzer will monitor the selected line for mea-

suring.

The turbidity alarm set points are adjustable at the HMI. The time delays before the

alarms become active are not adjustable.

5.7.15 ZeeWeed UF Train Triggers Alarms

5.7.15.1 ZeeWeed Triggers

A trigger is a normal event that can clear an alarm or be one of several points in a

sequence of events.

5.7.15.2 ZeeWeed Alarms

Alarms are used to identify a problem with the system. Depending on the nature of the

problem the alarm may either put the ZeeWeed, to STANDBY, or initiate a callout to notify

the operator that there is a problem. It is understood that the operator will acknowledge

134
the alarm and address the situation. If the problem is not corrected, production quality

and quantity will drop off quickly.

An alarm that is activated by an instrument, pressure transmitter, flow transmitters,

or level instrumentation, typically requires a pump or certain device to be on to generate

the required flow or pressure. Otherwise, the alarm will be ignored if the device to be

protected is off.

All alarms are indicated with a message on the screen. The operator cannot reset the

alarm without the correct password. All alarms and the time they occurred are recorded

on the alarm history screen.

Devices which are being controlled remotely cannot have their status changed by the

PLC.

Consult the CLC for details on specific alarms, the corresponding actions and reset

procedures.

Typical alarms that shutdown a train are listed in the following table.

Table 5.5: Alarms

Alarm Description Possible Causes for Alarm Reset

Alarm
High Flow Alarm - permeate Suction disconnecting from fittings.
reset button
Alarm
Low Flow Alarm - permeate Loss of prime of process pump
reset button
Pressure High-
High Alarm permeate Alarm
Suction disconnecting from fittings.
(measured by pressure reset button
Transmitter)
Transmembrane Fouled Alarm
Pressure Low,Low UF membranes reset button
VFD Alarm
Process pump Fault
Fault reset button
Insufficient Compressed Air Automatic restart with
Compressed
Supply to operate pneumatically sufficient compressed
Air Low pressure
actuated valves air pressure
Automatic restart when
Low Level Alarm Permeate flow rate is higher
the membrane tank is
membrane tank than the Feed flow rate
above a setpoint
Power Automatic restart after
Tripped breaker inside panel
Failure power is restored

5.7.16 ZeeWeed Cleaning

The membranes require cleaning to maintain performance. There are two types of clean-

ing methods; MAINTENANCE CLEANS and RECOVERY CLEANS.

Both MAINTENANCE CLEANS and RECOVERY CLEANS are operator initiated and

should have the operator present during the majority of the clean. The maintenance

cleans are short pulses chemical through the membranes without emptying the mem-

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brane tank. These pulses with chemical are used to prevent biological growth inside the

membranes and reduce the required frequency of recovery cleans.

Recovery Cleans are operator initiated and should have the operator present during

the majority of the clean. The recovery cleans commonly occur only twice a year with

sodium hypochlorite and twice a year with citric acid to remove fouling or scaling of the

membranes.

5.7.16.1 Sodium Hypochlorite Cleaning Equipment

Sodium hypochlorite is used to remove organic contaminants from the membranes. The

PLC will request a sodium hypochlorite pump for MAINTENANCE CLEANS and RECOV-

ERY CLEANS per operator selection, to run in specific steps during the cleaning proce-

dure. The stroke adjustment on the pump

is manual; it will be set during the commissioning. Further optimization of the pump

stroke can be done during plant operation.

Consult the OSC for these steps.

There is low level switch in the dosing tank, to provide feedback to the PLC for alarming

on the HMI. The operator can take necessary action of loading the chemical in the tank.

The pump running is interlock with the low switch. If the level low alarm is active the

pump will stop.

5.7.16.2 Citric Acid Cleaning Equipment

Citric acid is periodically used to remove inorganic contaminants from the membranes.

The PLC will request a citric acid pump for MAINTENANCE CLEANS and RECOVERY

CLEANS per operator selection, to run in specific steps during the cleaning procedure.

The stroke adjustment on the pump is manual; it will be set during the commissioning.

Further optimization of the pump stroke can be done during plant operation.

Consult the OSC for these steps.

There is low level switch in the dosing tank, to provide feedback to the PLC for alarming

on the HMI. The operator can take necessary action of loading the chemical in the tank.

The pump running is interlock with the low switch. If the level low alarm is active the

pump will stop.

Citric Acid tank is provided with a mixer. The mixer will run if the level is not low in

the citric acid tank.

It will stop in case of routine maintenance or failure or operator stops it in manual.

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5.7.16.3 Maintenance Clean

Maintenance Cleans are operator initiated. During a Maintenance Clean there are several

prompts which the operator must address. Consult the OSC and CLC for further details.

As a result it is suggested to have the operator present during the Recovery Clean so that

these prompts can be responded to in a timely manner.

The operator is required to turn the train in SEMI AUTO mode. The cleaning solution

for MAINTENANCE CLEANS is either citric acid or sodium hypochlorite. The operator

selects either M. Clean with Citric Acid button or M. Clean with Sodium Hypochlorite

button to select the cleaning mode and the type of cleaning solution.

The default steps for Maintenance Clean are:

1. Aerate the membrane tank.

2. Close the feed Sluice gate.

3. Initial backpulse with chemical cleaning solution.

4. Relaxation period for all cassettes for a defined duration

5. Repeated Backpulse with chemical cleaning solution. Shorter pulse duration than

step 2.

6. Relaxation period for all cassettes for a defined duration.

7. Repeats step 4 to 5 for pre-set number of iterations.

8. Aerate the membrane tank.

9. Open the feed sluice gate.

10. Proceeds to STANDBY.

5.7.16.4 Recovery Clean Controls

Recovery Cleans are operator initiated. During a Recovery Clean there are several prompts

which the operator must address. Consult the OSC and CLC for further details. As a re-

sult it is suggested to have the operator present during the Recovery Clean so that these

prompts can be responded to in a timely manner.

The operator is required to turn the train in SEMI AUTO mode. The cleaning solution

for RECOVERY CLEANS is either citric acid or sodium hypochlorite. The operator selects

either R. Clean with Citric Acid button or R. Clean with Sodium Hypochlorite button to

select the cleaning mode and the type of cleaning solution.

The default steps for Recovery Clean are:

1. Aerates the membrane tank;

2. Close the feed Valves to the membrane tank and drain membrane tank to Aeration

tank by starting of the RAS pump.

3. Drain the membrane tank to aeration tank using RAS Pump.

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 4. Backpulses the membrane tank for upto cleaning level then proceeds to next step

or until the tank is at a defined level then proceeds to step 6.

5. Relaxation period for all cassettes for a defined duration and then proceed to step

4.

6. Aerates the membrane tank for a defined duration;

7. Drain the membrane tank by starting RAS pump. After the membrane tank is

drained, stop the RAS pump;

8. Operator supervises the tank cleaning condition if there any debris and residue is

cleaned by service water.

9. Initial Backpulse upto membrane tank cleaning level

10. Start respective chemical transfer pump for the define time duration.

11. Final, extended relaxation period with intermittent aeration;

12. Start the RAS pump and transfer the cleaning solution to Aeration Tank.

13. Open Membrane inlet valve and Fills the membrane tank to defined level with feed;

14. Aerates the membrane tank;

15. Proceeds to OFF.

Consult the OSC and CLC for specific details on the steps and setpoints used in this

mode.

5.7.17 Password Access Privileges

The entire plant is controlled from the PLC through a HMI. The ability to silence the horn

and acknowledge alarms does not require a password, but alarms cannot be reset.

To gain access to make changes on the HMI, the operator is required to enter the

correct password. A screensaver blanks the screen after a set amount of time of inactiv-

ity. The screen is reactivated by a single touch. Reactivation cannot select a device or

operating mode.

In order to access the control screens, the individual must enter a correct password

then press Enter. There are three levels of password protection; Operator, Supervisor,

ADMIN. The operator password is factory set. The supervisor password can be modi-

fied from the HMI. There is no limit to the number of times another password can be

attempted. The password must be re-entered after a set amount of time of inactivity.

5.7.18 Screen Color-Coding

The color-coded train-status indicates whether the device or train is either running auto-

matically, in STANDBY, off, manually overridden, etc.

The HMI uses the color-coding shown below.

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 Table 5.6: HMI Colour Code

Color Valve Pump

Green Open On
Red Closed Off
Yellow Failure Failure

5.7.19 Power Interruption / Power Up

When a loss of power occurs, the train will immediately turns off all equipment and

proceed to Start-up step 1 after power returns, the plant powers up and train will start-

up automatically as described in the CLC. The CLC also specifies the mode that a train

will proceed to after power is restored.

5.8 Specifications of Membranes

The hollow fiber membranes of Zeeweed500 shall confirm to following specifications:

(i) The membranes should be of Reinforced, Ultrafiltration, Hollow fiber type and the

average pore size of the membrane shall not be more than 0.04 micron.

(ii) The membrane filtration mode should be Out to In with Backwashing facility and the

material used for the manufacturing of the membrane fibers shall be Polyvinylidene

Fluoride (PVDF).

(iii) The design flux should not exceed 30 LMH(Litres/Sqm/Hour).

(iv) Clean-In-Place System: The membranes shall be cleaned in-place without removal

from the membrane tank. The system shall consist of a chemical feed pump and

storage tank and include all interior piping, valves, and in-tank piping and supports.

(v) Back pulse flux shall be ≥ 34LM H.Chlorineexposureshallbe500, 000ppm/hrs

The minimum membrane warranty for life of membranes should be for 5 years where

the membrane manufacturer should offer minimum 2 years full replacement warranty

and additional 3 years on pro-rata basis which shall be reckoned from the date of com-

missioning of the plant.

5.9 Manual Coarse Screen 16mm and Manual Fine Screen

6mm

(vi)• The screens shall be rectangular in shape.

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 • The screens shall be fabricated out of Stainless steel 304 grade material and fixing

bolts shall be of stainless steel.

• The rectangular screens shall be made of SS flats 10 mm thick and 50 mm wide in

section (minimum dimensions).

• The screens shall be rigidly fixed to the frame. The screenings shall be first collected

on a perforated tray or slab.

• All the bypass screens shall be provided with 2 sets of cleaning rakes.

• Four nos. portable containers of 0.50 cum capacity shall be provided with suitable

hooks for lifting by chain pulley block.

5.10 Sludge Handling

As Sludge generated from different process units various depending upon the process

adopted, it is advised to provide sludge handling units and equipment like Sludge thick-

eners, Digesters, centrifuge, Vacuum filter press, and other ancillary units which is suit-

able for the process and which is sustainable from Operation Maintenance point of view.

The units and equipment shall be selected accordingly which occupies less space, power,

chemicals and maintenance.

5.11 Air blowers for Oxygenation

The blowers shall be provided for providing adequate oxygen into the reactor tank for

aeration. The blowers shall be capable of developing the required total pressure at the

rated capacity for continuous operation. The blowers shall be positive displacement rotary

twin lobe type.

Air Blowers

(a) Compressor blowers shall be of the positive displacement type, each provided with

inlet filter and silencer, pressure reducing valve, pressure gauges, pressure relief valve,

drain, air flow indicator and acoustic bend or silencer in the delivery branch. Bearing

housings and gear boxes shall be separated from the blower housings by air spaces. The

140
blowers shall be housed in a separate sound proof room to reduce the noise level or inside

acoustic enclosure. The noise level shall not exceed 85 dBA at 3 meter from the Blower.

(b) The bearings shall be generously designed to give long operational life. Bearings at the

drive end may be oil or grease lubricated. The gears and bearings at the non-drive end

shall be oil lubricated. The delivery velocity not exceeding 18 m/s and each blower shall

be provided with following components but not limited to:

• Common base frame for Blower Motor

• inlet silencer and filter

• Discharge Silencer non-return valve in delivery branch

• Butterfly valves in both inlet and delivery branches

• pressure relief valve or excess pressure safety device

• Bellows type couplings on inlet and delivery branches.

• Acoustics Enclosure

• Motor-Blower Direct coupling.

• Isolating valves, Pressure reducing valves Pressure gauges

(c) The interconnecting pipe work shall be flanged to GI pipes of medium grade. A drain

cock shall be provided at the lowest point in the each delivery pipe work along with reflux

valve. Individual stop valves and safety valves shall be provided for each unit.

(d) Blowers shall be driven by squirrel cage motors through a direct coupling. Blowers

shall not run above 1200 rpm.

(e) Each delivery branch shall include a drain at the lowest part and a reflux valve.

(f) The blower equipment specified herein is standard equipment for blowers handling

ambient air for use in aeration tank diffusers.

5.11.1 General Design Requirements

(i) The air blowers shall be of such design as to achieve energy efficient operation con-

tinuously over the range of design airflow rates at the discharge pressure that shall

remain practically constant.

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 (ii) Blower shall be fitted with a variable speed motor and be capable of operating be-

tween 80% and 110% of its nominal peak airflow demand. VFD not required for

mixing blower and membrane blower.

(iii) The discharge pressure shall be calculated by the Contractor dependent on the final

design layout of the aeration system and of the delivery manifold.

(iv) The blowers shall also be capable of supplying the design mass flow rate at maximum

ambient inlet temperature of 50◦ C.

(v) Each of the blowers shall be capable of operating without surge in parallel with the

other duty blower at the maximum mass flow against designed maximum gauge

pressure at the outlet pipe.

(vi) Performance curves for the blower system shall be submitted. Standard certified

factory test sheets showing the results of each test shall be supplied in triplicate to

the Executive Engineer along with delivery of the blowers. The blower unit shall be

capable to operate at maximum duty for continuous operation. The blower motor

shall not exceed a maximum speed of 1500 rpm and the blower shall not exceed the

manufacturers recommended maximum speed.

5.11.2 Blower General Arrangement

The blower arrangement shall have the following features:

(a) The blowers shall be positive displacement type

(b) Each blower shall be fitted with an acoustic enclosure;

(c) The arrangement shall be such that all blowers are accessible for operation and main-

tenance.

(d) The blowers shall be neatly arranged and housed in acoustic enclosure.

(e) The inlet air to the blower house shall be filtered to suit the blowers and aeration dif-

fusers selected;

(f) A blower removal system shall be provided so that any one blower can be removed as

a single unit and loaded onto a truck.

5.11.3 Ancillary Equipment for Blowers

The blowers shall be provided with the usual ancillary equipment for aeration duty, in-

cluding:

(a) Acoustic enclosure with fan cooling Discharge pressure switch, if required and

recommended by the blower manufacturer for the given duty conditions.

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(b) Discharge pressure relief valve

(c) Discharge check valve

(d) Discharge isolation valves

(e) Discharge silencer, designed to minimize noise propagation along the pipe work

(f) Vacuum switch, pressure switch, oil level indicator and any other monitoring device

shall be mounted outside the acoustic enclosure

(g) Inlet and outlet pressure gauges shall be mounted outside the acoustic enclosure

(h) Vibration absorbing mounting pads.

(i) all required support structures.

5.11.4 Blower Noise limits

The blowers supplied under this Contract shall be quiet in operation. Under any loading

condition from no load to full rated, the blower supplied shall comply with the noise

requirements.

5.11.5 Materials of Construction

The materials of construction for the blowers shall be at least equal in quality to the

following:

Table 5.7: Blowers: Materials of Construction

Casing C I conforming to IS: 210 Gr FG 260

Rotor Alloy steel
Shaft Carbon steel C40/EN 24/19
Timing gear Cast alloy steel
Pulley and gear side plates and cover CI conforming to IS 210 Gr FG 260
Impeller Manufacturers std
Base plate Mild Steel
Nuts and Bolts Stainless Steel

5.11.6 Testing

Table 5.8: Blowers: Tests

S.No Tests Specifications

1 Hydrostatic tests Twice the maximum working pressure
2 Performance test As per BS : 1571
3 Strip test Clearances with tolerance limit
4 Mechanical balancing ISO 1940 Gr. 6.3 or better
5 Visual Inspection Before painting

5.11.7 Filters and Silencers

(a) Filters shall be used to remove dust, etc. contained in the suction air. For this pur-

pose, a filter shall be mounted directly to the suction silencer of each blower. The filter

element shall be non-textile cloth or equivalent, and the element passage speed shall be

143
2 m/s max. The Contractor shall indicate the useful life period for the diffuser.

(b) The blowers shall receive filtered air individual replaceable filter elements suitable for

the intended duty.

(c) The filter elements shall be housed in an airtight housing which shall allow easy re-

placement of the filter elements. Replacement of elements shall be possible without the

use of tools.

(d) If the filter/silencer elements supplied are located out of doors a weatherproof cover

shall protect the filter element from rain.

(e) The filter unit shall be fitted with suitable vacuum gauges to indicate the suction pres-

sure into each blower. The gauges shall be industrial Bourdon of Schaffer type gauges

with a nominal diameter of 150 mm. The scale shall be suitably selected and shall in-

clude a red line to indicate the point at which the filter elements require renewal.

(f) Each blower intake shall be fitted with a differential pressure switch, which shall indi-

cate an alarm signal in the event of excessive pressure drop in the blower intake.

5.11.8 Flexible Connections

(a) The blower discharge shall be fitted with an approved flexible sleeve with fixing clamps

and a flanged outlet spigot for connection to site pipe work. If the blower inlet is via a

common plenum the inlet pipe shall be also fitted with a flexible connection.

(b) Flanges shall be drilled to Table D and shall comply with the required standard.

Sleeves shall be manufactured from an approved non-metallic material suitable for the

duty and location in which the blowers are to be installed.

5.11.9 Pressure Relief Valve

(a) The pressure relief valve shall be sized and adjusted to allow the full flow of the blower

to be discharged in the event of a blockage or valve closure in the downstream pipeline

and without overloading the drive motor.

(b) Each blower shall be fitted with a suitable pressure switch, which shall shut down the

blower in the event of excessive discharge pressure. The pressure setting shall be lower

than the set pressure of the pressure relief valves.

(c) The pressure relief valve shall be installed at a height above 2m from the floor and

away from blower suction point. The pressure relief valve shall be fitted with a silencer.

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5.11.10 Non-Return Valve

A non-return valve shall be installed on the discharge pipe work of each blower, upstream

of the blower isolation valve.

5.11.11 Isolating Valves

Isolating valves shall be installed on the delivery pipe work of the blowers; such that each

blower and all associated pipe work and valves upstream of the common distribution

manifold can be dismantled without disruption to the normal operation of the plant.

5.11.12 Temperature Measurement

Temperature sensor complete with gauge of an approved type shall be supplied for each

main distribution pipe work and for the blower room.

5.11.13 Piping Vibration

If the blower type selected produces a discharge flow with a pulsating characteristic, flow

pulsation dampers shall be installed on the blower intake and discharge, as required, to

eliminate excessive noise or vibration from this source.

5.11.14 Air Compressors

Compressor system shall comprise of compressors, after-coolers and air/dryers, duty/standby

air receivers together with control equipment, oil eliminating filters, flow regulators and

oil mist lubricators as required.

Compressor sets with at least 1 standby shall be provided complete with the following:

• Common base frame for Compressor Motor

• Single stage air-cooled unit

• Isolating valves

• Air filter and silencer

• Pressure relief valve or excess pressure safety device

• Pressure reducing valves

• Pressure gauges

• Off loading piston

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 • Automatic changeover (failure of duty unit)

• drain pipes

• Isolating valve

• V-Belt drive arrangement with Belt Guard

• Stoppers

• Air-receivers

• Others necessary appurtenances

(c) Compressors shall be arranged for automatic changeover on failure of the duty unit.

Failure of the duty unit shall initiate an alarm. Control equipment shall include au-

tomatic unloading valves, pressure switches for duty standby and alarm, and lockable

changeover switches.

(d) 1 Duty 1 Standby after coolers shall be provided. Water- cooled or air blast types

will be considered. Air receivers shall be designed and fabricated in accordance with rele-

vant approved standards. They shall be mounted vertically on steel feet so that sufficient

space is allowed for each access to the whole outside surface. Receivers shall be provided

with drain cocks piped to drain pressure gauges and relief and check valves.

(e) Supply of all necessary electrical components, devices, equipment, control panels, etc.

together with cabling, earthing provisions, etc. shall be the responsibility of the Contrac-

tor.

(f) Interconnecting pipe work shall be arranged to avoid low points, which may trap water.

(g) Unavoidable low points shall be provided with drain cocks piped to waste.

5.12 Diffused Air Aeration System

This section of the specification sets out the minimum requirements for the design and

selection of diffused air aeration system equipment.

The pipe works, instrumentation and the diffusers shall be correctly sized to deliver

the required quantity of air at the available pressure to meet all operating conditions. The

pipe work to the tank shall be sized for 125% of the required oxygen transfer capacity to

cater for the higher loading.

The aeration headers shall be designed for removal/replacement from/to the reactor with-

out taking the reactor off-line or dewatering the reactor. The Contractor shall be required

to demonstrate removal and replacement of the headers with the reactor on-line.

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5.12.1 Aeration diffusers

(a) Air diffuser system consist of tube type porous membrane of Acid resistant silicon

based rubber with diameter not exceeding 65 mm diameter size, Single piece injection

molded PP support tube, SS clamps.

(b) Entire diffuser has to be manufactured, assembled, tested in factory premises no site

work is permitted.

(c) Flat surfaces facing upwards as membrane surfaces shall not be accepted.

(d) The aeration tank is used to remove oxygen consuming organic matter from the ef-

fluent by biological treatment. Diffused aeration is used for air supply. The bubbles

produced from the diffuser are of extremely small size between 0.5 0.8 mm, thus the

total surface area that interacts is large and the contact time of bubble is large due to

slow rise of bubbles. The system is thus extremely power efficient in terms of oxygen

transfer efficiency. The flow of fine bubble of 0.8 mm in size provides a gentle mixing,

which prevents flock shear.

(e) Fine bubble diffuser consists of a porous membrane made of Acid resistant silicon

based rubber. Each diffuser is fully supported over the length and circumference on sin-

gle piece injection molded polypropylene (PP) tube with a RIDGE on the top to hold the

membrane in position against the velocity generated in the waste water.

(f) No drilled holes on the support tube are permitted and only channel type of arrange-

ment for entry of air into membrane is desired. Air opening on the membrane should be

0.8 - 1 mm with staggered perforation.

(g) The diffuser will be retained in place by two clamps. It is fitted to the pipe lateral by

CLIPIN arrangement. The laterals are connected to a pipe header. The wetted parts of the

system a re made of non-corrosive material specifically SS 304. During power shutdown

at the sewage treatment plant the membrane will contract and lose around the PP sup-

port pipe and means shall be provided to prevent any back flow.

(h) Each diffuser shall consist of the following:

• Minimum 65 mm OD PP injection moulded support pipe.

• Porous membrane made of silicon based rubber lateral.

• RCC support block with SS 304 clamping.

• Flexible Hose pipe (drop pipe for each diffuser assembly)

• PP Ropes for Lifting and guide position.

• Hose clamp

• Pipe connector

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 • GI barrel nipple with connector for connection with pipe.

(i) Complete diffuser shall be assembled at original factory level and site fabrication of

diffuser is not acceptable.

(j) All hardware accessories including clamps, fasteners, fan-hooks, eye bolts, should be

of SS 304 materials only.

5.12.2 Air Supply pipe work

General Design Criteria

(a) Many factors need to be incorporated in the design of the air distribution pipe work

to minimize the potential of noise problems occurring. Factors to be considered in the

design of the air pipe work to minimize noise level shall include:

• The diameter of the pipe work, to keep velocities low.

• The connection of the blower discharge pipes to the manifold should be ”wye”, not

at right angles.

• No blind flange at the end of the manifold.

• The manifold shall be designed to ensure air travels in one direction.

• The air pipe work shall be designed to minimize changes of direction and use large

radius bends. Flexible connections shall be provided between the diffuser assembly

nits and the main air supply pipe work to allow for any differential movements.

• Expansion and contraction shall be fully allowed for in the design and installation

of the air distribution pipe work.

• Rain taps shall be provided on the air pipe work to allow draining of moisture.

• The pipe work and the support brackets shall be made of SS 304 grade of stainless

steel.

• Pipe work shall have inbuilt flexibility such as packer flanges for reasonable con-

struction tolerances on the structures to which it is attached.

(b) Pipe shall be designed to ensure the efficient operation of the aeration system and

compliance with the noise limitations. All valves in the air delivery system shall be cor-

rectly selected for the duty. Calculations of Cv (head loss coefficient) values for the range

of flows and pressure losses across each valve should be prepared to ensure that each

valve has adequate range of control for the duty.

(c) However the air piping submerged in sewage has to be in SS304 conforming to I.S

148
specification. One spare drop pipe with diffuser elements shall be supplied by the Con-

tractor. This will be used to replace the choked diffusers drop pipe or on preventive basis

on rotation. The choked one will be attended to and used as spare drop pipe.

5.12.3 Air Supply Headers

The air supply headers run from the main air distribution pipe work to the down comers.

Pipe work shall have inbuilt flexibility such as packer flanges for future modifications

and to allow for reasonable construction tolerances on the structures to which it is at-

tached. An isolation valve for each main air supply pipe shall be installed at the point of

connection to the main distribution pipe work. The design of the main air supply header

shall incorporate all components necessary to enable the easy connection of the main

distribution pipe work to the main air supply header.

5.12.4 Blower Discharge Pipe work

The discharge pipe work from each blower shall be connected to a common manifold.

Flexible connections shall be provided between the blower assembly units and the dis-

charge pipe work to allow for any differential movements. The design of the manifold pipe

work shall incorporate all components necessary to enable the easy connection to the

main distribution pipe work.

5.12.5 Air Flow Measurement

(a) The amount of air being supplied to each air supply header shall be measured by the

installation of Flow measuring devices. The flow measuring devices shall be suitable for

the intended application. The sensor assembly shall be supplied with suitable fittings

which shall enable easy removal during maintenance. The accuracy of the flow meter

shall be within 5% of the minimum design flow rate. The installation shall provide ade-

quate length of straight pipe upstream and downstream of the flow meter to ensure the

accuracy of the meter is attained.

(b) Pressure and temperature sensors, shall be provided to measure the pressure and

temperature of the air in the pipe, upstream of the flow measurement device.

(c) Pressure and temperature compensation measurements shall be provided for volumet-

ric correction if the control air is based on airflow rate.

5.12.6 Pressure Gauges

Pressure gauges of an approved type shall be installed on each main distribution pipe

work and main header.

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5.12.7 Leak and Pattern Testing of Diffuser System

(a) The diffuser system shall be visually tested by filling the tanks with clean water to

level 1m above the top of the diffuser assembly units. Air shall then be passed through

the diffusers and a visual assessment of the diffuse operation shall be made.

(b) The visual assessment shall include the following minimum inspection:

• Checking all diffusers for installation level within the required tolerances

• Checking that all joints along the diffuser headers have been made airtight

• Checking the required air distribution of diffused air is achieved across the entire

tank floor.

5.13 Sluice Gate

5.13.1 Design Requirements and Construction Features

(a) The construction of sluice gates shall be in accordance with the specification and

generally as per AWWA C 560-00 /IS: 13349-1992 or other applicable standard. All

sluice gates shall be of the rising spindle type.

(b) The sluice gates shall be capable of performing the duties set in this Specification

without undue wear or deterioration. They shall be constructed so that maintenance is

kept to a minimum. All parts of sluice gate, including lifting mechanism components

shall be designed for the heads required with a minimum safety factor of five.

5.13.2 Frame

The frame shall be of the flange back type and shall be machined on the rear face to bolt

directly to the machined face of the wall thimble.

5.13.3 Guide

Guide shall be bolted to the frame or cast integrally with it and shall be machined on all

bearing and contact faces.

The length of guide shall be such that it should support the gate upon the horizontal line

of stem nut pocket.

Arrangement shall be made to prevent lateral movement of bolted on guides. They shall

be capable of taking the entire thrust produced by water pressure and wedging action.

Wedges or wedge facings shall be attached securely to the guides at points where, in the

closed position, they will make full contact with the wedging surfaces on the slides.

Seating Faces : Seating faces shall be made of full width, solid section; dove-tail strips of

stainless steel. They shall be secured firmly by means of counter sunk fixings in finished

150
dove-tail grooves in the frame and slide faces in such a way as to ensure that they will

remain permanently in place, free from distortion and loosening during the life of the

sluice gates.

The faces shall be of ample section and finished smooth.

5.13.4 Wedging Devices

Sluice gates shall be equipped with adjustable side, top and bottom wedging devices as

required providing contact between the slide and frame facing when the gate is in closed

position. All faces shall be machined accurately to give maximum contact and wedging

action. Wedges shall be fully adjustable with suitable adjusting screws and lock nuts and

so designed that they will remain in the fixed position after adjustment.

5.13.5 Lifting Mechanism

(a) Sluice gate shall be operated through suitable lifting mechanism which shall incorpo-

rate suitable gearing if required.

(b) Lifting mechanism shall be suitable for operation by one man under all conditions.

(c) Lifting mechanism shall incorporate a strong locking device suitable for use with a

padlock or padlock and chain.

(d) The manual contractor shall be of the hand wheel crank operated type and shall have

a lift nut threaded to fit the operating stem. Crank shall be removable. Ball or roller

thrust bearings shall be provide above and below the flange on the lift nut to take the

load developed in opening and closing the gate with a torque of 14kg-m on the crank.

Fittings shall be provided to lubricate gears and bearing.

(e) The design of the lift mechanism of the hand operated gates shall be such that the

slide can be operated with a torque of not more than 7 kg-m on the contractor after the

slide is unseated from wedges based on the operating head. The maximum crank radius

shall be 380mm.

(f) All gears and bearings shall be enclosed in cast iron housing with labyrinth seals. The

lifting mechanism shall be with a cast iron pedestal, machined and drilled to receive the

gear housing and suitable for bolting to the operating floor. The gates shall close with

clockwise rotation of the crank. The direction of rotation to close the gates shall be indi-

cated on the lift mechanism.

(g) A suitable means shall be provided for lubricating the stem threads directly adjacent

to the lift nut. An inspection cover shall be provided to access the lift nut and gearing.

(h) Stem shall be provided with a GI pipe cover shall be fixed to the head stock.

(i) Lift mechanism shall be provided with a suitable position indicator to show the position

151
of the gate at all times.

5.13.6 Lifting Lugs

Lifting lugs shall be provided for all gates.

5.13.7 Flush Bottom Seal

(a) When sluice gates are provided with flush bottom seals, the wedging device and facing

along the bottom edge of the slide and frame shall be omitted.

(b) A solid square cornered, resilient rubber seal shall be provided on the bottom facing

of slide. The seal shall be securely fastened to the bottom face of the slide by a retainer

bar and corrosion resistant metal fasteners. The top surface of the bottom facing of

frame shall be flush with invert of the gate opening. Bottom facing of the slide shall be

accurately machined to make contact with the seal when the slide is closed.

(c) Suitable arrangement shall be made for on all the sluice gates or actuators such that

the portable electric actuator is capable of operating all sizes of sluice gates.

(d) 1 No. of Portable type of electric actuator for closing and opening of sluice gates

shall be provided at each STP, so that the closing and opening operation time shall be

maximum of 10 minutes

(e) Suitable arrangement shall be made on all the sluice gates or actuators such that the

actuator is capable of operating all sizes of sluice gate, under this contract.

(f) Pipe hood shall be provided on the top of head stock to protect the spindle from damage,

dirt, dust, water etc. The hood shall be made of transparent fracture resistant poly

carbonate material. The hood shall have vent holes to prevent condensation.

(g) The material of construction of sluice Gate shall be as follows:

Table 5.9: Material of Sluice Gate

Component Material
Wall Thimble Cast Iron : IS 210 Gr. FG 200
Frame and Slide Cast Iron : IS 210 Gr. FG 200
Stainless Steel: ASTM Countersunk fixing
Seating faces
A276 type 316
Wedge Stainless Steel : ASTM A743 CF8M or SS316
Stem Stainless Steel: ASTM extension A276 type 316
Stem guide bracket Cast Iron : IS 210 Gr. FG 200
Stem nut Stainless Steel : ASTM A743 CF8M
Stem Coupling Stainless Steel : ASTM A276 type 316
Fasteners, anchor Stainless Steel : ASTM A276 type 316
Lifting mechanism,
Cast Iron : IS 210 Grade FG 200
Pedestal gear house cover and stem guide
Bronze : ASTM B 148
Lift nut
(CA952, CA954 or CA958)
Headstock Body Cast Iron : IS 210 Gr. FG 200

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5.14 Open channel Gates

The manufacture of open channel gates shall be in accordance with the manufacturers

standard.

All open channel gates shall be of the rising spindle type manually operated.

Open channel gates shall be tested as per manufacturers standard.

The open channel gates for pumping stations shall be CI sluice gates. All other gates

shall be aluminum gates.

The material of construction shall be as follows.

Table 5.10: Material of construction-Open channel Gates

Components Material Specification Grades

Gate frame, shutter, Headstock,
Flush bottom seal support bar, Cast Iron IS: 210 1993 FG: 260
Stop nut.
Sealing faces/ Seat facings Stainless Steel ASTM A276 AISI: 304, 316
Natural Rubber EPDM
Resilient rubber seal Rubber , Neoprene
rubber
Seal retainer bar Stainless Steel ASTM A276 AISI: 304, 316
Stem / Spindle Stainless Steel ASTM A276 AISI: 304, 316
Operating Nut/ Stem Nut Leaded Tin Bronze IS: 318 1981 LTB 1, LTB 2
Fasteners Stainless Steel ASTM A276 AISI: 304,
Anchor Bolts Stainless Steel ASTM A276 AISI: 304, 316
Yoke Mild Steel IS: 2062 1992 Grade A

5.15 Hand Operated Hoists and Trolleys

(a) Manual hoists shall be complete with hand-chain, trolley, pulley block, hook, hand

and load chains, brake and other accessories. They shall comply with the latest applicable

standards, regulations and safety codes in the locality where equipment will be installed.

(b) Each hoist shall be operated on a monorail (I-Beam). The factor of safety shall not

be less than 5. The load chain may be heat-treated to give ductility, toughness and

conforming to I.S. 3109/B.S. 1663/B.S. 3114. The load wheel is to be made from heavy

duty malleable castings. The hand chain is to Conform with B.S. 6405:1984 and hand

chain wheel may be made from pressed sheet steel with roller type guarding. Gears shall

be cut from solid cast or forged steel blanks or shall be stress relieved welded steel

construction. Pinions shall be of forged carbon or heat treated alloy steel. Strength,

Quality of Steel, heat treatment, face, pitch of teeth and design shall confirm to BS-

436, BS-545 and BS-721. Spur and helical gears must comply with B.S. 436 and worm

with B.S. 721. Bearing must be ball and roller type conforming to I.S. 2513/B.S.2525-

32:1954. Proper lubricating arrangements are to be provided for bearings and pinions.

The brake for the lifting gear shall be automatic and always in action.

153
(c) The proof testing of each chain pulley block is to be carried out as per latest applicable

standards. The safe working load is to be marked in such way that is clearly visible from

the operating level.

5.16 Pipe Work

5.17 Piping

The following table lists the types of process piping supplied . These specifications do not

include miscellaneous small bore tubing for instrument air, seal water lines, and so on.

Table 5.11: Piping

Permeate Header Piping in the Process Tanks uPVC PN 10

All Blower Discharge piping GI Pipes Class-B(Medium)
Blower line vertical drop pipes into all tanks SS 316
Diffuser Grid piping in all tanks uPVC PN 10
Chemical Feed System Piping CPVC, PE Tubing
Permeate line from membrane tank to Chlorine Contact SS316
Tank (a portion of the line is buried)
All RAS pipes Carbon Steel

5.17.1 uPVC

• Piping: Conforming to BIS/ASTM D1785

• Fittings: Conforming to BIS/ASTM D2467

• Flanges: Slip-ring (Van-Stone) Type

5.17.2 CPVC

• Piping: Conforming to BIS/ASTM F441

• Fittings: Injection moulded type

• Flanges: Slip-ring (Van-Stone) Type

5.17.3 Stainless Steel

• Rolled Pipe: Conforming to ASTM A778 for pipe >12“ ASTM A312 for <12“, ANSI

B36.19

• Cast Fittings: Conforming to ASTM A778, ANSI B36.19 ANSI B16.9

• Fabricated Pipe: From sheet conforming to ASTM A240

• Fabricated Fittings: From sheet conforming to ASTM A240

• Fitting dimensions conform to ANSI B16.9

154
 • Flanges: Welded or Slip-ring (Van-Stone) with drilling conforming to ANSI B16.9

The pipe works for the plant involves procuring, supply, laying and jointing of suitable

size electrically welded steel, stainless steel SS 304 grade, cast iron, ductile iron, uPVC,

RCC pipes along with matching specials etc. as required. All yard piping inside the plant

shall be cast iron or ductile iron. All pipe work and fittings shall be a class rating in

excess of the maximum pressure attained in service including any surge pressure. The

pipe work installation shall be so arranged to offer ease of dismantling and removal of

pumps or major items of equipment. CI/DI Piping above ground level shall be only flange

jointed and adequately provided with structural/ masonry supports.

Stainless steel AISI 304 expansion bellows which can take radial and axial misalign-

ment of minimum one percent of the valve nominal size and tie bolts shall be provided.

All pipe work shall be adequately supported with purpose-made fittings. When passing

through walls, pipe work shall incorporate a puddle flange. Flange adapters and union

shall be fitted in pipe work runs, wherever necessary, to permit the simple disconnection

of flanges, valves and equipment.

The Contractor shall be responsible for ensuring that the internal surfaces of all pipe

work are thoroughly cleaned before and during erection and commissioning. Cleaning

shall include removal of dirt, rust, scale and welding slag due to site welding. Before

dispatch from manufacturers works, the ends of the pipe, branch pipes etc., shall be

suitably removed until immediately prior to connections adjacent pipes, valves or pumps.

All bore pipes shall be blown through with compressed air before connection is made

to instruments and other equipment. No point of passage of pipes through floors or walls

shall be used as a point of support, except with the approval of IITH . All underground-

buried mild steel piping unless found otherwise necessary, shall be protected by the

application of hot coal tar enamel and fiberglass wrapping. The coating shall consist of

one coal‘ tar primer one coat, wrapping of fiber glass one more coat of enamel and the

final wrap of enamel impregnated fiber glass.

All water supply plumbing pipelines shall be of UPVC Class-3 thick-walled inside the

premises in concealed piping. They shall be GI class B in external locations and either

anchored externally with SS AISI fasteners or appropriately buried below the ground with

a sand cushion of 20 cm all round. All sanitary piping shall be of UPVC Type-B suitably

buried below the ground with a sand cushion of 20 cm all round. Changes in direction on

155
the ground shall be achieved with inspection chambers of 45 cm x 45 cm and heavy-duty

CI chamber covers.

5.17.4 Galvanized Iron pipe

The procurement, supplying, laying, jointing and testing at works and site of Galvanized

Iron (G.I.) pipes and fittings shall be in accordance with IS 1239 (Part I and II) and its

latest revisions. The general requirements relating to the supply of mild steel tubes shall

conform to IS 1387. The sulphur and phosphorus requirements in steel shall not exceed

0.05 percent each. The galvanizing of the pipes shall be as specified in IS 4736. The zinc

coating shall be uniform adherent, reasonably smooth and free from imperfections.

The pipes shall be galvanized before screwing. All screwed pipes and sockets shall

have pipe threads conforming to the requirements of IS 554. Gauging in accordance

with IS 8999 shall be considered as an adequate test for conformity of threads of IS 554.

Screwed tubes shall have taper threads while the sockets shall have parallel threads.

The specifications for G.I. pipes shall conform to relevant BIS code. The tolerances on

the length of pipes shall follow clause 11.0 of IS 1239 (Part I). The fittings for G.I. pipes

shall be of mild steel tubular or wrought steel fittings conforming to I.S. 1239 (Part II).

The laying of G.I. pipes and fittings shall follow the relevant I S code of practice. These

pipes shall be used for drinking water supply for the office and laboratory buildings. The

pipes shall be painted with two coats of anti-corrosive bitumastic paint.

The G.I. pipes and fittings shall be tested at site, after they are laid and jointed as per

standard specifications.

5.17.5 Unplasticized Poly Vinyl Chloride (uPVC) Pipes

The latest versions of Indian standards and codes of practice shall be adhered to for the

design, manufacturing, inspection, factory testing, packing, handling, and transporta-

tion, laying, and jointing of the uPVC pipes. The rubber rings shall be vulcanized from

Ethylene Propylene (EPDM) confirming to IS 5382. The uPVC pipes shall be of minimum

6 kg / sqcm and as per IS 4985 and the pipes for plumbing works in office building shall

be SWR (Type B) as per IS 13592, with electrometric sealing rubber ring joints. The uPVC

fittings shall be fabricated from Class 4 uPVC as per IS 4985.

156
 Marking on Pipe:

Each pipe shall be clearly marked as indicated below:

• Manufacturers name and trade mark

• Outside diameter (OD) in mm

• Class of pipe and pressure rating

• Month and year of manufacturing

• Length of pipe

• Marking of insert depth of spigot

Marking on rubber ring:

Each sealing ring shall be permanently marked with

• The manufacturers name or trade mark.

• The month and year of manufacture

• Diameter of pipe for which the ring is suitable.

• Type of rubber material

5.17.6 Ductile Iron Pipes

The DI pipes shall be centrifugally cast (spun) for Water and Sewage and confirming to IS

8329-2000. The pipes used shall be both gasket joints and flanged joints. The minimum

class of pipe to be used shall be class K-9 conforming to IS 8329. In general, pipes inside

the buildings and below the structures shall be jointed as double-flanged pipes and those

outside the building can be either EPDM gasket in accordance with IS 5382 and manu-

factured by the pipe manufacturer only.

The pipes shall be supplied in standard lengths of 5.5m and 6.00m length with suit-

ably rounded chamfered ends. Any change in the stipulated lengths will be approved

by the Enginneer-in-Charge or his representative. The flanged joints shall confirm to the

Clause 6.2 of IS 8329. The pipe supply will also include one rubber gasket for each flange.

Markings

All pipes shall be marked as per clause 18 of IS 8329 and shown as below:

157
 – Manufacturer name / stamp

– Nominal diameter

– Class reference

– A white ring line showing length of insertion at spigot end.

Specials for DI Pipes

The DI specials shall be manufactured and tested in accordance with IS 9523 . The

mechanical test and hydro static test shall confirm to clause 9 and clause 10 respectively

of IS 9523. The tolerances on dimensions shall be as per IS 9523. The manufacturer of

the pipes shall supply the fittings.

Supply

All the DI fittings shall be supplied with rubber rings for each socket. The rubber ring

shall conform to IS 12820 and IS 5382. Flanged fittings shall be supplied with one rubber

gasket per flange and the required number of nuts and bolts.

5.18 Sluice Valves

(a) Sluice valves shall be of rising spindle type. The valve shall be furnished with a

bushing arrangement for replacement of packing without leakage. Shoe and channel ar-

rangement shall be limited to valves of 450 mm and above. The gap between the shoe

and channel shall be limited to 1.5 mm.

(b) Valves of 450mm and above shall be provided with thrust bearing arrangement for

ease of operation.

(c) Valves of diameter 450 mm and above shall be provided with enclosed gear arrange-

ment for ease of operation. The operation gear of all valves shall be such that they can be

opened and closed by one man against an unbalanced head 15% in excess of the maxi-

mum specified rating. Valve and any gearing shall be such as to permit manual operation

in a reasonable time and not exceed a required rim pull of 400 N.

(d) All valves, spindles and hand wheels shall be positioned to give good access for oper-

ational personnel.

(e) All the hand wheels shall be arranged to turn in a clockwise direction to close the

valve. The direction of rotation for opening and closing of the valve shall be indicated on

the hand wheels.

(f) The material of construction of Sluice valve shall be as follows:

158
 Table 5.12: Sluice valve- Material of construction

SR.NO COMPONENT MATERIAL

(i) Body and Doors Cast Iron : IS:210 Gr FG 200
(ii) Spindle Stainless Steel: BS:970 Gr 431
(iii) Seat Rings Stainless Steel: BS:970 Gr 304
(iv) Back seat bush Bronze : IS:318 Gr LTB2
(v) Shoe and channel linings Stainless Steel : BS:970 Gr 304

5.19 Knife Gate Valves

The valve shall meet requirements of MSS SP 81. Outer body shall be provided with

inner liner in corrosion resistant Stainless Steel which shall extend into the gland. The

body shall be devoid of any wedge / dead pockets to avoid settling of suspended particles

and solids in the service fluid.

The gate/plate shall be precision buffed and the edge contoured to a knife edge. The gate

shall move along / be guided by the seat ring to ensure that it scrapes any deposit /

scale, enabling smooth uninterrupted movement.

Seat shall be so designed that there is no recess / relieved groove to harbour deposition

that could build-up and swamp the valve. The design to also incorporate bosses that

guide the gate and avoid deflection, ensuring positive shut-off.

The stem shall have double start threads cut in order to ensure smooth and speedy

operation. Gland packing shall offer minimal frictional resistance and precludes external

lubrication. As positive sealing element, the packing shall also include a resilient rubber

ring.

The knife edge and seat face in flow path shall be hard faced to a hardness of 400 to 450

BHN to counter erosion. In such cases, provision shall also be made to ensure the fluid

contact with the seat ring is minimal.

The material of construction of valve shall be as follows:

Table 5.13: Knife Gate Valve-Material of construction

S.No Component Material

(i) Body Cast Iron : IS:210 Gr FG 260
(ii) Inner lining Stainless Steel: BS:970 Gr 304
(iii) Knife gate / plate Stainless Steel: BS:970 Gr 304
(iv) Stem Stainless Steel : BS:970 Gr 304
(v) Seat ring / Boss Stainless Steel : BS:970 Gr 304
(vi) Gland housing Ductile Iron : BS 2789 Gr 500
Teflon impregnated with the asbestos
(vii) Gland packing
+rubber

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5.20 Butterfly Valve

(a) This valve shall be installed at the pipe-line to seal the water or air and to adjust the

flow.

(b) Valves shall be suitable for throttling operations and for infrequent operation after

periods of inactivity.

(c) The body of the valve shall be made from cast iron or ductile iron.

(d) Valves shall have fabricated steel, cast iron or ductile iron discs with a resilient rubber

sealing ring.

(e) Valve stem, shall be if stainless steel designed for both torsion and shearing stresses

when the valve is operated with permanently self-lubricated shaft stub bearing, sized to

withstand bearing loads.

(f) Butterfly valves shall be provided with hand-wheels and rack and pinion gearing oper-

ation. The valves shall be open by turning the hand-wheel in an anticlockwise direction.

The direction of valve opening and closing shall be marked on the hand-wheel casting.

(g) The valves shall be designed to hold the disc in any intermediate position between fully

opened and fully closed without creeping or fluttering by manual or electric operation.

The material of construction of valve shall be as follows:

Table 5.14: Butterfly Valve-Material of construction

S.No Component Material

1 Body Cast Iron or Carbon steel or equivalent
2 Disc Carbon steel or Cast iron or equivalent
3 Stem Stainless Steel or equivalent
4 Seat Rubber or equivalent

5.21 Non Return Valve

(a) The valves shall be suitable for mounting on horizontal pipe line.

(b) The internal parts shall be easily accessible for inspection through inspection hole.

(c) Hydraulic passages and doors shall be designed to avoid cavities.

(d) Valves shall be of swing type or ball type. Ball valves must house a freely moving ball

in such a way that return flow is effectively prevented.

(e) Valves shall be quick closing type with non-slam characteristics. In case of swing type,

the non slam characteristics shall be achieved by providing suitable combination of door

and hydraulic passages without any external lever/damping arrangement.

(f) Valves 450 mm and above shall be provided with supporting foot.

(g) Swing door valves of size 600mm and above shall be of multi-door type.

(h) Direction of the flow shall be clearly embossed on the valve body.

(i) Maximum pressure drop across the valve shall be 0.4 mwc.

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(j) Maximum allowable leakage rate shall be 7cc/hr/mm diameter.

The material of construction of valve shall be as follows:

Table 5.15: Non-return Valve-Material of construction

S. No Component Material
1 Body and Door Cast Iron : IS 210 Gr. FG 200
Stainless Steel : ASTM A743 CF8,
2 Body and Door Ring
BS970 Gr. 304 S11
3 Hinge Pin Stainless Steel : BS970 431 S29
4 Bearings Teflon

5.22 Telescopic Valve

(a) The telescopic valve shall be a proprietary item of proven design manufactured in cast

iron and adjustable to cater for 1000mm variation in level.

(b) The bell-mouth height shall be controlled by a hand-wheel operated from top of the

chamber.

(c) The bell-mouth, pipe work, spindle and head stock shall be robustly constructed with

adequate brackets of cast iron.

(d) The bell-mouth shall be connected by swept tees to a cast iron sludge outlet pipe of

300mm diameter.

The material of construction of valve shall be as follows:

Table 5.16: Telescopic Valve-Material of construction

S.No Component Material

1 Bell Mouth Cast Iron : IS:210 Gr. FG 200
2 Piping Cast Iron : IS:210 Gr. FG 200
3 Spindle Stainless Steel Gr. 304
4 Hand wheel Cast Iron : IS:210 Gr. FG 200

5.23 Pressure / Vacuum relief valves

(a) Pressure relief valves shall be capable of relieving pressure in the system to prevent

the system being pressurized in excess of a preset maximum allowable pressure. The

valves shall be drops tight under no flow conditions.

(b) Vacuum relief valves shall be capable of preventing the vacuum pressure to be de-

veloped in the system by allowing air entry. The valves shall be drops tight under no flow

conditions.

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 (c) The valve operation shall be achieved by the interaction of the inlet pressure and

an intermediate pressure produced by a pilot valve or relay system acting on the upper

side of the main valve.

(d) The pilot valve or relay system shall be actuated by a diaphragm connected to the

inlet pressure on its underside and a constant pressure on its upper side derived either

from weights or from a spring.

(e) Body ends shall be flanged and drilled to BS 4504.

5.24 Reduction Gear Units

(a) Reduction gear units, wherever provided shall be double reduction units without V-

belt and pulley. Gears shall be cut from solid cast or forged steel blanks or shall be of

stress relieved welded steel construction. Pinions shall be of forged carbon or heat treated

alloy steel. Strength, quality of steel, heat treatment, face, pitch of teeth and design shall

conform to BS: 436 and BS: 721. Split gears shall not be used. Gears and pinions shall

be pressed on and keyed to shafts.

(b) All pinions and gears are to be of the totally enclosed type up to the last stage of

reduction in all motions and shall be carried in fabricated steel gear cases which must

be dust-proof and firmly sealed to prevent oil leakages and shall be oil bath lubricated.

The gear boxes shall have covers split horizontally and arranged so that top half can be

removed for inspection. They shall be fitted with bolted type machined inspection covers

and with cast steel cartridge housings for carrying roller bearings.

(c) Dip sticks or indicator shall be provided for indicating the oil level. Guards shall

be strong enough to retain the whole gear or any part that might otherwise fall. No

overhanging gears shall be used. Drain plugs shall be provided on all gear cases. Lifting

lugs shall be provided for handling purposing.

5.25 Propeller Exhaust Fan

(a) The fan should comply with IS 2312.

(b) The blades shall be of mild steel and properly balanced so as to avoid noise and vi-

bration. The blade and blade carriers shall be securely fixed so that they do not loosen

in operation. The means provided for securing the fan mounting or fan casing to the wall

partition or window shall be such as to provide a secure fixing without damage to the fan

or wall.

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(c) Suitably designed guards shall be fitted to the inlet and the outlet side to prevent acci-

dental contact. No flammable material shall be used in the construction of fan. Moulded

parts, if used, shall be of such materials as to withstand the maximum temperature at-

tained in the adjacent component parts.

(d) The fan shall have protective insulation or be capable of being earthed. A fan with pro-

tective insulation may be of all insulated construction or have either double insulation or

reinforced insulation. Each fan should be provided with a 10 sq.mm mesh bird screen.

The sheet used for the cowl should be 14 G.

5.26 Air conditioning Equipment

Wall mounted split type air conditioners of 2.0 TR capacity each (Inverter Technology)

with five star rating shall be provided for the control room and the laboratory. Outdoor

condensing unit shall be located on the roof of the building or grouted on the external

side of the wall with suitable brackets.

5.27 Domestic Water Pump sets

The Pump shall be of Centrifugal type, self -priming and mono-block type, suitable for

pumping the clear water. All the necessary piping with union, bends and tees shall be

provided. Suction and discharge isolation valves and non-return valves on the discharge

side shall be forged steel. Piping shall be as per IS: 1239 heavy class.

5.28 Pumps
5.28.1 Open well Submersible Pumps

Submersible pumps shall be of the single entry design supplied complete with bolt-less

self- aligning duck-foot assemblies giving automatic connection to the discharge pipe

work.

Pumps to be used in Common Collection Sump shall be Cutter pumps.

The total head capacity curve shall be continuously rising towards the shut off with the

highest at shut off.

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

between the maximum and minimum system resistances.

The pumps shall be designed to handle solid sizes of up to 80 mm.

Pumps shall run smooth without undue noise and vibration.

The pump set shall be suitable for starting with discharge valve open and/or closed.

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 The pump set shall be capable of withstanding the accidental rotation in reverse di-

rection.

5.28.2 Submersible Pumps: Features of Construction

Pump shall be centrifugal, vertical spindle, non-clog, wear resisting, single stage type.

(Pump casing shall be of robust construction. Liquid passages shall be finished smooth

and designed as to allow free passage of solids. The volute tongue shall be filed to a

smooth rounded edge.

Double Mechanical seals shall be provided to protect the motor from ingress of liquid

along the shaft. The preliminary and secondary seals shall be oil-lubricated with tungsten

carbide or silicon carbide faces and they shall be equipped with an electrical monitoring

system for seal failure detection. Sensors are to be provided to detect if leakage of liquid

into the oil housing is above 30 % concentration

Double Mechanical seals shall be provided to protect the motor from ingress of sewage

along the shaft. The preliminary and secondary seals shall be oil-lubricated with tungsten

carbide or silicon carbide faces and they shall be equipped with an electrical monitoring

system for seal failure detection.

Impeller shall be non-clog open / semi open type for raw sewage and sludge application

and enclosed type for clear water / treated sewage / filet rate pumping application with

smooth blunt edges and large water ways so as to allow free passage of the large size

solids. It shall be free from sharp corners and projections likely to catch and hold rags

and stringy materials. The number of impeller vanes for pumps up to 1000 m/hr shall

be limited to two and shall be limited to three for the pumps higher than 1000 m/hr.

The critical speed of the rotor shall be at least 30% above the operating speed.

Pump sets shall have double bearings. The bearing life shall be minimum 40,000 hrs of

operation.

Each pump shall be complete with a cast iron delivery connection arrangement for fixing

to the concrete floor of the suction well. All necessary stainless steel fixtures required

for guiding the pumps during lifting / lowering shall be provided. The installation shall

facilitate automatic installation and removal of pump without a person entering the wet

well. Each pump shall be provided with a SS 304 lifting chain with suitable provision for

engaging the hook of the crane at 1 m interval.

Each pump shall be provided with an automatic coupling device for attaching the crane

hook to the pump at low level, even whilst the pump is submerged, without the need for

164
personnel to enter the well. This automatic coupling device shall easily and automatically

couple and uncouple the hoist hook and be complete with necessary accessories. All links

and cables shall be multi-stranded stainless steel.

The submersible pumps shall be suitable for operation with or without submergence. The

pump shall start and stop automatically based on level in the wet well. The synchronous

speed shall not exceed 1500 rpm at 50 Hz supply.

The materials of construction for submersible pumps shall be as follows :

Table 5.17: Materials of construction for submersible pumps

S.No Component Material

1 Impeller Stainless Steel : ASTM A743 CF8M
2 Casing Cast,Iron,to,IS:210,Gr,FG 200 with 1.5 to 2% Nickel
3 Shaft Stainless Steel : BS:970 AISI Gr 316
4 Bush Bronze IS 318 Gr. LT B2
5 Guide rail pipe Stainless Steel : BS:970 AISI Gr 304
6 Fasteners and Foundation Bolts Stainless Steel : BS:970 AISI Gr 316

Material test certificates shall be furnished by the Contractor and shall have the ap-

proval of Engineer-in-Charge.

The submerged cable shall be a multi-core flexible cord, vulcanized rubber insulated

with tough rubber sheath and outer PCP sheath to BS 6500.

Where both thermal protective and moisture-sensitive devices are incorporated within

the pump, both devices shall be brought out via separate conductors within the motor

cable, although one such conductor may be common.

5.29 Centrifugal Pumps

(i) Centrifugal pumps shall be of horizontal end suction type and shall have head/quantity

characteristics which fall continuously from the maximum pressure at closed valve

conditions and which are steep in order that variation in head shall have a minimal

effect on the quantity discharged.

(ii) The design speed of any pump with a duty flow greater than 20 l/s shall not exceed

1500 rpm. Pump motor ratings shall exceed the maximum pump power consump-

tion over the operational range of the pump by at least 10%.

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 (iii) Waterways through the pump shall be smooth in finish and free from recesses and

obstructions. Impeller passageways shall be as large as possible. The leading edges

of the impeller vanes shall be rounded and smooth.

(iv) Water velocities in the pump suction side shall not exceed 1.5m/s and on delivery

branches of a pump the velocity shall not exceed 2.0 m/s when the pump is oper-

ating within its specified duty range and within this working range there shall be no

discernible noise due to hydraulic turbulence or cavitations within either the pump

or its associated pipe work and valves.

(v) The NPSH requirements of the pumps, based on the 3% output drop criterion shall

be at least 2 m less than the NPSH available at every working condition.

(vi) The velocity of vibration shall be within 4.5mm/sec. Combined noise level of pump

motor system shall be limited to 85dBA at a distance of 1.85m from the equipment,

at manufacturers works.

(vii) The pump shaft shall be of stainless steel to BS: 970 Grade 410S21 compatible with

the impeller which shall be of stainless steel ASTM A743 CF8M and the impellers and

shaft sleeves shall be secured to the shaft by means of a key or keys. The impeller

retaining nut shall be fitted with a locking device. The pump casing shall be of Cast

iron to IS210 Gr.FG260, wearing rings shall be of Bronze to IS: 318 Gr.LTB2 and

shaft sleeve shall be of stainless steel to ASTM A 743 CA 15.

(viii) All parts exposed to wear shall be adequately protected by means of renewable

sleeves, bushes, wear rings etc which shall be arranged for easy inspection, ad-

justment, or replacement without removal of the pump casings, pipe work etc, or the

need to disturb the drive shaft alignment.

(ix) The pump thrust shall be taken by a combined thrust and radial type bearing assem-

bly capable of taking the weight of the moving parts and the hydraulic loads under

all conditions of operation with a minimum life of 100 000 hours.

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 (x) Bearing cooling arrangements if used shall be designed on the closed-circuit princi-

ple; open discharge of cooling water into the pumping station drainage system is not

permissible.

(xi) The pump casing and other parts of the pump subject to pressure shall be hydrauli-

cally tested by the manufacturer to at least one and a half times the maximum

working pressure.

(xii) Integral inlet and discharge flanges shall be provided and integral lifting lugs shall

be incorporated.

(xiii) Facilities shall be provided for the removal of air during priming and for draining.

(xiv) Glands may be fitted with mechanical seals or conventional soft packing. The gland

arrangement shall be designed for easy adjustment and removal of the seal.

(xv) When soft packed glands are used suitable means shall be provided for collecting

and preventing splashing of the gland leakage water.

(xvi) Drainage and gland leakage water shall be piped into the building drainage system.

(xvii) The shafts of pumps fitted with conventional packed glands shall be fitted with re-

movable gland sleeves.

(xviii) The rotating element of the pump and the motor shall be readily removable from the

pump casing without the need to disconnect the adjoining pipe work.

(xix) Rotating assemblies of pumps of 100 mm diameter inlet and over shall be statically

and dynamically balanced and shall be designed so that the first critical speed is at

least 50% greater than the maximum operating speed.

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(xx) Lubrication arrangements shall be so designed that there is no contamination of the

pumped fluid.

(xxi) On pumps of 75 mm inlet and over, tapping shall be provided at both the suction

and discharge flanges of suitable size for pressure gauges.

5.30 End Suction Pumps

(i) End suction pumps shall be horizontally mounted complete with drive motor on a

common base plate. The pump/drive coupling shall be of the spacer type to facili-

tate removal of the pump rotating element and bearing housing without dismantling

the pump casing, adjoining pipe work or drive motor. These types of pumps shall

be used for Filter backwash, Chlorination motive water and service water pumping

applications etc.

(ii) The dimensions of the pump shall be metric conforming to BS 5257 or its equivalent

standard. Flanges shall conform to BS EN 1092-2/BS 4504.

(iii) The bedplate shall be of substantial fabricated steel construction with floor fixing

bolt holes ready drilled. All holding down bolts etc. shall be supplied with the units.

(iv) The velocity at the entrance to the pump impeller shall not exceed 3.5 m/s.

(v) Impellers shall be provided with means to prevent abrasive matter reaching the

glands and with fully shrouded impellers, to prevent the trapping of matter between

the impeller vanes and the casing.

(vi) The speed of any pump shall not exceed 1500 rpm.

(vii) Glands may be fitted with suitable mechanical seals or conventional soft packing.

The gland arrangement shall be designed for ease of adjustment or removal of the

seal or packing material. Shafts shall be sleeved around the area of the gland when

soft pack glands are used.

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(viii) Flushing facilities shall be provided for mechanical seals or packed glands where

pump fluid may be contaminated with abrasive material. Where soft packed glands

are used, means shall be provided for collection of the gland leakage water, which

shall be piped into the drainage system through adequately sized ports.

(ix) Lubrication arrangements shall be so designed that there is no contamination of the

pumped fluid.

(x) The pumps and associated pipe work shall be, wherever possible, arranged so that

air can be completely expelled during priming. Where this is not possible, facilities

shall be provided for the removal of the trapped air. Adequate facilities shall be pro-

vided for drainage of the pumps for inspection purposes.

(xi) Tapping shall be provided at both the suction and discharge flanges for pressure

gauge equipment.

5.31 Pump Performance Guarantees

(i) The pump performance guarantee shall relate to the flow rate, the total head and

the efficiency of the pump when tested at the manufacturer’s work and shall obtain

approval of Engineer-in-Charge.

(ii) The pump shall operate at its design point within acceptance tolerances for flow rate

and total head laid down in BS EN ISO 9906:2000.

(iii) Each pump shall be tested at the manufacturer’s factory in accordance with BS EN

ISO 9906:2000 or other relevant standards in conjunction with one of the contract

motors.

(iv) This test shall be carried out on at least one pump set using the flexible coupling

and contract drive shaft arrangement to establish that the drive arrangement with

supports and couplings operates satisfactorily under all operating conditions.

169
 (v) Where similar drive shaft arrangements have been installed by the Contractor and

have been proven satisfactory in service this requirement may be withdrawn subject

to the approval of the Engineer-in-Charge.

(vi) A test shall be carried out of the performance from closed valve to the maximum

quantity that can be delivered under abnormally low discharge heads.

(vii) Sufficient readings shall be taken at each test to produce accurate curves of the

heads, flow, pump speed and power required at pump coupling throughout the op-

erating range of the pump.

(viii) Vibration and noise dB(A) levels shall be measured and shown to be acceptable and

shall have Engineer-in-Charges approval. The Contractor shall have Engineer-in-

Charge approval and provide acceptable test certificates, showing the NPSH require-

ment for the pump is at least 2 m less than the NPSH available under all working

conditions.

(ix) In the absence of the approved test certificates the supplier shall carry out a test on

one pump of each type to verify the NPSH requirement based upon the 3% output

drop criterion and shall take approval of Engineer-in-Charge.

(x) Test Certificates in duplicate shall be submitted to the Engineer-in-Charge immedi-

ately following each of the tests mentioned above. Performance curves shall also be

incorporated in the Operation and Maintenance Manual.

5.31.1 Single Pump Operation

• Head/quantity curve

• Motor kW input/quantity curve

• Overall efficiency/quantity curve

• NPSH required/quantity curve

• Vibration and Noise dB (A) levels

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5.31.2 Parallel Pump Operation

• Head/quantity curves

• Motor kW input/quantity curve

• Overall efficiency/quantity curve

• NPSH required/quantity curve

• Vibration and noise dB(A) levels

5.32 Progressive Cavity Pumps

(i) These pumps shall be used for handling thickened sludge transfer / feed applica-

tions.

(ii) Pumps shall be of the type in which a pumping action is generated by a helical

rotating eccentrically within a resilient stator in the form of a double internal helix.

The eccentric motion of the rotor shall maintain a constant seal across the stator as

it travels through the pump to give a uniform positive displacement.

(iii) Pumps shall be arranged generally with a single shaft seal at the suction end. Me-

chanical seals shall be used. If a flexible shaft is used to accommodate the eccentric

motion, a corrosion resistant shroud shall be fitted to prevent fibre build-up on the

shaft. Enlarged inspection access holes shall be fitted to the suction chambers of all

pumps for periodic removal of accumulated debris.

(iv) The shaft bearing shall be positively isolated from the fluid being pumped.

(v) The rotor material shall be selected for corrosion and abrasion resistance for the

fluid being pumped, and for prolonged service life. Hard chrome or other approved

coatings shall be not less than 250 micron thickness and shall be diffused in to the

base material. The rotor shall generally be single-stage and shall incorporate not less

than 3600 of twist, but for high-head applications, it may be necessary to use more

than a single-stage. The stator shall be of a resilient material selected for chemical

and abrasion resistance for the fluid being pumped.

(vi) Pump speed shall suit the application, where variable delivery output is needed; the

pump shall be provided with a variable-speed drive. The size and speed range of the

pump shall ensure that the highest expected duty point shall lie within the available

speed range.

171
(vii) Pumps shall normally be driven by a fixed-speed electric motor through reduction

gearing and the combined drive shall be continuously rated. Pump and motor shall

preferably be mounted in-line on a common base plate. Alternatively, the drive motor

may be top- mounted above the pump to minimize floor area, and shall be connected

by external V- belts and pulleys. V-belt drives shall have full guards of the type that

allow the belts observed without removal of the guard. Facilities shall be provided

for ready adjustment of belt tension.

(viii) Coupling guards shall be provided, which shall be rigid, securely fixed, and designed

so that removal is not necessary during normal operation, routine maintenance and

routine inspections. All motor enclosures shall be provided with ingress protection

to IP55. Motor anti-condensation heaters shall be provided and shall be suitable for

use on a 220V single- phase, 50Hz supply.

(ix) All bearing shall have a B10 design life of not less than 40,000 running hours and

shall be designed for loading 20% in excess of calculated maximum loading. Pumps

shall be fitted with individual dry-running protection to initiate pump trip. Dry-

running protection by under-current monitoring or pipeline-intrusive device shall

not be used.

Table 5.18: Progressive Cavity Pumps:Material of Construction

Component Material
Pump Housing CI IS 210 GR. FG220 or FG260
Rotar SS AISI 316(Hard chrome Plated)
Shaft SS AISI 410(Hard chrome Plated)
Stator Nitrite black
Type of drive V belt & Pulleys
Base plate MS fabricated
Seal type Gland packing (Asbestos Free)

5.33 Chemical Dosing Pumps

(i) Chemical dosing pumps shall be piston diaphragm or mechanical diaphragm type

as specified. Pumps may be simplex or duplex arrangements to suit the capacity

or process requirements. The pump design shall incorporate positive stroke return.

The maximum stroking speed shall not exceed 100 strokes per minute (spm). Pump,

motor and driving arrangement shall be mounted on a robust combined base plate.

(ii) Pump liquid ends shall be selected for compatibility with the pumped liquid. Suction

and discharge valves shall be the single ball type allowing a free flow self cleaning

action. Ball and seat materials shall be resistant to abrasion.

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 (iii) Pumps shall incorporate a variable stroke mechanism to allow the output to be varied

while the pump is running. Stroke adjustment shall be manual or where specified by

electrical or pneumatically controlled stroke positioner. A stroke length indicator and

digital stroke counter shall be fitted. Pumps shall be driven by a flange mounted IP 55

motor, via an oil bath reduction gearbox and variable stroke mechanism giving step

less adjustment between zero and maximum stroke length. Where flow proportional

dosing is required the variation of output shall be achieved by varying the speed of

the pump motor and not the pump stroke length.

(iv) The normal operating range of dosing pump shall be not less than 6:1.

(v) Mechanical Diaphragm: Diaphragm rigidly coupled to the drive train. Single suction

Pumps and discharge valves. Glandless. Accuracy: 3% of stoke.

(vi) Piston Diaphragm Pumps: Diaphragm hydraulically operated by liquid displaced by

a plunger and protected from excess pressure via a relief valve. Accuracy: 2% of

stroke.

(vii) Materials shall be selected to suit the chemicals being pumped. Liquid ends shall be

polypropylene, AISI 316 stainless steel, glass, or Hastelloy C. Diaphragm materials

shall be butyl rubber, PTFE, or Hypalon and glands shall be PTFE or Neoprene.

(viii) Each pump shall be provided with inlet and outlet isolating valves and where nec-

essary, with pressure relief and non-return valves. Dosing pumps shall be provided

with back pressure loading valves and pulsation dampeners in the delivery lines

depending on the downstream conditions.

(ix) A relief valve shall be incorporated in the delivery lines under conditions where the

pump discharge pipe can be shut off or where pressure may rise to an excessive

point. The relief valve shall be sized to handle the system pressure and to discharge

maximum pump output freely, and shall be located in the discharge line between

the pump and the first downstream isolating valve or in the case of dosing pumps

the back pressure loading valve. Relief valves when used on pumps handling non-

hazardous chemicals shall discharge the vented liquid to waste. When used on haz-

ardous chemicals the valve outlet shall be piped back to the suction supply tank or

bunded area. The open end of the return pipe shall be located where it is visible, so

that any relief valve leakage/operation can be detected.

(x) Pump transferring/dosing chemicals to systems under pressure shall incorporate a

pressure gauge on the pump delivery. Air cocks shall be provided for release of air

where necessary.

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(xi) Unless otherwise specified flushing connections shall be provided at each pump inlet

and flushing shall be manual. When flushing, water shall be discharged either locally

through a drain valve or to the point of application of the chemical. Facilities shall

also be provided for flushing chemical pump suction and delivery manifolds and

delivery lines to point of application.

(xii) Dosing pumps and motors shall preferably incorporate an integral reduction gearbox

drive which shall be totally enclosed and oil bath lubricated. The gear box shall

incorporate the cams for the diaphragm drive and shall be provided with filling and

drain connections and visible oil level indication.

5.34 Induction Motor (Submersible Motor)

5.34.1 Design Requirements

(a) The submersible motors shall generally conform to IS: 325 and the submersible cable

shall conform to IS: 9968 or relevant equivalent internationally approved standards. Ad-

ditionally the specific requirements mentioned in the following clauses shall also be met.

(b) The motor shall be three phase dry induction type with non-overloading characteris-

tics.

5.34.2 Performance and Characteristics

Motors shall be capable of giving rated output without reduction in the expected life span

when operated continuously under the following supply conditions:

• Variation in supply voltage (+)/(-) 10%

• Variation in supply frequency (+)/(-) 5%

• Motors shall be suitable for full voltage direct-on-line starting or star-delta starting.

• Motors shall be capable of starting and accelerating the load with the applicable

method of starting, without exceeding acceptable winding temperatures, when the

supply voltage is in the range 85% of the rated motor voltage.

• Motors shall be designed to withstand 120% of rated speed for two minutes without

any mechanical damage, in either direction of rotation.

• The motor vibrations shall be within the limits specified in the relevant standard.

• Except as mentioned herein, the guaranteed performances of the motor shall be met

with tolerances specified in applicable standard, IS: 9283-1979.

174
 • The enclosure for motor shall be IP-68.

• Minimum three number thermistors in series are to be provided to sense the stator

winding temperature.

• Bimetallic thermal switch to trip the motor against increase in temperature shall be

provided.

• The power rating of the motor shall be larger of the following:

–115% of the power input to the pump at duty point.

–105% of the power input to the pump at 75% head.

Motors shall be suitable for full voltage direct-on-line starting or star delta starting.

Minimum permissible starting voltage shall be 85% of the rated voltage.

5.34.3 Submersible Cable

(i) The power cable shall be PVC insulated and PVC sheathed, flexible, 3 core flat type.

The size of the conductor shall be adequate for continuous use under water and air.

The half core shall be used for earthing.

(ii) The control cable shall be PVC insulated PVC sheathed, flexible, flat type and shall

be adequate for continuous use under water and air. The control cable for stator

winding temperature sensor (Thermistors) 3 core x 2.5 sq. mm copper conductor

and for bimetallic thermal switch 2 core x 2.5 sq. mm copper conductor shall be

provided.

(iii) In case a joint is required to be made between the lead cable supplied with the motor

and the user’s cable connectors, a detailed procedure of cable jointing to make a

watertight joint shall be provided by the manufacturer.

(iv) The size of the conductor and length of cable should be suitably selected so that the

voltage drop at motor terminals does not exceed 3 percent of the rated voltage.

5.34.4 Earthing

(a) Earthing of the motor shall be done in accordance with the relevant provisions of

IS3043:1966.

(b) (For the purpose of earthing these motors, earthing connection may be made to dis-

charge pipe.

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5.34.5 Insulation

Any joints in the motor insulation such as at coil connections or between slot and end

winding sections shall have strength equivalent to that of the slot sections of the coil.

(a) The insulation shall be given tropical and fungicidal treatment for successful oper-

ation of the motor in hot, humid and tropical climate. The tropicalising treatment shall

be as per the applicable standard.

(b) The stator winding shall be made from high conductivity annealed copper conduc-

tor, PVC insulated winding wires conforming to IS: 8783:1978 for wet type motors. The

stator winding shall be of high conductivity annealed copper enameled insulated wires

conforming to IS: 4800 (Part-VII):1970 for dry type motors.

5.34.6 Temperature Rise

The temperature-rise test of the motor shall be taken with the motor coupled to the

suitable pump to give the full load output of the motor. When the various temperatures

are stabilized, the set is stopped and the temperature-rise of the stator winding by the

resistance method shall not exceed 35◦ C. During the test, the temperature of the cooling

water may not exceed 35◦ C. As the cable resistance will also be substantial, it is necessary

that while calculating the temperature rise by resistance method, due care is taken to

account for the correct hot and cold resistance of windings.

5.34.7 Constructional Features

(a) The motor shall be suitable for continuous duty as well as intermittent duty with or

without full submergence of the motor.

(b) Aluminum die cast rotor to be provided for better starting torque characteristics.

(c) The electric motor shall be suitable for 10 starts & stops per hour. d. Single phasing

and overload protection system shall be provided

(d) The motor degree of protection shall be IP68.

(e) Each motor shall be provided with minimum 25 m length of power control cables and

15 m length of lifting chain box (i.e.) for terminating power control cables for each motor.

5.34.8 Terminal Box

(a) Terminal box shall be of weather proof construction to eliminate entry of water and

dust.

(b) The terminals shall be of the stud type with necessary plain washers, spring washers

176
and check nuts. They shall be substantially designed for the current carrying capacity

and shall ensure ample phase to phase and phase to ground clearance.

5.35 Induction Motor

5.35.1 General

All motors shall comply with IEC 60034, 60072 and IS-325, 4029, 4722 including stan-

dards referred to therein.

5.35.2 Performance and Characteristics

1. The performance and characteristics of the induction motor are as defined in the

table below:

Table 5.19: characteristics of the induction motor

Description Unit Particulars

Type Squirrel cage Induction motor
Rating Kw (*)
Rated Voltage kV 0.415
Synchronous speed Rpm (*)
Quantity Nos. (*)
Horizontal/,Vertical,
Type of mounting (depending On application
and process requirement)
Duty type Continuous (S1)
Soft,starter/,Star-Delta,starter/Direct online
Method of starting (depending On application and
process requirement **)
Class of insulation F
Design ambient temperature 0C 50
Indoor/ Outdoor (depending On application and
Location
process requirement**}
Degree of Protection IP55
Cooling designation IC411
Terminal box LHS-looking from NDE end
1.1,kV,,3C,x,(*),sq.,mm. Aluminum,
External cable details
XLPE, armoured
Space heater for motor Required if motor rating is 30kW and above
(*) To be furnished by Contractor. Contractor should ensure that all the equipment
ratings are based on their system requirement and subject to Engineer-in-Charge
approval.
(**) Motors rating up to and including 5.5 KW shall be started by DOL starter, Motor
ratings above 5.5KW and up to or equal to 30 KW shall be started by Star- Delta Starter
and above 30 KW shall be started by soft starter.

2. Motors shall be energy efficient (IE 2 or better) squirrel cage induction motors (TEFC

type) with degree of protection for enclosure of IP 55. They shall be capable of start-

ing and accelerating the load for the method of starting, as per SLD without exceed-

177
 ing acceptable winding temperatures, when the supply voltage is 80% of the rated

voltage. Main conductor and insulation shall be non-hygroscopic and in accordance

with Class F of IEC 60085.

3. Motors shall be capable of giving rated output without reduction in the expected life

span when operated continuously under the following supply conditions:

– Variation in supply voltage 10%

– Variation in supply frequency 5%

4. Motors shall be capable of starting and accelerating the load with the applicable

method of starting, without exceeding permissible winding temperatures, when the

supply voltage is 80% of the rated voltage. Motors shall be capable of satisfactory

operation at full load at a supply voltage of 80% of the rated voltage for 5 minutes,

commencing from hot condition.

5. The Power rating of the motor shall be the larger of the following:

115% of the power input to the pump at duty point.

105% of the power input to the pump between 110% to 75% head.

6. Motors shall withstand the voltage and torque stresses developed due to the vector

difference between the motor residual voltage and the incoming supply voltage equal

to 150% of the rated voltage, during fast changeover of buses. The duration of this

condition is envisaged for a period of one second.

7. The locked rotor withstand time under hot conditions at 110% rated voltage shall be

more than the starting time at minimum permissible voltage by at least two seconds

or 15% of the accelerating time, whichever is greater. The locked rotor current of

motors shall not exceed 600% of full load current of motor which is inclusive of 20%

tolerance.

8. The motors shall be provided with class F insulation with temperature limited to

that of class B insulation.

9. Motors when started with the drive imposing its full starting torque under the speci-

fied supply voltage variations shall be capable of withstanding at least two successive

178
 starts from cold conditions and one start from hot condition without injurious heat-

ing of windings. The motors shall also be suitable for three equally spread starts per

hour under the above referred supply conditions.

5.35.3 Constructional Features

(a) Motors weighing more than 25 kg shall be provided with eyebolts, lugs or other means

to facilitate safe lifting.

(b) The motor construction shall be suitable for easy disassembly and re-assembly. The

enclosure shall be sturdy and shall permit easy removal of any part of the motor for in-

spection and repair.

(c) The rotor bars shall not be insulated in the slot portion between the inner core lami-

nations for squirrel cage motors.

(d) All bearings shall be fitted with oil or grease lubricators. Motor bearings shall not be

subjected to any external thrust load. Unless otherwise specified, motor bearings shall

have an estimated life of at least 40,000 hrs. It shall be possible to lubricate the bearings

without dismantling any part of the motor. All terminals shall be of the stud type of ade-

quate size for the particular duty, marked in accordance with an approved standard and

enclosed in a weatherproof box.

(e) The equipment shall be thoroughly degreased, all rust, sharp edges and scale removed

and treated with one coat of primer and finished with two coats of grey enamel paint.

5.35.4 Terminal Box

(a) Terminal boxes shall be of weather proof construction designed for outdoor service.

To eliminate entry to dust and water, gaskets of neoprene or approved equivalent shall be

provided at cover joints and between box and motor frame. It shall be suitable for bottom

entry of cables. It shall be capable of being turned through 360 degree in steps of 90

degree.

(b) The terminals shall be of the stud type with necessary plain washers, spring washers

and check nuts. They shall be designed for the current carrying capacity and shall en-

sure ample phase to phase and phase to ground clearances. Suitable cable glands and

cable lugs shall be supplied. (c) Separate terminal boxes shall be provided for each of the

following:

–Stator Leads

179
 –Space Heaters

5.35.5 Accessories

Drain Plugs: Motors shall be provided with drain plugs, so located to drain water, result-

ing from condensation or due to other causes, from all pockets in the motor casing.

5.35.6 Heating during Idle Period

(a) For motors rated below 30 kW, during idle periods, the stator winding will be connected

to required single phase, 50 Hz, AC supply for heating and elimination of moisture. The

supply will be connected between any two terminals.

(b) Motors rated 30kW and above shall have space heaters suitable for 230V, single phase,

50 Hz, AC supply. Space heaters shall have adequate capacity to maintain motor internal

temperature above dew point to prevent moisture condensation during idle period. The

space heaters shall be placed in easily accessible positions in the lowest part of the motor

frame.

5.35.7 Earthing Pad

Two independent earthing pads of non-corrodible metal shall be welded or brazed at two

locations on opposite sides complete with suitable bolt and washers for earthing. These

earthing pads shall be in addition to earthing stud provided in the terminal box.

5.35.8 Rating Plate

(a) The following details, in addition to those specified in applicable standards shall be

included on the rating plate.

(b) Rated voltage, kW rating, frequency, efficiency, power factor, temperature rise of wind-

ings in degree centigrade at rated load, and ambient conditions.

(c) Type of bearings, recommended lubricant, lubricating interval re-lubricating quantity.

5.35.9 Tests

(a) Motor shall be subjected to all the type test (one from similar rating of each lot)

and routine tests as per applicable standard, in the presence of the Engineer-in-Charge.

Copies of test certificates for all brought out items shall be furnished at the time of in-

spection for the IITH s approval.

(b) The Contractor shall ensure to use calibrated test equipment / instruments having

180
valid calibration test certificates from standard laboratories traceable to National / Inter-

national standards.

5.36 Equipment selection

(a) Equipment means all items that are mechanical, electrical, instrumentation, panels,

cables, switchgear, MCBs etc.

(b) Contractor shall select equipment to meet following criteria.

Equipment shall meet or exceed all the specifications mentioned in this Bid Document.

Equipment consuming electrical energy, specially pumps and blowers, shall be of energy

efficient design to have minimal possible OM cost, and shall be of standard approved

makes.

Equipment must be serviceable in India. Contractor shall obtain performance and war-

ranty certificates from the Manufacturers, and the same shall be in the name of the

Contractor and transferable to the IITH.

Before procurement, Contractor shall obtain IITH s approval for all equipment satisfying

the above conditions.

5.37 Manufacturer’s Experience

The proposed manufacturers of different equipment should have manufactured and op-

erated equipment in the last 5 years having specified constructional features equal to or

higher than the specified size and rating.

Reference to specifications/ codes of practice

Table 5.20: References to Codes

Description BIS No.

Centrifugally Cast (Spun) Iron pressure pipes for

Water, gas and sewage lncluding fittings. 1536-1989

Specifications for Centrifugally Cast (Spun) D.I. Pipes for

8329-1990
Water, Gas and Sewage.

D.I.Fittings for pipes for water, gas & seweage 9523-1980

Dimensional requirements of rubber gaskets for

Mechanical joints and 12820-1986

push on joints for the use With C.I/ D.I.Pipes

181
 Table 5.20: References to Codes

Description BIS No.

C.I. Specials for Mechanical and push on flexible joints for

13382-1992
pressure pipe lines for water, gas & sewage

Horizontally cast iron double flanged pipes for water,

7181-1986
Gas and Sewage

1538-1976
Cast iron fittings for pressure pipes for water, gas And sewage
(Part 1 to 24)

Rubber rings for jointing C.I.Pipes, R.C.C. Pipes & AC. Pipes 5382-1969

Rubber rings for jointing P.S.C. pipes 5382-1985

Hemp yarn 6587-1966

Rubber Insertion to be used in jointing CI/DI pipes 638-1979

Bolts & Nuts to be used in jointing CI/DI Pipes 1363-1967

Unplasticized PVC Pipes for potable water supplies 1363-1967

Injection moulded PVC socket fittings with Solvent 7834-1987

cement joints for water supplies. (Part 1 to 8)

10124-1988
Fabricated PVC fittings for potable water supplies
(Part 1 to 13)

Methods of test for unplasticized PVC pipes for

12235-1986
potable water supply

Sluice valves for water works purposes (50 to 300 mm Dia 780-1984

Sluice valves for water works purposes (300 to 1200 mm Dia 2906-1984

Surface boxes for sluice valves 3950-1979

Manhole covers for sluice valves 1726-1974

Laying of Concrete pipes 783-1985

Laying of Cast-Iron Pipes 3114-1985

126 of APSS
Laying of PSC Pipes
& 783-1985

Laying of C I Pipes 12288-1987

7634-1975
Laying and jointing of Unplasticized PVC pipes
(Part 3)

Stoneware pipes IS:651-1992

Code of Practice for Ancillary Stonewares in IS:4111-1986

sewerage system Part I & II

182
 Table 5.20: References to Codes

Description BIS No.

IS:12592-1998
Precast Manhole covers and frames
Part I & II

Code of Practice for plain and reinforcement

IS:456:2000
concrete

Batch type concrete mixer 1791-1968

Sheep foot roller 4616-1968

Safety code for excavation works 3764-1966

3696-1966
Safety code for scaffolds and ladders
(Part-I &II)

Safety code for piling and other deep foundations 5121-1969

Safety code for working with construction machinery 7293-1974

Government of India Manual on Water Supply

May 1999 ( Revised )
and Treatment

Gravel for packing 4091 1967

1785 1983
Hard drawn Steel Wire
( Part I and II)

Structural Steel 226 1975

Hard rolled mils steel for concrete 1139 1966

Hard drawn Steel Wire 1566 1982

British Standard 2494 1955

Welding Electrodes 814 1970

Steel Sheets 225 19

Guniting 7322 1994

3589 1966 and

Welded Joints
2041 1962

Tensile Test 223 1950

Earthing 3043 1966

5.38 SPECIFICATIONS FOR ELECTRICAL WORKS

This section of the specification sets out the standard for items of electrical system to

be executed by the Contractor. This section describes the basic system that has to be

adopted for the electrical power distribution of sewage treatment plant. The selection of

power distribution system equipment ratings and layout of the electrical equipment shall

183
consider ease of installation, maintenance and modular addition of equipment for future

expansion. All the components of the electrical system shall withstand the environmental

conditions of the region as described hereafter.

The equipment shall be complete in all respects and device not included in the speci-

fications but essential from code, regulation, statutory requirement, standard practice or

operational flexibility point of view shall be included by the Contractor.

5.38.1 Standards

The equipment standards applicable for the design and installation of the electrical, con-

trol, monitoring systems are the relevant Indian standards. Cognizance shall also be

taken of International standards i.e. International Electro Technical Commission (IEC)

where Indian standard is not available or not clear about the subject.

It shall be designed, assembled and tested to the satisfaction of the Executive Engineer

and shall conform to the relevant standards published by the Indian Standards Institu-

tion, wherever available, in order that specific aspects under the Indian Conditions are

taken care of.

The applicable standards established by the Bureau of Indian Standards govern the

materials and workmanship employed in the manufacture of all equipment/items are:

IS 191 - Copper Specification

IS 319 - Free Cutting Leaded Brass Bars, Rods Specification and Section

IS 325 - Three phase induction motors

IS 335 - New insulating oils

IS 374 - Electric ceiling type fans and regulators

IS 379 - Anhydrous sodium sulphate, pharmaceutical

IS 513 - Cold reduced low carbon steel sheets and strips.

IS 694 - PVC Insulated cables for working voltage up to and including 1100 V.

184
 IS 722 - Specification for AC Electricity Meters.

IS 732 - Code of practice for electrical wiring installations

IS 1079 - Hot Rolled Carbon Steel Sheet and Strip Specification. IS1169 - Electric

pedestal type fans and regulators IS1248 - Direct acting indicating analogue electrical

measuring instruments and their accessories

IS 1255 - Code of practice for installation and maintenance of power cables up to and

including 33kV rating.

IS 1271 - Thermal evaluation and classification of electrical insulation.

IS 1293 - Plugs and socket- outlets of rated voltage up to and including

250 volts and rated current up to 16 amperes Specification. IS 1544 - Cotton calico

IS 1554 - PVC insulated (heavy duty) electric cables

IS 1868 - Anodic Coatings on Aluminium and its Alloys Specification. IS 1897 -

Copper strip for electrical purposes Specification.

IS 1944 - Code of practice for lighting of public thoroughfare: Part 5 Lighting for grade

separated junctions, bridges and elevated roads.

IS 2026 - Power transformers

IS 2062 - Hot Rolled low, medium and high tensile structural steel

IS 2099 - Bushings for alternating voltages above 1 000 Volts

IS 2148 - Electrical apparatus for explosive gas atmospheres Flameproof enclosuresd.

IS 2190 - Selection, Installation and Maintenance of First-aid Fire Extinguishers code

of practice.

IS 2206 - Flameproof electric lighting fittings

IS 2253 - Designation for types of construction and mounting arrangement of rotating

electrical machines

185
 IS 2309 - Code of practice for protection of buildings and allied structures against

lightning.

IS 2419 - Dimensions for panel mounted indicating and recording electrical instru-

ments

IS 2544 - Porcelain post insulators for systems with nominal voltage ¿ than 1000 V.

IS 2546 - Specification for galvanized mild steel fire bucket. IS 2551 - Danger notice plates

IS 2629 - Recommended Practice for Hot-Dip Galvanizing of Iron and Steel

IS 2633 - Methods for testing uniformity of coating of zinc coated articles

IS 2667 - Fittings for rigid steel conduits for electrical wiring

IS 2705 - Current transformers

IS 2925 - Specification for Industrial Safety Helmets

IS 2993 - A.C. motor capacitors

IS 3043 - Code of practice for earthing

IS 3070 - Lighting arresters for alternating current systems

IS 3156 - Voltage transformers

IS 3231 - Electrical relays for power system protection

IS 3347 - Dimensions for porcelain transformer bushings for use in lightly polluted

atmospheres.

IS 3400 - Methods of test for vulcanized rubbers

IS 3419 - Fittings for rigid non-metallic conduits

IS 3427 - A.C. Metal Enclosed Switchgear and Control gear for Rated Voltages

Above 1 kV and Up to and Including 52 kV. IS 3480 - Flexible steel conduits for electrical

186
wiring

IS 3646 - Code of practice for interior illumination

IS 3837 - Accessories for rigid steel conduits for electrical wiring

IS 3842 - Application guide for electrical relays for ac systems

IS 3854 - Switches for domestic and similar purposes.

IS 3975 - Mild steel wires, formed wires and tapes for armouring of cables

IS 4759 - Hot-dip zinc coatings on structural steel and other allied products

IS 4770 - Rubber Gloves - Electrical Purposes Specification.

IS 4795 - Holders for Indicator Lamps for Electronic and Telecommunication Equip-

ment.

IS 5571 - Guide for selection of electrical equipment for hazardous areas

IS 5572 - Classification of hazardous areas (other than mines) having flammable gases

and vapours for electrical installation

IS 5578 - Guide for marking of insulated conductors

IS 5621 - Hollow insulators for use in electrical equipment

IS 5819 - Recommended short-circuit ratings of high voltage PVC cables.

IS 5831 - PVC insulation and sheath of electric cables.

IS 6229 - Method for Measurement of Real-ear Protection of Hearing Protectors and Phys-

ical Attenuation of Earmuffs.

IS 6600 - Guide for loading of oil immersed transformers

IS 6665 - Code of practice for industrial lighting

IS 7098 - Crosslinked polyethylene insulated PVC sheathed cables

IS 7752 - Guide for improvement of power factor in consumer installation.

IS 8130 - Conductors for insulated electric cables and flexible cords.

IS 8224 - Electric lighting fittings for division 2 areas

187
 IS 8468 - On-load tap changers

IS 8478 - Application guide for on-load tap changers

IS 8752 - Towing hook for use between trailers of up to 5 tonnes gross mass and

transport tractor

IS 8789 - Values of performance characteristics for three phase induction motors

IS 8828 - Electrical Accessories - Circuit Breakers for Over Current Protection for

Household and Similar Installations.

IS 9283 - Motors for submersible pump sets

IS 9334 - Electric motor operated actuators.

IS 9537 - Conduits for electrical installations

IS 9583 - Emergency lighting units

IS 9677 - Guide for limits of temperature-rise of the windings of electrical equipment

when tested by different methods

IS 9678 - Methods of measuring temperature rise of electrical equipment.

IS 9921 - Alternating current disconnectors (isolators) and earthing switches for volt-

ages above 1000 V

IS 9974 - High pressure sodium vapour lamps

IS 10118 - Code of practice for selection, installation and maintenance of switchgear

and control gear

IS 10322 - Luminaires

IS 10418 - Drums for electric cables

IS 10601 - Dimensions of terminals of high voltage switchgear and control gear.

IS 10810 - Methods of test for cables

188
 IS 11037 - Electronic type fan regulators

IS 11171 - Specification for Dry-Type Power Transformers.

IS 11353 - Guide for uniform system of marking and identification of conductors and

apparatus

IS 12065 - Permissible limits of noise level for rotating electrical machines

IS 12615 - Energy efficient induction motors- three phase squirrel cage.

IS 13340 - Power Capacitors of Self-healing Type for AC Power Systems having Rated

Voltage up to 650 V Specification.

IS 13341 - Requirements for ageing test, self-healing test and destruction test on

shunt capacitors of the self-healing type for ac power systems having a rated voltage up

to and including 650 V.

IS 13346 - Electrical apparatus for explosive gas atmospheres-General requirements

IS 13369 - Stationary lead acid batteries (with tubular positive plates) in monobloc

containers.

IS 13383 - Methods of Photometry of Luminaires. IS 13440 - Code of safety for methyl

chloride.

IS 13703 - Low Voltage Fuses for voltages not exceeding 1000V AC or 1500 V DC.

IS 13779 - AC Static Watt-hour Meters, Class1 2

IS 13849 - Specification for portable fire extinguisher dry powder type (constant pres-

sure).

IS 13875 - Digital measuring instruments for measuring and control.

IS 13925 - Shunt capacitors for ac power systems having a rated voltage above 1000 V.

189
 IS 13947 - Low-voltage switchgear and control gear

IS 14697 - AC Static transformer operated Watt hour and VAR Hour Meters

IS 14981 - Live working-Earthing or earthing and short-circuiting equipment using

lances as a short-circuiting device-lance working

IS 14927 - Cable trunking and ducting systems for electrical installations

IS 14993 - Saddles, pole clamps (stick clamps) and accessories for live working

IS 15086 - Surge arresters

IS 15652 - Insulating mats for electrical purposes Specification.

Other applicable standards established by the International Electro technical commis-

sion (IEC), NFC etc. govern the materials and workmanship employed in the manufacture

of all equipment/items are:

IEC 60076 - Power transformers - Part 11: Dry-type transformers.

IEC 60335 - Household and similar electrical appliances - Safety - Part 1: General

requirements.

IEC 60669 - Switches for household and similar fixed-electrical installations - Part 1:

General requirements.

IEC 60751 - Industrial platinum resistance thermometers and platinum temperature

sensors.

IEC 60789 - Medical electrical equipment - Characteristics and test conditions of ra-

dionuclide imaging devices - Anger type gamma cameras.

IEC 60896 - Stationary lead-acid batteries - Part 22: Valve regulated types Require-

ments.

190
 IEC 60947 - Low-voltage switchgear and control gear - Part 1: General rules. IEC

61537 - Cable management - Cable tray systems and cable ladder systems. IEC 61643

- Low-voltage surge protective devices - Part 12: Surge protective devices connected to

low-voltage power distribution systems - Selection and application principles.

IEC 61921 - Power capacitors - Low-voltage power factor correction banks.

IEC 62305 - Protection against lightning - Part 4: Electrical and electronic systems

within structures.

IEC 62271 - High-voltage switchgear and control gear - Part 101: Synthetic testing

Where provisions of the pertinent codes and standards conflict with these Specifi-

cations, Drawings and Datasheets or with each other, comply with the more stringent

provision. In such cases, the decision of Engineer-in-Charge, IITH shall be final and

binding .

5.38.2 Regulation

It is essential that the electrical power distribution system will comply in all respects with

the relevant statutory and regulatory instruments of state of Telangana and that of In-

dia. The relevant, state and national, statutory and regulatory instruments for electrical

installations are as follows:

The Indian Electricity Rules 1956

The Electricity Act 2003

5.38.3 Safety and security

It is essential at all times to maintain a safe system of working and to comply with all

enactments, regulations and working rules relating to safety, security, health and welfare

of all persons who may be affected by the work.

In particular it has to be ensured that only persons who are properly trained for their

duties are employed, and that the correct tools and procedures are used.

Nothing which has been written into or omitted from this document shall be taken to re-

lieve the Contractor from the obligations under this clause. No clause in this specification

shall prevent the executing agency from drawing the attention of the Engineer-in-Charge

to any feature of the works which is not consistent with normal safety practices nor pre-

vent him putting forward proposals at any time which would increase the safety of the

191
installations.

The design should include all reasonable precautions and provisions for the safety of op-

erating and maintenance personnel.

5.38.4 Electrical switchgear room environment

Electrical switchgear rooms shall be designed to provide a non-hazardous, clean and dry

location for the switchgear/motor control centers/power control centers and associated

equipment. Rooms shall be ventilated with air taken from non-hazardous and clean

areas.

5.38.5 Drawing, Instructions and Certificates

The Contractor shall supply with the tender a schematic electrical circuit diagram show-

ing thereon the various switches, cables and motors. Dimensions shall be in metric units.

On acceptance of the tender the Contractor shall submit 3 sets of the following draw-

ings for prior approval of Engineer-in-Charge:

Layout with cable, sizes and all details.

Circuit diagram

Wiring diagram of starters, factory-made panels.

Front elevation of the control panel.

5.38.6 Voltage and frequency variations

Electrical equipment shall function satisfactorily during voltage fluctuations within +10%

and -10% of the stated voltage levels and at frequencies within +/-5% of the stated fre-

quency.

5.38.7 Phase sequence

Phase sequence shall be specified in alphabetical order, each phase reaching its maxi-

mum in time sequence in this order. Bus bars shall be marked as R.Y.B. and N as seen

from the front or operating side of a switchboard or panel.

Cable terminals and apparatus which are to be connected directly or indirectly to supply

conductors shall be marked U.V.W. The neutral and earth shall be marked as N, E re-

spectively.

192
5.38.8 Compatibility

Components used with electrical switchgear, motor control gear and control panels shall

be uniform throughout the works in order to reduce spare holdings. Electrical enclosures

housing switchgear, motor control gear, control systems, terminations shall each be of

similar construction throughout the works in order to achieve a consistent appearance.

5.38.9 Enclosures

Enclosures shall be constructed to provide an adequate level of protection form the envi-

ronment. The following minimum standards shall be applied unless otherwise specified:

* Switchgear and control panels located in switchgear or control rooms - IP 54

* Switchgear and control panels located in plant rooms - IP 55

* Equipment located externally in sheltered locations - IP 56

* Equipment located externally in exposed locations - IP 65

* Equipment liable to be periodically submerged - IP 68.

The IP ratings are defined by IEC 529.

5.38.10 Potentially explosive areas

Ventilated dry wells and wet wells open to the atmosphere shall be considered to be non -

hazardous. Equipment shall be selected and installed and inspected in accordance with

the requirements IS 5571.

5.38.11 Identification

Each main and auxiliary item of plant shall have permanently attached to it in a conspic-

uous position a nameplate and rating plate. Upon these shall be engraved, in English,

the manufacturers name, direction of rotation, type and serial number of plant, details of

the loading and duty at which the item of plant has been designed. All indicating and op-

erating devices shall have securely attached to them or marked upon them designations

as to their function and proper manner of use. Provision shall be made to incorporate

descriptive numbering codes as indicated on the layout drawings.

Such nameplates, rating plates and labels shall be of a rigid type, at least 3 mm

thick, laminated and engraved plastic material, with black block capitals on a white

background. The labels shall be fixed by non-ferrous or stainless steel screws.

Warning labels shall be of similar construction with black block capitals on a yellow

background. Weatherproof labels for use outside the buildings shall be rigid type lami-

nated plastic. All field items shall be tagged with 50 25 mm engraved labels. The label

shall state the item tag number and hazardous area classification in case it falls under

193
it and shall be attached by a corrosion resistant ring to a fixed portion of the item. The

ring shall retain the tag securely but shall allow transfer to a replacement item when

necessary.

Warning labels shall be provided where necessary to warn of dangerous circumstances

or substances. Inscriptions or graphic symbols shall be black on yellow background and

to internationally recognized standards.

Instruction labels shall be provided where safety procedures such as wearing of protec-

tive clothing are essential to protect personnel from hazardous or potentially hazardous

conditions. These labels shall have inscriptions or graphic symbols in white on a blue

background.

5.38.12 Harmonics

The limits for harmonics in the power system as a result of non-linear loads are to be

limited to those standards imposed by the power supply company i.e. TSSPDCL.

5.38.13 Surge Protection

Surge protection shall be provided at the main control panel end of instrumentation

cabling connecting equipment located external to buildings.

5.38.14 Cable Support Systems

5.38.14.1 Trays for Power Cables:

Ladder type cable trays shall be used for power cables. Material of construction shall be

of hot dip galvanized steel. Minimum thickness of all ladder type cable trays shall be 2

mm for trays up to 300 mm width, thickness shall not less than 2.5mm for trays above

300mm up to 600mm.Height of all power cable trays shall be minimum 100mm

5.38.14.2 Cables External to Buildings and Structures

Cables external to buildings and structures shall be installed underground through suit-

able sized uPVC conduits , concrete ducts or shall be directly buried.

Where cables passes below internal or external roads or areas of hard standing, ca-

bles shall be laid through concrete ducts. Cable concrete duct systems shall incorporate

suitably located draw- pits/inspection chambers/pull boxes whenever there is change in

direction of route of the cable. Cables crossing below the walls or structures shall be laid

through uPVC conduits.

194
 Minimum 30 % space inside uPVC conduits and concrete ducts shall be kept for

future expansion. The minimum depth LV cable installation shall be 700 mm. Cable

trays and supports shall be in accordance with IEC 61537. Cable tray supports shall

provide adequate strength with minimum rigid support to the fully laden cable tray along

its entire length. All cable trays inside the control room, pump room and out of the trench

shall be closed. A maximum of two layers of cable shall be installed on any tray. All cable

trays shall be supported to prevent sagging.

5.38.14.3 Corrugated Flexible Conduit

uPVC corrugated flexible conduits shall be manufactured as per IS 9537 ideally suited

for electrical wiring and cable protection.

Use liquid tight flexible uPVC conduit for termination at Junction boxes, Local con-

trol stations (LCS), termination to motors, field instrumentation and process equipment

unless otherwise specified.

5.38.14.4 Conduit Fittings:

Fittings, as required, for use with conduit specified, with coating and colour same as

conduit shall be provided.

All conduit fittings and covers shall be weatherproof and watertight as per Indian stan-

dard 3419, unless otherwise noted.

5.38.14.5 Conduit Fastenings

Use uPVC straps for uPVC conduits and steel straps for galvanized steel / galvanized iron

conduits.

Channel type supports shall be provided for two or more conduits.

All surface installation horizontal runs of conduits should be secured at maximum

distance of 0.9 meters and vertical runs of conduits should be secured at maximum dis-

tance of 1.2 meters.

Fastening should be properly tightened to restrict thermal movement of conduit.

195
5.38.14.6 Expansion Fittings or couplers

Appropriate water tight expansion sleeves with bonding where conduit crosses a struc-

tural expansion joint or to accommodate for thermal movement due to temperature

change on surface installations, complete with grounding strap and clamps shall be pro-

vided.

Expansion couplers shall be installed with a short side coated with solvent cement and

coupler pushed firmly over the conduit down the nib. The slip side coated with silicon

grease receives the conduit to a midpoint to the nib. This will then permit for expansion

or contraction providing the conduit is free to move in the saddle.

5.38.14.7 Outlet and Conduit Boxes

Outlet boxes shall be sized in accordance with IS 3419.

Appropriate Switch boxes shall be provided where wiring devices such as switches, fan

regulators etc. are grouped.

Blank cover plates shall be provided for boxes without wiring devices.

Where outlet boxes are used for more than one system appropriate combination of

barriers shall be provided.

Outlet boxes made from uPVC or galvanized steel and shall be suitable for mount-

ing/fixing on masonry and/or concrete construction and shall be flush mounted or sur-

face mounted as per site requirement.

All fittings, boxes and covers, in below grade areas, shall be weatherproof conforming

to relevant IS unless otherwise noted.

Outlet boxes, conduit boxes and fittings for hazardous locations shall be as per IS

5571.

uPVC and galvanized steel boxes with fittings (bends elbows, tees crosses etc) for

surface wiring of switches and receptacles.

5.38.14.8 Hazardous Areas

For hazardous areas, provide epoxy coated rigid galvanized steel conduit, conduit fittings,

compound, etc., to conform to the code requirements for the specific type of hazardous

i.e. Zone 1. All boxes, fittings and joints shall be threaded for connection to conduit

terminations and shall be explosion proof. Threaded joints shall be made up with at least

five threads fully engaged.For flexible connections at motor terminals, provide liquid tight

flexible conduit and fittings approved for Zone 1 locations. Conduit, conduit fastener

and conduit fittings shall be of rigid galvanized steel as manufactured by recognized

manufacturers.

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5.38.14.9 Markers

300 mm wide polyethylene Cable Marker Tape, Red in colour with the following imprinted

continuously over its entire length: DANGER-sign of Scull Bones BURIED ELECTRIC

CABLE BELOW.

The Cable route marker post in circular in shape made up of hot dip galvanized steel

of approximate diameter 100 mm and thickness not less than 4 mm. shall be used for

cable route indication. The inscription shall indicate the presence of a cable below, the

depth and voltage rating.

5.38.14.10 Sealing Compound

Conduit fitting shall be installed in the system using solvent cement for restriction of

water in it and silicon grease where installation is subject to frequent changes.

PVC solvent cement shall be used as a method of joining uPVC conduit into fitting like

couplings, adaptors, bends and boxes, especially formulated for watertight joint.

5.39 LV switchgear

The switchgear shall be designed and manufactured in accordance with IS 13947 and

IEC 60947. The Motor Control Centre (MCC) shall be intelligent. A MCC is considered in-

telligent when the MCC utilises intelligent components, such as overload relays, starters,

controller and functional units are interconnected via fieldbus systems.

The MCC shall be designed using Form 4 separation and shall contain, at the mini-

mum, the following items:

Main Incomer Feeders including 20% spare feeders. Plant end equipment starters.

The MCC shall have top cable entry with front access only.

The MCC Main Incomer protective device shall be rated to ensure discrimination with

all upstream and downstream protective devices.

The MCC shall be provided with an earth bar and shall form the main earth terminal

for the installation.

The MCC shall be fitted with thermostatically controlled anti-condensation heaters

where required. Provision of communication with each feeder with PLC shall be provided.

MCC incomer shall be MCCB for rating up to 630A. For rating above 630A, ACB shall be

preferable.

5.39.0.1 PCC / MCC:

Unless otherwise specified, every 415 V motor control centre (MCC) shall be of the floor-

standing multi-compartment type complying with IS 13947 and IEC 60947.

197
 The overall enclosure of the MCC shall be to IP54 for indoor use. Except for any

with drawable circuit breaker, busbar and cabling alley, a hinged door shall be provided

for each compartment of the MCC. The door shall be interlocked with any switch-fuse

or MCCB/MPCB fitted in the compartment and intended as a means of isolation for the

circuits inside the compartment so that the door can only be opened when the switch-fuse

or MCCB/MPCB is in the Off position.

Every motor starter and other functional unit shall be installed in a dedicated com-

partment.

Except for with drawable air or moulded case circuit breakers, every motor starter and

other functional unit shall be of the fixed or swing-out type, where:

fixed means that, except for those components which must be mounted on the com-

partment door, the starter or other functional unit is fixed within the compartment

swing out means that, except for those components which must be mounted on the

compartment door and any components fixed within the compartment, the starter or

other functional unit is mounted on a hinged panel which can swing out when the com-

partment door is open. Swing- out units will only be acceptable for starters, rated equal

to or less than 7.5 kW.

Except for the compartment doors, all removable covers, the removal of which gives

access to live electrical circuits shall be fixed by means of bolts.

Switches and indicating meters such as ammeters, voltmeters, etc shall not be posi-

tioned above 1800 mm or below 300 mm. Devices for isolation and switching shall be

accessible within the zone 300 mm to 1800 mm above floor level.

Every fuse in the power circuit shall be of the HRC type unless otherwise stated.

Wiring inside the MCC shall incorporate copper conductors, the minimum acceptable

cross- sectional area being 2.5 mm2 for power circuits and 1.5 mm2 for control and

monitoring circuits. Wiring for power circuits shall be phase colour identified throughout

in accordance with IS 732. Alphanumeric identification ferrules shall be fitted to each

end of each wire forming part of a control and monitoring circuit. Each ferrule shall

completely encircle the wire. The identification of each wire shall be unique and shall

correspond to that shown on the manufacturers schematic and wiring diagrams.

5.39.0.2 Busbar:

The cable connections from the busbars to the functional units shall be kept as short as

practicable and shall be sized, routed and supported to minimise the risk of a fault.

It shall be necessary to use tools to remove the covers from the busbar system com-

partment. Each removable cover shall bear a warning label engraved on it.

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 Wherever a voltmeter, kW, kWh, kVA, kVAh or similar meter is fed directly from the

busbar system or from the cable side of an air circuit breaker, it shall be protected by

MCB or fuses.

5.39.0.3 Distribution board

All the switch Boards, Panels shall be neatly wired using 1100/660V PVC insulated

stranded copper cable of minimum 2.5 sq.mm. Copper Bus Bars also may be provided to

suit the requirements.

Each wire shall be identified at both ends with cable marker.

Distribution Boards shall be housed in metal clad case or board conforming IS 4237.

The Sub- distribution Boards (SDB) shall be equipped with rigidly fixed miniature circuit

breaker complying IS 8828 in the phase leads with over load and short circuit protection.

The MCBs shall have adequately sized terminals for the outgoing leads. The distribution

boards shall have adequately rated phase and neutral bus bars of high conductivity cop-

per. Earth the bus bar with the necessary number of terminals for connecting the earth

continuity conductors.

Each SDB shall have schematic diagram or single line diagram pasted or permanently

fixed inside the cover stating the details of circuit incomer and rating of MCB. Non-

flammable insulating shields shall be provided to prevent fire hazards during operation

of MCBs. The SDB shall not be mounted at a height exceeding 1800 mm from ground

level.

Main Distribution Boards shall be wall mounted. Main Distribution Boards shall be

erected in each switching room, and sub-distribution boards shall be located according

to the distribution of load and the equipment to be connected and its location.

Each lighting distribution board (LDB) Incomer shall be provided with ELCB. Each

outgoing feeder of LDB shall be provided with MCB. Power distribution board shall be

provided to cater window/split/cassette type air-conditioning load and auxiliary load (e.g.

welding, drill machine, Grinder, EPABX etc.)

5.39.0.4 Spare compartment

Minimum 20% of spare feeders shall be provided in each MCC panel. Each spare com-

partment shall be equipped to the extent that would enable it to be converted into a

direct on line starter/star delta/soft starter at a later date without having to de-energise

the busbars or shutdown any other circuit.

5.39.0.5 Local push button station

Construction features

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 The constructional features of the local push button stations shall be as follows :

(a) Metal enclosed, weather proof, suitable for mounting on wall or steel structures.

The enclosure shall be sheet metal of 2 mm thickness.

(b) Outdoor type push buttons shall be completely weather, dust and vermin proof and

shall be provided with cannopy. Degree of protection shall be IP:55.

(c) Metal parts shall be given tropicalising treatment as per standards and painted

with one coat of epoxy primer and two coats of light grey epoxy paint.

(d) Provided with inscription plates of rear engraved with white letters on black back-

ground.

(e) The letter size shall be 6 mm.

(f) Provided with two earthing terminals suitable for 14 SWG G.I. wire.

(g) Provided with removable undrilled gland plate and cable glands for appropriate

sizes of cable. The cable entry shall be from the bottom.

(h) Push button contacts shall be designed for extra robust both mechanical and elec-

trical operation. High quality material shall be used in their construction to ensure me-

chanical life exceeding 10 million switching operations. The contact shall be of silver alloy

of 10 A continuous current rating.

Push buttons

(a) All push buttons shall be:

i. Fitted with two (2) normally open and two (2) normally closed contacts rated to carry

and break 6 Amps at 415 Volts (10 A at 240 V AC). ii. Provide integral escutcheon plates

marked with its function.

(b) The open/close/start push buttons shall be of the momentary contact push to

actuate type and shall be green in colour. (c) The stop push buttons shall be stay put

type with mushroom knob and shall be red in colour.

Type of Push Button Stations

The following types of push button stations shall be supplied:

(i) Push button station type A - Each P.B. station suitable for indoor installation and

shall comprise two push buttons viz. START and STOP for control of non-reversible

motors.

(ii) Push button station type B - Each P.B. station for indoor installation and shall

comprise of three push buttons viz. OPEN CLOSE and STOP for control of reversible

motor.

200
5.39.0.6 Earthing conductor:

A suitably sized tinned copper earth-bar shall be provided in an accessible location inside

and along the length of the motor control centre. If the MCC is to suit bottom-entry

cables, the earth- bar shall be at the bottom of the MCC. If the MCC is to suit top-entry

cables, the earth-bar shall be at the top of the MCC.

5.39.0.7 Air Circuit Breaker(ACB):

Air circuit breakers shall be utilised for rated current equal to or greater than 630 ampere.

Where air circuit breakers are specified, the operating mechanism of each air circuit

breaker shall have mechanical ‘ON’ and ‘OFF’ indicators and a manual trip device fitted

with means for locking. Hand charged and motor charged spring mechanisms shall have

mechanical indicators to show ‘SPRINGS CHARGED’ and ‘SPRINGS DISCHARGED’.

Operating mechanisms of the hand charged and motor charged spring types shall be

arranged so that release of the springs to close the circuit breaker can only be achieved

by a deliberate action. It shall not be possible for vibration or mechanical shocks to

release the charged springs. Motor charged spring mechanisms shall be arranged so

that charging is initiated automatically following a discharge, and the necessary limit

stops and switches for the automatic control of the charge once initiated, shall form an

integral part of the mechanism. It shall be possible to hand charge a motor charged

spring mechanism in an emergency.

Spring operated mechanisms shall be provided with volt-free contacts to give indica-

tion that the springs are charged.

The closing solenoids of d. c. solenoid operated mechanisms shall be suitable for

operation at a minimum of 80% of the nominal supply voltage and shall not malfunction

or cause excessive vibration when energised at 120% of the nominal supply voltage.

To facilitate maintenance and adjustment of contacts, it shall be possible to slow-close

the circuit breaker. This operation shall only be possible in the fully withdrawn position.

Any necessary operating handle, lever or tube shall be supplied.

Each circuit breaker shall be trip free and be provided with the following mechanical

interlocks:

It shall not be possible to withdraw or to replace the circuit breaker from the service

position unless the breaker is open.

It shall not be possible to attempt to close the breaker unless the closing springs are

fully charged.

It shall not be possible to remove the circuit breaker from its fixed cassette without

manually overriding a catch.

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 Each circuit breaker shall be versatile enough so as to accommodate rating plug.

Each circuit breaker shall have mechanical indicator to display the deterioration sta-

tus of the contacts.

5.39.0.8 Moulded case circuit breaker (MCCB)

Moulded Case Circuit Breaker(MCCB) shall be a circuit breaking device which can make,

withstand and break current whose intensity is atmost equal to its nominal current and

protection device which can automatically break over current which may occurs as a

result of fault in the installation.

The terminals and connections between all current carrying parts shall be designed to

assure permanently low resistance connections.

MCCB shall have rated operational voltage of 415V, 50Hz power supply system.

MCCB shall have minimum fixed symmetrical interrupting capacity i.e. ICS=50

MCCB shall have at least 2 Numbers each NC and NO spare auxiliary contacts as

required. MCCB shall conform to the latest application of standard IS 13947-2. MCCB

shall have minimum power loss as defined by the standard IS 13947.

MCCB shall be current limiting type with let through energy limit as specified in

IS/IEC 60947. MCCB housing shall be heat resistant and having high impact strength.

MCCB shall have under voltage release feature.

All incomer MCCB shall be microprocessor based with adjustable overload (40% to

100%), short circuit (2 to 10 IN) and earth fault protection (10 to 50%) and shall have

RS 485 communication compatibility. All Incomer MCCB shall be provided with rotary

handle. All other MCCBs will be thermal magnetic type with earth fault protection.

MCCB terminals shall be protected against finger contact to IP 2X degree of Ingress

Protection to provide total safety to the operating personnel.

Considering MCC panel, 3Pole + Neutral MCCBs will be used as a main incomer and

for power distribution and 3Pole MCCB will be used for outgoing for each motor load.

Also 3Pole + Neutral MCCB/MCB with ELCB will be used as an incomer to lighting DB.

MCCB Operating mechanism shall be quick- make, quick-break and trip-free type.

The ON, OFF and TRIP positions of the MCCB shall be clearly indicated and visible to the

Contractor when mounted as in service.

MCCBs shall be capable of withstanding the thermal stresses caused by overloads

and locked rotor currents of values associated with protective relays settings of the motor

starting equipment and the mechanical stress caused by the peak short-circuit current

of value associated with the switchgear rating. The maximum tripping time under short

circuit shall not exceed 20 milliseconds.

202
 MCCB terminals shall be suitable for accepting spreader links to receive cable lugs for

cable sizes relevant to circuit ratings. Phase barriers should be provided for isolation of

the poles.

Clearly-labelled isolating circuit breakers shall be provided for each incoming power

supply. Switches shall be spring loaded contacts that close fully without requiring full

operation of the handle. The handle and cover shall be interlocked so that the handle

cannot be operated when the cover is open and the cover cannot be opened unless the

switch is in the off position. The on and off positions of each switch shall be indicated

clearly.

5.39.0.9 Miniature Circuit Breaker (MCB):

MCBs required shall be of single-pole or three pole (with or without neutral) types.

The rated voltage for single pole and three pole (with or without neutral) shall be 240

V 415 V, 50 Hz frequency respectively.

All Single pole and three pole (with or without neutral) MCBs shall be suitable for 10

KA as per IS: 8828.The procedure for making the Short Circuit test and the test circuit

etc. shall be in accordance with the IS: 8828.

5.39.0.10 Instrument Transformers

Potential Transformers:

Potential transformers shall conform to IS 3156 and IEC 186, dry type for indoor use,

with following characteristics:

Nominal voltage : 415 V. Rated frequency: 50 Hz. Voltage ratio: as per control circuit

requirement.

Potential transformer shall be equipped with fuse holder and fuses.

Current Transformers:

Current transformers(CT) shall conform to IS 2705, IEC 60044-1, dry type for indoor

use complying with following characteristics:

The CTs shall be of solid core with round window type with accuracy 0.2% for con-

sumer check metering.

The secondary leads shall be terminated with tinned Cooper rose contact terminals

with arrangements for sealing purposes.

Polarity (both for primary and second leads) shall be marked.

The CTs shall be varnished, fiberglass tape insulated or cast resin, air-cooled type.

Only super enameled electrolytic grade copper wires shall be used.

The CTs shall have marking and nameplate as per IS 2705 in addition to class of

insulation ISF. The markings shall be indellible. The nameplate shall be securely fixed

203
to the body of the CT and contain following data

Nominal voltage class: 415V. Rated frequency: 50 Hz. Rated primary current: as

indicated in approved SLD or as per feeder requirement. Secondary Ampere rating of CT

shall be 5A where CT and metering /protection units are in same panel. 1A -where CT

and metering /protection units are in different panel.

Short-time dynamic current rating, 2.5 times the rated short-time thermal current

rating. Short-time thermal current rating shall be 100 times primary rating.

5.39.0.11 Metering and Switchboards Instruments

Indicating Instrument and Meters:

Measuring instrument i.e. ammeter,volt meter and Energy meters mounted on each

cubicle of control panel shall be digital. Digital energy meter for measuring total wattage,

power factor with all electrical parameter shall be provided at incomer side and shall have

0.5 class accuracy.

5.39.0.12 Digital Indicating Instruments

Digital Indicating Instruments shall be of 96mm square

For digital meters, display shall be red colour LED.

All digital meters (ammeter, voltmeter) will be of 3 1/2 digits display. Accuracy class

shall be Class 1.0 unless otherwise specified. Auxiliary Supply shall be 230V AC.

Digital Meter shall conform to IS 13875 and IEC 61010.

Type test report from NABL/ERTL or NABL accredited lab shall be provided.

Digital Energy Meter (Multifunctional Meter): General Requirements The meter shall

be suitable for operation in 3 - phase networks, balanced as well as unbalanced load,

four quadrant metering.

It shall be possible to use the multifunction meter directly in 415V (L-L) networks.

The current primary inputs shall be configurable at site in steps for measuring x / 5

A or 1 A current transformers through front buttons.

The multifunction meters shall be suitable for operation up to 45 Degree Celsius.

The meters shall be work on 230V AC power supply. The multifunction meters shall

have degree of protection against ingress of dust water. The multifunction meters shall

have backlit LCD/LED display with adjustable contrast. The meter shall be tamper-proof

(password protected) to avoid mishandling by unauthorized person.

Accuracy of meter shall be 0.5 unless otherwise specified.

It shall conform to IS14697, IS13779, IEC62052, IEC 62053.

204
5.40 Measured Values requirement

All metered values will be in ”true RMS” values. The monitor shall include a keypad al-

lowing for the viewing of different selected values. The monitor shall display the following

values:

Table 5.21: Measured Values requirement

Voltages Phase-phase / phase-neutral

Currents Per phase / neutral
Apparent, active and reactive power Three phase total
Power factor Individual phase and total average
Frequency 50 Hz +/- 5%
a) Voltage - phase-phase
b) Line current
Minimum / maximum values c) Active, Reactive and Apparent Power
d) Power factor
e) Frequency
Active energy Import/ export
Reactive energy Import/ export
Three phase average rating for active and
Energy demand per measuring period
reactive power: 30 min.
Minimum / maximum rating values
Shall be possible to be measured
within the measuring period

Measurement Accuracy

The meter shall have at least 3 pulse Input and 2 volt free pulse output as standard

The meter shall have LED output configurable for active, reactive and apparent energy

for testing of accuracy communication.

The meters shall have inbuilt RS485.

5.40.0.1 Indicating Lamps:

Indicating lamps shall be of the LED type, with low watt consumption. Indicating lamp

shall be of the double contact, glass lens cap type rated for operation for either a 230

V a-c voltage. Indicating lamps shall be provided with series resistances to avoid short

circuiting of control supplies in the event of fusing of the LED. Lamps shall be provided

with translucent lamp covers. Bulbs and lenses shall be interchangeable and easily

replaceable from the front.

5.40.0.2 Push Buttons

Illuminated type, momentary action, flush type pushbuttons shall be provided. It shall be

sealed to at least IP54. Push button colors will be Green for Start and Red for Stop. Con-

tact shall be silver plated. Operating voltage of push button will be 230V AC. “Start“and

“Stop“ push buttons shall be provided for non-reversible motors. Mechanical life of push

205
button shall be minimum 1, 00,000 cycles. Operating temperature of push button is 45
◦
C.

5.40.0.3 Fuses

For short circuit protection, Semiconductor fuses shall be used for soft starter operated

motors. HRC Fuses of suitable characteristics shall be provided for feeders unless other-

wise specified.

5.40.0.4 Control Switches

Positions labeled, heavy-duty Contactors standard, multiple contacts rated 230V, 5A,

AC. For Mode Selectors use make before break contacts. The selector switches shall be

bump-less.

5.41 Motor Starter

Each motor starter shall incorporate the following features in addition to complying with

the requirements specified elsewhere in the specification.

A suitably rated 3-phase neutral (four pole) MCCB as a means of isolating the starter

from the busbars and to provide short-circuit protection. A facility shall be provided to

enable the MCCB to be padlocked in the Off position only.

Where any control or monitoring circuit inside the starter compartment operates at

a voltage in excess of 24 V d.c. and is energised from outside the starter compartment,

both poles of the circuit shall enter the starter compartment via miniature circuit breaker

(MCB) so that the circuit inside the starter is isolated when the MCB is open.

An isolating transformer shall be provided to feed the control and monitoring circuit.

The primary of the transformer shall be fed from one phase and the neutral; the phase

connection shall be protected by fuse. The output from the secondary shall be 110V/

240 V. One pole of the transformer secondary shall be earthed and a fuse shall be fitted

in the other pole. An earthed metallic screen shall be provided between the transformer

primary and secondary windings.

A test switch to enable the control and monitoring circuit to be tested while the main

circuit feeding the motor is isolated. The test switch shall only be accessible when the

starter compartment door is open. The switch shall take the form of a pushbutton which

has to be pulled out to select the test position and pressed in to select the normal position.

The test button shall be located in the compartment so that the starter cannot remain in

the test mode when the compartment door is shut.

An ammeter shall be provided to measure the line current drawn by the motor. The

206
ammeter shall be connected on the compartment door with help of Ammeter selector

switch. The ammeter shall have an extended range to suit the motor locked rotor current

and an adjustable red pointer which can be used to indicate the motor full load current.

Following Relay Protection shall be provided

A Run relay, the coil of which shall be rated at energised from the relevant control and

instrumentation compartment

An Available relay

An Inhibit relay, where appropriate

One or more Trip relays, where appropriate

A Local switch-disconnector closed relay, where appropriate. This relay shall only be

energised when the switch-disconnector local to the pump is closed.

An overload and single phasing protection device

A motor over-temperature protection device to suit the thermistors or thermostat fitted

in the motor

Other drive protection relays, as appropriate

The following control devices mounted on the starter door: A Red Start pushbutton

A Green Stop pushbutton

A Yellow Lamp test button

The following indicator lamps mounted on the starter door: A Red lamp for pump

Stopped

A green lamp for pump Running

An amber lamp for Fault

Motor Starting

In selecting the appropriate type of fixed speed starter for a motor, account shall be

taken of the following factors:

The torque/speed curves of the driven equipment and of the motor

The calculated frequency of starting each motor and the starts/hour for which the

motor is suitable

5.41.1 Voltage regulation

The motor starter shall be one of the following types:

Direct-on-line

Star-delta

Soft start

Variable frequency drive

207
 Of these, direct-on-line starters shall be provided wherever the voltage regulation

which results is within the specified limits. DOL starter shall be used for the motor

rating up to 7.5kW

For the motor rating above 7.5 kW, star delta starter shall be utilized

If soft-start units shall be provided for motor rating above 55 kW, the appropriate

characteristics (e.g. voltage ramp, pump start and possibly soft stop) shall be determined.

Variable frequency drive (VFD) shall be used where speed variation is essential or can

be done by keeping process requirement unchanged. Selection of proper VFD shall be

done to save the energy.

5.42 Electric Motor

Matching to Driven Equipment

The kW rating of each electric motor shall greater than 10% of the power absorbed

by the drive at the duty point. For motors to be operated by variable frequency drives

(VFD), the kW rating to be used in this computation shall be the nominal kW rating of

the motor derated as required, to allow for diminished cooling and increased losses .The

torque/speed characteristic of each motor shall be adequate to accelerate the drive to the

required operating speed in an acceptable time.

Frequency of Starting

The Contractor shall calculate the maximum number of starts per hour which could

occur for each drive under automatic control. Each motor shall be suitable for the calcu-

lated maximum number of hot/cold starts per hour.

Energy Efficient Motors

All motors shall comply with IS 325.

All motor shall be of EFF-2 class as per IS 12615.

Motors to be installed in classified areas shall conform to the requirements of IS:

5571. Motors for Use in Variable Frequency Drive Systems Every motor which is to be

fed from a frequency converter (variable frequency drive) shall be suitable for continuous

operation at any speed within the specified speed range and with the harmonics generated

by the frequency converter. Enhanced cooling and design of the motor windings shall be

provided where necessary to meet this requirement.

Anti-Condensation Heaters

Except for the motors in submersible pumps, submersible mixers and submersible

propellers, an anti-condensation heater shall be fitted to every motor located in areas

where condensation on the motor may occur (e.g. damp, unheated room).

Anti-condensation heaters shall be sized to raise the temperature inside the motor

208
several degrees above the dew point temperature. The heater surface temperature shall

not exceed 200C.

A warning label, black letters on a yellow background shall be fitted to the relevant

terminal box to indicate that the heater may be energised while motor is de-energised.

Heater terminals shall be shrouded. On larger motor, a separate terminal box shall be

provided.

Over-Temperature Protection

The protective over-temperature device shall be in close thermal contact with each

phase of the stator windings. For upper and lower bearing also over temperature protec-

tion shall be provided. These shall be provided for every motor which satisfies any of the

following criteria:

It is operated as a variable speed drive.

It is subject to onerous operating conditions such as a high maximum number of

starts per hour or a long run-up time.

It is installed in a potentially hazardous area. Motor rating equal to or greater than

22kW. For submersible pump motors, thermostatic devices will be an acceptable type of

over-temperature sensor. Otherwise, each over-temperature sensor shall be a thermis-

tor. All thermistors shall be connected together to provide a single electrical circuit for

connection to an external relay which will be capable of tripping the motor.

Overload Protection

Electric motors having a rating equal to or greater than 0.37 kW shall be provided with

control equipment incorporating overload protection of the motor.

5.42.1 Cable Termination Facilities

Wherever a motor forms part of a submersible machine, it shall be supplied complete

with a factory-fitted cables and IP 68 terminal box. These cables shall be long enough to

permit termination in a conveniently located junction box and shall, in any event, be not

less than 15 metres long.

For every other motor, cable termination boxes shall be provided and be suitable for

air termination of cables. They shall be sealed with a neoprene gasket to provide dust

and weather protection. Each box for the termination of power cables shall be the largest

standard box which the motor manufacturer can offer for the motor frame size concerned.

Cable termination boxes for phase-to-phase voltages in excess of 1000 V shall be

treated with anti- tracking varnish.

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5.42.2 Other Requirements

Every electric motor rated at 0.37 kW or more shall be three phase squirrel cage induction

type and type of duty shall be as per process requirement. The type of duty shall conform

to IS 12824. Any motor rated under 0.37 kW shall be of the same type or shall be a single

phase motor if this is more appropriate. All motors excluding motors for submersible

application shall be Totally Enclosed Fan Cooled (TEFC) type.

Motor bearings shall be provided with facilities to add additional lubricant. For grease

lubricated bearings grease nipples shall be provided and a grease relief feature incor-

porated. Oil lubricated bearings shall be provided with sight glasses which provide an

accurate indication of bearing oil level when the motor is in use.

Unless otherwise specified, motors shall be provided with class F insulation, the per-

missible temperature rise above the specified ambient temperature shall be limited to

that specified in the applicable Indian standards for class B insulation.

The Motor shall conform to IS 12065 for limits of noise levels and shall conform IS

12075 for vibration severity limit.

5.43 Portable Emergency luminaries

Portable Emergency luminaries shall be provided as follows:

1 number each, 2 X 18 W CFL, inside each PMCC, Control room, Office etc. (minimum

1 hour emergency duration)

1 number each , LED type single beam light for Dry well, Wet well, process areas etc.

(minimum 1 hour emergency duration)

Emergency EXIT facias using photoluminescence material in green colour at strategic

locations (e.g. Dry well exit, PMCC room, Control room etc.) shall be provided.

5.44 Electrical Protection

Over-Current Short Circuit Protection:

All electrical Plant and Materials shall be provided with over-current and short circuit

protection. This shall be arranged, as far as is practicable, so that a fault on any item

of electrical plant is automatically interrupted without interrupting the operation of any

other healthy plant.

Residual Current (Earth fault) Protection:

Residual current protection (sensitivity 100 mA) shall be provided for all socket outlets

except those for hand lamps.

Residual current protection (sensitivity 300 mA or Primary winding of every fed by a

210
circuit breaker (instantaneous operation) and every motor rated at 30 kW and over. The

residual current protection shall operate within 5 seconds of the fault being detected.

Other Forms of Drive Protection

Where specified, recommended by the driven equipment manufacturer or where oth-

erwise appropriate, other forms of drive protection such as low power, low current or

over-torque based on the measurement of electrical parameters shall be provided. Each

type of such protection device shall be of a type tested by the equipment manufacturer.

Wherever low power or low current protection is provided, the motor starter circuit

shall be arranged so that the low power and/or low current protection is overridden:

For a suitable timet after starting the motor, to prevent spurious tripping of the drive

before it has achieved its steady state operating condition

Whenever the Test mode has been selected at the motor starter

In the starter for each screen drive, an over-torque protection relay, type tested by the

manufacturer of the protection relay shall be provided to prevent damage to the equip-

ment.

Following Protection shall be provided for the motors

Short circuit protection Overload Protection Earth fault Phase Unbalance/ Failure

Locked Rotor/ Stall Protection Warning before occurring of fault Thermistor protection (if

applicable)

Components

Components for use in low voltage assemblies shall be in accordance with IEC 60947

Fuses and Links

Fuses used for the protection of power circuits shall of the high rupturing capacity,

HRC type. Semiconductor fuses shall be utilised to protect the soft starter.

Fuses shall comply with IEC 60947. Fuse carriers and bases shall be black. The

carrier and base for each neutral link shall be white. Fuses and links shall be positioned

to enable easy removal of the carrier without risk of contact with live parts.

Switches, Switch Disconnectors and Switch-Fuses

Every switch, switch disconnector and switch-fuse for use in a power distribution or

motor power circuit at up 1 kV A.C. shall comply with IEC 60947, utilisation category

shall be AC 23B, and shall be suitable for padlocking in the Off position only.

Contactors for Use at Below 1 kV

Utilisation category for each contactor for use at below 1 kV shall comply with IEC

60947. It shall be maintenance free and where possible allow replacement of the coil,

without disturbance to the wiring.

Indicator Lamp Circuits

211
 Every indicator lamp circuit shall be fused separately from any functional circuit so

that an indicator lamp failure will not result in the failure of any functional circuit. A

lamp test facility shall be provided for each logical group of indicator lamps, as follows:

Common lamp test button shall be provided on the front facia of the switchboard or motor

control centre for which indicator lamps are provided

Holding the lamp test button shall cause all the related indicator lamps to be illumi-

nated. On releasing the button, the lamps shall return to there normal state.

Indicator lamps shall be based on LED semiconductor technology. Harmonics The

arrangement of the electrical system shall be such that any harmonics generated by the

electrical do not:

Exceed the limits permitted at the point of common coupling with the electricity supply

companys electricity distribution system

Cause malfunction of any electrical Plant or of any electrical system

Lead to overheating of any electrical Plant, Materials or of any electrical system.

To limit the harmonics generated by electrical Plant, every rectifier rated in excess of

3 kVA shall be of the 6, 12, 18 or 24 pulse type.

When designing a system utilising variable frequency drives (VFDs), provision shall be

made to minimise the introduction of additional harmonics into the power grid as per

standard IEEE 519.

5.45 Earthing

Earthing of Power or Motor Control Centre, Distribution Boards:

Each switchgear, control panel and distribution boards shall be provided with an earth

busbar running along its entire length. The earth busbar shall be located at the bottom

of the Switchgear, Control Panel and Distribution Board.

Earth busbars shall be of Galvanized Iron except in PMCC where it has to be of copper

and shall be rated to carry the rated symmetrical short circuit current of the associated

board/panel for one second. Earth busbars shall be supported to withstand stresses

induced by the momentary current of value equal to the momentary current rating of the

associated switchgear/switchboard.

Positive connection of all the frames of equipment mounted in the switchboard to

the earth busbar shall be maintained through conductors of size equal to the ground

busbar or the load current carrying conductor, whichever is smaller. Earthing of draw

out equipment frames shall be achieved through a separate plug-in contact.

All instrument and relay metallic cases shall be connected to earth busbar by means

of 1100 V grade, PVC insulated, stranded, tinned copper, 2.5 sqmm. Conductor shall be

212
looped through the case earth terminals. The earthing Galvanized iron conductor located

below ground level shall be coated with the tar material and also every welded joint for

earthing shall be coated with tar material.

5.46 Equipment Erection and Commissioning

a) In accordance with the specific installation instructions, as shown in manufacturers

drawings or as directed by the Engineer-in-Charge or Engineer-in-Charge’s Representa-

tive the Contractor shall unload, erect, install, wire, test and place into use all electro

mechanical equipment included in the contract. Equipment shall be installed in a neat

manner so that it is level, plumb, square, and properly aligned and oriented.

b) The Contractor shall furnish all supervision, labour, tools, equipment, rigging ma-

terials and incidental materials such as bolts, wedges, anchors, concrete inserts etc.

required to completely install, test and adjust the equipment.

c) Manufacturers drawings, instructions and recommendations shall be correctly followed

in handling, setting, testing and commissioning of all equipment and care shall be exer-

cised in handling to avoid distortion to stationary structures, the marring of finish, or

damaging of delicate instruments or other electrical parts.

d) The Contractor shall erect and commission the equipment as per the instructions of

the Engineer-in-Charge .

e) In case of any doubt/misunderstanding as to correct interpretation of a manufacturers

drawings or instruction, necessary clarification shall be obtained from the Engineer-in-

Charge or the Engineer-in-Charge’s Representative. The Contractor shall be held re-

sponsible for any damage to the equipment consequent to not following a manufacturers

instructions correctly.

f) The Contractor shall move all equipment into the respective buildings through regu-

lar doors or floor openings provided specifically for the equipment. The Contractor shall

make his own arrangement for lifting of equipment.

g) Where assemblies are supplied in more than one section, the Contractor shall make

all necessary mechanical and electrical connections between sections including the con-

nections between bus bars /wires. The Contractor shall also carry out the adjust-

ment/alignments necessary for proper operation of the circuit breakers. All insulators

and bushings shall be protected against damage during installation. Insulators or bush-

ings chipped, cracked or damaged due to negligence or carelessness shall be replaced by

the Contractor at his own expense.

h) The Contractor shall take utmost care in handling instruments, relays and other deli-

213
cate mechanisms. Wherever the instruments or relays are supplied separately, they shall

be mounted only after the associated control panels have been erected and aligned. The

blocking material/mechanism employed for the safe transit of the instruments and relays

shall be removed after ensuring that the panels have been completely installed and no

further movement of the same would be necessary. Any damage to relays and instru-

ments shall be immediately reported to the Engineer-in-Charge or Engineer-in-Charge’s

Representative.

i) Switchgear and motor control centre shall be installed in accordance with the latest

Indian Standard Code of Practice 10118 and manufacturers instructions. The switchgear

and motor control centre panels shall be installed on finished surface or concrete or steel

sills. The Contractor shall be required to install and align any channel sills which form

part of the foundations. Tape or compound shall be applied where called for by manufac-

turers drawings. The base of outdoor type units shall be sealed in an approved manner

to prevent ingress of moisture.

j) Care shall be taken during handling of insulating oil to prevent ingress of moisture or

foreign matter. In the testing, circulation, filtering, or other wise handling of oil, rubber

hose shall not be used. Circulation and filtering of oil, the heating of oil by regulated

short- circuit current during drying runs and sampling and testing of oil shall be in ac-

cordance with manufacturers and the latest Code of Practice IS : 10028.

k) After installation of all power and control wiring, the Contractor shall perform oper-

ating tests on all switchgear and power control centre / motor control centre to verify

the proper operation of switchgear/panels and the correctness of the interconnections

between various items of equipment. This shall be done by applying normal a-c or d-c

voltage to the circuits and operating the equipment. Megger tests for insulation, polarity

checks on the instrument transformer, operation tests on equipment, and manufacturers

installation tests shall be carried out by the Contractor who shall also make all necessary

adjustments as specified by the manufacturer for proper functioning of the equipment.

l) Equipment furnished with finished coats of paint shall be touched up by the Contractor

if their surface is spoiled or marred while handling.

m) Foundation work and grounding - in of fixing bolts or channels for all switchgear, mo-

tors, motor control centre will be carried out by the Contractor.

n) All commissioning tests shall be carried out at site after completion of installation.

o) Contractor shall ensure to use calibrated test equipment having valid calibrations test

certificates from standard laboratories traceable to National Standards.

p) All the electrical equipment will be run on a trial basis for a minimum period of 30 days.

q) Following safety procedure and practice shall be implemented by Contractor in switchgear

214
room as per latest edition of IS: 5216.

(1) Rubber mat

a) In front of LV switchgear in switchgear room.

(2) Shock treatment charts

a) One chart near LV switchgear.

(3) Caution/Danger board

a) LV switchgear/motor : 3 Nos.

b) PDB/MLDB/LDB : 2 Nos.

Painting

a) All sheet steel work shall be phosphated in accordance with relevant standards for

phosphating iron and steel.

b) Oil, grease, dirt and swarf shall be thoroughly removed by emulsion cleaning. c)

Rust and scale shall be removed by pickling with dilute acid followed by washing with

running water, rinsing with slightly alkaline hot water and drying. d) After phosphating,

thorough rinsing shall be carried out with clean water, followed by final rinsing with

dilute dichromate solution and oven drying. e) The phosphate coating shall be sealed

by the application of two coats of ready mixed, stoving type zinc chromate primer. The

first coat may be flash dried while the second coat shall be stoved. f) After application

of the primer, two coats of finishing synthetic enamel paint shall be applied, with each

coat followed by stoving. The second finishing coat shall be applied after completion of

tests. The colour for the finishing paint shall be as specified. g) Each coat of primer and

finishing paint shall be of a slightly different shade to enable inspection of the painting.

h) The final finished thickness of paint film on steel shall not be less than 100 microns,

and shall not be more than 150 microns. i) Finished painted appearance of equipment

shall present an aesthetically pleasing appearance, free from dents and uneven surfaces.

j) Material not complying with the foregoing requirements are liable to be rejected.

Galvanising

Wherever galvanising has been specified, the hot dip process shall be used. The gal-

vanised coating shall be of uniform thickness. Galvanising shall be carried out after all

drilling, punching, cutting, bending and welding operations have been carried out. Burrs

shall be removed before galvanising. Any site modification of galvanised parts should be

covered well by zinc rich primer and aluminium paint.

Galvanising of material shall be carried out in accordance with the latest editions of

IS:2629, 2633, 4759 and 6745.

215
5.47 Erection, Testing and Commissioning
5.47.1 Testing General

Testing of the critical items (LV Switchgear and cables etc., in case of electrical discipline

) at the manufacturers premises will be required in accordance with the conditions of

contract. All inspection, examination and testing shall be carried out in accordance with

appropriate national and or international standards.

All instruments used for such tests shall be calibrated and certified by an approved

independent testing authority not more than 9 months prior the test in which they are

used. The Engineer-in-Charges Representative reserves the right to impound any instru-

ment immediately after test for independent testing. A certificate shall be produced by

the Contractor prior to carrying out every test showing the reading obtained, calculations

and full details of the calibration certificates referred to.

If the Engineer-in-Charges Representative witnesses a test he shall be given a copy of

the test results and certificates immediately. Whether he witnesses a test or not, copies

of test certificate shall be sent to the Engineer-in-Charges Representative. No item of the

plant shall be forwarded to the site until its test certificate has been approved in writing

by the Engineer-in-Charges Representative. Six copies of the test certificates shall be

supplied in suitable folders with proper index.

Certificates shall be clearly identified by serial or reference number where possible

to the material being certified and shall include information required by the relevant

reference standard or specification clause.

5.47.2 Inspection at Manufacturer‘s Premises

The inspection of all critical equipment (required to be supplied to complete the works)

shall be done as detailed in this specification. Only defect free and sound material meet-

ing the technical requirements of this specification and in accordance with a high stan-

dard will be acceptable to the Engineer-in-Charge.

To meet the requirements of inspection, testing (including testing for chemical analy-

sis and physical properties) arrangement shall be made by the Contractor and test cer-

tificates shall be submitted to the Engineer-in-Charge. Engineer-in-Charge will have

the right to witness or inspect the above mentioned testing/inspection at final stage as

desired by him. Calibration certificates or test instruments shall be produced for the

Engineer-in-Charges consent in advance of testing and if necessary instruments shall be

recalibrated or substituted before the commencement of the test. Items of plant or con-

trol systems not covered by standards shall be tested in accordance with the details and

programme agreed between the Engineer-in-Charge and Contractor.

216
 If during or after testing, any item of the plant fails to achieve its intended duty or

otherwise prove defective it shall be modified or altered or replaced as necessary, retested

and re-inspected as required by the Engineer-in-Charge.

At least 21 days advance notice shall be given to the Engineer-in-Charge before the

specified tests are to be carried out.

No material is to be delivered to site without the above described inspection having

been carried out and clearance is given for dispatch or officially waived off in writing by

the Engineer-in-Charges Representative

5.48 Automation of Sewage Treatment Plant

The complete Sewage Treatment Plant, shall be fully automatic based on PLC based con-

trol system. PLC based automation system with application software shall be offered to

control all pumps, valves, blowers, VFDs, probes etc., as per Contractors design includ-

ing I/Os with 20% spares. HMI Panel to comprise up-to-date standard PC with CPU,

monitor, printer, SCADA software with dynamic flow charts, pictures, screens, alarms,

historical trends, reports etc. SACDA based Automation system to monitor and control

the plant continuously. The Contractor shall submit a detailed plant control philosophy

for the approval of the IITH .

5.49 Instrumentation & Automation Specifications

This part covers the general requirements for the Design, Delivery, Installation, Inspec-

tion, Testing and Commissioning of the Instrumentation, Control, Automation / Supervi-

sory Control and Data Acquisition (SCADA),HMI system.

217
5.49.1 PLC Specification

Table 5.22: Specifications of PLC

Sl.
SPECIFICATIONS DESCRIPTION
No.
A Design PlC Makes : Siemens / Allen Bradly /Honeywell
Free Floor Standing Modular Type Suitable For
1 Type of PLC Panel
Indoor Installation With 1No Front Opening/ Rittal Panel
B PLC Specifications
Din Rail Mounted Micro PLC With Panel Mounted
1 Controller HMI, or Suitable Controller With Provision For Futurexpansion
and Ethernet Port
2 I/O Module 32Ch/16Ch/8Ch/4Ch As Per The IO Configuration
3 Power Supply 24V DC SMPS
4 Ethernet Switch As per IO Configuration Requirement
SCADA & PC Or 16 inch Panel
C
Mounted HMI
SCADA Runtime Lic With Suitable Tags Runtime Lic,
Latest Version. With Control, Monitoring, Alarm Status,
Data Logging, Report Generation (Excel & Crystal),
1 SCADA Specifications
Trends, Graphical, Unlimited Screens, Analysis,
Push Mail (Optional), Process Flow Diagrams,
Animations
Dell/HP Make PC With 22 inch LED
Monitor, 1TB HDD, I 7, 64Bit Processor,
2 PC
4GB RAM, licensed Antivirus & Windows
OS Loaded, 4 GB graphic card
D General Requirements
1 Degree Of Protection Ip 54- Certificate Required
2 Fabrication-Base 75 Mm Ismc- Invert ”C”
3 Frame/Gland Plate And Non Ferrous Gland Plates
Cover/Doors
4 Gaskets / Blanking Plates Neoprene Rubber /To Be Provided For All Modules
5 Hardware/Bolts & Corrosion Resistant
Nuts/Washer
From Top/Bottom Will Be Confirmed With
6 Cable Entry
Detachable Gland Plate
7 Max Operating Height 2000 mm
8 Panel Make Rittal
E UPS
1 Specifications 1KVA Offline UPS
F Others
PC/Laptop based web view
1 Web View
shall be provided for monitoring trends, alarms etc.,
Including PLC Programing And Logic
2 Specifications
Development and SCADA Customisation
hline

5.49.2 MCC Specifications

Table 5.23: MCC Specifications

SR NO SPECIFICATIONS DESCRIPTION

A DESIGN

218
 FREE FLOOR STANDING,

COMPARTMENTALISED,
1 TYPE OF MCC NON DRAWOUT TYPE, MODULAR TYPE

SUITABLE FOR INDOOR INSTALLATION

WITH DOUBLE FRONT OPENING.

4P, amps ELECTRICALLY OPERATED

2 INCOMER RATING OF MCC
MCCB WITH LSIG PROTECTION

4P, amps ELECTRICALLY OPERATED

3 MCCB
MCCB WITH LSIG PROTECTION

DIGITAL MULTIFUNCTION METER TO MEASURE

4 METERING FOR INCOMER
V, A, KWH, KVAR,PF,Hz

5 SYSTEM FAULT LEVEL 50 KA FOR 1 SEC

6 SYSTEM NEUTRAL GROUNDING SOLIDLY EARTHED

415V AC,+/- 10% / 50 Hz +/- 3%,

7 INCOMING VOLTAGE /FRE-
3PHASE-4WIRE,
QUENCY

230V AC OR 110V AC (THRO CONTROL

8 CONTROL VOLTAGE
TRANSFORMER)

MCCB / MPCB SELECTED FOR TYPE 2

9 TYPE OF ISOLATOR
CO ORDINATION

NON DRAWOUT
10 TYPE OF MCCB TYPE FOR MCCB, SINGLE FRONT

3PHASE WITH NETURAL (TPN),

DOUBLE FRONT,SHALL NOT OPEN IN ON

11 TYPE OF FEEDER CONDITION,

UNLESS FEEDER IS SWITCHED OFF.

12 SEISMIC CONDITION IF APPLICABLE

B STARTERS

DOL/ STAR DELTA/ VFD /SOFT

1 TYPE OF STARTERS STARTER (REFER ELECTRICAL

LOAD LIST)

2 MOTOR STARTER CONTACTOR , WITH MPCB

3 SPARE MOTOR STARTER REFER ELECTRICAL LOAD LIST

219
 MOTORS WITH LOCAL ISOLATOR LPBS FOR ALL 3 PH MOTORS &
4 SWITCH/MAINTENANCE SWITCH ISOLATOR BOX FOR ALL SINGLE

WITH FEEBACK TO PLC PH MOTORS

C VFD

1 SUITABLE FOR PUMP/BLOWR APPLICATION

3 RFI FILTERS REQUIRED

4 CURRENT HORMONIC FILTERS IF REQUIRED (OPTIONAL)

5 OPERATING CONSOLE SURFACE MOUNTING TYPE

6 PROVISION FOR THERMISTER REQUIRED FOR MOTORS >75KW

CONNECTIVITY

7 INCOMING CABLES TO VSD XLPE/PVC TYPE

D GENERAL REQUIREMENTS

1 DEGREE OF PROTECTION IP 54

2 EXTENSION FACILITY /INTER- TO BE PROVIDED AT BOTH ENDS

CHANGABILITY

3 FABRICATION-BASE 75 MM ISMC

4 FRAME/GLAND PLATE AND NON FERROUS GLAND PLATES

COVER/DOORS

NEOPRENE RUBBER /TO BE

5 GASKETS / BLANKING PLATES
PROVIDED FOR ALL MODULES

6 HARDWARE/BOLTS & CORROSION RESISTANT

NUTS/WASHER

FROM TOP WITH DETACHABLE

7 CABLE ENTRY
GLAND PALTE

8 MAX OPERATING HEIGHT 2200 MM

E BUSBAR

1 AUXILIARY BUS BARS ALUMINIUM

HIGH CONDUCTIVITY ALUMINIUM

2 MAIN / VERTICAL BUSBARS
( E91E GRADE )

3 MINIMUM SIZE OF MAIN / VERTI- SIZING SHALL BE 20% HIGHER THAN

CAL BUSBAR LOAD

COLOUR CODED HEAT SHRINKABLE PVC

4 BUS BAR INSULATION SLEEVES OF 1.1 KV GRADE WITH SUITABLE

SUPPORTS

220
 PERFORATED SHEET STEEL /
5 PROTECTION FOR AUXILIARY
INSULATING MATERIAL
BUSBARS

6 PHASE TO PHASE TO EARTH MIN 25 MM

CLEARANCE

CURRENT TRANSFORMER / POTENTIAL

F
TRANSFORMER
TYPE CAST RESIN - SQUARE TYPE

WIRING WILL BE CARRIED OUT WITH 600/1100 V

G WIRING GRADE PVC INSULATED STRANDED COPPER

CONDUCTOR

1 CONTROL CIRCUIT WIRING 1.5 SQ.MM.

CT CIRCUIT WIRING /POWER CIRCUIT

2 2.5 SQMM/ as per switch gear rating
WIRING

3 FERRULES PVC, FEEDER IDENTIFICATION AT

BOTH ENDS

4 NO OF SPARE TERMINALS MIN 10%

For DOL : 2 DI : Auto /Manual , Run feedback,

H INTERFACEING WITH PLC
1 DO : command from PLC

For VFD : 2 DI : Auto /Manual , Run feedback,

1 AO : SPEED REF.

I INDICATION (LED LAMPS)

1 MCC INCOMER FEEDER MAIN SUPPLY L1, L2, L3 ON.

2 MCC OUTGOING ON, OFF, TRIP, AUTO/MANUAL SE-

FEEDER(MOTOR) LECTED

COPPER STRIP THROUGHOUT THE BOTTOM

LENGTH OF MCC,ALL DOOR, MOVABLE

J EARTHING
PARTS SHALL BE EARTHED USING FLXIBALE

COPPER WIRE.

SIZE 50X6 MM GI GLAT

FINAL PAINT POWDER COATED WITH

K PAINTING COLOR SIEMENS GREY RAL 7035 AND

BASE CHANNEL COLOR BLACK

221
 SINGLE LINE DIAGRAM, SCHEMATIC

DIAGRAM FOR EACH TYPE STARTER,

L Documents to be submitted for
BOM. PANEL GA DRAWING, MOUNTING
approval
ARRANGEMENT DRAWING

ALL ROUTINE & ACCEPTANCE TESTS SHALL,

BE CARRIED OUT AT MANUFACTURER‘S PLACE

M ROUTINE TESTS
UNDER HIS CARE & EXPENSE

AS PER APPROVED QAP

N DESIGN CODES & STANDARD IS 3427 METAL ENCLOSED

SWITCHGEAR

O MAKES OF THE COMPONENTS

1 MCC SWITCHGEAR ABB/SCHNIDER/SIEMENS

2 VARIABLE FREQUENCY DRIVES ABB/SCHNIDER/SIEMENS/DANFOSS

2 CONTCATORS- POWER /AUXIL- ABB/SCHNIDER/SIEMENS

LIARRY

3 FUSES - POWER / CONTROL ANY REPUTED MAKE

4 DIGITAL METERS / ANALOG ME- CONSERVE

TER

PUSH BUTTON/SELECTOR SWITCHES

5 TECHNIK
/INDICATION LAMPS

6 TERMINALS ELEMEX / PHEONIX

7 CURRENT TRANSFORMER KAPPA / KALPA

5.49.3 Reference Standards

Unless otherwise approved, instrumentation and Automation shall comply with relevant

quality standards test procedures and codes of practice collectively referred to as Refer-

ence Standards including those listed below in accordance with the requirements detailed

elsewhere in this specification.

Table 5.25: Reference Standards

BS 89-2:1990,
Direct acting indicating analogue electrical
EN 60051-2:1989,
measuring instruments and their accessories.
IEC 60051-2:1984

BS 1042 (Various) Measurement of fluid flow in closed conduits

222
 Symbolic representation for process measurement
BS 1646-1:1979, 3511/
control functions and instrumentation.
I-1977
Basic requirements

Pressure gauges. Bourdon tube pressure gauges.

BS EN 837-1:1998
Dimensions, metrology, requirements and testing

BS EN 60751:1996,
Industrial platinum resistance thermometer sensors
IEC 60751:1983

BS 3680 (Various) Measurement of liquid flow in open channels.

Recommendations for design of scales and

BS 3693:1992
indexes on analogue indicating instruments

BS EN 60770-1:2011, Transmitters for use in industrial-process control

IEC 60770-1:1999 systems.Methods for performance evaluation

Mechanical vibration in rotating machinery.

BS 4675-2:1978,
Requirements for instruments for measuring
ISO 2954-1975
vibration severity

BS EN 60584-1:1996,
Thermocouples. Reference tables
IEC 60584-1:1995

BS 5308 (Various) Instrumentation cables

Specification for degrees of protection

BS EN 60529:1992
provided by enclosures (IP Code)

Measurement of fluid flow. Methods of

BS ISO 11631:1998
specifying flowmeter performance

Analogue signals for process control systems.

BS 5863-1:1984,60381 1:1982
Specification for direct current signals

Analogue signals for process control systems.

BS 5863-2:1980,60381- 2:1978
Specification for direct voltage signals

Industrial-process measurement and

BS EN 60654-1:1993,
control equipment.
IEC 60654-1:1993
Operating conditions. Climatic conditions

Code of practice for instrumentation in process

BS 6739:1986
control systems: installation design and practice

Basic and safety principles for man-machine interface,

BS EN 60073:2002 marking and identification. Coding principles

for indicators and actuators

223
 Specification for graphical symbols for
BS 1553 (Various)
general engineering

Instrumentation Symbols
ISA-5.1-1984 - (R1992)
and Identification

ISA-5.4-1991 Instrument Loop Diagrams

ANSI/ISA-7.0.01-1996 Quality Standard for Instrument Air

ANSI/ISA-18.1-1979 -(R1992) Annunciator Sequences and Specifications

Dynamic Response Testing of Process

ISA-26-1968
Control Instrumentation

Electrical Transducer Nomenclature

ISA-37.1-1975 - (R1982)
and Terminology

Specifications and Tests for Strain Gage

ISA-37.3-1982 - (R1995)
Pressure Transducers

ANSI/ISA-50.00.01-1975 Compatibility of Analog Signals for Electronic

(R2002) Industrial Process Instruments

ANSI/ISA-51.1-1979 -
Process Instrumentation Terminology
(R1993)

ISO 9000 and ISO 9004 Quality Management Systems

IEEE 60587 Power Supply Surge Protection

Programmable Controllers–
IEC 61131-3
Programming Languages

Industrial Communication Network-

IEC 61158-2
Communication Protocols

Information technology -Structured

BS /ISO 9075
Query Language (SQL)

Code of practice for Documentation of

BS 5515
Computer Based Systems

Recommendation for Achievement of

BS 7165
Quality in Software

BS EN 50081 Electromagnetic Compatibility

Symbolic representation for process

ISO 3511
measurement control functions - instrumentation

Information technology - 7 Layer

ISO-OSI
Communication Model

IEEE 472-1974 Surge protection.

224
 IEC-8705101 Modbus Protocol Conversion

(b) All standards which the Contractor intends to use but which are not part of the

above Standards or other listed Reference Standards, shall be submitted to the Engineer-

in-Charge for consent before any design against that standard proceeds.

5.50 Qualification Criteria for Instrumentation and Au-

tomation System integrator

(i) Instrumentation and Automation system integrator hereinafter called system inte-

grator(SI) shall be in possession of minimum ISO 9001, Quality Management System

certification, conferred by an accredited agency.

(ii) The SI must be an authorized system integrator for the PLC hardware and SCADA

and Operational Database Management Software (ODMS) manufacturer. Valid au-

thorization certificates shall be submitted for verification.

(iii) The SI shall have minimum of 10 years experience of ICA projects execution within

India. It shall demonstrate capability and resources for integrating/interfacing con-

trol systems for different Original Equipment manufacturers products/system as

well as coordination with multiple agencies for contract execution. References for

minimum of (5) locations where the automation equipment (software hardware) has

been successfully installed, along with name, address and contact number shall be

submitted.

(iv) SI must have their branch in Hyderabad to ensure timely after sales service.

(v) SI shall use latest technology/versions of hardware and software products/components

from Instrumentation and Automation original component/original equipment man-

ufacturers (whose products are proposed) shall be in possession of an ISO 9001 or

above, Quality Management System certification, conferred by an accredited agency.

(vi) All hardware and software proposed shall have been successfully in operation in a

waste water application for a period of at least five (5) years and be from established

225
 and reputed OEM.

5.50.1 Documents to be submitted during Bid Submission

(i) (a) Include a complete conformance to each and every reference standards or part

of the specifications. Use a chart format with specification part identified, indicate

whether each part is in compliance, a deviation or an exception to the specific part.

If an exception or deviation, include a narrative description as to how the deviation

or exception can benefit the end-user of the system over that item specified.

(ii) Provide a Schematic block diagram of the proposed system showing all major com-

ponents and their interconnections and interrelationships. Label each diagram and

indicate all external power and communications interfaces.

(iii) Provide a written summary on operation and control philosophy of the proposed au-

tomation system, covering the principal functions and capabilities of the systems PC,

PLCs, system communications and general system capabilities (maximum number

of network nodes and I/O points, communication protocols available, etc.).

(iv) Provide an equipment list with descriptive literature for the proposed system. List

shall include all major hardware items, the name of the manufacturer, the quantity

provided, and selected model numbers. Technical schedules for Instruments, PLC

SCADA, ODMS shall be duly filled in with relevant details.

(v) Provide an operating system and software applications list with descriptive literature

for the proposed system. Include all major software items, supplier name, quantity,

and model numbers. (No proprietary software shall be accepted).

(vi) Information is required for:

(1) Name and version of the operating system.

(2) Name and version of the proposed computer Contractor graphical user interface,

software package (SCADA).

(3) Name and version of the PLC on-line/off-line programming software for all con-

trollers

(4) Name and version of any required communications software, firmware, etc.

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 (5) Name and version of the specified report application software, Operational data

management software(ODMS).

(6) Name and version of the specified maintenance application software if any.

(vii) Describe how system data points are linked from the system database into various

applications such as reporting or maintenance. If via DDE (Dynamic Data Exchange)

describe specifically the steps required to import data automatically and on-line into

the proposed software applications.

(viii) Briefly describe the required procedure for configuration and/or programming of the

proposed system to add a simple PLC and additional I/Os to the system in the future.

Describe in detail, specifically how communications are programmed for the future

remote PLC and the necessary changes required at the main controller.

(ix) Provide a description of any software required to program, troubleshoot or diagnose

any devices in the system.

(x) Provide a tentative construction schedule for completion of the project within the

specified Contract period. Indicate the following activities with milestones: Mobi-

lization, radio communications licensing, submittal preparation, submittal review,

equipment procurement, equipment assembly, system configuration and program-

ming, factory testing, system delivery, system installation, start up, field testing and

training, and post acceptance routine service intervals.

(xi) Describe the SIs provisions for service, technical assistance and replacement parts

for the proposed system. Do provide the SIs contact number. Identify with resumes,

all personnel who will be providing technical support services for the project after it

is accepted.

(xii) The Contractor shall provide the above required details/documents during the bid

submission. Failure to do so will be treated as a non-responsive bid and lead to

technical disqualification. Contractor to take note the importance of this obligation.

5.51 General Submissions

(a) The Contractor shall make submissions to the Engineer-in-Charge of all design draw-

ings, schedules and complete

documentation relating to instrumentation, control and Automation equipment and sys-

tems provided under this Contract. (b) These submissions shall include, where relevant,

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the following:

5.51.1 Functional design specification

(i The Contractor shall submit a complete functional design specification (FDS) for ap-

proval by the Engineer-in-Charge within 3 months of the award of contract. This

document shall serve as the primary mechanism by which the Engineer-in-Charge

may confirm that the Contractor possesses an accurate understanding of the system

and its control requirements. The Contractor is encouraged to obtain clarifications

and to suggest refinements to the control descriptions contained in this Specification.

(ii The FDS shall comprise an overall description of the plant, its functioning and con-

trol, and a detailed description of each section of the control system covering modes of

operation, manual overrides, set-point and parameter selection and adjustment. The

detailed description shall include a step-by-step control description which defines the

function of each piece of equipment and each control action and interlock, including

details of the program in each programmable item. Proposed SCADA screens shall

form an integral part of FDS submission.

(iii The format of the program details may be chosen by the Contract, however it is sug-

gested that this format be chosen to satisfy the requirements of the software design

documentation, if applicable, as described elsewhere.

(iv The FDS shall describe the fail-safe features incorporated into the design, for the

event of failure of a plant item or system, or loss of an input signal affecting a control

loop or process sequence.

(v The FDS shall describe control actions taken and monitoring functions which remain

available during a power failure, and any automatic controls or sequencing which

take place during system start-up and shut-down.

(vi The FDS shall be presented in a clear and precise manner and shall include figures

or drawings where appropriate.

(vii The Contractor shall submit and obtain approval of the FDS from the Engineer-in-

Charge before beginning the detailed control system design.

5.51.2 Drawings and schedules

(i) ) Process and instrumentation diagram shall comply with BS 1646 and BS 1553.

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 (ii) General arrangement drawings of field-mounted instruments showing installation

details.

(iii) General arrangement drawings of instrument and control panels, fully dimensioned

in plan and elevation views, showing foundation and fixing details, access doors,

clearances, cable-entry positions, weight and lifting arrangement.

(iv) Layout drawings of panel facias showing instruments, controls and details of all

labels.

(v) Layout drawings of panel interior showing equipment, terminal blocks and cable

ways.

(vi) Annunciator arrangement and engraving details.

(vii) Internal circuit and wiring diagrams for instrument and control panels.

(viii) Schematic control diagrams.

(ix) Instrument loop diagrams.

(x) Instrument wiring and piping diagrams.

(xi) Interconnection wiring diagrams.

(xii) Cable block diagrams, drawings and schedules.

(xiii) Instrument system and panel power distribution diagrams.

(xiv) Programmable-device functional design specifications which shall include hardware

details, logic flow charts, ladder diagrams and program listings.

(xv) Schedules of inputs to and outputs from programmable controllers and telemetry

outstations.

(xvi) Labeling schedules.

(xvii) Comprehensive testing schedules for all off-site, on-site, pre-commissioning and

commissioning tests and take-over tests.

(xviii) All other drawings necessary for the provision of ducts, openings, trenches, fixing

holes for panels and the like and for the complete understanding of the operation,

maintenance and extension of the system including any required for the contractor

to dismantle, repair, maintain, modify or extend the Plant.

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5.51.3 Data and calculations

• Manufacturers catalogues and data sheets.

• Calculations to support control system design.

• Specification for protective coatings and painting.

• Certificates

• Manufacturers works tests.

• Pre-installation checks.

• Pressure-testing schedules.

• Instrument loop test check sheets.

• Installed instrument performance tests.

• System tests.

• Statutory certificates of compliance (such as hazardous area equipment).

5.51.4 Operation and maintenance instructions

Operation and maintenance instructions shall include

(a) Composite manual describing the functional and operation of each piece of equip-

ment.

(b) Composite manual for testing and servicing every system and individual item.

5.52 Design
5.52.1 Basic Features

Instrumentation, Control, Automation/SCADA / HMI system shall be designed, manu-

factured and installed to achieve the following basic requirements:

(a) to maintain the highest standards of availability, reliability and accuracy and to

give clear warnings of any deterioration in performance;

(b) to suit the abilities of the staff who will:

i. use the systems;

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 ii. Service the systems;

(c) to measure, indicate, process, store and control the relevant parameters, as speci-

fied;

(d) to give clear warnings of dangerous and other abnormal conditions and to initiate

plant safety procedures, shutdowns and corrective measures as specified to assure the

safety of operations and maintenance personnel and plant and to store and collate the

data, as required;

(e) to derive, present and utilize, as required, such additional data as required to facilitate:

i. the most efficient operation of the plant;

ii. the routine maintenance of the plant

5.52.2 Design Requirements for Instrumentation, Control, Automa-

tion (PLC/SCADA / HMI) Systems

(a) The instrumentation, control, automation (SCADA / HMI) installations shall fully com-

ply with design standards, regulations and the material and workmanship requirements

of the Specification.

(b) The electrical plant installations, associated instrumentation, control and automa-

tion systems shall also comply with and be tested in accordance with the latest edition of

BS 7671 or equivalent Indian standards.

(c) All equipment and materials incorporated in the system shall be selected, designed

and rated to operate under the defined performance duties and specified site conditions

and to maintain a high level of operational reliability.

(d) The instrumentation, control and monitoring system equipment and materials shall

have an operational life of not less than 15 years, unless otherwise approved by the

Engineer-in-Charge.

5.52.3 Site Conditions

(a) Temperature and Humidity Range.

The equipment shall be installed in an environment having a temperature range of 0

C to 50 C and a maximum relative humidity of 100 % (non-condensing). The SI shall

use, where required, fans, heaters, and air conditioning units to maintain a correct work-

ing temperature for his equipment. All Parts of the equipment shall be constructed of

materials or treated to prevent the formation of mould, fungus or any corrosion over the

temperature and relative humidity ranges specified.

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 (b) EMI/RFI Noise Immunity.

The equipment to be provided shall be adequately protected against interference from

the use of radio transmitters, at any point external to the equipment housings and no

malfunction of the equipment shall result from this cause. Responsibility for the correct

and reliable operation of the equipment shall rest with the Contractor, who must ensure

that the equipment is adequately protected against the ingress of radiated, mains-borne

signal- borne interference.

(c) Generated Interference.

The Contractor shall ensure that the computer, instrumentation and communications

equipment conforms to BS EN 50081-1or equivalent Indian Standard for noise emissions.

(d) Coordination.

The SI shall check with other disciplines to ensure that equipment and material can

be installed in space provided. Coordinate with other disciplines, to share the informa-

tion necessary for them, to execute their work. Details on Drawings, which are specific,

regarding dimensions, are for information purposes.

5.52.4 Enclosure/Panel Details

Enclosures and mounting boards

(a) Enclosures shall be in any form of, board, cabinet, panel, desk, box or case used

to protect, contain or group instrumentation, control equipment.

(b) All equipment in or on enclosures shall be arranged logically and, as far as possi-

ble, symmetrically, with projections kept to a minimum. Each enclosure and board shall

be designed on ergonomic principles and shall permit in-situ and safe access for any nor-

mal adjustment, maintenance and servicing. The top of enclosures shall have downward

slope i.e. from front to rear.

(c) Enclosures mounted for indoor application or inside buildings shall have a minimum

rating of protection as IP 54.

(d) Enclosures for outdoor applications or in places where splashing may occur, shall have

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a minimum rating of protection as IP 65.When enclosures are to be provided for outdoor

application and are located, where exposure to direct sunlight will give rise to high sur-

face temperature rises above the manufacturer‘s recommendation (normally 40◦ C), the

enclosure shall include a sun shield fitted to the top of the enclosure. The sun shield

shall prevent direct sunlight from reaching the instrumentation for the full day through-

out the year, and shall have louvered ventilation.

(e) Fixing arrangements for surface-mounting enclosures shall be external to the enclo-

sure and shall ensure that the rear face of the enclosure is not in contact with the surface

to which it is fixed.

(f) Enclosures shall have hinged access doors, fitted with recessed lockable handles.

(g) Doors shall be of rigid construction and provided with close-fitting flexible seals in re-

cesses to prevent the ingress of liquids, moisture, dust and vermin. Hinges shall be of the

lift-off pattern and one hinge shall engage before the other for ease of fitting. Wherever

necessary, removable access covers secured by quick-release fasteners shall be provided

to ensure ease of maintenance for all installed apparatus.

(h) Mounting plates, brackets and racks shall be provided for all other internal equip-

ment which shall be hinged or otherwise arranged with quick-release fasteners or cap-

tive screws to give quick and easy access to equipment, securing screws, terminals and

wiring.

(i) Enclosures for two or more devices with electrical circuits shall have gland plates and

terminal blocks as specified elsewhere.

(j) Each enclosure shall be designed for the safe testing and servicing of equipment with

the power on. Each part which may be live under any circumstances shall be so covered

or shielded as to prevent inadvertent contact.

5.52.5 Panel design and construction

(a) Unless otherwise specified, all instrument panels, instrument cubicles, control pan-

els, control consoles and desks, associated equipment and terminal racks, telemetry and

electronic equipment racks and the like shall be free-standing, floor mounted units and

shall conform to the requirements of this part and will hereafter be referred to as panels.

(b) The design and dimensions of control consoles and desks shall be determined ac-

cording to their intended function and shall be in accordance with the requirements of

the Specification. The height shall not exceed 1400mm above the finished floor level.

(c) Unless otherwise specified the height of panels shall be not greater than 2130mm

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(overall) (excluding lifting devices) above finished floor level.

(d) Controls, switches and push-buttons shall be positioned below or adjacent to any as-

sociated indicating instrument. Panels for use in locations such as pumping stations and

machinery rooms shall have anti-vibration mountings.

(e) The side, rear and front clearance of apparatus shall allow safe and unobstructed ac-

cess to all terminals and to parts, requiring maintenance.

(f) Panel layout drawings shall include a list of all instruments, accessories and compo-

nents contained therein. Separate schedule or bill of material of instruments, accessories

and components shall be provided. The panel drawing shall display a legend of each

item/component as provided in Separate schedule or bill of material.

5.52.6 Panels Major

(i) Panels shall be constructed generally as specified in the preceding clause. Panel ma-

terial shall be prime-quality, cold-rolled and annealed mild steel or zinc-coated mild

steel sheet, suitably braced and stiffened as necessary with flat bar or angle to form

a rigid structure.

(ii) Panel fronts shall be flat and free from bow or ripple. Exterior corners and edges

shall be rounded or welded and ground to give a smooth overall appearance.

(iii) Flanged edges shall be straight and smooth.

(iv) Materials shall be chosen with due regard to the panel size, number of cut-outs, in-

strument weight and position of center of gravity and method of fabrication, with the

following minimum thickness:

(1) instrument bearing surfaces, gland plates and pneumatic distribution plates;

3mm;

(2) internal mounting plates, 3mm;

(3) doors, covers and filler panels, 2mm.

(v) No design involving the use of externally-visible assembly or fixing bolts and screws

or any design resulting in dust or water-collecting crevices will be accepted.

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 (vi) When a panel is constructed in sections, the sections shall be designed for ease of

assembly during installation and, in any case, shall not exceed 2m in length. All

necessary nuts, bolts, washers and the like shall be supplied and included in the

same shipment as the relevant sections. Sections exceeding 1m in length shall be

provided with double doors.

(vii) Each panel shall be mounted on a self-draining base frame fabricated from 150mm

deep, steel channel section which shall be drilled or provided with clamps for bolting

to the floor. The base frame shall be set back from the panel front face to give a toe

space of not less than 25mm. The outside of the base frame shall be covered with an

approved kicking strip.

(viii) Ceiling and other filler panels shall be fabricated from sheet steel and adequately

stiffened. Each section shall have 50mm returned edges along all four sides and

shall be braced to the main steelwork of the panel.

(ix) A chequer-plate floor shall be provided inside and above the level of the base frame,

having openings suitable for the bottom entry of cables where applicable.

(x) Sufficient removable un-drilled gland plates, in sections convenient for handling,

shall be fitted close to the appropriate terminal blocks and not less than 230mm

above the panel floor or not less than 230mm below the panel top. The gland plates

shall have removable side covers giving access to both sides of the gland plate and en-

suring vermin-proof and dust-proof construction. Gland plates of a surface mounted

enclosure may form a part of the base or top.

(xi) Panels containing instruments using a fluid as the transmission medium shall have

distribution plates with bulkhead unions for the termination of internal and external

pipe work.

(xii) All doors shall open outwards and all doors in one panel assembly shall use the same

lock and key combination.

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 (xiii) Panel design shall ensure adequate ventilation and air circulation without permit-

ting the entry of vermin or dust. Panels installed in control rooms or other clean

condition areas shall have louvers to allow air circulation. Temporary closures shall

be provided to prevent the entry of dust and vermin during transit and installation.

After commissioning has been completed, all entries except air circulation louvers

shall be sealed.

(xiv) No equipment other than front-of-panel items shall be mounted on panel wall sur-

faces.

(xv) If electrical and non-electrical instruments are mounted in the same panel, the panel

shall be subdivided internally to separate the electrical and non-electrical sections.

(xvi) All connections shall be arranged to ensure that no accidental damage to cabling or

electrical components can occur in the event of failure of any non-electrical compo-

nent or connection.

(xvii) Provision shall be made for safe and easy handling during transit and installation.

(xviii) If lifting eyes are provided, they shall be reversible and panel tops shall be reinforced

where necessary

(xix) Where equipment is specified to be installed at a future date, space shall be allocated,

and cutouts with removable masking plates, brackets, supports, wiring, terminals

and piping and the like shall be provided.

(xx) Panels shall be finish-coated at the place of manufacture before commencing the in-

stallation of apparatus and other fittings.

5.52.7 Panels Minor

(i) Panels for installation on the Plant which contain relatively few items of equipment,

or where so specified elsewhere, shall be classed as minor panels and shall be con-

structed generally as specified in the preceding clause and comply with this Clause.

236
 (ii) Panels shall be fabricated from sheet steel or other approved material not less than

2.5mm thick suitably braced to form a robust and rigid structure. Exterior corners

and edges shall be rounded to give a smooth overall appearance and assembly bolts,

screws or rivets shall not be visible on the front face.

(iii) The design shall be such as to ensure adequate ventilation and air circulation where

required, without permitting the entry of vermin. Openings for cables shall be made

vermin-proof. Doors shall be hinged and shall be provided with close-fitting flexible

seals in recesses to prevent the ingress of liquids, moisture, dust and vermin. Unless

otherwise specified, panels shall be suitable for floor mounting and shall not exceed

2130mm in height. Where wall/surface-mounted panels are provided, the fixing

shall prevent the ingress of moisture and the rear of the enclosure shall be not less

than 10mm from the wall.

(iv) Panels shall be extensible, and symmetrically arranged as far as possible with pro-

jections kept to a minimum. Where two or more panels are fitted together, they shall

form a flush-fronted continuous panel of uniform height. Front door and top cover

dimensions shall match. Instruments, relays, and control devices shall be mounted

at a height not more than 1800 mm and not less than 300mm from floor level.

(v) The arrangement of equipment within each enclosure shall be such as to permit easy

access for installation and maintenance. No instruments, relays or other components

shall be mounted on rear access doors or removable covers.

5.52.7.1 Panel protection

(a) Adequate facilities for isolation and protection by miniature circuit breaker or fuse

for each instrumentation and control circuit and sub-circuit shall be provided and shall

be so arranged that any interruption causes minimum disruption of plant, operates the

appropriate alarm and cannot result in any unsafe operating condition.

(b) All fuses shall be of the cartridge pattern and main fuses shall be of the high rup-

turing capacity type. Fuse and solid-link carriers and bases shall be of plastic molded

insulating material of an approved make. Ceramic materials will not be accepted. Live

connections shall be efficiently shrouded and it shall be possible to change fuses with

power on without danger of contact with live metal. The fuses shall be rated to give maxi-

mum protection to the equipment in circuit and the rating shall be permanently inscribed

on the fuse label and on the fuse carrier. Unless necessary for the protection of particular

equipment, miniature circuit breakers used for individual circuits in a panel or control

237
desk shall not trip on over-voltage or under-voltage.

(c) Bases for solid links shall not be interchangeable with those for fuses. Fuses and

links in the same circuit shall be mounted opposite each other in separate adjacent rows

and shall not alternate in the same row. At least 10% and not less than two unallocated

miniature circuit breakers or fuses and links shall be provided in each panel distribution

board. Miniature circuit breakers and fuses of similar size and rating shall be of the same

make and type.

(d) At least 10%, and not less than two, spare fuses and links of each rating shall be

provided and fitted in clips inside the panel.

(e) Each instrument requiring a power supply shall be individually wired and protected

so that, in the event of a failure in one circuit, the remainders are unaffected. Power

supply circuits shall be of sufficient rating that any protective device may operate with-

out reducing the voltage at the terminals of any other component to an unacceptable level.

5.52.7.2 Panel isolation

(a) Clearly-labeled isolating circuit breakers shall be provided for each incoming power

supply. Switches shall be of the quick make-and-break type with spring loaded contacts

that close fully without requiring full operation of the handle. The handle and cover shall

be interlocked so that the handle cannot be operated when the cover is open and the

cover cannot be opened unless the switch is in the off position. The ‘on‘ and ‘off‘ positions

of each switch shall be indicated clearly.

(b) Circuit breakers for panel power supplies shall be mounted near an access point and

in positions where they may be operated easily from a standing position.

(c) Plug-in isolating links or devices of an approved type shall be provided in any circuit

that may still be live when the power supply isolators are in the off position, as, for

example, in circuits controlling equipment whose power supply is independent of the

panel. Such links or devices shall be properly screened and, if not incorporated in or

adjacent to their associated outgoing terminals, shall be labeled with suitable warning

notices.

(d) Any item of panel equipment to which panel internal wiring is connected with a plug

and socket instead of terminals shall be wired in flexible cable of adequate rating between

the free plug and a socket mounted adjacent to the device.

(e) The power supply connector shall be a socket.

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5.52.7.3 Panel terminal blocks

(a) External wiring for panel power supplies shall be terminated on the appropriate isola-

tor. Signal cables from strain gauges, analyzers, resistance thermometers, retransmitting

slide-wires and thermocouples may be terminated at their appropriate instruments.

(b) A terminal block shall be provided as the interface between the corresponding con-

ductors of each internal and external wire and each internal and external connection

except those listed above. The terminal blocks shall be mounted vertically where possible

and not nearer than 230mm to the floor or less than 230mm from an incoming cable

gland.

(c) Terminal block rows shall be spaced apart by not less than 150mm and arranged to

permit convenient access to wires and terminals and to enable ferrule numbers to be read

without difficulty.

(d) Other circuits shall be grouped on the terminal blocks according to the classification

given in the clause for Panel internal wiring which shall be clearly marked along the

corresponding section of each terminal board. Groups of different voltages on the same

board shall be separated by insulated barriers.

(e) All connections shall be made from the front of terminal blocks and no live metal shall

be exposed at the back. All terminal blocks shall be of the type which clamps the wire

securely and without damage between two plates by means of a captive screw and which

permits removal of any terminal without disturbance to adjacent terminals. Pinch-screw

type terminal blocks will not be accepted. Terminal moldings shall be in melamine to BS

1322, polyamide or equivalent. Terminal rails shall be hot-dip galvanized. Current bars

between the two connection points of each terminal block shall be of copper or brass with

tin/lead alloy plating. All steel parts shall be zinc-plated and passivated with a yellow

chromate layer. Terminal blocks for input and output analogue signals and for circuits

containing volt-free contacts internal or external to the cabinet shall be of the Clip on

type SAKC or equivalent which permit the connection of a test millimeter or continuity

meter without disconnecting any wiring. Terminal blocks for power supplies for equip-

ment external to the panel shall permit the isolation of the item of external equipment

without affecting the operation of any other circuit within or outside the panel.

(f) No more than one core of external cables or two internal wires shall be connected to

any terminal. If terminal blocks are used as common points for two or more circuits,

individual terminals with the appropriate number of permanent cross connections shall

be provided. The lengths of exposed cable cores shall be sufficient to reach any terminal

in the appropriate row or rows. The cores shall be formed into a neat loom and a separate

239
loom shall be provided for each cable.

(g) Each row of terminal blocks shall contain at least 20% spare terminals over the num-

ber required for terminating all cores of external cables in that row. Unless otherwise

specified, each external cable shall contain at least 20% spare circuits, with a minimum

of one spare circuit.

(h) Terminal blocks shall be numbered consecutively in a sequence different from that

used for identifying wiring. The terminal numbers, voltage grouping and terminal board

layout shall correspond precisely with wiring diagrams so that quick and accurate iden-

tification of wiring can be made.

(i) All the terminal boards shall be provided with covers of transparent insulating material

that does not sustain combustion and shall be sectionalized where possible to give access

to groups of terminals without uncovering all boards. Terminals which may be live when

the panel is isolated from its main supplies shall be suitably labeled to minimize the risk

of accidental contact.

5.52.7.4 Panel internal wiring

Panel circuits shall be segregated into the following categories:

(a) Group 1: Power control and very-high-level signal wiring (above 50V):

(1) AC power supplies;

(2) DC power supplies;

(3) AC current signals above 50mA (such as CT circuits);

(4) AC voltage and control signals above 50V (such as PT circuits).

(b) Group 2: High-level signal wiring (6V to 50VDC):

(1) signals from conventional electronic transmitters and controllers (such as digital

or 4mA to 20mA);

(2) circuits to alarm annunciators and other solid-state devices

(3) digital signals;

(4) emergency shut-down and tripping circuits;

(5) on/off control circuits;

(6) intrinsically safe circuits;

(c) Group 3: Low-level signal wiring (5V DC and below):

240
 (1) signals from thermocouples;

(2) signals from resistance thermometers and re-transmitting slide-wires;

(3) signals from analytical equipment and strain gauges.

(d) For Group 3 wiring, internal connections to the instruments shall be made by one

of the following methods:

(1) The twisted, screened conductors of the external cable shall be led direct to their

appropriate instruments via ducting systems installed for this purpose during construc-

tion of the panel;

(2) The conductors of the external cables shall be terminated on terminals segregated

from all other categories and the connections to the appropriate instruments shall be

made using twisted pairs with individual screening installed for this purpose during con-

struction of the panel.

(3) Internal wiring for all circuits in Group 2 except those sharing a common connection

shall be multithreaded, twisted pair, 0.75mm minimum copper conductors with HPDE or

PVC- insulated cable of adequate grade and rating.

(4) Wiring for circuits in other Groups or sharing a common connection shall be run in

stranded, 1.0mm minimum copper conductors with 250V grade, PVC-insulated cable of

adequate grade and rating.

(5) Wiring sheath colors shall be black for AC circuits, and grey for DC circuits (excluding

thermocouple circuits) and blue for Group 2.6 circuits. Circuits supplied at 240V, be-

tween 240V and 110V DC shall also be physically segregated from each other and from

other circuits. Access to wiring and components of circuits having voltages exceeding

240V shall not be possible unless and until the circuit has been isolated.

(6) Separate ducts, trunking, cable looms, tray work and the like shall be provided within

the panel for each category with at least 150mm between parallel paths of Group 1 and

those of any other Group. Intrinsically-safe circuits and their terminals shall be segre-

gated from other circuits and terminals.

(7) All wiring shall be neatly and securely fixed by insulated cleats, bunched and se-

cured by approved plastic strapping or run in approved insulated wiring trunking or

non-corrodible flexible tubing. Not more than 75% of the capacity of trunking, ducts,

looming, or tubing shall be used. Insulated earth wiring shall be so arranged that access

to any equipment or connection point or the removal of any item of equipment is unim-

241
peded.

(8) Wiring for future equipment shall be secured and terminated on terminal blocks. Lac-

ing for wiring looms shall be of rot-proof cord or plastic strips. Inter-section wiring in

multi- section cabinets shall be via a terminal block in each section.

5.52.7.5 Panel wiring identification and termination

(a) Identification ferrules shall be fitted at both ends of each wire. The numbers or letters

used shall correspond with the appropriate wiring diagram. The ferrules shall be of plas-

tic insulating material with permanent black characters on a color coded background for

numbers and on a white background for letters, unaffected by oil or water. They shall be

so arranged that they can be read logically from left to right when viewed normally.

(b) The system of wire identification shall be such that wires in the same circuit on

opposite sides of a terminal shall have the same reference, and this system shall be

continued through all external cabling.

(c) Terminal ferrules (spade, tongue, crimped connections) shall be provided on each

conductor.

5.52.7.6 Panel Earthing

(a) A continuous copper earth bar of not less than 25mm x 6mm cross section shall run

the full length of each panel and shall be securely fixed and bonded electrically to the

main frame. The cable gland-plates and the earth bar shall be provided with suitable

brass terminals of not less than 6mm diameter for connecting the metal cladding or ar-

mouring of all incoming and outgoing cables to the station earthing system.

(b) A second continuous copper earth bar of not less than 25mm X 6mm cross section,

electrically isolated from the steelwork of the panel and metal cladding and armoring of

cables, shall be provided for earthing the signal earth connection of each instrumentation

and control device and the screen(s) of each instrument cable not earthed elsewhere to

the station instrumentation earth plate. The earth bar shall have sufficient brass ter-

minals as specified above for each instrumentation and control device and the screen of

every shielded cable plus 20% spare terminals

(c) In multi-section panels, each earth bar shall be electrically bonded to the correspond-

ing bars in the adjacent section(s).

(d) The earth pit for instrumentation system shall be separate. Electric earth pit shall not

be used for earthing of instrumentation equipment. All signal cable screens (analogue

and digital) shall be terminated onto the instrument earth bar. Signal cable screens shall

be earthed at the control panel end only. Screens at the field end shall be tied back and

242
insulated.

(e) Surge Protection Device associated with the control and instrumentation system shall

be earthed to the instrument earth in accordance with the SPD manufacturers recom-

mendations.

5.52.7.7 Panel lighting

Each panel shall be adequately illuminated internally, as evenly and as free from dazzle

as possible, by fixed fluorescent lighting controlled from totally-enclosed light switches

and by totally enclosed door-operated switches positioned so as not to interfere with ac-

cess. There shall also be one installed inspection lamp per three metres of panel length

or part thereof with adequate flexible connection cable to reach any point in the panel.

The control switch for an inspection lamp shall form part of the lamp assembly. Lighting

circuits shall be fused independently of any instrumentation and control circuit and de-

signed to allow lamps to be replaced safely and shall be fed from a distribution board and

circuit breaker connected on the live side of the main panel ac supply circuit breaker.

5.52.7.8 Panel ventilation

(a) Each panel shall be provided with ventilation fans as required to ensure that equip-

ment within the panel is maintained within manufacturers recommendations, with due

regard to the environment in which the panel will be mounted. Fans shall be controlled

by a suitably-labeled enclosed switch mounted internally in an accessible position.

(b) Fans shall be mounted with their axes horizontal and shall be arranged to draw clean

air into the panel. Air entries shall have filters which can be renewed from outside the

panel and shall be designed to prevent the entry of rain, spray, injurious fluids, sand or

dust.

5.52.7.9 Panel labels

(a) All control gear shall be fully labeled with the KKS code identifying the equipment des-

ignation/function, all external and internal components, all rating data, detailed equip-

ment operating data and for danger and hazard warning.

(b) Labels shall be provided for every panel to describe the duty or otherwise identify the

panel and its sections and every instrument, component and item of equipment mounted

internally and externally. Where applicable, front-of-panel labels shall be as detailed in

the Specification. Wording shall be clear, concise and unambiguous and shall be subject

to review by the Engineer-in-Charge before manufacture. Each label shall be perma-

nently secured to the surface near the item to which it refers. Externally- fitted labels

243
shall be of Perspex or other approved transparent plastic, with letters and numbers rear-

engraved and filled with black.

(c) The rear surface of each Perspex label shall be finished with a coat of paint of the

same colour as the panel external finish. Instrument duty labels fitted externally shall be

below the item to which they refer. Embossed tape or similar adhesive labels will not be

approved.

(d) Laminated materials or rear-engraved and filled plastic shall be used for internally

fitted labels, which shall be white with engraved black letters.

(e) Labels conforming to the requirements of the preceding paragraphs or other approved

means shall be provided:

i. to describe or identify circuits or circuit components;

ii. to identify DC polarity;

iii. to warn or remind about dangerous or potentially-dangerous circumstances;

iv. wherever elsewhere specified.

(f) Unless otherwise specified, all engraving shall be in plain block letters, 4mm high.

(g) The minimum practicable number of different sizes shall be used.

5.52.7.10 Panel finish

(a) For control and instrument panels, desks and cubicles a hard, smooth, durable fin-

ish, free of blemishes, finish shall be provided. Before painting, all external welds and

any rough areas shall be smoothed, and all surfaces shall be thoroughly cleaned and

free from scale, contaminates, corrosion or grease. If rust-proof or Zintec steel has not

been used in the construction, the panel shall be treated with a passivating agent such

as phosphoric acid. All internal surfaces shall have a minimum of three coats of paint of

which the first shall be an approved anti-rusting priming coat and the final coat shall be

an opaque gloss white enamel. All external surfaces shall have not less than five coats of

paint of which the first shall be an approved etch-priming coat, and the second and third

suitable undercoats, all of which shall be rubbed smooth when dry before application of

the next coat. The undercoats shall be easily distinguished in shade or colour from the

priming and finishing coats. The two final coats shall be of stove enamel paint, gloss or

semi-matt finish, to a colour and finish to be advised by the Engineer-in-Charge. Stoving

shall be carried out in accordance with the recommendation of the paint manufacturer.

244
(b) The overall dry film thickness (DFT) shall be between 100 and 150 microns.

(c) Nuts, bolts, washers and other fixing devices which may have to be removed for tran-

sit or maintenance purposes shall be galvanized or otherwise finished to an approved

standard.

5.53 Instruments and ancillaries

5.53.0.1 General

(a) All instruments, gauges and control equipment which perform similar duties shall be

of uniform type and manufacture throughout the Plant in order to facilitate maintenance

and the stocking of spare parts.

(b) All equipment shall be fully tropicalised and suitable for the worst environmental

operating conditions. Panel-mounted instruments shall be of the electrically operated

flush mounted type and shall have damp-proof and dust-proof cases.

(c) Instruments mounted outside instrument panels shall have weatherproof and dust-

proof cases. Instrument cases shall be of corrosion-resistant material or finish.

(d) Instrument screws (unless forming part of a magnetic circuit) shall be of brass or

bronze. Access to terminal compartments of instruments mounted outside panels or

other enclosures shall not expose any working part. Moving parts and contacts shall be

adequately protected from the ingress of dust. Where applicable instruments shall be

easily withdraw able from its housing for maintenance without interrupting its signal.

(e) Unless otherwise specified, instruments shall be finished in the manufacturers stan-

dard colour. Instrument dials shall be of such material that no peeling or discolouration

will take place with age under tropical conditions.

(f) Plant-mounted indicators and gauges shall be sized to give full legibility when viewed

from a position with convenient and easy access or from the point at which any operation

requiring observation of the gauge is performed. The minimum diameter for any gauge

shall be 150mm except where forming part of standard instruments and accessories such

as air-sets.

(g) Dials and bezels shall be of bronze and internal components shall be of stainless steel,

bronze or other corrosion-resistant material.

(h) Unless otherwise specified, all functions shall be transmitted electrically and all ana-

logue signal transmission systems shall be in accordance with BS 5863: Part 1 or equiv-

alent and shall use a signal of digital or 4mA to 20mA DC. Where possible, measuring

systems shall be designed so that any necessary power supply is taken from the appro-

priate instrument panel.

245
(i) Transmitting devices shall have integral indicators to monitor the output signal or con-

nections suitable for use with a portable test meter, and shall be capable of meeting the

performance requirements specified in the BS EN 60770-1or equivalent. For the impor-

tant and critical processes the transmitting devices, such as pressure, temperature and

level gauges, shall have a reference gauge installed locally for easy reference for the oper-

ation and maintenance staff.

(j) The transmitters shall be provided with LCD meters.

(k) Equipment mounted in enclosures shall be suitable for continuous operation at the

maximum internal temperature possible in service, due account being taken of internally-

generated heat and heat dissipated by other plant. All components shall be rated ade-

quately and circuits shall be designed so that change of component characteristics within

the manufacturers tolerances shall not affect the performance of plant. All equipment

shall be designed to operate without forced (or fan) cooling.

(l) Equipment provided with anti-condensation heaters shall be capable of operating with-

out damage if the heaters are left on continuously. Unless provided with unalterable fac-

tory configured ranges, measuring instruments shall have zero and span adjustment.

(m) Field mounted instruments shall be mounted such that they are easily viewable and

easily accessible for maintenance.

(n) Instruments not mounted in panels shall be supplied complete with all brackets,

stands, supporting steelwork and weatherproof enclosures (separate from the instru-

ment cases) necessary for securing them in their working positions and affording com-

plete protection at all times including periods of servicing, adjustment, calibration and

maintenance.

(o) Each installation shall incorporate a valve and pipework for obtaining a sample repre-

sentative of the fluid at the position of the permanent meter and drain. If the measuring

and sampling points are remote from each other, the test and sample facilities shall be

provided at both points.

(p) In order that maintenance and inspection may be carried out safely and conveniently,

instruments mounted in elevated and open work areas shall be provided with safety lad-

ders and a sufficiently sized working platform with weather shade.

5.53.0.2 Indicating Instruments and Meters

(a) All instruments and meters shall be flush mounted and generally of the same pattern

and appearance throughout and those which perform similar duties shall be of uniform

type and manufacture.

246
 (b) Indicating instruments shall be fitted with an externally accessible zero adjuster.

They shall have no parallax error and their normal maximum reading shall be approxi-

mately 60% full scale deflection.

(c) Ammeters in motor starter circuits shall be capable of withstanding the starting cur-

rent and shall have a compressed overload scale. The ammeter shall have an adjustable

and sealable red pointer set to indicate normal full load current. The physical size of the

ammeter shall be in line with the size of the relevant starter.The minimum size to be used

is 0.25 DIN.

(d) Indicating instruments shall comply with IS 1248, BS 89 or IEC 60051 and shall be

of industrial grade accuracy.

(e) Kilowatt-hour meters shall comply fully with IS 722 or BS 5685 Class 2 and shall have

industrial grade accuracy (2.5%). Three element units shall be used for 3 phase 4-wire

systems. Two element units shall be used for 3 phase, 3-wire systems.

5.53.0.3 Indicator Lights

(a) Indicator lights shall not be less than 20 mm in diameter and shall be panel mounted

type with metal bodies adequately fastened so that the lamps shall be capable of replace-

ment from the front of the apparatus without disturbance to the lamp holder or panel

wiring. Lamp holder shall be keyed into panels to prevent rotation. Lens colors shall

comply with BS EN 60037 as follows:

i. power ‘on‘ - white*

ii. running - green

iii. tripped/alarm - red

iv. status (open, closed, etc) - blue

v. ready to start - blue

vi. warning (no imminent danger) - amber

Note: *white may be used where doubt exists as to which other colour to use.

(b) The lights shall be under-run to give long life either by use of a resistor to limit

voltage to 90% normal value or by using higher voltage lamps.

(c) The indicating lamps on control panel shall be cluster of LED’s.

247
5.53.0.4 Push buttons

(a) Colours of pushbuttons shall generally comply with IS 6875, BSEN 60947, 60037 or

IEC 60073 and in particular shall be as follows:

i. stop, emergency stop - red

ii. start -green

iii. jogging/inching - black

iv. reset (when not also acting as a stop) - blue

v. lamp test - blue

vi. override/alarm accept -yellow

5.53.0.5 Cable

Instrumentation cable

(a) Instrumentation cable in between conventional measuring transmitters and ana-

logue process controllers, such as digital or 4mA to 20mA DC output from a constant-

current source, (hereinafter referred to as high-level signals) shall be of polyethylene or

PVC insulated with stranded conductors and laid up as twisted pairs with one twist per

50mm approx. Each cable shall have an overall screen of braided copper or mylar backed

aluminium foil giving a minimum coverage of 85%, a steel wire armouring shall be insu-

lated from the screen and from any ducting and an overall PVC sheath shall be provided.

For runs exceeding 30 metres or for all inputs to a data logger, computer or microproces-

sor, multi-core cables shall have an individual screen of braided copper or mylar-backed

aluminium foil for each signal pair. The minimum conductor size shall be 24/0.2mm

but shall be of greater cross-sectional area if required for the satisfactory operation of

associated plant. Cables for intrinsically safe systems shall comply with BS 5308 and the

relevant certificate.

(b) Cables from strain gauges, analyzers and the like, such as 0 to 100mV (hereinafter

referred to as low-level signals see also below) shall be as specified above and shall have

an individual screen for each signal pair.

(c) Cables from indicating devices to alarm or tripping circuits shall be as specified above

for high level signals but shall use cables, cable trays, ducts and conduit separate from

those for other high-level circuits.

(d) Cables for high-level signals, low-level signals, resistance thermometers and thermo-

248
couples shall be segregated from each other and each shall be separated from cables for

power, communications and other electrical services. Other cables running in the vicinity

of instrumentation cables shall be twisted at the rate of one twist per 50mm approxi-

mately and shall be separated from instrumentation cables by a distance of not less than

300mm.

(e) Initiating devices for plant protection and personnel safety shall be connected by in-

dividual cables directly to the tripping or safety device and shall not be routed via any

intermediate junction, marshalling box, cabinet, relay etc. The outer sheaths of such

cables shall be orange coloured.

5.53.0.6 Cable termination boxes

(a) Cable termination boxes shall have double-ended screw terminals with removable

links to facilitate core isolation during testing. Each box shall contain sufficient termi-

nals for every conductor plus 20% spare terminals. Cable termination boxes shall have

cable sealing chambers and insulated glands with earthing terminals so that the armour-

ing may be earthed or isolated from earth, as circumstances dictate.

(b) Termination boxes for use within buildings shall be of sheet steel with hinged or re-

movable front covers. All other termination boxes shall be cast steel or heavy gauge

sheet steel construction giving protection to IP55. All termination boxes shall be hot-dip

galvanised or approved equivalent finish. Each terminal box shall have a removable, un-

drilled gland plate and the Contractor shall supply and fit the requisite number of cable

glands.

(c) At each cable termination box, each cable core (including spares) shall be identified by

a numbered slip-over type collet. The numbering for a particular cable core shall be the

same throughout its length.

(d) Cable joints shall be only at points approved by the Engineer-in-Charge.

(e) Each cable joint shall be of the straight-through type. The conductors shall be ferrule-

jointed with the insulation maintained by heat-shrink sleeving. Joint closure shall be

made with epoxy resin and the completed joint shall be impervious to water if submerged

or in waterlogged ground. If cast iron joint boxes be used, they shall be provided with

cable glands and, after installation and testing, shall be covered with Densomastic HD

compound or equal; so that all sharp corners, bolts and projections are moulded to a

smooth surface. Two lappings of Densopol grade ZN 50mm tape, or equal, shall then be

applied overall. Jointing shall be carried out on each conductor, including any provided

in excess of the minimum quantity specified. All materials and things of every kind re-

249
quired for the cabling jointing shall be provided by the Contractor.

5.53.0.7 Cable labeling

(a) At each end of each cable, in a uniform and visible position, a label shall be fixed

on the cable to indicate the site cable number and route, and the number and size of

conductors. Labels shall be made of brass, aluminium, lead or copper strip, engraved

and retained by suitable non-rusting or non-corrodible binding wire passing through two

fixing holes, one at either end of the label. If the cable gland is not normally visible, then

the label shall be fixed inside the panel by means of screws.

(b) Three-phase power cable cores shall be identified R, Y, B or colour-coded red, yel-

low, blue so that the correct three-phase sequence is preserved throughout the system.

Single-phase power cable cores shall be colour-coded red and black.

(c) Control cables shall have individual cores identified by means of suitable perma-

nent ferrules bearing the same number at both ends. Core identification shall occur at

every point of termination using an approved system of colour-coded ferrule markers.

The size of these ferrule markers shall be such as to match the overall diameter of con-

ductor plus insulation. Numbering shall read from the termination upwards on all cores.

(d) Each cable and core shall bear the same number at both ends of the cable and core

respectively.

i. Power terminations colour, number or letter.

ii. Control terminations letter or number or both.

5.53.0.8 Cable terminations

(a) All PVCSWAPVC, PVCPVC and XLPESWAPVC cables shall be terminated with mechan-

ical glands which shall comply with BS 6121. They shall seal the inner and outer cable

sheaths against ingress of dirt and moisture and provide adequate mechanical support.

Each cable gland shall be protected by corrosion- resistant molded PVC hoods, covering

the entire assembly from the overall sheath to the gland neck.

(b) Glands for armoured cables shall provide a positive armour clamp to the enclosure so

that no tension is applied to the termination. The clamp shall also provide a high level of

earth continuity and be of adequate size to withstand the full fault current of the system

250
for one second.

(c) All glands shall be provided with an earthing tag. For cables of 4mm or less, a serrated

washer may be used instead for earth continuity.

(d) The cable termination and sealing equipment shall be obtained from the cable man-

ufacturer, or other approved supplier, and shall be purpose-made for the type, size and

grade of cable concerned. The application of these materials shall be strictly in accor-

dance with the manufacturers instructions.

(e) Through joints shall be permitted only on long cable runs outside buildings.

(f) Where such joints are necessary; the cables shall be jointed with epoxy or acrylic resin

Cold-setting compound which has been pre-measured and pre-packed ready for use. The

boxes shall be of a split moulded plastic type with filling vents for compound.

(g) Bonding straps shall be fitted with armour clamps across the joint for filling the box

with compound. Wrapped pressure type joints shall not be accepted.

(h) Conductor cores shall be jointed number to number or color to color.

5.53.0.9 Cable installation-general

(a) Cables which are to be run on walls, ceilings or other building structures shall, unless

otherwise agreed by the Engineer-in-Charge, be secured on cable trays or enclosed in

conduit or trunking.

(b) Every cable shall be neatly laid vertically or parallel to adjacent walls, beams or

other structural members. Cables shall preferably not to be installed in areas of direct

sunlight.

(c) Where this is unavoidable, approved sun shields shall be supplied and installed.

(d) Where the building structure incorporates purpose-built covered duct or trench sys-

tems for main cables, instrumentation cables shall be segregated and installed on tray

work or otherwise secured to the sides of the duct or trench.

(e) Where the structure incorporates general service ducts or trenches containing pipe

work, chemical lines and other services, all cabling shall be segregated from the other ser-

vices and shall be run on the walls unless otherwise agreed by the Engineer-in-Charge.

(f) Cables shall be spaced to prevent interference between power and signal cables, and

to avoid unnecessary crossovers.

(g) The spacing of clips, saddles and cleats shall prevent the sagging of the cables. The

method of fixing clips etc. shall be by means of non-corrodible screws inserted into wall

fixings, e.g. raval plugs.

251
(h) Cable hangers, cleats, saddles, brackets, wall fixing and similar supporting devices

shall be of an approved type and shall provide adequate strength for the cables it sup-

ports. All these wiring accessories shall be non-corrosive. Self-locking plastic buckle clips

and strapping shall not be used. The arrangement and fixing of each cable shall permit

the removal and replacement of any cable without disturbance to any other cable or the

fixings thereof.

(i) When cables are terminated in any particular item /equipment, special care shall be

taken to ensure that the cables finally approach the equipment from a common direction

and are individually terminated in an orderly and symmetrical fashion.

5.53.0.10 Drawings and schedules

(a) Block diagrams to show control cabling systems with each cable and terminal equip-

ment being identified as in the cable schedules.

(b) Cable route and layout drawings. For those items which are underground, these

drawings shall include the following:

i. route plans and sectional views for all cable runs, cable trays, cable ducts and cable

trenches;

ii. the position of all marker posts, joints, draws pits etc.

iii. cable schedules shall detail the cable number, type, voltage, size, route length and

number of cores or pairs. Control-cable schedules shall detail the connected and spare

core numbers, diagram number for connected equipment, core ferrule and terminal ref-

erence number.

5.53.0.11 Data and calculations

Manufacturers catalogues and data sheets for all cables and fittings. Cable sizing Calcu-

lations.

Test certificates:

(a) Routine Tests and Type Test certificates shall be submitted.

252
5.53.0.12 Cable trays and cable tray support

(a) Cable trays shall be ladder type and of heavy-gauge galvanized steel.

(b) Cable trays shall be installed using factory-made supports, joints and junction/bend

pieces. Wherever tray and cable tray supports/sections are cut and shaped on Site, cut

edges shall be dressed and painted with at least two coats of cold galvanizing compound

(c) Cable tray support systems shall be secured to walls and ceilings by pre-formed gal-

vanized interlocking channel.

5.53.0.13 Flexible conduits

(a) Flexible conduit shall be of the waterproof galvanized type of PVC wire-wound type

with cadmium plated mild steel couplings. Lengths of flexible conduit shall be sufficient

to permit withdrawal, adjustment or movement of the equipment to which it is attached

and shall have a minimum length of 300mm. Flexible conduit shall not be used as a

means of providing earth continuity. A single earth conductor of adequate size shall be

installed external to the conduit complete with earth terminations.

(b) Where conversion from rigid conduit to flexible metallic conduit is to be made, the

rigid conduit shall terminate in a trough-type box. The flexible conduit shall extend from

this box to the equipment; the earth continuity cable shall be secured to the box and to

the piece of equipment. The use of lid facing screws and the like will not be permitted.

Adaptors shall incorporate a grub screw or a gland to prevent the flexible conduit becom-

ing loose.

5.53.0.14 PVC conduit

(a) Where galvanized conduit would be liable to corrosion, PVC conduit shall be installed.

(b) PVC conduit shall be of the oval or round high impact non-flame-propagating type

as specified and self-extinguishing, conforming to BS EN 61386-21. Surface and con-

cealed installations shall be generally as described for steel conduit.

(c) PVC conduit fittings shall comply with BS 4607. They shall all be white unless speci-

fied otherwise.

(d) Jointing shall be carried out using PVC solvent and socketed accessories.

(e) Expansion couplers shall be fitted in straight surface runs at a distance of every 12m.

253
The free end shall be sealed with non-setting mastic to form a waterproof seal.

(f) Purpose-made bends may be used providing that the cable bending radius is main-

tained. Cracked or crinkled conduit will be rejected.

(g) The conduit shall be suitable for use in ambient temperatures of between 5C and +50C

and shall not be installed in areas that receive direct sunlight. A separate protective con-

ductor (earth continuity conductor) shall be installed.

(h) Adaptable boxes and accessories shall be made from heat-resistant insulating mate-

rial. The minimum wall thickness of boxes having a nominal internal depth of 16mm or

less shall be 1.5mm. For deeper boxes, the minimum wall thickness shall be 2mm. All

boxes which are intended to support luminaries or other heat sources shall have either

external fixing lugs riveted to the metal inserts or utilize steel insert clips.

5.53.0.15 Cable installation methods

General

(a) All cabling installation methods shall be subject to the approval of the Engineer-in-

Charge.

Installation directly into the ground

(a) Where cables are buried in the earth, the bottom of the excavated trenches shall

be freed of sharp stones and other projections and covered with sand to a depth of 50mm.

(b) Cables shall be unrolled from drums without loops and kinks, and care shall be

taken when laying to avoid damage to the outer sheath by drawing over sharp projections.

(c) Cables shall be snaked into the trenches to avoid tension in the cables during back-

filling or from subsequent settlement. After laying, cables shall be covered to a minimum

depth of 100mm of compacted sand and shall have a layer of red bricks for protection.

The bricks shall be overlaid with marker tape.

(d) When cables of different voltages are laid together at the same depth, vertical cable

tiles shall be used to segregate the cables.

(e) ICA and communication cables shall be laid not closer than 750 mm to high voltage

cables.

(f) A sufficient number of rollers shall be provided so that the cable does not touch the

ground or twist during pulling.

254
5.53.0.16 Installation in underground ducts

(a) Underground ducts shall be constructed of impact-resistant uPVC and laid at a mini-

mum depth of 500mm (to the duct centre), surrounded by at least 75mm of sieved sand.

At road crossings, Upvc ducts of minimum diameter 100mm shall be laid at a minimum

depth of 1000mm (to the duct centre). The ducts shall be encased by 150mm concrete

on all sides.

(b) When installing cables in ducts, the following measures shall be observed:

(1) Cables shall be pulled in a straight line;

(2) Rollers shall be positioned at the edges of draw pits both at the drawing-in and

drawing out points over which the cables shall be drawn;

(3) UPVC pipes and cable sheaths shall be coated with an approved lubricant;

(4) Sufficient draw-in points shall be provided and adequate room allowed for installation

of cables;

(5) The pulling rope shall be guided by rollers.

(6) Only one power cable shall be drawn into each duct.

(c) Whenever a duct is laid in the ground, a draw-wire shall be pulled through with at

least1000mm excess at each end and the draw-wire left in position if the duct is not to

be used immediately.

5.53.0.17 Sealing cable entries into buildings

(a) Whenever cables pass through walls below ground level, the point of entry shall be

sealed against the ingress of water. This shall be achieved with silicone foam or similar.

(b) All cable entries into a building shall be in ducts and where the cables pass in or out

of ducts, together with any spare ducts, the ducts shall be sealed against the ingress of

moisture by means of duct stoppers and bituminous compounds or by any other method

approved by the Engineer-in-Charge. The stopper shall have a fire resistance of at least

30 minutes.

255
5.53.0.18 Marking of underground cables

(a) The location of all underground cables shall be identified by

(1) Brass plates fixed to the exterior surface of all walls of buildings 300mm above

ground level and directly above the point where cables pass through the wall;

(2) Marker posts in road verges and the like at intervals of not more than 30 mtrs and at

all junctions and changes of direction along the route;

(3) Marker posts at 10m intervals within an enclosed site and at all junctions and changes

of direction along the route.

(b) Marker posts shall be of concrete, not less than 200mm high above ground with

an inscribed brass or enamel metal plate. The inscription shall indicate the presence of a

cable below, the depth, classification and voltage rating.

(c) A drawing or sample of a typical marker post shall be submitted for the approval of

the Engineer-in-Charge.

5.53.0.19 Installation in cable trunking

(a) Cable trucking shall be manufactured from mild steel of not less than 1.25mm and

shall be hot-dip galvanized. The Contractor shall ensure that the size of the trunking

is adequate for the number of cables to be installed together with 50% spare capacity.

Trunking shall have minimum dimensions of 50mm X 50mm.

(b) Segregation of cables shall be carried out if required using continuous sheet steel bar-

riers with the bottom edge welded to the trunking. The trunking shall have two return

flanges for rigidity. Where necessary, additional strengthening straps shall be fitted inter-

nally. The cover shall overlap the trunking and be made of the same gauge. Fixing screws

for covers shall be recessed and be of the self-retaining quick-fix type. All bends, tees and

intersections shall be of the gusset type and shall, wherever possible, be purpose-made

by the manufacturer and of a matching design to the main trunking.

(c) Cables shall be retained in the trunking when the cover is removed by means of straps.

Internal connecting sleeves shall be fitted across joints in the trunking and earth conti-

nuity ensured by bonding each section of trunking to a continuous earth wire.

(d) Non-flammable fire barriers shall be inserted where the trunking passes through walls

or floors. Conduit connections to trunking shall be made by flanged couplings and male

bushes

(e) Trunking shall be supported at intervals not greater than 2m horizontally or 2.5m

256
vertically.

(f) Crossings over expansion joints shall be made in flexible conduit

(g) Should it be necessary to cut or drill a section of trunking, the bared ends shall im-

mediately be given a coat of zinc-rich cold galvanizing paint.

(h) Cable and trunking runs shall be determined by the Contractor and approved by the

Engineer-in-Charge before any work is started. The run shall be at least 150mm clear of

plumbing and mechanical services.

(i) Trunking systems erected outside a building shall be weatherproof.

5.53.0.20 Installation in buildings

(a) Cables required to be run on walls, ceilings, or other structures shall be carried on

substantial cleats, either in groups or simply at spacings determined by rating require-

ments, supported on tray or ladder racks or enclosed in conduit or trunking.

(b) All cables shall be neatly run vertically or parallel to adjacent walls, beams or other

structural members. (c) The spacing of clips, saddles and cleats shall be such as to pre-

vent the sagging of the cables during their installed life. The method of fixing clips and

the like shall be by means of no corrodible screws inserted into approved wall fixings.

(d) Cable hangers, cleats, saddles, brackets and similar supporting devices shall be of an

approved type and of adequate strength for the cables they are supporting. They shall be

treated to withstand site conditions without corroding. Self-locking plastic buckle clips

and strapping shall not be used.

(e) Hangers shall be spaced according to recommendations in the IEE Wiring Regulations.

Allowance shall be made for expansion and contraction of the cables.

(f) Cables shall be located between 50mm pegs spaced at 40mm centers across a rung so

that a 40mm or 80mm space is maintained between cable centers. Cleats shall be used

where the ladder racking is vertical.

(g) Cables shall be run at least 150mm clear of plumbing and below heating and hot water

pipe work.

5.53.0.21 Cable installation in conduits

(a) Conduits shall be either galvanised heavy-gauge steel screwed type or light-gauge steel

no screwed type, steel or PVC. Accessories shall either be malleable cast iron or pressed

steel.

(b) A space factor of 40% shall not be exceeded and, in any case, conduit shall have a

257
minimum diameter of 20mm. The tubing is to be perfectly smooth inside and out and free

from imperfections. Both ends of every length of tubing shall be reamed and all sharp

edges removed before erection.

(c) Where conduits converge, adaptor boxes shall be used. Conduits shall be connected

by means of male brass bushes and couplings. Where conduits are greater than 25mm

diameter, straight through joint boxes shall be of the trough type. Where conduit or fit-

tings are attached to equipment casings, the material of the casing shall be tapped for a

depth of not less than 10mm or male bushes and flanged couplings may be used

(d) Hexagonal lock nuts shall be used at running joints. They shall seat firmly and evenly

on to mating faces. All function boxes, draw-in boxes, and inspection fittings shall be

placed so that the cables can be inspected, withdrawn and re-wired during the life of the

installation.

(e) Generally not more than two bends or offsets or one coupling will be permitted without

a suitable inspection accessory. Fish wires shall not be left in conduits during erection.

The whole of the installation shall be arranged for a loop-in type of system with joints

being carried out at switches, isolators or appliance fittings.

(f) Ends of conduits which are liable to be left open for any length of time during building

operations shall be plugged to prevent the ingress of dirt and covers shall be fitted on all

boxes.

(g) Generally, conduits shall not cross expansion joints of buildings. Where they cannot

be installed in any other manner, a galvanised flexible conduit shall be used across the

expansion joint. A total of 150mm movement shall be allowed.

5.54 Process Instrumentation

General

(a) Instrumentation system shall be designed, manufactured, installed and tested to

ensure the high standards of operational reliability. All electronic components shall be

adequately rated and circuits shall be designed so that change of component character-

istics shall not affect plant operation.

(b) All instrumentation equipment shall be new, of proven design, reputed make, and

shall be suitable for continuous operation. Unless otherwise specified, all instruments

shall be tropicalised. The outdoor equipment shall be designed to withstand tropical

rain. Wherever necessary space heaters, dust and water proof cabinets shall be provided.

Instruments offered shall be complete with all the necessary mounting accessories.

(c) Electronic instruments shall utilize solid state electronic components, integrated cir-

258
cuits, microprocessors, etc., and shall be of proven design.

(d) No custom made hybrid type integrated circuits shall be used.

(e) Unless otherwise stated, overall accuracy of all measurement systems shall be 1% of

measured value, and repeatability shall be 0.5%.

(f) Unless otherwise specified, the normal working range of all indicating instruments

shall be between 30% and 80% of the full scale range.

(g) On resumption of the supply following a power failure the instruments and associated

equipment shall start working automatically.

(h) The instruments shall be designed to permit maximum interchangeability of parts and

ease of access during inspection and maintenance.

(i) Unless otherwise stated, field mounted electrical and electronic instruments shall have

minimum ingress protection as IP-66.

(j) The instruments shall be designed to work at the temperature, humidity, and chlorine

contamination that may prevail at site. Instrument enclosure shall have corrosionresis-

tant properties.

(k) Enclosures of all the field instruments shall have locking arrangement.

(l) All field instruments, and cabinets/panel mounted instruments shall have tag plates/name

plates permanently attached to them. Details of proposed inscriptions shall be submitted

to the IITH for approval before any labels are manufactured.

(m) All coated parts of sensors shall be made out of non-corrosive material capable of

working against chlorine content up to 5 ppm.

(n) For all field instruments, surge protection devices (SPD) shall be provided at both ends

of the connecting cable for protection against static discharges / lightning and electro-

magnetic interference.

(o) Individual pair screened, overall screened, armoured cables shall be used for analogue

signals and armoured, overall screened cable shall be used for digital signal cables.

5.55 Flow Measuring Systems

(a) Flow measuring system shall consist of flow sensor / transducers, flow transmitter

and flow computer.

(b) Flow transducers shall be rugged in construction and shall be suitable for continuous

operation. Flow transducers shall have waste waterproof construction and shall be suit-

able for installation in underground /above ground pipelines.

(c) To avoid the effects of disturbances in the velocity profile, a straight and an unin-

terrupted run, on upstream as well as on downstream side of the location of the flow

259
sensor/transducer shall be provided in accordance with the recommendations of the flow

meter manufacturer.

(d) The flow transmitter shall be suitable for field or panel mounting. It shall process the

input signal and provide 4-20 mA DC and RS 485 output signal with open bus protocol,

proportional to flow rate. The flow range shall be adjustable.

(e) A zero span adjustment facility shall be provided for flow transmitter and indicator.

(f) Within given limits, flow measurement shall not be affected by physical properties of

sewage viz., temperature, pressure, viscosity, density etc.Contractor shall provide com-

pensating electronic circuits if required. The overall accuracy of flow measuring systems

shall be at least 1.0 % of the measured value unless otherwise stated.

5.56 Open Channel Flow meter

(a) Open channel flow measuring systems shall consist of level transducer, flow trans-

mitter cum flow computer. The level of the fluid in the flume shall be measured by the

ultrasonic level transducer. The flow measurement shall be take help of physical charac-

teristics of the flume.

(b) The level transducer shall be suitable for flange or bracket mounting as per site re-

quirement and shall have minimum ingress protection as IP66. It shall have ambient

temperature compensation and adjustable datum setting facilities.

(c) The design and application of ultrasonic level transmitters shall take into account the

flume/channel physical dimensions, construction details, process fluid, the presence of

foam, granules, size etc.

(d) The installation shall avoid any degradation of performance from spurious reflections,

absorption, sound velocity variations, sensor detection area, temperature fluctuations,

specific gravity changes and condensation. For application where spurious reflections

are unavoidable the control unit shall be provided with facilities for spurious reflection

rejection.

5.57 Level Measuring System

5.57.1 Ultrasonic Level Meters

(a) Ultrasonic level measuring devices applied for fluid level measurement shall comprise

a transducer, transmitter and remote indicator.

260
 (b) The transducer shall be suitable for flang1e or bracket mounting as per site require-

ment and shall have an ingress protection as IP 65. It shall have ambient temperature

compensation and adjustable datum setting, facilities.

(c) The accuracy of the sensor shall be 0.25% of the measurement or better.

(d) It shall have an integral programming keyboard and shall provide a digital display of

the measured variable. It shall be provided with diagnosis facilities and shall provide an

isolated 4 to 20 mA DC and RS 485 output signal with open bus protocol, proportional to

the range of measurement.

(e) The design and application of ultrasonic level meters shall take into account the vessel

or channel construction, the material, size, shape, environment, process fluid or mate-

rial, the presence of foam, granules, size etc.

(f) The installation shall avoid any degradation of performance from spurious reflections,

absorption, sound velocity variations, sensor detection area, temperature fluctuations,

specific gravity changes and condensation. For applications where spurious reflections

are unavoidable the control unit shall be provided with facilities for spurious reflection

rejection.

(g) If turbulence exists, shielding, stilling tubes, still well or other measures shall be pro-

vided to avoid its effects on the measurement.

5.57.2 Conductivity Level Switches

(a) The electrodes used for conductivity level switches shall be stainless steel. Single

electrode systems (one electrode per holder) shall be used (except where their use is im-

practical) with insulated electrodes such that only the tip of each electrode is exposed to

the liquid at the operating level.

(b) Relay or control units operating with level electrodes shall have adjustable sensitivity.

Electrodes for use in fluids of low or variable conductivity shall be fitted with conductivity

discs.

(c) Where relay or control units are not mounted in control panels, they shall be provided

with surface mounting enclosures with a degree of protection as IP 52 for indoor location

and IP 65 for outdoor location.

Pressure gauges and transmitters

(a) Pressure gauges shall comply with BS EN 837-1 or equivalent and have concentric

scales. For especially arduous duty where the gauge is subject to pressure pulsations

and/or vibration, it shall be provided with a glycerin-filled dial and line snubbers shall be

261
used. Bourdon-tube type differential-pressure gauges shall be capable of withstanding

full line pressure on any side with the other side vented to atmosphere without damage

to or effect on the calibration. No plastic material shall be used in their construction.

Internal parts shall be of stainless steel, bronze or approved corrosion-resistant material.

(b) The minimum diameter for round pressure gauges shall be 150mm unless specified

otherwise or where the gauge forms part of a standard item of equipment.

(c) Unless specified elsewhere the accuracy for pressure gauges shall be 1% of range, for

diaphragm gauges and for differential gauges 1.5% of range or better.

(d) Where compensation of more than 2% of the instrument span is needed for the

difference in level between the instrument and the tapping point, the reading shall be

suitably adjusted and the amount of compensation shall be marked on the dial.

(e) The zero and span of a pressure transmitter shall not change by more than 0.1% of the

span per Celsius degree change in ambient temperature. After application for 10 minutes

of pressure at 130% of maximum pressure, the change in zero and span shall not exceed

0.1% of the span.

(f) Pressure transmitters shall have an accuracy typically better than 0.1% of span, de-

pending on the application and shall be protected to BS EN 60529: IP 65 standard or

higher standard. For transmitters installed in meter chambers liable to flooding or un-

derwater applications, they shall be to BS EN 60529: IP 68 standard and shall operate

up to maximum submergence of 20 metres of water.

(g) Pressure transmitters shall provide a digital or 4mA to 20mA DC output proportional

to the pressure range.

(h) Pressure gauges and transmitters shall have primary isolating valves, 2 or 3 way valve

manifold and vents, in such a way that it has the facility to calibrate the gauges or trans-

mitters without removal.

5.57.3 Strain-gauge pressure transducers and transmitters

(a) Strain-gauge pressure transducers shall use thin film sensors without bonding.

(b) Each instrument housing shall be of all-welded Grade X 4 CrNiMo 17 12 2 stainless

steel or equivalent and hermetically sealed. Non-interacting, zero and span adjustments

shall be provided on each transducer. The measuring diaphragm shall be isolated from

the process fluid by a no corrodible barrier diaphragm. The mean time between failure

for any model of strain-gauge transducer shall be not less than 15 years, and the perfor-

262
mance of the measurement system shall be as given below, or higher performance:

i. accuracy: 0.1% of calibrated span, including linearity

ii. hysteresis and repeatability;

iii. repeatability: 0.05% at maximum span; iv. stability: 0.1% of upper range limit over

6month period;

v. over-pressure: sustain a 400% over-pressure without damage;

vi. RFI / EMI effect: less than 1% of span with 500MHz at 5W direct contact; power-

supply variation effect: 0.01% per volt variation.

vii. load variation effect: 0.0002% per ohm of loop-resistance variation.

viii. temperature: 29◦ C to +82◦ C range; total thermal error of 0.75% of span over 0◦ C to

50◦ C;

ix. protection: IP 65.

(c) Strain-gauge transducers which do not have terminals for their cable connection,

shall have integral sealed-cable assemblies, installed in conduit and terminated at weath-

erproof junction boxes, protected to IP 65 each mounted near to its associated process

transmitter. A digital or 4mA to 20mA dc output signal proportional to the transducer

range shall be provided.

(d) Strain-gauge pressure transmitters shall be generally as the transducer except that it

shall incorporate a waterproof pressure transmitter producing a digital or 4mA to 20mA

output signal.

(e) Provision for transducer venting shall be provided.

5.58 Analytical Analyzers and Transmitters

(a) General:

This section covers individual elements to measure and transmit pH. Transmitters

shall convert the sensor measurement to a 4 to 20 mA dc signal capable of transmission

into at least a 500 ohm load at 50 V or less. Power supply shall be 240 Vac, 50 Hz. Refer-

ence accuracy of the output signal shall be 1 percent of measured span or better. Output

signal shall be electronically isolated from ground to permit connection to a receiver with

a grounded input. Transmitters shall be provided with an indicating scale having at least

a 0.1 meter calibrated length. Operating ambient temperature shall be -5 to + 50 degree

C or better. Transmitted signals shall be linear with the measured variable excepting pH

263
which shall be linear with pH.

5.58.1 Sensor Measurement Principles and Features

Each type of sensor shall use the measuring principle and incorporate the features ap-

propriate to it as specified below:

i. pH sensors shall measure hydrogen ion activity and oxidation-reduction potential

respectively in the process medium. The pH sensor shall consist of a glass measuring

electrode, a reference electrode, a solution ground and a temperature sensor for compen-

sation in the transmitter. The reference electrode shall be the non flowing type with an

electrolyte diffusion rate through a non-reactive porous membrane or plug which shall

not require electrolyte refill more often than once per year. ORP sensors shall use the

same elements specified for pH sensors except that electrode shall be platinum and no

temperature compensation is required. pH and ORP sensor assemblies shall incorporate

an integrally mounted preamplifier for the measuring electrode. Sensors shall operate

over a temperature range of -5 to + 100 Degree Celsius or better.

5.58.2 Construction

Transmitter and sensor enclosures shall be rated NEMA 4 . If not so specified, they

may be the manufacturer’s standard which is compatible with the corrosivity of the at-

mosphere normally in contact with the enclosure. All parts of sensors, their assemblies

and supporting parts which are wetted by the process medium shall be constructed of

stainless steel and/or plastic unless specified otherwise on the Schedule. When speci-

fied on the Schedule, pH assemblies shall be provided with integrally mounted ultrasonic

cleaners.

5.58.3 Total Dissolved Oxygen Monitoring System

(a) The Dissolved Oxygen (D.O) monitoring system shall consist of a sensor, transmitter,

indicating converter and electrode cleaning equipment. Accuracy shall be + 0.5% full

scale for DO, barometric pressure + 0.27 kPa and temperature + 0.3Degree Celsius.

(b) The sensor shall not require zero point calibration and shall last approximately 2

years with a DO level of 3-5 mg/l and 3-5 years with a DO level of 1-2 mg/l. The trans-

mitter shall allow the DO sensor to be fitted without the use of tools. The transmitter

264
shall deliver an output signal proportional to the DO level and measured temperature.

The following alarms shall be detected and transmitted.

i. Membrane puncture

ii. Depleted or worn out DO sensor

iii. System/electronic fault.

(c) The indicating converter shall perform auto calibration of the system and com-

pensate for sensor age, temperature, barometric pressure, relative humidity and liquid

salinity. It shall display OD concentration, temperature, sensor balance lifetime (mg/l x

hours or %) and rh selected for calibration.

(d) Construction: The DO sensor shall consist of a prefabricated, disposable, sealed car-

tridge that slides easily into the transmitter without special tools. Systems that require

re- generation (refill of electrolyte and membrane change) will not be acceptable. The

sensor shall use the Clarks principle, with a gold cathode, silver wire anode and a non

toxic electrolyte of potassium chloride. The pre-stressed membrane shall be of Teflon and

bonded onto the DO sensor.

(e) The transmitter shall be protected to IP 67 and supplied with 6m of cable for connec-

tion to a junction box. The converter shall be housed in a NEMA 4 x enclosure and be

mounted on handrail or panel up to 200m from the sensor. It shall be interchangeable

without the need for recalibration or reprogramming of the system by using a sensor spe-

cific storing device continuing all settings and calibration.

(f) The sensor and transmitter shall be installed in a self cleaning polystyrene ball float,

which shall float on the surface of the water and allow the sensor to be inserted by ap-

proximately 125mm into the water. The ball shall be constructed to fit the sensor and

transmitter and leave a smooth surface to prevent accumulation of dirt or grease. Con-

structions where the sensor protrudes will not be acceptable.

5.59 Surge Protection Devices

(a) Surge protection devices (SPDs) shall be suitable for withstanding the surge arising out

of high energy static discharge / lightning strikes and protect the instrument to which it

is connected against damage. SPDs shall provide protection through the use of quick act-

ing semiconductors like Tranzorb, zener diodes; varistors and an automatic disconnect

and reset circuit. SPDs shall be passive and shall require negligible power for operation.

During the occurrence of a surge it shall clamp on the allowable voltage and pass the

265
excess voltage to the ground. The SPD shall be self resetting to minimize the down time

of the measurement loop

(b) SPD s shall be provided to protect devices transmitting and receiving analogue and

digital signals derived from outdoor field instrumentation.

(c) The surge protection device shall be rated for surge rating of 10 KA.

5.60 Programmable Logic Controllers

General

(a) Programmable Logic Controllers (PLC) shall be provided to perform combinational

and sequential logic functions, status monitoring and report functions with counter and

timer facilities. The entire STP shall be designed in a way to facilitate complete automatic

mode of control via PLC based SCADA systems.

(b) PLC shall comprise of necessary processors, Simplex input/output (I/O) modules,

communication interface modules and Human-Machine Interface (HMI) required per-

forming the desired functions.

(c) PLC shall have the following attributes

i. carry out sequential logic implementation for operations of plant;

ii. carry out computation and interfacing for data acquisition, data storage and re-

trieval; iii. it shall accept downloaded program from a programmer;

iv. it shall have different functional modules to perform the desired functions;

v. it shall scan the inputs in time cycles and update the status of its outputs.

(d) The PLC system shall be expandable, OPC Compatible and shall be modular in

construction, so as to be capable of future expansion without hardware modifications.

(e) PLC s shall be microprocessor based. PLC s shall use standard known protocols and

structures for communication outside the system.

(f) In case of system failure or power supply failure the outputs shall attain a predeter-

mined fail safe condition (this shall normally be ‘off‘).

(g) The PLC used shall have a proven record in the type of application concerned and in

the prevailing environmental conditions.

(h) PLC shall be of an approved type from a major international manufacturer.

266
(i) PLC System (Panel) should be housed in a dust free environment.

5.60.1 PLC Coding

(a) The Contractor/SI shall supply, install, program and commission the PLC using the

PLC manufacturer recommended windows based, PLC code and documentation software.

The PLC code shall be structured as per best industry standard and shall have compre-

hensive sub-routine and rung annotation. PLC shall be coded using FBD language.

(b) The Contractor/SI shall provide a suitable PC complete with PLC code and doc-

umentation software as specified in the bid document as agreed with the Engineer-in-

Charge based on the FDS submitted.

5.61 HMI (Human Machine Interface)/SCADA

General

(a) The HMI shall be suitable for day to day operation by non-computer literate per-

sonnel in the monitoring and operation of the treatment works.

5.61.1 Human Machine Interfaces (HMI)

(a) Human Machine Interface (HMI) shall be provided at Monitoring Room.

(b) The SCADA system shall provide efficient and safe operation of the process plant by

detection of alarm and error conditions, to alert the Contractor to these conditions by

both visual and audible alarm, to monitor all important system parameters and provid-

ing facilities for plant optimization. The system will allow Contractors, technicians and

Engineers to issue commands to change system parameters, start and stop equipment,

provide configuration tools and operate diagnostic facilities from Contractor Workstations

(OW) and Engineering workstation (EW), after successful log-on by security password.

(c) The System shall perform all the necessary functions for the optimum monitoring,

control and operation of the entire system.

(d) The HMI shall be constructed to a high standard to provide a high profile feature and

focal point for visitors to the Sewage Treatment Plant (STP).

(e) SCADA/HMI system shall be housed in an air-conditioned environment.

267
5.61.2 Uninterruptible Power Supply (UPS)

(a) The power for Programmable Logic Controllers (PLC) and Supervisory Control and Data

Acquisition (SCADA/HMI) shall be derived from independent UPS.

(b) The UPS provided shall be sized to provide power to maintain system operation for

a period of minimum 30 minutes back up, in case of power failure.

(c) The above feature should be demonstrated during Factory Acceptance Test (FAT) &

Site Acceptance Test (SAT).

Recommended Equipment Specifications

5.62 Major Equipment

5.62.1 Air Blowers

PD Blowers

Table 5.26: PD Blowers

Range As per P & ID

Blower Type Positive displacement Rotary Twin Lobe Blower
Model As per Manufacturer Specification
Manufacturer Kay International / Everest / Usha/ Kulkarni / Swam/
Equivalent
Casing and Lobes C.I FG 260 ; IS 210
Shafts EN 24 ( 817 M 40; BS 970)
EN 353 (817 M 40; BS 970)
Gears
( Case Hardening & Ground)
Common Base MS Fabricated; IS 2062
Frame
Bearings SKF/Equivalent Make
Drive Type V Belt Drive
Guard Perforated Plate V Belt drive Guard
Motor TEFC, Class F Insulation
Accessories Common base frame, suction filter, Suction silencer, dis-
charge silencer, pressure gauge, non return valve, safety
valve, V belts, V belt guard, drive & driven pulleys, foun-
dation bolts, all fixing nuts & bolts, Inter connecting piping
with motor

5.62.2 Process Pumps (RAS Pump)

Recirculation Pumps The following table lists typical specifications for MLSS Recircula-

tion Pumps. This specification applies to pumps that will be drawing mixed liquor from

the bioreactor or Membrane Tank for recirculation.

268
 Table 5.27: Recirculation Pumps

Pump Type Submersible

Manufacturer KSB/ Grundfos/ABS
Flow, M3/Hr As per P & ID
Dis. Pressure, Bar As per P & ID
Configuration Submersible
Casing Cast Iron
Stuffing Box Cover As Per Manufacturer
Impeller SS
Seal Manufacturer / Type As per Manufacturer / Process requirement
Seal Lubrication Water
Coupling Flexible
TEFC
NEMA Design B
Motor
Class F insulation
Class B Temperature rise

5.63 Centrifuge

Centrifuge is used for sludge dewatering.

Table 5.28: Centrifuge

Capacity Range As per P & ID

Manufacturer Alfa Laval / Andritz / Humboldt/ Pennwalt/ Hiller
Type Screw conveyor with gear box Centrifuge
Bowl Material SS316/304
Material for other parts in SS316/SS304
contact with sludge
Start Up method DOU, Star Delta, VFD

5.64 Ejectors

The following table lists typical specifications for ejectors which are used to remove air for

the process piping.

Table 5.29: Ejectors

Manufacturer PIAB
Model
Feed Pressure (MAX) 101.5 psi
Noise Level 65-70 dBA
Temperature Range 14F - 176F
Weight 3.74lb - 3.96lb
Material AL, PA, NBR, SS, TPE

5.65 Chemical Pumps

The chemical pumps, listed below, are used with the membrane CIP systems for adding

high volumes of chemical solution within a short period of time, for example, to the CIP

269
wash flow through the membranes during cleaning.

5.65.1 Metering Pump (Chemical Dosing Pumps)

Metering pumps are used in chemical feed applications where a higher degree of accuracy

is required.

Table 5.30: Chemical Dosing Pumps

Capacity Range As per P & ID

Manufacturer Prominent / Asia LMI / Equivalent
Type Diaphragm Positive displacement pumping action
Wetted Ends PVDF
Diaphragm PTFE ( Teflon)
Balls Alumina Ceramic/glass
Drive Motor
TEFC
NEMA Design B
Motor
Class F insulation
Class B Temperature Rise

5.66 Air Compressors Driers

5.66.1 Air Compressors

Air compressors are used for pneumatic valve operations. Where possible they will be

freestanding, tank mounted units. The compressor system, air receivers and other equip-

ment will be sized to provide adequate air for the ZeeWeed system operation. The final

sizing of the compressor will depend on the air requirements of the actuators provided

with the valves included with the Membrane Filtration System. Oil Lubricated Compres-

sors:

Table 5.31: Oil Lubricated Compressors

Operating Range As per P & ID

Manufacturer ELGI
Series PLT Series or equal
Compressor Type Two Stage, Oil-Lubricated
Maximum Pressure Up to 175 PSIG
Lubrication Pressure lubrication with Positive Displacement Oil Pump
Drive Belt driven with belt guard
Motor EPAct High Efficiency, Up to 25 HP, 1800 RPM
Accessories Pressure Gauge, Pressure Relief Valve, Tank Drain, Shut-
Off Valve, Enclosed Belt Guard, Pressure Switch and Inlet
Filter.

5.66.2 Air Receivers

Receivers will be horizontal standing with compressors mounted whenever possible. ASME

Code Construction supplied with a pressure gauge, pressure relief valve, and automatic

270
drain valve.

Table 5.32: Air Receivers

Receiver Tank Horizontal Painted Carbon Steel

Receiver Tank Based on MIT and/or plant service air requirements
Volume
Accessories Receiver Tank Solenoid Auto Drain, Receiver Tank Dis-
charge Isolation Valve, Pressure Relief Valve, Pressure
Gauge

5.66.3 Refrigerated Air Drier

Refrigerated air driers are supplied for operation with the compressor units. Each drier

has a condensing unit, refrigerant evaporator, mechanical separator, automatic conden-

sate discharge valve, pre-filter, and after-filter. The drier is equipped with filters to remove

oil carryover, oil aerosols, and other particulate matter.

Table 5.33: Refrigerated Air Drier

Air Dryer Refrigerant Air Dryer

Manufacturer Reputed Make as approved by EIC
Model QPNC
Capacity Based on MIT and/or plant service air requirements
Connections NPT Threaded
Accessories Auto Drain

5.67 Miscellaneous Appurtenances

The compressor system is supplied with the necessary pressure relief valves, coalescing

filters, particulate air filters, process air regulator assemblies, automatic drain valves,

and controls, as required, to provide a complete functional system.

General Service Filter for Valve Service Air

Table 5.34: General Service Filter for Valve Service Air

Type General Purpose Coalescing Filter

Manufacturer Reputed Make as approved by EIC
Inlet & Outlet= Threaded 3/8“ 1“ NPT;
Connections Automatic Brass Drain= Threaded 1/8“NPT
(size varies based on system capacity)
Body Aluminum
Filter Size 1 Micron
Accessories Includes differential gauge, audible alarm, internal automatic drain
and liquid presence indicator.
Approvals ISO 8573.1 Class 2 solids, Class 4 oil

271
5.68 Pre-Screening
5.68.1 Coarse and Fine Screen (6mm Mechanical Screen)

Table 5.35: 6mm Mechanical Screen

Capacity Range As per P & ID

Manufacturer Contec/ Andritz/Jash/Bilfinger/Auric Equivalent
Type Internally Fed inline, In channel, Drum Screen with integral or sepa-
rate screening, Compactor
Service Raw Sewage
MOC SS 304
Operation Automatic
Screen Size 6 mm 10 mm
Water Type Raw sewage upstream of equalization tank

5.68.2 2 mm punched hole Screen

Table 5.36: 2 mm punched hole Screen

Capacity Range As per P & ID

Manufacturer Contec/ Andritz/Jash/Bilfinger/Auric Equivalent
Type Drum screen/ In Channel Screen
MOC SS 304
Operation Automatic
Screen Size 2 mm
Water Type Equalized sewage

5.69 Fine Bubble Diffuser System

The aeration system is designed for installation within the bioreactor process tanks to

provide air for the biological process. A typical fine bubble aeration(retrievable type) sys-

tem is described in the chart located below.

The diffuser unit is a fine pore, flexible membrane diffuser capable of providing a high

level of oxygen transfer efficiency with maximum operating flexibility.

Table 5.37: Fine Bubble Diffuser System

Type Fine Pore flexible membrane type

Manufacturer EDI/ SSI/ OTT
MOC EPDM
90mm x 1000mm /
Diameter x Length
90mm x 500mm
Accessories SS316 Clamps

5.70 Valves

The following are the general specifications for the main types of valves to be used.

272
5.70.1 Butterfly Valve 4 to 12“ diameter

Table 5.38: Butterfly Valve 4 to 12“ diameter

Type Butterfly Valves

Service Vacuum Rated /Non-Vacuum Rated
Manufacturer AUDCO/ Inter Valve / Crane / Tyco /BDK/Bray
Wafer Pattern
Style
( Lug Pattern Valves for Tank drain Applications, Maint Purposes)
Body Cast Iron, Epoxy Coated
Disc 316 Stainless Steel Shaft 416 Stainless Steel
Shaft 416 Stainless Steel
Seat EDPM
Manual Operators Under 6 Manual Lever 6 & Larger Gear

5.70.2 Butterfly Valve 14 to 24“ diameter

Table 5.39: Butterfly Valve 14 to 24“ diameter

Type Butterfly Valves

Service Vacuum Rated /Non-Vacuum Rated
Manufacturer AUDCO/ Inter Valve / Crane / Tyco /BDK/Bray
Wafer Pattern
Style
( Lug Pattern Valves for Tank drain Applications, Maint Purposes)
Body Cast Iron, Epoxy Coated
Disc 316 Stainless Steel Shaft 416 Stainless Steel
Shaft 416 Stainless Steel
Seat EDPM
Manual Operators Gear

5.70.3 Process check Valves

Table 5.40: Process check Valves

Type Wafer Butterfly Check

Manufacturer AUDCO/ Inter Valve / Crane / Tyco/BDK/Bray
Style Wafer suitable for installation between ANSI # 150 flanges
Body Cast Iron
Disc 316 Stainless Steel
Shaft 316 Stainless Steel
Seat BUNA N

5.70.4 Chemical Feed Lines

Table 5.41: Chemical Feed Lines

Type Check
Manufacturer George Fischer/Equivalent
Style Ball or Swing Check
Body PVC
Disc PVC

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5.70.5 Waste water, Mixed Liquor and Sludge Lines

Table 5.42: Waste water, Mixed Liquor and Sludge Lines

Type Elastic Swing Check

Manufacturer AUDCO/ Inter Valve / Crane / Tyco/BDK/Bray
Flow Area Design allows full Pipe size flow area when fully open
Style Flanged Suitable for installation between ANSI # 150 flanges
Body/Cover Ductile, Iron IS
Viton ( durometer 70) internally reinforced with steel and
fabric reinforcement;
Disc/ Flapper removable without removing the valve body from the line.
Disc/ flapper captured in the body by the cover to allow the disc to have
elastic flex from the closed position to full open position.
Disc/Flapper Viton with an elastic spring to assist the closure against a small head
Arm to minimize disc slamming.
Style Wafer suitable for installation between ANSI # 150 flanges
Shaft 316 Stainless Steel
Seat BUNA N
Internal Coating Epoxy NSF approved coating
Exterior Coating Blue Metal Primer
Position Indica- External Position indicator W/ Proximity switches for the closed posi-
tor tion
Pipeline Pressure 50 Psig
Body 316 Stainless Steel
Disc 316 Stainless Steel
Shaft 17.4 PH
Seat Teflon

5.70.6 Chemical Feed Lines (<3“)

Table 5.43: Chemical Feed Lines

Type Ball
Manufacturer George Fischer/Equivalent
Style Tru Union
Body, Plug, Shaft PVC
Seals EPDM or Viton
Manual Operators Manual Lever

5.70.7 Control Valves

Control Valves are valves (butterfly, gate or ball) with double acting pneumatic actuators

and electro- pneumatic positioners.

Mixed Liquor Re-circulation Wasting Lines ( 2“ 36“)

274
 Table 5.44: Control Valves

Type Knife gate

Manufacturer AUDCO/ Crane / Tyco/BDK/Bray
Style Lugged, AR Series
Body GG25 ( Cast Iron)
Gate 304 Stainless Steel
Shaft Carbon Steel
Seat EPDM
Manual Opera- All Sizes Handwheel Operated
tors
End Caps Ductile Iron
Pistons Ductile Iron
Output Shaft Plated Alloy Steel C4140
Shaft bushings Stainless Steel
Piston Guidelines Reinforced PTFE
Fasterners 18 8 Stainless Steel
Piston O Rings Buna N
Air Solenoid 4 way NEMA 4, 120/1/60
Limit Switches Tyco Avid ZR Plus with Position monitor and T Sensor Proximity
Switches

5.71 Miscellaneous Valves

5.71.1 Instrument Isolation Valves

The Instrument isolation valves typically used throughout the membrane system are

listed in the following table.

Table 5.45: Instrument Isolation Valves

Type Ball Valve

Manufacturer AUDCO/ Crane
Style Reduced Port Threaded
Body/ Ball 316 Stainless Steel
Seat PTFE
Connection Typically 0.5“NPT

5.71.2 Solenoid Valves

The Solenoid valves typically used throughout the membrane system are listed in the

following tables.

Table 5.46: Solenoid Valves

Type Solenoid Valve

Service Air/Water
Manufacturer Tyco / Inter Valve
Model As per Manufacturer
Style F NPT, Normally Closed
Body 316 Stainless Steel / Brass

275
5.71.3 Pneumatic Actuators

Table 5.47: Pneumatic Actuators

Type Double Acting Cylinder Rack & Pinion Drive

Manufacturer
Operating Pressure 550 Kpa ( 80 Psig)
Body Material Extruded Aluminum Alloy, Anodized
Travel Shop 304 Stainless Steel
End Caps Die Cast Aluminum Alloy
Pistons Die Cast Aluminum Alloy
Output Shaft Carbon Steel ( Zinc Plated)
Shaft Bearings Engineered Polymer Devlon
Fasteners Stainless Steel
O Rings Nitrile
Air Solenoid 4 Way, NEMA 4 or Equal
Additional Features Open and Closing Speed Control
Position Control Electro Pneumatic Avid Eazical Intelligent Positioner 4 20mA Input

5.71.4 General Service PVC Valves

Table 5.48: General Service PVC Valves

Type Double Acting

Manufacturer George Fisher / Equivalent
Operating Pressure 550 Kpa ( 80 Psig)
Body Material Poly Amide w/Glass Fiber
End Caps Poly Amide w/Glass Fiber
Pistons Die Cast Aluminum Alloy
Output Shaft Stainless Steel
Fasteners Stainless Steel
O Rings Nitrile

5.72 Process Instrumentation

The following process instruments are included with the ZeeWeed System. Output signals

from all these instruments are connected to the PLC System.

5.72.1 Flow switches

Flow switches are included to provide flow confirmation in air or water lines from blowers

and pumps respectively.

276
 Table 5.49: Flow switches

Application Air Liquid

Manufacturer Switzer/ Emmerson/ E & H Switzer/ Emmerson/ E & H
Series As per Manufacturer
recommendation As per Manufacturer
recommendation
Probe Sensor Flat Face Sensor
Sensor Type/Material
316 Stainless Steel 316 Stainless Steel
Process Connection O.75“ NPT
Accuracy +/- 5%
Housing 304 Stainless Steel NEMA 4X
Integral LCD Yes, 4 Digit
Power/Connection 18 30 VDC/0.5“NPT

5.72.2 Electromagnetic Flow meters (Flow transmitter)

Flow meters are included for monitoring the permeate flow from each train, the reject

flow from each train and back pulse/CIP flow to the membranes as well as a train‘s re

circulation flow.

Table 5.50: Electromagnetic Flow meters

Manufacturer E & H / Emerson /

Series As per Manufacturer recommendation
Process Connection ANSI # 150 flanged
Housing Aluminum NEMA 4X
Flow tube 304 Stainless Steel
Liner PTFE
Accuracy +/- 0.5%
Operator Interface Local
Output HART, 4 20 mA DC, Scaled pulse Output
Power/connection 85 260 VAC 60 Hz/ 0.5“ NPT
Seal EPDM
Power 120 VAC/60
Power Connection 0.5“ NPT Conduit, Type H Electrical

5.72.3 Level transmitters

Level transmitters are included for monitoring the liquid levels in the membrane tanks

or in the inlet flow distribution channel to each series of membrane tanks. They are also

included on the bac kpulse/CIP tank, if applicable. Two basic types of level transmitters,

top and side entry, are generally used with ZeeWeed Membrane Systems depending on

the application and both are described below.

277
 Table 5.51: Level transmitters

Manufacturer E & H or equivalent as approved.

Application Top Entry Side Entry
1.5“ to 3“ 150# Flange
3“ 150 # Flange
Process Connections ( 316 Stainless Steel) & 1.5“
( 316 Stainless Steel)
NPT Connections available.
1.5“, 2“ and 3“ 150 # Flange
Mounting ( 316 Stainless Steel) & 1.5“
NPT Connections available.
Output Signal HART 4 20 mA
Voltage 11.5 to 30 VDC
Contite Sensor with metallic
Diaphragm
diaphragm alloy C4
Housing Aluminum NEMA 4X
Integral LCD Yes

5.72.4 Pressure Transmitters

Pressure transmitters monitor the vacuum applied to the membranes during permeating

and the positive pressure applied during back pulsing. The pressure transmitters are

mounted on the permeate collection header pipes included with the ZeeWeed system

and are typically calibrated at 15 psi to +20 psi. Typical specifications are listed in the

following table.

Table 5.52: Pressure Transmitters

Manufacturer E & H/ Emerson/ Eq

Model As per Manufacturer recommendation
Output Signal 4 20mA HART PROT
Voltage 11.5 30 VDC
Diaphragm Ceramic
Housing Aluminum NEMA 4X
Integral LCD Yes

5.72.5 Turbidi meters

Continuous on-line turbidi meters are included as a means of verifying the integrity of

the membranes by taking water samples from the discharge side of the permeate pumps.

Typical component specifications are listed below.

278
 Table 5.53: Turbidi meters

Manufacturer Hach /Equivalent

Model As per Manufacturer recommendation
Range 0- 100 NTU
Inlet 0.25“ FNPT
Outlet 0.5“ FNPT
Outlet Signal 4 20 mA
Power 220V/1ph/50 Hz
Display SC 100
Sensor, analyzer unit, interconnecting cable, alarm relays
Accessories for indication of alarm conditions and one (1)
Formazin Calibration Kit.

5.72.6 Dissolved Oxygen Sensors Analyzers

Dissolved oxygen sensors are immersed within the bioreactor and signal cabled to the

PLC. Sensors are typically installed within the aerated zone of each bioreactor tank and

other areas of the plant at Istitute‘s discretion. Typical specifications are listed in the

following table.

Table 5.54: Dissolved Oxygen Sensors Analyzers

Manufacturer E& H/HACH/EMERSON/Eq

Model OXY 1100/4100
Range 0-10 mg/L
Resolution 0.1 mg/L
Transmitter OXY 4100, Ball/Float Type
Output Signal 2 x 4-20 mA
Power Supply 85-264 V AC
Display LCD supplied on Signal Convertor
Sensor & Float
Transmitter
Accessories
Mounting Bracket
Signal Converter (sized as needed)

5.72.7 Float Level Switches

Where included, float level switches are to be provided.

5.72.8 Pressure Gauges

Pressure gauges are included for the various pumps and blowers included with the Zee-

Weed system. Pressure gauges are liquid filled and are Ashcroft or equal with 316SS

wetted parts. Pressure gauges are supplied complete with isolation ball valves gauge

cocks between the pressure gauge and the process line.

5.72.9 Pressure Switches

Pressure switches are provided for high-pressure alarm on the permeate collection pipes

to prevent over-pressurizing of the membranes during back pulsing. In addition, pressure

279
switches are included to provide low pressure warning for the compressed air for the

pneumatic valves. The types of flow switches used in the different applications are listed

in the following table.

Table 5.55: Pressure Switches

Permeate Lines United Electric J6 Series or equal with 316 Stainless Steel wetted parts
and bellows
Compressed Air United Electric H100 Series or equal with 316 Stainless Steel wetted
Line parts and bellows

5.73 Motor Specifications

General Duty Electrical Motors supplied with the equipment generally have the specifi-

cations outlined in the following table.

Table 5.56: Motor Specifications

Less than 0.5 HP 230 VAC/ 1 ph/ 50 Hz

415V/ 3pH/ 50 HZ
NEMA Frame
0.5HP or More Design B
NEMA Class B Temperature Rise
Meeting EPACT Efficiency Requirements

5.74 Control Systems

5.74.1 Motor Control Center (MCC)

The MCC will house the circuit breakers, motor starters, and VFDs for all electrical mo-

tors on equipment that is supplied by GE ZENON ULC. The MCC will be supplied with a

main breaker, appropriately rated for the motor loads noted above.

The MCC, with the following feature and specifications:

Table 5.57: MCC

Section Dimensions 90“ high x 20“ deep x 20“ wide

Number of Sections To Be Determined
MCC Connection 3 Pole Main Circuit Breaker
Enclosure Type NEMA 1 fully gasketted with bottom plates
Cable Entry Top
Ground Lug Size #6 AWG 250 kcmil (2 supplied as standard)
Main Bus Rating To be confirmed during final design
Main Bus Bracing 42 kA (RMS)
Main Bus Material Copper/ Tin Plated
Horizontal Ground Bus Size 0.25“ x 1 (may vary according to application)
Horizontal Ground Bus Location Bottom
Vertical Ground Bus Type Copper / Tin Plated

280
5.74.2 Variable Frequency Drives

The Variable Frequency Drives (VFDs) will be mounted within the MCC, as described

above, and will be of the same manufacturer as the MCC. The VFDs will be Cutler-

Hammer SVX9000, with the following features and specifications:

Table 5.58: VFD

Input Voltage Range 208 -240V, 380 -500V or Range 525 -690V
-15% of Minimum;
Input Voltage Tolerance
+10% of Maximum
Input Frequency Tolerance 45 to 66 Hz
Service Factor 1.0
Efficiency 97.5% at rated amps

281
Recommended Equipment Specifications

5.75 Major Equipment

5.75.1 Air Blowers

PD Blowers

Table 5.59: PD Blowers

Range As per P & ID

Blower Type Positive displacement Rotary Twin Lobe Blower
Model As per Manufacturer Specification
Manufacturer Kay International / Everest / Usha/ Kulkarni / Swam/
Equivalent
Casing and Lobes C.I FG 260 ; IS 210
Shafts EN 24 ( 817 M 40; BS 970)
EN 353 (817 M 40; BS 970)
Gears
( Case Hardening & Ground)
Common Base MS Fabricated; IS 2062
Frame
Bearings SKF/Equivalent Make
Drive Type V Belt Drive
Guard Perforated Plate V Belt drive Guard
Motor TEFC, Class F Insulation
Accessories Common base frame, suction filter, Suction silencer, dis-
charge silencer, pressure gauge, non return valve, safety
valve, V belts, V belt guard, drive & driven pulleys, foun-
dation bolts, all fixing nuts & bolts, Inter connecting piping
with motor

5.75.2 Process Pumps (RAS Pump)

Recirculation Pumps The following table lists typical specifications for MLSS Recircula-

tion Pumps. This specification applies to pumps that will be drawing mixed liquor from

the bioreactor or Membrane Tank for recirculation.

Table 5.60: Recirculation Pumps

Pump Type Submersible

Manufacturer KSB/ Grundfos/ABS
Flow, M3/Hr As per P & ID
Dis. Pressure, Bar As per P & ID
Configuration Submersible
Casing Cast Iron
Stuffing Box Cover As Per Manufacturer
Impeller SS
Seal Manufacturer / Type As per Manufacturer / Process requirement
Seal Lubrication Water
Coupling Flexible
TEFC
NEMA Design B
Motor
Class F insulation
Class B Temperature rise

282
5.76 Centrifuge

Centrifuge is used for sludge dewatering.

Table 5.61: Centrifuge

Capacity Range As per P & ID

Manufacturer Alfa Laval / Andritz / Humboldt/ Pennwalt/ Hiller
Type Screw conveyor with gear box Centrifuge
Bowl Material SS316/304
Material for other parts in SS316/SS304
contact with sludge
Start Up method DOU, Star Delta, VFD

5.77 Ejectors

The following table lists typical specifications for ejectors which are used to remove air for

the process piping.

Table 5.62: Ejectors

Manufacturer PIAB
Model
Feed Pressure (MAX) 101.5 psi
Noise Level 65-70 dBA
Temperature Range 14F - 176F
Weight 3.74lb - 3.96lb
Material AL, PA, NBR, SS, TPE

5.78 Chemical Pumps

The chemical pumps, listed below, are used with the membrane CIP systems for adding

high volumes of chemical solution within a short period of time, for example, to the CIP

wash flow through the membranes during cleaning.

5.78.1 Metering Pump (Chemical Dosing Pumps)

Metering pumps are used in chemical feed applications where a higher degree of accuracy

is required.

283
 Table 5.63: Chemical Dosing Pumps

Capacity Range As per P & ID

Manufacturer Prominent / Asia LMI / Equivalent
Type Diaphragm Positive displacement pumping action
Wetted Ends PVDF
Diaphragm PTFE ( Teflon)
Balls Alumina Ceramic/glass
Drive Motor
TEFC
NEMA Design B
Motor
Class F insulation
Class B Temperature Rise

5.79 Air Compressors Driers

5.79.1 Air Compressors

Air compressors are used for pneumatic valve operations. Where possible they will be

freestanding, tank mounted units. The compressor system, air receivers and other equip-

ment will be sized to provide adequate air for the ZeeWeed system operation. The final

sizing of the compressor will depend on the air requirements of the actuators provided

with the valves included with the Membrane Filtration System. Oil Lubricated Compres-

sors:

Table 5.64: Oil Lubricated Compressors

Operating Range As per P & ID

Manufacturer ELGI
Series PLT Series or equal
Compressor Type Two Stage, Oil-Lubricated
Maximum Pressure Up to 175 PSIG
Lubrication Pressure lubrication with Positive Displacement Oil Pump
Drive Belt driven with belt guard
Motor EPAct High Efficiency, Up to 25 HP, 1800 RPM
Accessories Pressure Gauge, Pressure Relief Valve, Tank Drain, Shut-
Off Valve, Enclosed Belt Guard, Pressure Switch and Inlet
Filter.

5.79.2 Air Receivers

Receivers will be horizontal standing with compressors mounted whenever possible. ASME

Code Construction supplied with a pressure gauge, pressure relief valve, and automatic

drain valve.

284
 Table 5.65: Air Receivers

Receiver Tank Horizontal Painted Carbon Steel

Receiver Tank Based on MIT and/or plant service air requirements
Volume
Accessories Receiver Tank Solenoid Auto Drain, Receiver Tank Dis-
charge Isolation Valve, Pressure Relief Valve, Pressure
Gauge

5.79.3 Refrigerated Air Drier

Refrigerated air driers are supplied for operation with the compressor units. Each drier

has a condensing unit, refrigerant evaporator, mechanical separator, automatic conden-

sate discharge valve, pre-filter, and after-filter. The drier is equipped with filters to remove

oil carryover, oil aerosols, and other particulate matter.

Table 5.66: Refrigerated Air Drier

Air Dryer Refrigerant Air Dryer

Manufacturer Reputed Make as approved by EIC
Model QPNC
Capacity Based on MIT and/or plant service air requirements
Connections NPT Threaded
Accessories Auto Drain

5.80 Miscellaneous Appurtenances

The compressor system is supplied with the necessary pressure relief valves, coalescing

filters, particulate air filters, process air regulator assemblies, automatic drain valves,

and controls, as required, to provide a complete functional system.

General Service Filter for Valve Service Air

Table 5.67: General Service Filter for Valve Service Air

Type General Purpose Coalescing Filter

Manufacturer Reputed Make as approved by EIC
Inlet & Outlet= Threaded 3/8“ 1“ NPT;
Connections Automatic Brass Drain= Threaded 1/8“NPT
(size varies based on system capacity)
Body Aluminum
Filter Size 1 Micron
Accessories Includes differential gauge, audible alarm, internal automatic drain
and liquid presence indicator.
Approvals ISO 8573.1 Class 2 solids, Class 4 oil

285
5.81 Pre-Screening
5.81.1 Coarse and Fine Screen (6mm Mechanical Screen)

Table 5.68: 6mm Mechanical Screen

Capacity Range As per P & ID

Manufacturer Contec/ Andritz/Jash/Bilfinger/Auric Equivalent
Type Internally Fed inline, In channel, Drum Screen with integral or sepa-
rate screening, Compactor
Service Raw Sewage
MOC SS 304
Operation Automatic
Screen Size 6 mm 10 mm
Water Type Raw sewage upstream of equalization tank

5.81.2 2 mm punched hole Screen

Table 5.69: 2 mm punched hole Screen

Capacity Range As per P & ID

Manufacturer Contec/ Andritz/Jash/Bilfinger/Auric Equivalent
Type Drum screen/ In Channel Screen
MOC SS 304
Operation Automatic
Screen Size 2 mm
Water Type Equalized sewage

5.82 Fine Bubble Diffuser System

The aeration system is designed for installation within the bioreactor process tanks to

provide air for the biological process. A typical fine bubble aeration(retrievable type) sys-

tem is described in the chart located below.

The diffuser unit is a fine pore, flexible membrane diffuser capable of providing a high

level of oxygen transfer efficiency with maximum operating flexibility.

Table 5.70: Fine Bubble Diffuser System

Type Fine Pore flexible membrane type

Manufacturer EDI/ SSI/ OTT
MOC EPDM
90mm x 1000mm /
Diameter x Length
90mm x 500mm
Accessories SS316 Clamps

5.83 Valves

The following are the general specifications for the main types of valves to be used.

286
5.83.1 Butterfly Valve 4 to 12“ diameter

Table 5.71: Butterfly Valve 4 to 12“ diameter

Type Butterfly Valves

Service Vacuum Rated /Non-Vacuum Rated
Manufacturer AUDCO/ Inter Valve / Crane / Tyco /BDK/Bray
Wafer Pattern
Style
( Lug Pattern Valves for Tank drain Applications, Maint Purposes)
Body Cast Iron, Epoxy Coated
Disc 316 Stainless Steel Shaft 416 Stainless Steel
Shaft 416 Stainless Steel
Seat EDPM
Manual Operators Under 6 Manual Lever 6 & Larger Gear

5.83.2 Butterfly Valve 14 to 24“ diameter

Table 5.72: Butterfly Valve 14 to 24“ diameter

Type Butterfly Valves

Service Vacuum Rated /Non-Vacuum Rated
Manufacturer AUDCO/ Inter Valve / Crane / Tyco /BDK/Bray
Wafer Pattern
Style
( Lug Pattern Valves for Tank drain Applications, Maint Purposes)
Body Cast Iron, Epoxy Coated
Disc 316 Stainless Steel Shaft 416 Stainless Steel
Shaft 416 Stainless Steel
Seat EDPM
Manual Operators Gear

5.83.3 Process check Valves

Table 5.73: Process check Valves

Type Wafer Butterfly Check

Manufacturer AUDCO/ Inter Valve / Crane / Tyco/BDK/Bray
Style Wafer suitable for installation between ANSI # 150 flanges
Body Cast Iron
Disc 316 Stainless Steel
Shaft 316 Stainless Steel
Seat BUNA N

5.83.4 Chemical Feed Lines

Table 5.74: Chemical Feed Lines

Type Check
Manufacturer George Fischer/Equivalent
Style Ball or Swing Check
Body PVC
Disc PVC

287
5.83.5 Waste water, Mixed Liquor and Sludge Lines

Table 5.75: Waste water, Mixed Liquor and Sludge Lines

Type Elastic Swing Check

Manufacturer AUDCO/ Inter Valve / Crane / Tyco/BDK/Bray
Flow Area Design allows full Pipe size flow area when fully open
Style Flanged Suitable for installation between ANSI # 150 flanges
Body/Cover Ductile, Iron IS
Viton ( durometer 70) internally reinforced with steel and
fabric reinforcement;
Disc/ Flapper removable without removing the valve body from the line.
Disc/ flapper captured in the body by the cover to allow the disc to have
elastic flex from the closed position to full open position.
Disc/Flapper Viton with an elastic spring to assist the closure against a small head
Arm to minimize disc slamming.
Style Wafer suitable for installation between ANSI # 150 flanges
Shaft 316 Stainless Steel
Seat BUNA N
Internal Coating Epoxy NSF approved coating
Exterior Coating Blue Metal Primer
Position Indica- External Position indicator W/ Proximity switches for the closed posi-
tor tion
Pipeline Pressure 50 Psig
Body 316 Stainless Steel
Disc 316 Stainless Steel
Shaft 17.4 PH
Seat Teflon

5.83.6 Chemical Feed Lines (<3“)

Table 5.76: Chemical Feed Lines

Type Ball
Manufacturer George Fischer/Equivalent
Style Tru Union
Body, Plug, Shaft PVC
Seals EPDM or Viton
Manual Operators Manual Lever

5.83.7 Control Valves

Control Valves are valves (butterfly, gate or ball) with double acting pneumatic actuators

and electro- pneumatic positioners.

Mixed Liquor Re-circulation Wasting Lines ( 2“ 36“)

288
 Table 5.77: Control Valves

Type Knife gate

Manufacturer AUDCO/ Crane / Tyco/BDK/Bray
Style Lugged, AR Series
Body GG25 ( Cast Iron)
Gate 304 Stainless Steel
Shaft Carbon Steel
Seat EPDM
Manual Opera- All Sizes Handwheel Operated
tors
End Caps Ductile Iron
Pistons Ductile Iron
Output Shaft Plated Alloy Steel C4140
Shaft bushings Stainless Steel
Piston Guidelines Reinforced PTFE
Fasterners 18 8 Stainless Steel
Piston O Rings Buna N
Air Solenoid 4 way NEMA 4, 120/1/60
Limit Switches Tyco Avid ZR Plus with Position monitor and T Sensor Proximity
Switches

5.84 Miscellaneous Valves

5.84.1 Instrument Isolation Valves

The Instrument isolation valves typically used throughout the membrane system are

listed in the following table.

Table 5.78: Instrument Isolation Valves

Type Ball Valve

Manufacturer AUDCO/ Crane
Style Reduced Port Threaded
Body/ Ball 316 Stainless Steel
Seat PTFE
Connection Typically 0.5“NPT

5.84.2 Solenoid Valves

The Solenoid valves typically used throughout the membrane system are listed in the

following tables.

Table 5.79: Solenoid Valves

Type Solenoid Valve

Service Air/Water
Manufacturer Tyco / Inter Valve
Model As per Manufacturer
Style F NPT, Normally Closed
Body 316 Stainless Steel / Brass

289
5.84.3 Pneumatic Actuators

Table 5.80: Pneumatic Actuators

Type Double Acting Cylinder Rack & Pinion Drive

Manufacturer
Operating Pressure 550 Kpa ( 80 Psig)
Body Material Extruded Aluminum Alloy, Anodized
Travel Shop 304 Stainless Steel
End Caps Die Cast Aluminum Alloy
Pistons Die Cast Aluminum Alloy
Output Shaft Carbon Steel ( Zinc Plated)
Shaft Bearings Engineered Polymer Devlon
Fasteners Stainless Steel
O Rings Nitrile
Air Solenoid 4 Way, NEMA 4 or Equal
Additional Features Open and Closing Speed Control
Position Control Electro Pneumatic Avid Eazical Intelligent Positioner 4 20mA Input

5.84.4 General Service PVC Valves

Table 5.81: General Service PVC Valves

Type Double Acting

Manufacturer George Fisher / Equivalent
Operating Pressure 550 Kpa ( 80 Psig)
Body Material Poly Amide w/Glass Fiber
End Caps Poly Amide w/Glass Fiber
Pistons Die Cast Aluminum Alloy
Output Shaft Stainless Steel
Fasteners Stainless Steel
O Rings Nitrile

5.85 Process Instrumentation

The following process instruments are included with the ZeeWeed System. Output signals

from all these instruments are connected to the PLC System.

5.85.1 Flow switches

Flow switches are included to provide flow confirmation in air or water lines from blowers

and pumps respectively.

290
 Table 5.82: Flow switches

Application Air Liquid

Manufacturer Switzer/ Emmerson/ E & H Switzer/ Emmerson/ E & H
Series As per Manufacturer
recommendation As per Manufacturer
recommendation
Probe Sensor Flat Face Sensor
Sensor Type/Material
316 Stainless Steel 316 Stainless Steel
Process Connection O.75“ NPT
Accuracy +/- 5%
Housing 304 Stainless Steel NEMA 4X
Integral LCD Yes, 4 Digit
Power/Connection 18 30 VDC/0.5“NPT

5.85.2 Electromagnetic Flow meters (Flow transmitter)

Flow meters are included for monitoring the permeate flow from each train, the reject

flow from each train and back pulse/CIP flow to the membranes as well as a train‘s re

circulation flow.

Table 5.83: Electromagnetic Flow meters

Manufacturer E & H / Emerson /

Series As per Manufacturer recommendation
Process Connection ANSI # 150 flanged
Housing Aluminum NEMA 4X
Flow tube 304 Stainless Steel
Liner PTFE
Accuracy +/- 0.5%
Operator Interface Local
Output HART, 4 20 mA DC, Scaled pulse Output
Power/connection 85 260 VAC 60 Hz/ 0.5“ NPT
Seal EPDM
Power 120 VAC/60
Power Connection 0.5“ NPT Conduit, Type H Electrical

5.85.3 Level transmitters

Level transmitters are included for monitoring the liquid levels in the membrane tanks

or in the inlet flow distribution channel to each series of membrane tanks. They are also

included on the bac kpulse/CIP tank, if applicable. Two basic types of level transmitters,

top and side entry, are generally used with ZeeWeed Membrane Systems depending on

the application and both are described below.

291
 Table 5.84: Level transmitters

Manufacturer E & H or equivalent as approved.

Application Top Entry Side Entry
1.5“ to 3“ 150# Flange
3“ 150 # Flange
Process Connections ( 316 Stainless Steel) & 1.5“
( 316 Stainless Steel)
NPT Connections available.
1.5“, 2“ and 3“ 150 # Flange
Mounting ( 316 Stainless Steel) & 1.5“
NPT Connections available.
Output Signal HART 4 20 mA
Voltage 11.5 to 30 VDC
Contite Sensor with metallic
Diaphragm
diaphragm alloy C4
Housing Aluminum NEMA 4X
Integral LCD Yes

5.85.4 Pressure Transmitters

Pressure transmitters monitor the vacuum applied to the membranes during permeating

and the positive pressure applied during back pulsing. The pressure transmitters are

mounted on the permeate collection header pipes included with the ZeeWeed system

and are typically calibrated at 15 psi to +20 psi. Typical specifications are listed in the

following table.

Table 5.85: Pressure Transmitters

Manufacturer E & H/ Emerson/ Eq

Model As per Manufacturer recommendation
Output Signal 4 20mA HART PROT
Voltage 11.5 30 VDC
Diaphragm Ceramic
Housing Aluminum NEMA 4X
Integral LCD Yes

5.85.5 Turbidi meters

Continuous on-line turbidi meters are included as a means of verifying the integrity of

the membranes by taking water samples from the discharge side of the permeate pumps.

Typical component specifications are listed below.

292
 Table 5.86: Turbidi meters

Manufacturer Hach /Equivalent

Model As per Manufacturer recommendation
Range 0- 100 NTU
Inlet 0.25“ FNPT
Outlet 0.5“ FNPT
Outlet Signal 4 20 mA
Power 220V/1ph/50 Hz
Display SC 100
Sensor, analyzer unit, interconnecting cable, alarm relays
Accessories for indication of alarm conditions and one (1)
Formazin Calibration Kit.

5.85.6 Dissolved Oxygen Sensors Analyzers

Dissolved oxygen sensors are immersed within the bioreactor and signal cabled to the

PLC. Sensors are typically installed within the aerated zone of each bioreactor tank and

other areas of the plant at Istitute‘s discretion. Typical specifications are listed in the

following table.

Table 5.87: Dissolved Oxygen Sensors Analyzers

Manufacturer E& H/HACH/EMERSON/Eq

Model OXY 1100/4100
Range 0-10 mg/L
Resolution 0.1 mg/L
Transmitter OXY 4100, Ball/Float Type
Output Signal 2 x 4-20 mA
Power Supply 85-264 V AC
Display LCD supplied on Signal Convertor
Sensor & Float
Transmitter
Accessories
Mounting Bracket
Signal Converter (sized as needed)

5.85.7 Float Level Switches

Where included, float level switches are to be provided.

5.85.8 Pressure Gauges

Pressure gauges are included for the various pumps and blowers included with the Zee-

Weed system. Pressure gauges are liquid filled and are Ashcroft or equal with 316SS

wetted parts. Pressure gauges are supplied complete with isolation ball valves gauge

cocks between the pressure gauge and the process line.

5.85.9 Pressure Switches

Pressure switches are provided for high-pressure alarm on the permeate collection pipes

to prevent over-pressurizing of the membranes during back pulsing. In addition, pressure

293
switches are included to provide low pressure warning for the compressed air for the

pneumatic valves. The types of flow switches used in the different applications are listed

in the following table.

Table 5.88: Pressure Switches

Permeate Lines United Electric J6 Series or equal with 316 Stainless Steel wetted parts
and bellows
Compressed Air United Electric H100 Series or equal with 316 Stainless Steel wetted
Line parts and bellows

5.86 Motor Specifications

General Duty Electrical Motors supplied with the equipment generally have the specifi-

cations outlined in the following table.

Table 5.89: Motor Specifications

Less than 0.5 HP 230 VAC/ 1 ph/ 50 Hz

415V/ 3pH/ 50 HZ
NEMA Frame
0.5HP or More Design B
NEMA Class B Temperature Rise
Meeting EPACT Efficiency Requirements

5.87 Control Systems

5.87.1 Motor Control Center (MCC)

The MCC will house the circuit breakers, motor starters, and VFDs for all electrical mo-

tors on equipment that is supplied by GE ZENON ULC. The MCC will be supplied with a

main breaker, appropriately rated for the motor loads noted above.

The MCC, with the following feature and specifications:

Table 5.90: MCC

Section Dimensions 90“ high x 20“ deep x 20“ wide

Number of Sections To Be Determined
MCC Connection 3 Pole Main Circuit Breaker
Enclosure Type NEMA 1 fully gasketted with bottom plates
Cable Entry Top
Ground Lug Size #6 AWG 250 kcmil (2 supplied as standard)
Main Bus Rating To be confirmed during final design
Main Bus Bracing 42 kA (RMS)
Main Bus Material Copper/ Tin Plated
Horizontal Ground Bus Size 0.25“ x 1 (may vary according to application)
Horizontal Ground Bus Location Bottom
Vertical Ground Bus Type Copper / Tin Plated

294
5.87.2 Variable Frequency Drives

The Variable Frequency Drives (VFDs) will be mounted within the MCC, as described

above, and will be of the same manufacturer as the MCC. The VFDs will be Cutler-

Hammer SVX9000, with the following features and specifications:

Table 5.91: VFD

Input Voltage Range 208 -240V, 380 -500V or Range 525 -690V
-15% of Minimum;
Input Voltage Tolerance
+10% of Maximum
Input Frequency Tolerance 45 to 66 Hz
Service Factor 1.0
Efficiency 97.5% at rated amps

295
Chapter 6

List Of Approved Makes

The items of supply included in the foregoing lists are only indicative and not exhaustive.

Any item not mentioned in the above lists and is required for satisfactory completion of

the DSITC Works shall be procured after obtaining approval of the make and MOC from

Engineer-in-Charge.

6.1 List of Approved Makes for STP Components

Table 6.1: List of Approved Makes-STP

Sl No Item Make

1 Manual Coarse screen of 16 mm & fine screen ASR/AuricTechno ser-

of 6 mm of 162.5m3/hr for 3 streams of 650 vices/Jash Procedyne

kld and peak factor is 2.0

2 Mechanical fine screen of 6mm of 162.5m3/hr ASR/AuricTechno ser-

for 3 streams of 650 kld and peak factor is 2.0 vices/Jash Procedyne

3 Oil and grease removal system (Belt Oil Skim- Potential Engineering

mer) of 162.5m3/hr for 3 streams of 650 kld

and peak factor is 2.0

Johnson/KSB/Kirloskar
4 Collection sump transfer pumps Cap:
/Grundfos
65m3/hr@ 11mwc TDH Submersible cen-

trifugal for each 650 kld

5 Mixing Blowers with acoustic hood for equal- Kay Engineering/Everest/

ization tank only for each 650kld Capacity: Kulkarni

195Nm3/hr @ 6 MWC. Twin Lobe blowers.

6 Mixing Blowers with acoustic hood for SHT Kay Engineering/Everest/

and sewage collection sump tanks. Capacity: Kulkarni

110Nm3/hr @ 4.5 MWC. Twin Lobe blowers.

296
 Table 6.1: List of Approved Makes-STP

Sl No Item Make

7(a) Coarse Bubble Diffuser in equalization tank re- EDI/OTT/Rehau /Titan aer-

trievable type for 650kld ation

7(b) Coarse Bubble Diffuser in CCS and SHT re- EDI/OTT/Rehau /Titan aer-

trievable type/fixed type for 650kld ation

8 Bioreactor feed pump for 650kld Johnson /KSB/ Kirloskar/

Grundfos

ASR/AuricTechno services
9 Mechanical Screen 2mm punched hole at inlet
/Jash Procedyne
of Aeration tank

10 Process Blowers with acoustic hood and VFD Kay Engineer-

for 650 kld Type: Twin Lobe type ing/Everest/Kulkarni

11 Membrane Blowers with acoustic hood for 650 Kay Engineering/Everest/

kld Type: Twin Lobe type Kulkarni

12 Fine Bubble Diffuser for 650 kld aeration tank EDI/OTT/Rehau/Titan aera-

(approx. 36 nos.) tion

13 ZW500D Leap 48 Module short cassette, 27.9 GE

sqm per module

14 RAS (Recycle) pump Type: non-submersible Johnson/ KSB/ Kirloskar/

type Grundfos/KBL

15 Permeate Pumps with VDF for 650kld Johnson/ KSB/ Kirloskar/

Grundfos/KBL

16 FRP Back pulse tank Milton Roy / Grundfos /

Prominent

17 FRP Sodium Hypochlorite dosing tank system Milton Roy / Grundfos /

for membrane cleaning Prominent

18 FRP Sodium Hypochlorite dosing pumps for Milton Roy / Grundfos /

membrane cleaning Prominent

19 FRP Citric acid dosing tank Milton Roy / Grundfos /

Prominent

20 FRP Citric acid dosing pumps for membrane Milton Roy / Grundfos /

cleaning Prominent

Johnson/KSB/Kirloskar/
21 Sludge transfer pump @ 3.5 m3/hr
Grundfos/KBL

297
 Table 6.1: List of Approved Makes-STP

Sl No Item Make

22 Centrifuge suitable for 3.5 m3/hr flowrate Alfa Laval/

Hiller/AndritZ/Pennwalt

23 Poly electrolyte dosing tank and mixer for Milton Roy / Grundfos /

sludge dewatering- 0- 100 lph @ 2bar Prominent

24 Poly electrolyte dosing pump for sludge Milton Roy / Grundfos /

dewatering- 500 litres Prominent

25 Post Hypochlorite dosing tank system for per- Milton Roy / Grundfos /

meate side- 200 litres Prominent

26 Post Hypochlorite dosing pumps for permeate Milton Roy / Grundfos /

side- 5-10 lph @ 1.5bar Prominent

27 Air Compressor 20 Nm3/hr @ 7 bar ELGI/Ingersoll

28 MCC for equipments noncompartmental type Siemens/Schneider/ABB

floor mounted.

Control panel Skytech/

I Logicon/ Cotmac and

29 DIN rail mounted Micro PLC with panel
assembled with components
mounted HMI equipments
of GE/ Allen Bradley / Siemens/AB

30 UPS for 30mins power supply. Emersion, Liebert, Numeric

31 Computer System with computer table Hp,DELL,Lenovo

32 Laser Printer Hp,Samsung, Canon

33 Air Conditioner Daikin/Hitachi

Inter valve/ Bray/FIP/ GF /BDK/ Astral/Haw

34 Ball, butterfly, check valves etc.
VASS/Tyco/Jash

35 Respective motors and VFD ABB/Bharat Bhi-

jilee/Crompton

Greaves/Siemens /Dan-

foss

298
 Table 6.1: List of Approved Makes-STP

Sl No Item Make

36 1no. Flowmeter at drum screen inlet, 1no. Endress &

level switch in Equilization tank, 1.no. air flow Hauser/Emerson/ Forbes

switch in process blower line, 1no. flow me- marshall/Krohne/Hach/GE

ter in sludge line of RAS pump, 1no. pres- Sensing/Pune Techtrol /

sure transmitter in permeate line, 1no. level Levco/Wika/Waree/Forbes

transmitter in membrane tank, 1no flowmeter marshall/General Instru-

in permeate pump line, 1no. Turbidity meter at ments/ Waree

outlet of permeate pump, 1no. level switch in

sludge holding tank. Respective level switches,

pressure indicators.

37 uPVC pipes Astral/Finolex/Supreme

38 GI Pipes/ MS Pipes Tata, SAIL, Jindal

39 DI pipes Tata Kubuto, Electrosteel

40 Raw materials, chemicals, and utilities during As approved

equipment start-up and operation.

41 Disposal of Initial Start-up wastewater and as- As approved

sociated chemicals.

42 Laboratory Assistance during Erection and As approved

commissioning of STP plant as required.

43 STP room ventilation system and fire fighting As approved

44 Storage of Equipments As approved

45 Eye wash and safety shower As approved

46 5 ton manual Chain pulley for membrane tank As approved

area.

47 chain pulley block of required capacity Indef or As approved

48 Equipment Lifting system and arrangement for Indef or As approved

other equipments if required.

49 Treated water transfer pumps As approved

50 UV system As approved

51 Softener feed pumps and hydro-pneumatic As approved

pumps

52 Softener system As approved

53 Puddle pipes and insert plates As approved

299
 Table 6.1: List of Approved Makes-STP

Sl No Item Make

54 Bulk Chemical storage tanks ( if required) As approved

55 Equipment anchor bolts As approved

56 Disposal of membrane preservative As approved

57 Hydro testing of all field installed piping As approved

58 Emergency lighting As approved

300
6.2 List Of Approved Makes for Electrical Works

Sl No Item Approved Make

(a) Motors ABB/Crompton

Greaves/Kirloskar/Siemens

(b) LV switch gear/PMCC ABB/ Larsen and Toubro/

Legrand/ /Siemens.

(c) Air circuit breaker/ MCCB / MCB ABB/Larsen and Toubro/ Schnei-

der Electric / Siemens

(d) Switch/fuse unit ABB/Larsen and Toubro/ Schnei-

der Electric / Siemens

(e) DOL /Star Delta Starters / Soft ABB/Larsen and Toubro/ Schnei-

starters der Electric / Siemens

(f) Contactors ABB/Larsen and Toubro/ Schnei-

der Electric / Siemens

(g) Indicating lamps Ess Bee (L&T)/ Siemens/ IEC/

Technik

(h) Instrument Transformers ABB/KAPPA/Jyoti /Pragati Elec-

tricals/Siemens

(i) Push button EssBee ( L&T) / Siemens/Technik

or equivalent

(j) Indicating meters Automatic Electric /IMP/ Secure /

Meco.

(k) Terminal blocks Connect well/ELMEX/WAGO

(l) Lugs DOWELL /Jainsons

(m) Cables Polycab / RPG / Finolex /Havells

(n) Cable tray Profab /Delta System, Legrand

(o) Cable glands Braco / Comet

(p) Annunciation Minilec / Proton

(q) Digital energy meter Secure / Larsen and

Toubro/Conzerve

(r) Control switch Kaycee /Switron

(s) Fuse Copper Bussman / Larsen and

Toubro Siemens

(t) Conduit AKG Industries /BEC conduit

/Precision ppi/

301
6.3 Preferred makes for Instrumentation and Automa-
tion Equipment

Table 6.2: Preferred makes for Instrumentation and Automation Equipment

Sl No Item Make
Altop Industries /Aadarsh Industries /
(a) Pressure Gauge
WAAREE
Siemens /Forbes Marshall Pvt. Ltd /
Endress + Houser Pvt. Ltd /
(b) Pressure Transmitter
Klay Instruments B.V. /
Precision Instrument Co.
(c ) Float level switch ABS/ITT/SBEM Pvt.Ltd.
ABB/ Endress + Houser Pvt. Ltd /
Ultrasonic
(d) Nivo Control Pvt. Ltd./
Level Transmitter
SBEM Pvt. Ltd./Siemens
ABB/ Endress + Houser Pvt. Ltd /
(e) Magnetic Flow Meter Nivo Control Pvt. Ltd. /
Forbes Marshal /Siemens.
ABB/ Endress + Houser Pvt. Ltd /
(f) Ultrasonic flow Transmitter Nivo Control Pvt.Ltd./
Forbes Marshal /Siemens
Honeywell/ ABB/ LARSEN &TOUBRO/
(g) PLC
Schneider Electric/ Siemens
Endress + Houser Pvt. Ltd/
(h) Analytical Instruments
HACH instrument
(i) UPS APC

302
Chapter 7

Annexures

7.1 Form of Performance Security (Guarantee) Bank Guar-

antee Bond

Performance Security (Guarantee) Bank Guarantee Bond

In consideration of the Director, IITH (hereinafter called The Government) having of-

fered to accept the terms and conditions of the proposed agreement between ...............

and ............... (hereinafter called the said Contractor(s)) for the work ............... (hereinafter

called the said agreement) having agreed to production of an irrevocable Bank Guaran-

tee for Rs............ (Rupees ............only) as a security/guarantee from the contractor(s) for

compliance of his obligations in accordance with the terms and conditions in the said

agreement.

1. We, ............. (hereinafter referred to as the Bank) hereby undertake to pay to the

Government an amount not exceeding Rs. ............. (Rupees ............. Only) on demand by

the Government.

2. We, ............. (indicate the name of the Bank) do hereby undertake to pay the

amounts due and payable under this guarantee without any demure, merely on a de-

mand from the Government stating that the amount claimed as required to meet the

recoveries due or likely to be due from the said contractor(s). Any such demand made

on the bank shall be conclusive as regards the amount due and payable by the bank

under this Guarantee. However, our liability under this guarantee shall be restricted to

an amount not exceeding Rs. ............. (Rupees ............. only)

3. We, the said bank further undertake to pay the Government any money so de-

manded notwithstanding any dispute or disputes raised by the contractor(s) in any suit

or proceeding pending before any court or Tribunal relating thereto, our liability under

this present being absolute and unequivocal. The payment so made by us under this

bond shall be a valid discharge of our liability for payment there under and the Contrac-

tor(s) shall have no claim against us for making such payment.

303
 4. We, ............. (indicate the name of the Bank) further agree that the guarantee herein

contained shall remain in full force and effect during the period that would be taken

for the performance of the said agreement and that it shall continue to be enforceable

till all the dues of the Government under or by virtue of the said agreement have been

fully paid and its claims satisfied or discharged or till Engineer- in-Charge on behalf of

the Government certified that the terms and conditions of the said agreement have been

fully and properly carried out by the said Contractor(s) and accordingly discharges this

guarantee.

5. We, ............. (indicate the name of the Bank) further agree with the Government that

the Government shall have the fullest liberty without our consent and without affecting

in any manner our obligation hereunder to vary any of the terms and conditions of the

said agreement or to extend time of performance by the said Contractor(s) from time to

time or to postpone for any time or from time to time any of the powers exercisable by the

Government against the said contractor(s) and to forbear or enforce any of the terms and

conditions relating to the said agreement and we shall not be relieved from our liability by

reason of any such variation, or extension being granted to the said Contractor(s) or for

any forbearance, act of omission on the part of the Government or any indulgence by the

Government to the said Contractor(s) or by any such matter or thing whatsoever which

under the law relating to sureties would, but for this provision, have effect of so relieving

us.

6. This guarantee shall not be discharged due to the change in the constitution of the

Bank or the Contractor(s).

7. We, ............. (indicate the name of the Bank) lastly undertake not to revoke this

guarantee except with the previous consent of the Government in writing.

8. This guarantee shall be valid up to ............. unless extended on demand by the Gov-

ernment. Notwithstanding anything mentioned above, our liability against this guarantee

is restricted to Rs. ............. (Rupees .............) and unless a claim in writing is lodged with

us within six months of the date of expiry or the extended date of expiry of this guarantee

all our liabilities under this guarantee shall stand discharged.

Dated the ............. day of ............. for ............. (indicate the name of the Bank)

304
7.2 Form of Earnest Money Deposit Bank Guarantee Bond

Form of Earnest Money Deposit Bank Guarantee Bond

WHEREAS, contractor .................. (Name of contractor) (hereinafter called ”the contractor”)

has submitted his tender dated ............. (date) for the work of ..............................................

(name of work) (hereinafter called ”the Tender”)

KNOW ALL PEOPLE by these presents that we ......................................... (name of bank)

having our registered office at ................................... (hereinafter called ”the Bank”) are

bound unto Indian Institute of Technology Hyderabad in the sum of Rs ..........................

(Rs. in words ................................................. ) for which payment well and truly to be made

to the said Indian Institute of Technology Hyderabad the Bank binds itself, his successors

and assigns by these presents.

SEALED with the Common Seal of the said Bank this ................. day of ................ 20 ....

THE CONDITIONS of this obligation are:

(1) If after tender opening the Contractor withdraws, his tender during the period of

validity of tender (including extended validity of tender) specified in the Form of Tender;

(2) If the contractor having been notified of the acceptance of his tender by the Indian

Institute of Technology Hyderabad

(a) fails or refuses to execute the Form of Agreement in accordance with the Instruc-

tions to contractor, if required;

OR

(b) fails or refuses to furnish the Performance Guarantee, in accordance with the provi-

sions of tender document and Instructions to contractor,

OR

(c) fails or refuses to start the work, in accordance with the provisions of the contract and

Instructions to contractor,

OR

(d) fails or refuses to submit fresh Bank Guarantee of an equal amount of this Bank

Guarantee, against Security Deposit after award of contract.

We undertake to pay to the Indian Institute of Technology Hyderabad up to the above

amount upon receipt of his first written demand, without the Indian Institute of Tech-

nology Hyderabad having to substantiates his demand, provided that in his demand the

Indian Institute of Technology Hyderabad shall note that the amount claimed by his is

due to him owing to the occurrence of one or any of the above conditions, specifying the

occurred condition or conditions.

This Guarantee shall remain in force up to and including the date* ............. after the

305
deadline for submission of tender as such deadline is stated in the Instructions to con-

tractor or as it may be extended by the Indian Institute of Technology Hyderabad , notice

of which extension(s) to the Bank is hereby waived. Any demand in respect of this Guar-

antee should reach the Bank not later than the above date.

DATE .............

WITNESS .................

SIGNATURE OF THE BANK SEAL

(SIGNATURE, NAME AND ADDRESS)

*Date to be worked out on the basis of validity period of 6 months from last date of

receipt of tender.

306
7.3 Affidavit to be submitted by the bidder

Proforma of affidavit to be submitted by the bidder regarding eligibility.

”I/We undertake and confirm that eligible similar work(s) has /have not been got exe-

cuted through another contractor on back to back basis. Further that, if such a violation

comes to the notice of IITH, then I/We shall be debarred for biding in IIT Hyderabad

contracts in future forever. Also, if such a violation comes to the notice of IIT Hyder-

abad before date start of work, the Engineer-in- Charge shall be free to forfeit the entire

amount of Earnest Money Deposit/ Performance Guarantee.”

(SIGNATURE, NAME AND ADDRESS)

307
7.4 Form of Supplementary Agreement

FORM OF SUPPLEMENTARY AGREEMENT

This Agreement made this day the ....................... 20 ............... between Executive Engi-

neer, IIT Hyderabad, Kandi-502285, Sangareddy (District, Telangana, India, on be-

half of Director, IIT Hyderabad, hereinafter called the First Party and M/s ..........................,

having registered office at .......................... , hereinafter called the Second Party, which

expression shall include his successors and assigns, shown as under :

(1) That this Agreement shall be called Supplementary Agreement to the Agreement No.

...........

relating to the Design, Supply, Installation, Testing, Commissioning and Operating

650 kLD STP at IIT Hyderabad

entered into by the parties to this Agreement.

(2) That WHEREAS the Second Party has substantially completed the execution of Part

A of the work described in and covered by the Agreement No. ............... except the items

mentioned in the Schedule annexed to this Agreement and whereas the items of the work

mentioned in the Schedule annexed to this agreement cannot now be executed on ac-

count of being operational and maintenance items;

and whereas both the parties are desirous that the items mentioned in the Schedule an-

nexed to this Agreement should be executed by the Second Party after the completion of

the Part A of the said agreement, it is hereby further agreed as under : (a) That Second

Party shall and will execute the work covered by the items mentioned in the Schedule

annexed to this Agreement at the rates and as per the terms and conditions and scope of

work and services listed in the original Agreement No. ............... whatsoever called upon

to do so by the Engineer-in-Charge, within a period of three years from the date hereof.

(b) That the Second Party shall have absolutely no claim of whatsoever nature against the

Second Party for doing the work mentioned in the Schedule under Part B of the original

Agreement No. ............... (c) That the Second Party shall have to execute all the items

which the Engineer-in-charge consider necessary. (d) That the Second Party shall start

with the work of the remaining items mentioned in the Schedule under Part B of the

original Agreement No. ............... within ............... days from ............... on the receipt of a

letter to the effect from the Engineer-in-Charge or from any date fixed in the said letter

and shall complete the said work within the time fixed by the Engineer-in-Charge or as

extended by him from time to time. (e) That on the due execution and completion of this

Agreement by the parties, the bill of the Second Party in relation to the work already

done by him under the Original Agreement No. ............... shall be provisionally finalized

by the First Party and payment on account, if any amount due, shall be made to the

308
Second Party provided that the First Party shall have a right to retain such amount as

is considered reasonable by him as a security for the execution of the work mentioned

in the Schedule under Part B of the original Agreement No. ............... and the First Party

shall have right to deal with the said amount of security as he thinks proper under the

terms and conditions of the Original Agreement. Further, on the due execution and orig-

inal completion of this Agreement, the Second Party shall be entitled to claim back his

security deposit relating to the work in question, subject to the right of the First Party

to retain such amount as he thinks reasonable as mentioned above soon after or three

months or as the case may be mentioned in clause of the Original Agreement, is over.

(f) That the final bill relating to the entire work under the two agreements shall be pre-

pared after the completion of the entire work covered by Agreement No. ............... and this

Agreement.

(3) Except as modified by this Agreement the said Agreement No. ............... shall remain

in full force and effect.

IN WITNESS WHEREOF THE ABOVE MENTIONED PARTIES HAVE PUT THEIR SIGNA-

TURE ON THIS DAY THE .......................

309
7.5 Proforma of Guarantee Bond for Performance of Treat-
ment System

PROFORMA OF GUARANTEE BOND FOR PERFORMANCE OF TREATMENT SYSTEM

This agreement made this ........................ day of ...................... two thousand ...............................

between M/s ................ (hereinafter called the Guarantor of the one part) and the Director,

IIT Hyderabad hereinafter called the Government of the other part).

Whereas this agreement is supplementary to the original contract (hereinafter called

the Contract) dated ................... made between the Guarantor of the one part and Gov-

ernment of the other part, whereby the Contractor, inter alia, undertook to render the

Sewage Treatment Plant in the said Contract recited, completely to treat the sewage to

meet the effluent treated water parameters as specified below:

Required Effluent Quality

Table 7.1 shows the expected effluent quality upon equipment start-up and running of of

the plant.

Table 7.1: Required Effluent Quality Parameters

Parameter Unit Required

Biological Oxygen Demand 5-day (BOD5) mg/l <5
Total Suspended Solids mg/l <5
Turbidity NTU <1
Hardness of softened water mg/l <50
Total coliform, MPN per 100 ml, Max <100
Oil and grease Not detectable
Colour and Odour Clear, Not objectionable
Residual Chlorine mg/l >1 as total Cl

And whereas the Guarantor agreed to give a guarantee to the effect that the said

sewage treatment plant will perform for three years to be reckoned from the date of

commissioning of the plant.

During this period of guarantee the Guarantor shall make good all defects and for that

matter, shall replace at his risk and cost the electro-mechanical equipment, instrumen-

tation listed in Section-6 of contract and in case of any other defect being found he shall

render the electro-mechanical equipment, instrumentation listed in Section-6 of contract

at his cost to the satisfaction of the Engineer-in-charge, and shall commence the works

of such rectification within seven days from date of issuing notice from the Engineer-in-

charge calling upon him to rectify the defects, failing which the work shall be got done

by the Institute by some other Contractor at the risk and cost of the contractor, and in

the later case the decision of the Engineer-in-charge as to the cost recoverable form the

Guarantor shall be final and binding.

310
 That if the Guarantor fails to execute the sewage treatment plant meeting the param-

eters of required effluent quality or commits breaches hereunder then the Guarantor will

indemnify principal and his successors against all loss, damage, cost, expense or other-

wise which may be incurred by him by reason of any default on the part of the Guarantor

in performance and observance of this supplemental agreement. As to the amount of loss

and/or damage and/or cost incurred by the Government, the decision of the Engineer-

in-charge will be final and binding on the parties.

In witness whereof these presents have been executed by the Obligor .................. and

by ................................. for and on behalf of the President of India on the day, month and

year first above written. Signed, sealed and delivered by OBLIGOR in the presence of

2.

Signed for and on behalf of THE PRESIDENT OF INDIA by .......... in the presence of.

311
7.6 Information Regarding Eligibility Letter of Transmit-
tal

INFORMATION REGARDING ELIGIBILITY LETTER OF TRANSMITTAL

( To be submitted on the Letter Head of the bidder)

From:

...............

...............

...............

To

The Engineer-in-Charge

IIT Hyderabad

Subject: Submission of bids for the work of ................

Sir,

Having examined the details given in press notice and bid document for the above work,

I/we hereby submit the relevant information.

1. I/we hereby certify that all the statements made and information supplied in the en-

closed forms A to H and accompanying statement are true and correct.

2. I/we have furnished all information and details necessary for eligibility and have no

further pertinent information to supply.

3. I/we submit the requisite certified solvency certificate and authorize the Engineer-in-

Charge, IIT Hyderabad to approach the Bank issuing the solvency certificate to confirm

the correctness thereof. I/we also authorize Engineer-in-Charge, IIT Hyderabad to ap-

proach individuals, employers, firms and corporation to verify our competence and gen-

eral reputation.

4. I/we submit the following certificates in support of our suitability, technical knowledge

and capability for having successfully completed the following works:

Name of work:

Certificate from:

Enclosures:

Date of submission:

Signature(s) of Bidder(s).

Seal of bidder

312
7.7 Proforma of Forms A,B,C,D,E,F,G for Evaluation Cri-
teria

PROFORMA OF FORM A,B,C,D,E,F ,G FOR EVALUATION CRITERIA

FORM A

FINANCIAL INFORMATION

I. Financial Analysis Details to be furnished duly supported by figures in balance sheet/

profit loss account for the last five years duly certified by the Chartered Accountant, as

submitted by the applicant to the Income Tax Department (Copies to be attached).

Gross Annual Turnover

Financial Year Profit/ Loss
from Construction Works
2016-17
2015-16
2014-15
2013-14
2012-13

II. Financial arrangements for carrying out the proposed work.

III. Solvency Certificate from Bankers of the bidder in the prescribed Form B.

Signature of Chartered Accountant with Seal Signature of Bidder(s).

FORM B FORM OF BANKERS CERTIFICATE FROM A SCHEDULED BANK

This is to certify that to the best of our knowledge and information that M/s./ Sh

................... having marginally noted address, a customer of our bank are/is respectable

and can be treated as good for any engagement up to a limit of Rs ................... (Rupees

................... )

This certificate is issued without any guarantee or responsibility on the bank or any of

the officers.

(Signature)

For the Bank

NOTE (1) Bankers certificates should be on letter head of the Bank, sealed in cover ad-

dressed to tendering authority.

(2) In case of partnership firm, certificate should include names of all partners as recorded

with the Bank.

313
FORM C: DETAILS OF ALL WORKS OF SIMILAR CLASS COMPLETED DURING THE

LAST SEVEN YEARS ENDING LAST DAY OF THE MONTH ......

314
 Table 7.2: Form ’C’

Name and
Litigation address
Cost of Date of
Name of Owner or Stipulated Actual /Arbitration* /telephone
work in commencement
S.No. work/project sponsoring date of date of case in number of Remarks
crores of as per
and loacation organization completion completion pending/progress officer to
Rupees contract
with details* whom reference
may be made

* Indicate gross amount claimed and amount awarded by the Arbitrator.

Signature of Bidder(s)

315
7.8 Projects Under Execution or Awarded

FORM D PROJECTS UNDER EXECUTION OR AWARDED

316
 Table 7.3: Form ’D’

Name and
address
Cost of Date of Upto date Slow progress
Name of Owner or Stipulated /telephone
work in commencement percentage ,if any
S.No. work/project sponsoring date of number of Remarks
crores of as per progress and reasons
and loacation organization completion officer to
Rupees contract of work there-of
whom reference
may be made

* Indicate gross amount claimed and amount awarded by the Arbitrator.

Signature of Bidder(s)

317
7.9 Performance Report of Works

FORM E PERFORMANCE REPORT OF WORKS REFERRED TO IN FORMS B & C

1. Name of work/project location:

2. Agreement no.:

3. Estimated cost:

4. Tendered cost:

5. Date of start:

6. Date of completion:

(i) Stipulated date of completion:

(ii) Actual date of completion:

7. Amount of compensation levied for delayed completion, if any:

8. Amount of reduced rate items, if any:

9. Performance Report:

Quality of work : Very Good/Good/Fair/Poor

Financial soundness : Very Good/Good/Fair/Poor
Technical Proficiency : Very Good/Good/Fair/Poor
Resourcefulness : Very Good/Good/Fair/Poor
General Behaviour : Very Good/Good/Fair/Poor

Dated:

Engineer-in-Charge or Equivalent:

Phone, Fax and Mobile Number:

e mail address:

318
7.10 Structure & Organization

FORM ”F” STRUCTURE ORGANISATION

1. Name address of the bidder:

2. Telephone no./Telex no./Fax no.:

3. Legal status of the bidder (attach copies of original document defining the legal status):

(a) An Individual

(b) A proprietary firm

(c) A firm in partnership

(d) A limited company or Corporation

4. Particulars of registration with various Government Bodies (attach attested photocopy):

Organisation/Place of registration Registration No.

i.
ii.
iii.

5. Names and titles of Directors Officers with designation to be concerned with this work:

6. Designation of individuals authorized to act for the organization:

7. Was the bidder ever required to suspend construction for a period of more than six

months continuously after he commenced the construction? If so, give the name of the

project and reasons of suspension of work:

8. Has the bidder, or any constituent partner in case of partnership firm, ever abandoned

the awarded work before its completion? If so, give name of the project and reasons for

abandonment:

9. Has the bidder, or any constituent partner in case of partnership firm, ever been de-

barred/black listed for tendering in any organization at any time? If so, give details:

10. Has the bidder, or any constituent partner in case of partnership firm, ever been

convicted by the court of law? If so, give details:

11. In which field of Civil Engineering construction the bidder has specialization and

interest?:

12. Any other information considered necessary but not included above.:

Signature of Bidder(s)

319
7.11 Details of Technical & Administrative Personnel to
Be Employed for The Work

FORM ”G” DETAILS OF TECHNICAL & ADMINISTRATIVE PERSONNEL TO BE

EMPLOYED FOR THE WORK

Professional
How these
Number experience
Total would be
S.No. Designation available for Name Qualifications and details Remarks
Number involved in
this work of work
this work
carried out

Signature of Bidder(s)

320
7.12 Details of Construction Plant and Equipment Likely
To Be Used in Carrying Out the Work

FORM ”H” DETAILS OF CONSTRUCTION PLANT AND EQUIPMENT LIKELY TO BE

USED IN CARRYING OUT THE WORK

Sl. Name Capacity Ownership status Current

No. Age Condition Remarks
No. of or Type Presently To be location
Leased
equipment owned purchased

Signature of Bidder(s)

321
7.13 Application Form for Purchase of Bid Documents

To

The Engineer-in-Charge,

Indian Institute of Technology Hyderabad

Subject: Purchase of Tender documents

Sir,

*I/We am/are registered with the CPWD as Class ............. contractor/contractors and our

Registration no. is .............. It is certified that the said registration is valid as on date

..............

2. *I/We am/are not registered with CPWD.

3. *I/We am /are registered contractor(s) with MES/Railways/PT/State PWD also.

Particular of the Authority, class and tender amount/limit upto which I/we am/are eligi-

ble to tender are furnished below:

Authority Class Tendering limit

It is certified (confirmed) that this registration/these registrations is/are valid as on date

and we shall inform the department ourselves as soon as my / our registration expires or

is cancelled/revoked.

The particulars of work done are furnished/enclosed (for State PWD contractors) *I/We

request that permission may be granted to me/us for the purchase of tender document

for the work of ....................

Your faithfully,

(Contractor)*

(*Strike out inapplicable portion)

322
7.14 Running Account Bill Form 27A and Final Bill Form
27B (For scheduled payments to Contractor)

323
 FORM 27-A
RUNNING ACCOUNT BILL
(Referred to in paragraph 11.3.2)
(To be used for “intermediate payments” to contractors on lump-sum contracts)

Cash Book Voucher No. date

Name of Contractor –

Name of Work –

Serial No. of the Bill –

No. and date of his previous Bill for this work –

Reference to agreement –

Date of written order to commence work –

I. - ACCOUNT OF WORK
Rs.
1. Approximate value of work done up to date excluding the
measured up additions and alterations.
2. Value of measured up additions and alterations.
3. Deduct amount to be withheld.
4. Balance i.e. “up to date” intermediate payments (Items 1+2-
3)K
5. Deduct intermediate payment already made as per entry “K”
of the last Running Account Bill
6. Intermediate payment now to be made (Item 4 – 5) D
7. Amount of ‘Secured’ advances as per entry “E” of Account II
8. Total payments now to be made as detailed below* -
(a) By recovery of amounts creditable
to this
work .. .. .. .. .. .. .. G
___________________________________
___________________________________

(b) By recovery of amounts creditable to

other works or heads of account .. .. H
(i) Taxes __________________________
(ii) Security Deposit ________________
(iii) Other recoveries ________________

(c) By Cheque .. .. .. .. ..
* The total figures against item 8 should be tested to see that it agrees with the total of
items 6 & 7
 FORM 27-A – Contd
.
II. Account of “Secured” Advances Allowed on the Security of Materials Brought to Site
Reasons for
*Deduct Quantity Reference
non-
quantity outstanding to
Quantity Full rate as Reduced clearance of
utilized in (including Divisional
outstanding assessed by rate on ¶ Up to date advance
work quantity Description Officer’s
from the Unit which amount of when
measured brought to of materials written
previous Divisional advance is advance outstanding
since site since order
bill Officer made more than
previous previous authorizing
three
bill bill) the advance
months
1 2 3 4 5 6 7 8 9 10
Rs.

Total amount outstanding as per this account (c)

Deduct : - amount outstanding as per entry (c) of previous bill

Net amount since previous bill (in words) Rupees. (E)

* Entries relating to each description of materials should be posted in column 3. First enter the difference between the quantities in columns 1
and 2, then show this entry below the quantities if any brought to site against which a further advance has been authorised, this entry being
prefixed by the plus sign. Finally, strike the total of the two entries which will represent the total quantities outstanding.
¶ Entries in column 8 show the money values of the total quantities outstanding as in column 3.
 FORM 27-A – Contd

III. CERTIFICATES AND SIGNATURES

I have satisfied myself by *

that the value of work done up to date excluding the measured up additions and
alterations is not less that Rs. ………………. Conformably with the contractor’s
agreement and that with the exception of authorised additions and alterations the work
has been done according to the prescribed drawings and specification.

2. The detailed measurements of authorised additions and alterations upto date were
made by ………………. on ………….. and are recorded at page ………… of
Measurement Book No. ………………

3. Certified that the plus quantities of materials shown in column 3 of Account II

above have actually been brought by the contractor to the site of the work and the
contractor has not previously received any advance on their security (2) that those
materials are of imperishable nature and are all required for use on the work for which a
lump sum for finished work has been agreed upon and (3) that a formal agreement signed
and executed by the contractor in accordance with paragraph 10.2.24 (a) of the central
P.W.A. code is recorded in the Divisional office.

Signature of Contractor

………………………………………
Dated signature of officer
Preparing the bill Rank………………………………….

Pay ¶ (Rs……………………………………………………………….only )

………………………………………
Dated signature of officer
Authorizing the payment Rank………………………………….
 IV – ACQUITTANCE

Received Î (Rs. ………………………………………..) as an intermediate payment in

connection with the contract referred to above.

Stamp

$ Witness Full Signature of Contractor

Cash
Paid by me by dated
Cheque No.

………………………………………
Dated signature of the person
actually making the payment Rank………………………………….

* Here specify the method employed for estimating the value of work.

¶ Here specify the net amount payable vide Item 8(c) of Account I.

Î The Payee’s acknowledgement should be for the gross amount paid as per
item 8 (a +b+c) of Account I.

$ Payment should be attested by some known person when the payee’s acknowledgement
is given by mark, seal or thumb impression.
 FORM 27-A – Contd

V – REMARKS

(This space is reserved for any remark which the Disbursing Officer or the Divisional
Officer may wish to record in respect of the execution of the work/check of measurements
or the state of contractor’s account.)

For use in Divisional Office

Checked

A/c. Clerk Divi. Actt.

For use in Pay and Accounts Office

Audited Reviewed

Accountant JAO/AAO Pay & Accounts Officer

 To be printed on yellow papers only
FORM 27-B
FINAL BILL
(Referred to in paragraph 11.3.1,11.3.3,11.4.5 and 11.5.3 of C.P.W.A Code. )
(To be used for “final payments” to contractors on lump-sum contracts)

Cash Book Voucher No. dated

Name of Contractor –

Name of Work –

Serial No. of this Bill –

No. and date of his previous Bill for this work –

Reference to agreement –

Date of written order to commence work –

Date of actual completion of work –

I. - ACCOUNT OF WORK EXECUTED

Sub-work, Rate Unit Up to date Remarks

Sub-Head or Quantity Amount
item of work
Rs. Lump sum Rs
for each

Additional
Work

Deduct
Omissions

Total Value
of Works
done to date
‘F’
 FORM 27-B – Contd.

II. Certificates and signatures

I certify that the work has been completed in accordance with the prescribed
drawings and specification and after taking into account all the authorized additions and
alterations the value of work done, up-to-date, conformably with the terms of the
contractos’s agreement, is Rs………
2. The detailed measurements of the authorized additions and alterations
mentioned above were made by …………..on…….. and are recorded at page………..of
Measurement Book No……………….. and I am satisfied that they are correct.

Signature of Contractor
Dated signature of the certifying Engineer. Rank………….

* This certificate must be signed by the Executive Engineer or any officer empowered by
the local Administration to sign it.

III. Memorandum of payments

1. Total Value of Work done up-to-date as per ‘F’ of Account I Rs.

Of this Bill
2. Deduct:-
(i) Up-to-date intermediate payments already
As per entry ‘K’ of Account I of
last Bill No……………dated…….. (D)
(ii) Total Secured Advances outstanding as per
Entry ‘C’ of Account II last Bill No……
Dated…….. (E)
3. Payments now to be made:-
(a) By recovery of amounts creditable to this
Work (G)

(b) By recovery of amounts creditable to

Other works or heads of account…..

(C) By Cheque………………………… (H)

Pay ¶ (Rs……………………………………………………………….only )

………………………………………
Dated signature of officer
Authorizing the payment Rank………………………………….
 IV – ACQUITTANCE

* Received (Rs. ……………) Rupees ………………………………………only

as above in full settlement of all demands on account of the contract.

Stamp

Amount in Vernacular

¶ Witness Full Signature of Contractor

Cash
Paid by me by dated _____________
Cheque No.

………………………………………
Dated signature of the person
actually making the payment Rank………………………………….

* The payee’s acknowledgement should be for the gross amount as per item 3 (a+b+c) of
Account III.

¶ Payment should be attested by some known person when the payee’s acknowledgement
is given by a mark, seal or thumb impression.
 V – REMARKS

(This space is reserved for any remarks which the Disbursing Officer or the Divisional
Officer may wish to record in respect of the execution of the work,check of measurements
or the state of contractor’s account.)

For use in Divisional Office

Checked

A/c. Clerk Divi. Actt.

For use in Pay and Accounts Office

Audited Reviewed

Accountant JAO/AAO Pay & Accounts Officer

7.15 MoU with Technology Provider

MEMORANDUM OF UNDERSTANDING

Between

................... ( Bidder)

And

Suez Water Technologies Solutions (I) Pvt. Ltd. (Technology Provider)

Entered into this ............ day of.............., 2017, by and between Suez Water Technolo-

gies Solutions (I) Pvt. Ltd., a company incorporated in India under the Companies Act,

1956, having its registered office at .................................... (hereinafter called or Technology

Provider) and ....................... (hereinafter called Bidder) a company incorporated in India

under the Companies Act 1956, having its head office at ..............................

RECITALS:

1. WHEREAS Technology Provider is in the business of ..............................

2. WHEREAS Lead Bidder is in the business of ..............................

3. WHEREAS this MEMORANDUM OF UNDERSTANDING is applicable solely for

DSITC (Design, supply, Installation, trial run and Commissioning) of electro-mechanical,

instrumentation ,electrical, piping, automation works of the 1 * 650 KLD UF Hollow Fiber

MBR based STP project of IIT Hyderabad (the Project).

4. WHEREAS the Technology Provider agrees to provide the necessary design, en-

gineering of the MBR systems to the Bidder for the Project, subject to mutually agreed

Terms Conditions. Design and Engineering support shall be as described in Chapter 5 :

Scope of Work and Services, Section 4.5 of the bid document.

5. WHEREAS the Technology Provider agrees to supply the MBR membranes and

cassettes along with technical advisory services and supervision of installation and com-

missioning to the Bidder for the Project, subject to mutually agreed Terms Conditions

6. WHEREAS the Technology Provider agrees to provide membrane warranty for a

period five years ( 2 year full replacement and 3 year pro-rated warranty) , subject to

mutually agreed Terms Conditions. Process guarantee (limited to TSS, Turbidity, Flow

333
and BOD) would be applicable as per the Tender requirements of the Project provided the

Bidder supplies equipment as per the Technology Provider design specifications.

7. WHEREAS the Bidder agrees to take support of the Technology Provider for post-

commissioning periodic reviews (once in every three months ) and services to ensure STP

and MBR process health check-up for a period of Three(3) years after commissioning of

the STP, subject to mutually agreed Terms Conditions

8. WHEREAS this MEMORANDUM OF UNDERSTANDING would be valid for the pe-

riod of Project bidding, execution and commissioning and OM period of three (3) years

with an option to renew on a mutually agreeable basis.

In addition to the above, the scope of technology provider shall include the following:

7.15.1 Technical Advisory Services during Pre-Construction

The Contractor shall undertake the design of the proposed sewage treatment plant in con-

sultation with the Technology Provider. Technology provider shall scrutinize the design

calculations of all electro-mechanical, instrumentation, piping, electrical and automation

of control systems and vet the same. Similarly, all deliverable drawings/documents in-

cluding Maintenance Manual shall be vetted by the Technology Provider duly affixing the

signature of authorized signatory along with seal of Suez Water Technologies & Solutions

(I) Pvt. Ltd., .

7.15.2 Technical Advisory Services during Equipment Installation

In support of unloading the equipment, rigging the equipment into place, installing in-

terconnecting piping, installing interconnecting wiring, installing power wiring, installing

pneumatic lines, verifying adequate drainage, testing for adequate water and air pressure,

testing power supply and testing interconnecting wire circuitry.

7.15.3 Technical Advisory Services during Post-Installation

Inspection of installation work, address questions, develop punch list of completion items

necessary prior to next visit including technical advisory services in support of loading

membrane elements / cassettes (if not loaded in factory)

7.15.4 Technical Advisory Services during Equipment trial run

Includes technical advisory services in preparing the equipment to operate I/O verifica-

tion, support for flushing & back washing system, operating the equipment manually,

334
I/O verification, operating the equipment automatically, testing control system, techni-

cal advisory services in support of membrane loading, flushing preservative, and system

sanitization

7.15.5 Technical Advisory Services during Commissioning of plant

(Performance Test)

Includes technical advisory services in support of set-up of and witness performance

test of 72 hours / 3 days continuous operating run without intervention beyond normal

operational activities.

7.15.6 Formal Training

This shall include formal on-site training to staff of Contractor and IITH that typically

takes place after the commissioning of the plant. This does not include informal training

that takes place with an operator being present and assisting the technicians performing

start-up. The on-site training program shall also include site safety training. The training

program shall be properly documented and a report shall be submitted to IITH.

7.15.7 Other Services

The technical services listed above shall include at least 4 trips to site with total 20

working days on-site availability for above mentioned services. Travel time to and from

the job site for Technology Provider‘s Field Service personnel is not included in the 20

days period.

In addition to above technical services, the contractor shall arrange representative of

Technology Provider at kick-off meeting to be held at site after award of work.

As specified in the Conditions for O&M Services, the contractor shall arrange visits of

the Technology provider to the plant once in every three months for complete performance

audit of the plant and submit such audit report to the Institute.

7.15.8 Performance Guarantee

As specified in the bid document the Technology Provider shall submit performance guar-

antee bond for the quality of treated sewage by furnishing to IITH a joint undertaking with

Contractor to this effect.

IN WITNESS WHEREOF, THE PARTIES HAVE EXECUTED THIS MEMORANDUM OF

UNDERSTANDING ON THE DATE, MONTH AND YEAR FIRST ABOVE WRITTEN.

335
 FOR AND ON BEHALF OF FOR AND ON BEHALF OF

(Bidder) (Technology Provider)

IN THE PRESENCE OF:

WITNESS

1.

2.

336