THE HASHEMITE KINGDOM OF JORDAN

Ministry of Water & Irrigation

Water Authority of Jordan

SANITATION PROGRAMME: NEXUS AND RESOURCES

PROTECTION
COMPONENT C3: REHABILITATION AND UPGRADE OF
THE WWTP IN AS SALT
BIDDING DOCUMENTS
Contract No: 10/2020/SW
BMZ No. 2014 65 079
Volume 2
Part 3 of 3
May 2020

Section VII. Works Requirements

1. Specifications
a) Technical Specifications
1: General Specifications
2: Civil, Structural and Building Works
3: Mechanical Specifications
4: Electrical Specifications
5: General Instrument Specifications
6: Documentation
7: Testing on Completion
8: Operation and Maintenance by the Contractor
 THE HASHEMITE KINGDOM OF JORDAN
Ministry of Water & Irrigation
Water Authority of Jordan

SANITATION PROGRAMME: NEXUS AND RESOURCES

PROTECTION
COMPONENT C3: REHABILITATION AND UPGRADE OF
THE WWTP IN AS SALT
BIDDING DOCUMENTS
Contract No: 10/2020/SW
BMZ No. 2014 65 079

Volume 2.4

May 2020

Section VII. Works Requirements

1. Specifications
a) Technical Specifications
1: General Specifications
2: Civil, Structural and Building Works
3: Mechanical Specifications
4: Electrical Specifications
5: Instrument Specifications
6: Documentation
7: Testing on Completion
8: Operation and Maintenance by the Contractor
 Sanitation Programme: NEXUS and Resource Protection Tender Documents – Vol.2
Component 3 Salt WWTP Technical Specifications
Part 4 Electrical Specifications

Part 4: Electrical Specification

Table of Contents

page

1 General Electrical Specification ...................................................................... 1

1.1 Applicability ........................................................................................................... 1
1.2 Installation Standards............................................................................................ 1
1.3 Main Electricity Supply .......................................................................................... 1
1.4 Materials ................................................................................................................. 2
1.5 Polarity ................................................................................................................... 2
1.6 Workmanship ......................................................................................................... 2
1.7 Switchboards and Multi-Motor Control Boards ................................................... 3
1.7.1 Construction .......................................................................................................... 3
1.7.2 Busbars .................................................................................................................. 4
1.7.3 Fuses ...................................................................................................................... 4
1.7.4 Terminals ................................................................................................................ 4
1.7.5 Auxiliary Switches ................................................................................................. 5
1.7.6 Labels ..................................................................................................................... 5
1.7.7 Panel Earthing ........................................................................................................ 6
1.7.8 Small Wiring and Terminal Blocks........................................................................ 6
1.7.9 Indicating Lamps ................................................................................................... 6
1.7.10 Cable Connection .................................................................................................. 6
1.7.11 Instruments ............................................................................................................ 7
1.8 Current Transformers ............................................................................................ 7
1.8.1 Voltage Transformers ............................................................................................ 8
1.8.2 Safety Notice and Equipment................................................................................ 8
1.9 Circuit Breakers ..................................................................................................... 8
1.9.1 Air Break Circuit Breakers .................................................................................... 8
1.9.2 Moulded Case Circuit Breakers .......................................................................... 10
1.10 Fuse Switches General ........................................................................................ 11
1.10.1 Enclosure ............................................................................................................. 11
1.10.2 Fuses .................................................................................................................... 11
1.11 Isolating Switches................................................................................................ 11

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 Sanitation Programme: NEXUS and Resource Protection Tender Documents – Vol.2
Component 3 Salt WWTP Technical Specifications
Part 4 Electrical Specifications

1.12 Fuses and Links ................................................................................................... 12

1.13 Motor Starters General ........................................................................................ 12
1.14 Interlocking .......................................................................................................... 13
1.15 Protection ............................................................................................................. 13
1.16 Motor Protection .................................................................................................. 13
1.16.1 Protection Relays ................................................................................................. 13
1.16.2 Electric Motors General ....................................................................................... 14
1.17 Reactive Power Compensation ........................................................................... 16
1.18 Distribution Boards ............................................................................................. 16
1.19 Remote Control Push Button Station ................................................................. 17
1.20 Cables ................................................................................................................... 18
1.21 Plastic Insulated Wire-armoured Cable (PVC SWA PVC) .................................. 19
1.22 PVC Insulated Cables .......................................................................................... 19
1.23 Building Services Wiring ..................................................................................... 19
1.24 Cable Installations ............................................................................................... 20
1.25 Cabling Methods .................................................................................................. 20
1.26 Cable Trench Work .............................................................................................. 22
1.27 Cable Tray Work................................................................................................... 23
1.28 Conduit Systems.................................................................................................. 24
1.29 Flexible Conduit ................................................................................................... 25
1.30 Cable Trunking ..................................................................................................... 26
1.31 Socket Outlets ...................................................................................................... 26
1.32 Outdoor/External Lighting ................................................................................... 26
1.33 Lighting Switches ................................................................................................ 27
1.34 Lighting Fittings ................................................................................................... 28
1.35 Emergency Lighting ............................................................................................ 28
1.36 Earthing General .................................................................................................. 28
1.37 Earthing Systems................................................................................................. 29
1.38 Earthing Nests ..................................................................................................... 29
1.39 Location of Nests ................................................................................................. 30
1.40 Battery Units ........................................................................................................ 30
2 Particular Electrical Specifications ............................................................... 31
2.1 General Requirements ......................................................................................... 31
2.2 MCCs and Switchboards ..................................................................................... 31
2.2.1 Scope of Works .................................................................................................... 31

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Component 3 Salt WWTP Technical Specifications
Part 4 Electrical Specifications

2.2.2 General data ......................................................................................................... 32

2.2.3 Switchgear Enclosures........................................................................................ 32
2.2.4 General Notes ...................................................................................................... 33
2.2.5 Colour ................................................................................................................... 33
2.2.6 Motor Overload Relays ........................................................................................ 33
2.2.7 Drive Protective Devices ..................................................................................... 34
2.2.8 Incomer Interlocking ............................................................................................ 34
2.2.9 Cubicle Arrangements ......................................................................................... 34
2.2.10 Spare Cubicles ..................................................................................................... 34
2.2.11 Reactive Power Compensation Unit ................................................................... 34
2.2.12 Signalling lamps .................................................................................................. 34
2.2.13 Process Instruments ........................................................................................... 35
2.2.14 Circuit Breakers ................................................................................................... 35
2.2.15 Existing Electrical Equipment ............................................................................. 35
2.2.16 Abbreviations regarding switchgears ................................................................ 35
2.2.17 Main Low Voltage Switchgear ............................................................................. 36
2.2.18 Automatic Synchronization Panel ...................................................................... 37
2.2.19 Motor Control Centre MCC1 ................................................................................ 38
2.2.20 MCC2A .................................................................................................................. 38
2.2.21 MCC2-B................................................................................................................. 39
2.2.22 MCC3 .................................................................................................................... 39
2.2.23 MCC4 .................................................................................................................... 40
2.2.24 MCC5 .................................................................................................................... 41
2.2.25 Descriptions of the MCC feeders and starters ................................................... 41
2.2.26 PLC and Instrumentation components at the MCCs ......................................... 44
2.2.27 The I & C cubicle and auxiliary equipment......................................................... 44
2.2.28 Standard LCP for drives ...................................................................................... 44
2.2.29 Standard LCP for Actuators ................................................................................ 44
2.2.30 Emergency push buttons (EPB) ......................................................................... 45
2.2.31 LCPs, EMP and Maintenance Switches at the Screens ..................................... 45
2.2.32 LCPs, EMP and Maintenance Switches at the Grease Chambers ................... 45
2.2.33 LCPs, EMP and Maintenance Switches at the Grit Chambers .......................... 45
2.2.34 LCPs, EMP and Maintenance Switches for the Grit Classifiers ........................ 45
2.2.35 LCPs, EMP and Maintenance Switches for the PSTs ........................................ 46
2.2.36 LCPs, EMP and Maintenance Switches for the ASTs ........................................ 46

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Component 3 Salt WWTP Technical Specifications
Part 4 Electrical Specifications

2.2.37 LCPs, EMP and Maintenance Switches for the FSTs ........................................ 46
2.2.38 LCPs, EMP and Maintenance Switches for the RAS and WAS pumping
stations......................................................................................................... 46
2.2.39 LCPs, EMP and Maintenance Switches for the Sludge Thickeners.................. 46
2.2.40 LCPs, EMP and Maintenance Switches for the Drainage Pumping Stations ... 46
2.3 Automation ........................................................................................................... 46
2.3.1 General Control Philosophy ................................................................................ 47
2.3.2 Fault and Faulty Value Handling ......................................................................... 47
2.3.3 Control of the screens station ............................................................................ 47
2.3.4 Control of the Return Pumping Station at the overflow tank ............................ 48
2.3.5 Control of the Grease and Grit Chambers.......................................................... 48
2.3.6 Control of the PSTs ............................................................................................. 49
2.3.7 Control of the ASTs ............................................................................................. 49
2.3.8 Controls of the FSTs ............................................................................................ 49
2.3.9 Control of the Return Activated Sludge Pumping Station ................................ 50
2.3.10 Control of the Waste Activated Sludge Pumping Station ................................. 50
2.3.11 Control of the Thickener...................................................................................... 50
2.3.12 Control of the Mechanical Dewatering Station .................................................. 50
2.3.13 Control of the Polymer Dosing ........................................................................... 50
2.3.14 Control of the Thickened Sludge Pumping Station ........................................... 50
2.3.15 Control of the Drainage Pumping Station .......................................................... 51
2.3.16 Control of the Sand Filter Station ....................................................................... 51
2.3.17 Control of the UV Disinfection Station ............................................................... 51
2.3.18 Wash water booster ............................................................................................. 51
2.4 Standby Stationary Diesel Generator ................................................................. 51
2.4.1 Scope of Works .................................................................................................... 51
2.4.2 Innovation............................................................................................................. 51
2.4.3 Electricity Supply ................................................................................................. 52
2.4.4 Configurations ..................................................................................................... 52
2.4.5 Generating Unit .................................................................................................... 52
2.4.6 Ambient Temperature .......................................................................................... 52
2.4.7 Generator.............................................................................................................. 52
2.4.8 Prime Mover ......................................................................................................... 53
2.4.9 Engine Type ......................................................................................................... 53
2.4.10 Engine Mounted Control Panel ........................................................................... 53

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Component 3 Salt WWTP Technical Specifications
Part 4 Electrical Specifications

2.4.11 Engine Governor .................................................................................................. 54

2.4.12 Engine Speed Characteristics............................................................................. 54
2.4.13 Engine Lubrication .............................................................................................. 54
2.4.14 Cooling System .................................................................................................... 55
2.4.15 Jacket Water Expansion Tank............................................................................. 55
2.4.16 Jacket Water Temperature Control Valves......................................................... 55
2.4.17 Engine Starting System ....................................................................................... 55
2.4.18 Engine Heater ....................................................................................................... 55
2.4.19 Generator Set Bedplate ....................................................................................... 55
2.4.20 Spillages ............................................................................................................... 56
2.4.21 Colour ................................................................................................................... 56
2.4.22 Fuel System.......................................................................................................... 56
2.4.23 Exhaust System ................................................................................................... 57
2.4.24 Warning Labels .................................................................................................... 57
2.4.25 Earthing ................................................................................................................ 57
2.4.26 Generator Operating Mode .................................................................................. 58
2.4.27 Generator Control Panel ...................................................................................... 58
2.4.28 Construction Information .................................................................................... 61
2.4.29 Protection relays .................................................................................................. 61
2.5 Lightening Protection and Earthing Systems .................................................... 61
2.5.1 Scope of Works .................................................................................................... 61
2.5.2 Earthing and Lightning Protection Standards ................................................... 61
2.5.3 Earthing systems ................................................................................................. 61
2.5.4 Earth Value ........................................................................................................... 62
2.5.5 Earth Rods............................................................................................................ 62
2.5.6 Earth Pits .............................................................................................................. 62
2.5.7 Earth Conductors................................................................................................. 62
2.5.8 Equipotential Bonding ......................................................................................... 62
2.5.9 Earth Bars............................................................................................................. 62
2.5.10 Lightning Protection ............................................................................................ 63
2.5.11 Acceptance Testing Earthing Systems .............................................................. 63
2.6 Supervisory Control and Data Acquisition (SCADA) System ........................... 63
2.6.1 Scope of Works .................................................................................................... 63
2.6.2 Innovation............................................................................................................. 63
2.6.3 General ................................................................................................................. 63

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Part 4 Electrical Specifications

2.6.4 Functional Requirements .................................................................................... 64

2.6.5 Communication Network ..................................................................................... 64
2.6.6 Electricity Supply ................................................................................................. 64
2.6.7 Hardware .............................................................................................................. 64
2.6.8 Software General ................................................................................................. 65
2.6.9 SCADA Program .................................................................................................. 65
2.6.10 Access Levels ...................................................................................................... 66
2.6.11 Operator Interface ................................................................................................ 66
2.6.12 Configuration ....................................................................................................... 67
2.6.13 Screen Graphics .................................................................................................. 67
2.6.14 Management Reporting ....................................................................................... 68
2.6.15 Graphical Standards: ........................................................................................... 68
2.6.16 Analogue Values .................................................................................................. 69
2.6.17 Alarms .................................................................................................................. 70
2.6.18 Real Time and Historical Trending ..................................................................... 71
2.6.19 PLC Program ........................................................................................................ 71
2.6.20 Software server specifications ........................................................................... 72
2.6.21 Software client specifications ............................................................................. 72
2.6.22 Visualization ......................................................................................................... 72
2.6.23 Historical data ...................................................................................................... 72
2.6.24 Reporting .............................................................................................................. 72
2.6.25 Equipment ............................................................................................................ 73
3 Particular Photovoltaic (PV) Electrical Specifications ................................. 73
3.1 Scope of work ...................................................................................................... 73
3.2 Minimum Guaranteed PV Plant Performance .................................................... 74
3.3 General site description ...................................................................................... 74
3.4 Cable trenches ..................................................................................................... 74
3.5 PV Modules .......................................................................................................... 75
3.6 PV Modules Cleaning Systems ........................................................................... 75
3.7 Technical requirements ....................................................................................... 75
3.8 Technical Due Diligence ...................................................................................... 77
3.9 Installation of PV Modules................................................................................... 77
3.10 Inverters ............................................................................................................... 78
3.10.1 Determination of the inverter .............................................................................. 78
3.11 AC (DC) Combiner boxes .................................................................................... 79

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Part 4 Electrical Specifications

3.12 Monitoring System ............................................................................................... 79

3.13 General requirements .......................................................................................... 79
3.14 Cables ................................................................................................................... 81
3.14.1 General ................................................................................................................. 81
3.14.2 DC cables ............................................................................................................. 82
3.14.3 DC connector type ............................................................................................... 82
3.14.4 AC cables ............................................................................................................. 82
3.14.5 Cable identification .............................................................................................. 83
3.14.6 Cable Arrangement .............................................................................................. 83
3.15 Signal List............................................................................................................. 83
3.16 Transformers........................................................................................................ 83
3.17 Lightning Protection ............................................................................................ 83
3.18 Training Requirements ........................................................................................ 83
3.19 Component Warranties........................................................................................ 84
3.19.1 PV Modules .......................................................................................................... 84
3.19.2 Inverters ............................................................................................................... 85
3.19.3 Other components ............................................................................................... 85
3.20 Yield Analysis ...................................................................................................... 85
3.20.1 Degradation .......................................................................................................... 86
3.21 GUARANTEED PV PLANT PERFORMANCE ...................................................... 86
3.21.1 Key Performance Indicators and Acceptance Procedure ................................. 86
3.21.2 Production ............................................................................................................ 89
3.21.3 Performance Ratio ............................................................................................... 89
3.21.4 Availability ............................................................................................................ 91

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Component 3 Salt WWTP Technical Specifications
Part 4 Electrical Specifications

PART 4: Electrical Specification

1 General Electrical Specification
1.1 Applicability
The following clauses specify general requirements and standards of workmanship for the
equipment and all installations. General specification clauses shall apply where appropriate
except where particularly redefined in the individual specification clauses.
1.2 Installation Standards
The work shall be executed in a neat and workmanlike manner. All work shall be carried out
in accordance with the requirements of:
(a) Regulations in force in Jordan, where applicable;
(b) Relevant BS specifications;
(c) Recommendations issued by the International Electro-Technical Commission IEC:
No. 298 High voltage enclosed switchgear
No. 694 Basic installation level for 11 kV
No. 56 High voltage circuit breakers
No. 60 High voltage test requirements
No. 185/186 Current transformer
No. 694 Common clause
No. 76 Power transformers
No. 129/265/420 Load breaker fuse combination and isolators
No. 502/540 MV cables lying
No. 28A LV creepage distance and clearances
No. 157 LV circuit breakers
No. 158 LV contactors
No. 185 LV current transformers
No. 337 LV auxiliary circuits
No. 439 LV general part
No. 408 LV air breaks switch disconnectors and fuse
No. 144/529 Degree of protection
No. 34-1:14 Rotating Electrical Machines
(e) Where VDE Standards are quoted in these Technical Specifications, equivalent
international Standards may be applied provided the requirements of Clause 1.1 are
fully complied with.
1.3 Main Electricity Supply
The electricity supply will be provided by the Jordanian Electric Power Co JEPCO. The exact
characteristics of the incoming power feeding shall be obtained from the Jordanian Electric
Power Co JEPCO and suitably rated equipment shall be provided.

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Part 4 Electrical Specifications

Generally the electricity supply shall be:

MV 33000 , or 11000 volts 3 phase 50Hz
LV 400 volts 3 phase and neutral 50Hz,
230 volts 1 phase and neutral 50Hz,
1.4 Materials
(1) All materials incorporated in the Works shall be the most suitable for the duty
concerned. All materials shall be new and of first classification commercial quality, free
from imperfections and selected for long life and minimum maintenance.
(2) The use of dissimilar metals in contact shall be avoided, but where unavoidable these
materials shall be selected so that the natural potential between them does not exceed
250 mV. Electroplating or other treatment of contacting surfaces shall be employed as
necessary to reduce the potential difference to the desired limit.
(3) All materials and materials finishes shall be selected for long life under the Site
conditions specified and shall be de-rated by the approved factors given in the latest
issue of the IEC standards and the relevant VDE system or equivalent. Tropical grade
materials and panel components shall be used.
(4) All electrical components shall be of robust construction and de-rated to ensure long
life and trouble-free operation under the extreme site environmental conditions,
selected for minimum maintenance, capable of withstanding and operating under
voltage surge and fluctuation conditions. The minimum de-rating for all electrical
equipment including cables shall be in accordance with the relevant approved national
electrical standards appertaining to the Site climatic and environmental conditions.
1.5 Polarity
(1) The polarity of all apparatus used for the Works specified shall be arranged as follows:
(a) For two poles apparatus the “phase” or “live” pole to the top (or left hand side)
and the “neutral” or “earthed” pole at the bottom (or right hand side). On plug and
socket outlets the polarity shall conform to BS and IEC standards.
(b) For three or four poles apparatus the phases in order, BROWN, BLACK, GREY
and BLUE NEUTRAL reading from top to bottom or left to right in the case of
vertical or horizontal layout respectively.
(2) Layouts are viewed facing the front of the apparatus.
(3) All cables shall be so connected between main switchboards, distribution boards, plant
and accessories so that the correct sequence of phase colours is preserved throughout
the system.
(4) All cable cores shall be identified with phase colours. Where more than one phase is
incorporated on a common system in one room then the live cores shall be BROWN,
BLACK, or GREY as appropriate and fittings and switch accessories shall be
permanently labelled and segregated in accordance with IEC standards No. 502 and
540.
1.6 Workmanship
(1) Particular attention shall be paid to the appearance of all cable runs, the arrangements
of which shall be agreed by the Engineer before the commencement of installation. The
installation shall be completed to the highest standard of neatness with respect to the
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Component 3 Salt WWTP Technical Specifications
Part 4 Electrical Specifications

visible cable runs, the arrangement and alignment of apparatus and fittings. Conduit
shall be surface run with the exception of the control/office room where all fittings shall
be suitable for flush installation.
(2) The positions of all equipment are shown diagrammatically on the Contract Drawings,
but the exact locations shall be agreed with the Engineer before the commencement of
installation.
(3) There shall be included for the fixing of all switches, fuse boards, switchgear, cables,
fit-tings, cable trays, accessories and all other items comprising the electrical
installation.
(4) All holes for fixing shall be made by means of a rotary drill, not of the percussion type,
screws shall be secured with rawl plugs or similar approved devices.
(5) A single shot cartridge tool may be used only at the discretion of the Engineer.
(6) Should the installer propose to use junction boxes in auxiliary control cable circuit for
the purpose of marshalling a number of cables feeding to a common item of equipment
full de-tails shall be given to the Engineer. The installer shall only proceed after receipt
of the written approval of the Engineer. Any such junction boxes shall be of the wall
mounting pattern with double terminals. All cores shall be ferruled and identified in
accordance with the system schematic and cable diagrams.
(7) All electrical installations, other than lighting and socket outlets, mounted externally to
buildings shall be provided with a permanent sun-shade canopy.
1.7 Switchboards and Multi-Motor Control Boards
Switchboards and multi-motor control boards shall comply with the following requirements:

1.7.1 Construction
(1) Distribution switchboards and motor control boards shall consist of a number of
cubicles of equal height and depth mounted side by side to form a composite board of
uniform and pleasing appearance.
(2) The maximum height of any operating control shall not exceed 1,800 mm.
(3) All main cubicles shall be constructed from sheet steel of a minimum thickness of 2mm
and shall be totally enclosed welded construction arranged for wall mounting or floor
fixing with removable back covers and hinged front doors interlocked that the doors can
not be opened when the breaker or starter is in the “ON” position if so specified. All
cubicle doors shall be fitted with chromium plated key operated latches using a
triangular shaped key. The size and weight of any removable cover shall be such that it
can be handled easily by one person. The metal base of the cubicles shall be provided
with removable plates below the cable gland trays. All cubicles shall be dust and
corrosion and damp protected and be fully vermin proofed. The method of vermin
proofing shall be such that additional cables can be added or removed after the initial
installation has been completed. All steel parts shall receive corrosion protection
treatment before painting, except moving parts, which shall be greased. The outside of
the cubicles and the interior of the compartments shall be stove-enamelled to IEC
standard, enclosure protection to IP 54.
(4) Compartments shall be easily accessible for maintenance purposes. Barriers shall be
included between each compartment to contain an internal fault as defined in IEC

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standards to ensure safe maintenance on any outgoing circuit when the remainder of
the board is live.
(5) Cubicles shall not rely on any removable portion for their rigidity.
(6) Boards shall be arranged for ready extension at each end.
(7) Particular specifications shall be as indicated in the Drawing and described hereafter.

1.7.2 Busbars
(1) Busbars and connections shall be identified by phase colour marking and adequately
supported by suitable insulators the whole to be mechanically and electrically designed
to withstand the full fault capacity as specified.
(2) All busbars and connections shall be rated for continuous operation. The mechanical
and dielectric strength of busbars and support shall be capable of withstanding the
worst conditions of electrical surge which can occur in the installation.
(3) Busbars and primary connections shall comply with BS 159 as appropriate and shall be
housed in air insulated enclosures with a time rating compatible with the switchgear.
(4) Busbars shall be of high conductivity tinned copper with PVC sleeving and moulded
PVC shrouds shall be provided over joints.
(5) Bolted copper busbar links shall be provided as necessary to allow a switchboard to be
manufactured in sections. These links shall only be used to allow the transportation
and erection on site of a modular switchboard. The links may also be used as
necessary for maintenance purposes. The link section shall be easily accessible from
the front or top of the board and shall have a lockable cover. Provision for storing the
links, nuts and bolts shall be made in the switchboard.
(6) Busbars for 400v switchboards and MCC’s shall be rated at least 50kA for 3 seconds.

1.7.3 Fuses
(1) All fuses shall be H.R.C. according to IEC 129,265 and 420 and one spare fuse for
each fuse fitted in the panel shall be supplied clipped adjacent to the position in which it
would be in service.
(2) A complete schedule of all fuses in the panel shall be affixed in convenient position in
the panel.
(3) Neutral links shall not be arranged in fuse holders but shall be separately bolted copper
links with one link for each fuse.

1.7.4 Terminals
(1) All terminals for outgoing connections shall be located at a low level in the
compartment adjacent to the cable gland trays.
(2) Provision for accommodation of rising armoured cables shall be provided with
adequate cable supports and a form of cable entry seal either of hardwood or similar
approved material shall be provided.
(3) Space shall be provided to accommodate cable glands of appropriate size for incoming
and outgoing circuits and non-ferrous gland plates shall be supplied where single core
cables are terminated. All glands and trays shall be adequately earthed.

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Component 3 Salt WWTP Technical Specifications
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(4) Cable disconnecting links shall be provided where specified and shall be used for
maintenance purposes only. The links shall be fitted to the busbar risers immediately
before the cable terminations and shall be easily accessible. The links shall be labelled
“ISOLATING LINK” and the circuit or cable reference shall be quoted.

1.7.5 Auxiliary Switches

(1) Auxiliary switches for indication, protection, interlocking and supervisory purposes shall
be readily accessible and enclosed in a transparent dust-proof cover.
(2) Adequate secondary disconnection shall be included between the fixed portion of a
circuit breaker and the moving portion.
(3) Spare auxiliary contacts two normally open and two normally closed shall be provided
on each unit and wired to suitable accessible spare terminals.

1.7.6 Labels
(1) The Contractor shall supply and fit engraved labels to all items of system, etc.
throughout all installations. System reference numbers shall correspond to those used
in the operating and maintenance manuals. Labels shall be white laminated plastic with
engraved black letters and shall have chamfered edges using either stainless steel
nuts and bolts or permanent adhesive. Labels shall be engraved in English. The main
circuit label shall measure 150 x 60 mm. All door mounted instruments and controls
shall have labels of 40 x 15 mm. All devices installed inside the enclosure shall be
labelled.
(2) For electrical panels, switchgear etc. labelling shall be as follows:
(a) All external labels shall be white laminated plastic with engraved black letters in
English and Arabic. Edges shall be chamfered. The labels shall be affixed with
stainless steel nuts and bolts.
(b) All internal labels shall be engraved multi-layered plastic (Traffoloyte or similar)
affixed with stainless steel nuts and bolts.
(c) Each compartment door shall have a title label and each door mounted
component or control shall have a function label.
(d) Every internal component shall be identified and each fuse shall be labelled with
identification of fuse type or fuse current capacity.
(e) Compartments with doors or covers not interlocked at an isolator shall have an
external label affixed thereto as follows:
DANGER - LIVE TERMINALS
with flash and voltage in red letters on white background in English and Arabic.
(3) In addition to the above system identification labels the Contractor shall ensure each
item of machinery shall have manufacturers identification / rating plate detailing in
English the following:
 Manufacturers name and address;
 Model / type identification;
 Serial number;
 Year of manufacture;
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Part 4 Electrical Specifications

 Appropriate rating details;

 Other relevant details, limitations etc.

1.7.7 Panel Earthing

A continuous copper earth bar shall run the length of the switchboard with terminal for
connection to the station earthing system; the cross-sectional area shall be in compliance
with and meet the requirements of IEC publication 364-5-54.

1.7.8 Small Wiring and Terminal Blocks

(1) All switchboards and instrument panels wiring shall be carried out in PVC insulated
cable, in a neat and systematic way and securely fixed and arranged so that access to
the apparatus is not impeded. The minimum wire size shall be of 1.0 mm² cross
sectional area.
(2) All terminal blocks for the connection of small wiring shall comprise shrouded anti-
tracking mouldings of melamine-phenol or comparable material with provision for
securing conductors either by high tensile screws and clamps or alternatively in the
case of small telephone type conductor by solder tag connection. All terminals at
voltages above 110 V shall be fitted with transparent protective covers.
(3) Terminal blocks shall be arranged to facilitate easy access to both terminals and wiring
ends. Connections for outgoing circuits to auxiliary pilot cables shall be provided with
test links.
(4) Identification ferrules or reference numbers shall be fitted on the wires at both ends and
letter and number shall correspond to the appropriate wiring diagram and colour codes
to IEC 445.
(5) Terminations shall be of the latest practice and restricted to no more than two wires per
terminal.

1.7.9 Indicating Lamps

(1) All indicator lamps shall be multiple LED type and shall be low voltage with self
contained transformer or low voltage DC.
(2) Lamps shall be well ventilated and the design shall permit removal of lamp glass and
bulb from the front of the unit.
(3) Indicating lamps shall be supplied by an individually fused circuit.

1.7.10 Cable Connection

(1) A cable termination gland box at least 150 mm above floor level and pointing
downwards shall be provided for each circuit except where otherwise indicated.
(2) Where single core cables are to be accommodated a non-magnetic gland plate shall be
provided. with fit cables glands.
(3) The individual terminals shall be provided with pressure type cable lugs of ample size
and connected to the current carrying elements by means of corrosion resistant bolts
nuts and washers.
(4) Where cables are metal sheathed or armoured the sheathing and/or armouring shall
also be earthed at the end box.

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(5) Un-drilled gland plates shall be provided approximately 300 mm above floor level for
the reception of conduits and threaded glands. Boxes and glands shall be within the
cubicles except where otherwise approved.
(6) Prior to manufacture the Contractor shall confirm cabling termination requirements with
the Engineer.

1.7.11 Instruments
(1) All indicating instruments shall be of 90o scale type flush mounted and generally of the
same appearance throughout. They shall comply with IEC recommendation and be of
industrial grade accuracy. Instruments shall be hermetically sealed or tropicalised.
Instruments shall have external zero adjustment and have black bezels. They shall be
positioned such that they can be easily read and the dial centres shall be not less than
400mm and not more than 1800 mm above finished floor level. Meters shall be fitted
with an adjustable pointer or shall be inscribed on the scales to indicate the normal
circuit rating for the associated plant.
(2) Instruments shall have a square front appearance with width dimensions as follows:
72 mm Ammeters up to (1.2 x Full load current) A, voltmeters up to 600 V
96 mm All other instruments
(3) Ammeters fitted in a motor circuit shall have a suppressed scale to indicate the
maximum starting current.
(4) Kilowatt hours meters shall be arranged to register 3 phase 4 wire unbalanced loads
except as otherwise indicated.
(5) All instruments shall be mounted adjacent to the relevant circuit breaker switch or
starter unless separate panel suites are specified herein.
(6) At points of connection of potential circuits to LV busbars etc., HRC fuses shall be
provided to protect the auxiliary wiring. For cubical gear these fuses shall be housed
inside and readily accessible. Additional fuses to clear individual instrument faults shall
be provided and accessible from the front of the cubical where otherwise specified.
1.8 Current Transformers
(1) Current transformers shall comply with IEC 185 and should be suitably rated and de-
signed to carry out the desired appropriate function - viz. metering or protection.
(2) The short time current rating should not be less than 3 seconds.
(3) Identification labels giving type, ratios, accuracy limit factor, rating output and serial
numbers shall be fitted.
(4) Duplicate rating labels are to be fitted on the exterior of the mounting chambers
suitably located to enable reading without removal of any cover. Labels shall be
supplied for multi-ratio current transformers indicating the connection required for
alternative ratios.
(5) Bar type current transformers shall be supplied in preference to those with wound
primaries. Short time current factors shall relate to the full fault level for three seconds.
For over-current protection the product of VA rated burden and rated accuracy limit
factor shall be less than 150 unless otherwise agreed with the Engineer.
(6) One secondary terminal of each current transformer shall be earthed through a
removable link at the switchgear.
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1.8.1 Voltage Transformers

(1) Voltage transformers shall be of the isolatable type with a secondary three phase
voltage of 110 Volts and shall comply with IEC 186.
(2) Epoxy resin insulated shall be acceptable.
(3) The primary shall be protected by HRC fuses which together with the connection
between the fuses and the primary conductors shall be adequately rated to withstand
the short circuit rating of the switchgear.
(4) Fuses shall be included to protect the secondary windings and they shall have safe
access for renewal.
(5) Safety shutters shall be provided to automatically cover the fixed contacts when the
trans-former is isolated. Shutters shall be coloured yellow when isolating contacts are
connected to the feeder side of the circuit and inscribed CIRCUIT.

1.8.2 Safety Notice and Equipment

For each switchboard the Contractor shall supply the following equipment which shall comply
with IEC standards No. 694 and 349:
1No. Electrical grade rubber mat 1000m wide extending the full length of the
switchboard
1No. Pair of electrical grade rubber gloves
1No. Notice in English and Arabic advising treatment for a person suffering from
electric shock
1.9 Circuit Breakers
1.9.1 Air Break Circuit Breakers
(1) The air break circuit breakers shall comply with the following and be suitable for
control-ling loads, the site climatic conditions and comply with IEC 157 for 400 V, 3-
phase, 50 Hz wire operation for use on the breaking capacity of the fault current in
accordance to the short circuit calculation for the fault level for each system. ASTA or
KEMA test certificates shall be forwarded with the quotation. Moulded Case Circuit
Breakers (MCCB) will not be accepted for use where Air Circuit Breakers (ACB) are
specified. Contractors shall include with their offer a schedule showing circuit breakers
and their respective loads.
(2) The circuit breakers should be horizontally isolated draw-out pattern air break type
complete with operating mechanism for closing by 48 Volt DC motor and manual
operated and the circuit breaker operation when in the isolated and withdrawn position
shall be provided, auxiliary jumper connections being included if necessary.
(3) Locking by means of padlock or removable key in the open position shall be possible.
(4) The operating mechanism shall have a mechanical “ON/OFF” indicator and a manual
trip device fitted with means for locking test terminal blocks healthy trip lamp (coloured
white) and associated pushbuttons set of auxiliary switches “SUPPLY AVAILABLE”
lamps (blue) (on incoming units only) cable boxes complete with glands of suitable size
for the accommodation of the incoming and outgoing cables entering from below.
(5) Each circuit breaker shall be provided with an operation counter.

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(6) Closing and tripping batteries shall comply with these Specifications.
(7) Auxiliary contacts for the indication of breaker state for use at 230V AC shall be
provided.
(8) Slow closing of the circuit breakers to facilitate maintenance and contact adjustment
shall be provided. This operation shall be possible only with circuit breaker in the fully
withdrawn position. Any necessary handle or lever shall be included in the schedule of
spare parts.
(9) All circuit breakers shall be provided with interlocks to ensure that:
(a) Circuit breakers can not be plugged in or isolated when it is closed.
(b) The Circuit breaker can not be closed until it is fully plugged in or completely
isolated.
(c) The Circuit breaker can not be closed in the service position without completing
the auxiliary circuit between the fixed and moving positions.
(d) With the circuit breaker earthing device in position tripping may only be effected
by a manual device in the operating mechanism.
(10) The following flush mounting equipment shall be fitted to the front of each of incoming
circuit breaker panel (both mains and standby):
1 No. Under voltage relay
1 No. Phase sequence relay
1 No. Triple pole flush mounted over-current relay arranged for two poles over-
current and one pole earth protection with auxiliary relay for instantaneous
remote trip and indication.
1 No. Voltmeter (0-500V) with selector switch for phase/phase, phase/neutral and off
positions fitted to line side of incomer.
1 No. Kilowatt hour integrating meter
1 No. Kilovar integrating meter
1 No. Kilowatt meter
1 No. Pilot lamp of the transformer type with protection fuses, colour blue, for
“SUPPLY AVAILABLE” when illuminated.
1 No. Pilot lamp with protection fuses, colour white, for “Trip Circuit Healthy” when
illuminated.
1 No. Set of Test Blocks for C.T’s and P.T’s.
NOTE: Interlocks are required between mains, incomers and standby incomers such
that it shall be impossible to have both closed at the same time (except in the
with-drawn position). These shall be arranged such that all permissive and all
prohibitive signals are present before a circuit breaker may be closed.
(11) Any other interlocking shall be provided as necessary to ensure the safe operation and
maintenance of all electrical equipment provided under the Contract.
(12) Individual shutters which automatically operate as the truck is racked in and out, shall
be provided for busbar and circuit spouts. When closed the shutter shall effectively
prevent any contact with either the bus bar or circuit connections and also seal the
spouts against the ingress of dust. The shutters are to be coloured and painted in bold
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characters with BUS BARS (red) or CIRCUIT (yellow) as appropriate in English.

Provision shall be made to lock each shutter in the closed position.
(13) All low voltage circuit breakers shall be housed in control boards which comply with the
requirements of this specification.
(14) The height of any controls shall not exceed 1,800 mm.
(15) There shall be a purpose designed separate attachment earthing device. The device
shall be arranged to earth either the cable box or busbar side of the circuit breaker and
shall be stored in a suitable robust container which shall include details of assembly
and use.
(16) To facilitate the removal of circuit breaker for maintenance there shall be supplied, if
necessary, a purpose designed hand operated trolley.

1.9.2 Moulded Case Circuit Breakers

(1) The enclosure shall be so constructed that the cover cannot be opened until the switch
is fully opened and the construction shall be such that when the cover is opened a
competent examiner can override the interlock and operate the switch. After such
operation the cover shall be prevented from closing with the switch position indicator in
a false position.
(2) Switch shall be provided with mechanical “ON/OFF” indicators and operating handles.
(3) Means shall be provided for locking the switch in the “OFF” position only.
(4) Unless otherwise indicated, circuit breakers shall be manually operated and shall
provide thermal-magnetic, inverse-time-limit overload, and instantaneous, short circuit
protection.
(5) Breakers shall be moulded case type, rated 400 Volts, 2 or 3 pole and have 100 A or
larger frames. The minimum interrupting rating shall be 30.kA symmetrical at 400 Volts.
(6) The breakers shall be supplied with the following overload and short circuit rating as
follows:
(a) 100 A frame: Fixed long time and instantaneous ampere setting
(b) 225 A frame: Interchangeable long time and adjustable instantaneous
ampere setting
(c) 400 A frame: Interchangeable long time adjustable instantaneous fault
ampere setting
(d) 600 / 800 A frame: Interchangeable adjustable solid state trip
a. Long time ampere
b. Long time delay
c. Instantaneous ampere
d. Ground fault ampere
e. Ground fault ampere
(e) 1,500 A frame Interchangeable adjustable solid state trip
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and above: a. Long time ampere

b. Long time delay
c. Instantaneous ampere
d. Ground fault ampere
e. Ground fault ampere
(7) The solid state trip circuit breakers shall be supplied with a portable testing unit to allow
for periodic trip setting testing.
(8) Time current characteristic curves and other necessary information and data for each
size of breaker furnished shall be provided. Where M.C.C.B. are used for feeding they
shall be equipped with the same instruments as described for air circuit breaker.

1.10 Fuse Switches General

Fuse switches shall comprise flush mounted heavy duty composite air break switches and
fuse units complying with IEC 439 and shall be rated and equipped as detailed. Composite
units shall be contained within an enclosure of metal and shall be fitted with an earthing
terminal irrespective of any means or connections such as is provided for attaching
armouring or other metallic covering of the cable supplying the composite unit.

1.10.1 Enclosure
(1) The enclosure shall be so constructed that the cover can not be opened until the switch
is fully opened and the construction shall be such that when the cover is opened a
competent examiner can override the interlock and operate the switch. After such
operation the cover shall be prevented from closing with the switch position indicator in
a false position.
(2) Switch shall be provided with mechanical “ON/OFF” indicators and operating handles.
(3) Means shall be provided for locking the switch in the “OFF” position only.

1.10.2 Fuses
(1) The fuse shall either include a suitable fuse carrier or it shall be capable of isolation. If
the fuse carrier is included it shall be such that when it is being withdrawn normally or
when it is completely withdrawn the operator is completely protected from accidental
contact with any live metal of its fuse link, fuse contacts and fixed contacts.
(2) If the fuse is capable of isolation it shall be so interlocked with the switch that isolation
is complete before the fuse enclosure can be opened, further the switch shall be
prevented from closing while the fuse-cover is open.
1.11 Isolating Switches
The compartment isolating switch shall interrupt all supplies into the compartment to enable
safe maintenance to be undertaken. Isolators shall be of the fault break load make design.
Isolators shall have metal handles and a facility shall be provided to enable the isolator to be
padlocked in the “OFF” position only. One padlock with 4 keys shall be supplied for each
isolator on the board.

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1.12 Fuses and Links

(1) All fuses shall be of the HRC cartridge pattern to IEC 439 and suitable for site climatic
conditions.
(2) Fuse holders and fittings shall be made of moulded plastic insulating material of an ap-
proved make. Ceramic materials will not be accepted. Fuse fittings shall be fully
shrouded and it shall be possible to change the fuses without danger of contact with
live metal. For every fuse in service a spare shall be provided, clipped local to the duty
unit.
(3) When incorporated in distribution boards fuse fittings shall have basic sizes 16, 32, 63,
100 and 200 A, and the fuse holders shall be able to accept fuse links of that rating or
any BS rating down to the next basic size.
(4) HRC fuse cartridges, where used in distribution boards, shall be manufactured in
accordance with IEC 129, 265, 420 and 439.
(5) Fuses and links in the same circuit shall be mounted above each other in separate
rows and shall not alternate in the same row.
1.13 Motor Starters General
(1) The starter cubicles as required are to form part of a Motor Control Centre and as such
circuit connections protection devices and the like shall comply with the installation
standard specified. The cubicles shall be easily accessible for maintenance purposes
and shall be damp, dust and corrosion-proof. The motor starter shall be of rating to
carry the full load current of its rated duty at its most severe load conditions. All starters
shall be capable of at least 15 starts per hour at 100 percent full load torque. motor
starters shall be of the Direct on Line (DOL), star delta , Soft starter , or variable speed
drive type. The motor starter shall be of rating to carry the full load current of its rated
duty at its most severe load conditions.
(2) The following equipment shall be mounted on the front of control panel:
1 No. Ammeter fitted with suppressed scale to read motor running and starting
current.
1 No. Pilot lamps to indicate “SUPPLY ON” (green) and “MOTOR RUNNING” (red).
1 No. Pilot lamp to indicate “MOTOR FAILED” (amber).
1 No. “MANUAL/OFF/AUTO” selector switch.
1 set “START/STOP” push button.
1 No. Externally operated overload reset push button.
1 No. Motor and cubicle heater “OFF/AUTO” control switch.
1 No. Hour counter reading to 9999 hours.
1 No. Duty label.
(3) In view of the fact that overload indication of all drives may be required each starter
should be designed for this purpose.
(4) The signal for this remote indication will be taken via auxiliary contact fitted to the
isolators and contactors or relay of the individual starters.

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(5) The motors in some groups will be required to operate in a predetermined sequence
and starters should include suitable auxiliary relays and contacts.
(6) All starters shall contain a totally enclosed dustproof timer or the operation will be con-
trolled by a timer in the automatic section which shall have multiple contacts and also
be to-tally enclosed dustproof which shall prevent pump(s) starting after a power failure
until after a prudent time has elapsed. The timer(s) or contact shall be adjustable in the
range 50 percent to 200 percent of the anticipated maximum delay which shall be
taken as twice the total time required for all pumps to start and run steadily having
been started consecutively. The timer(s) or contacts shall be set to give individual
sequential start after a power failure with no drive starting until its predecessor has
reached full steady running.
1.14 Interlocking
(1) Mechanical interlocking shall be provided where possible. All electrical interlocking
shall be of the double type having separate permissive and prohibitive interlocks. Thus
to allow a device to operate there must be an absence of prohibitive signals and a
presence of permissive signals from the remaining devices in the interlocked system.
(2) Suitable equipment shall be provided mechanically to prevent a device being manually
operated when a prohibitive signal from another part of the interlocked system is
present.
1.15 Protection
(1) All protective relays shall conform to the latest edition of IEC Standard 157-1 and be
suit-able for the climatic site conditions fully sealed against ingress of moisture, or dirt
and tropicalised.
(2) The relay shall have automatic thermal compensation for variation in the temperature
between 0 to 55°C.
(3) All protective relays shall be supplied in flush mounted metal cases with glass
windows.
(4) Relays shall be mounted on a withdrawable chassis with plug-in facilities.
(5) Each individual element of the relay shall initiate a flag to indicate that the element has
operated. The element and flag shall be reset by operating an external reset button
mounted on the front of the relay case.
1.16 Motor Protection
For all motors up to 75 kW three single pole wound magnetic adjustable overloads high set
for starting and stalling protection and three single pole thermal overloads for overload and
single phasing prevention shall be provided.

1.16.1 Protection Relays

(1) Protection relays shall alternatively be accommodated in the housing of the circuit
breakers for protection of their downstream line sections against various kinds of fault.
(2) The Contractor shall in any case provide suitable back-up protection for short-circuit re-
lays and earth-fault relays by proper time setting of successively arranged relays and
their mutually inter-connected controls so that in case of a fault in any section of the
400 V grid only the faulty section will be disconnected, whereas all healthy parts of the

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grid will remain in operation. Subsequently relay setting schemes shall be furnished by
the Contractor for approval by the Engineer.
(3) The following relays and associated current transformers shall be applied for all 400 V
circuit breakers to be installed.
(a) Overload or overcurrent relays with either an inverse time delay overcurrent re-
lease or a definite time delay overcurrent release whichever type is more suitable
and interconnected to it.
(b) Short-circuit relay with instantaneous overcurrent release.
(c) Earth-fault relay or earth leakage relay with a three phase sum current trans-
former acting on a response current from 0.2 to 0.7 times the rated current which
can be set in several steps. The delay time of the release shall also be variable in
several steps between 100 and 500 millisec in order to attain the above
mentioned back-up protection.
(d) Undervoltage relays shall be installed only in circuit breakers used for feeders of
large motors in order to avoid automatic restarting of motors after voltage
recovery following a power failure.
(4) All relays shall be equipped with respective fault communicators and indicators for
audible and visible fault indication in the control room. A fault panel shall be part of the
supply. Connection works shall be included.
(5) Auxiliary switches to be actuated by the operating mechanism shall be available in
sufficient quantities to cover all control, indication, operation and protection
requirements.
(6) The Contractor shall submit circuit diagrams of all main, control and protection-circuits
of the circuit breakers to be used.

1.16.2 Electric Motors General

(1) Motors shall be selected from the following to satisfy the Contractor’s requirement and
comply with the Local Electricity Authority power current restrictions:
(2) All motor frames shall be Totally Enclosed Fan Cooled (TEFC) and shall be protected
so as to exclude the ingress of falling dirt or moisture conforming to a degree of
protection not less than IP 55.
(3) In addition, all outdoor motors shall be provided with suitable covers to protect them
from direct sunlight.
(4) All motors shall be provided with the windings being connected to 6 terminal
arrangements in the terminal box to allow either DOL starting or a method of assisted
start.
(5) Motors up to 37 kW shall suitable for DOL starting having a starting current not greater
than 7 x full load current (FLC).
(6) Unless specified elsewhere, motors above 37 kW shall have their starting current
restricted to 2.5 x FLC and shall use one of the following starting methods:
 Solid State Reduced Voltage (Soft) Start.
 Variable speed (frequency) drive.

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(7) Submersible pump motors because of inherent design are to generally comply with the
foregoing.
(8) Centrifugal pumps on unscreened sewage shall give at least 100% full load torque on
starting.
(9) All motors shall be suitable for operation on a 400 V, 50 Hz, 3 phase supply.
(10) All motor enclosures shall satisfy and be selected from:
 IP55 for general purpose drives and for outdoor or machines subject to splashing
or washing down
 IP68 for submersible machines
(11) The motors shall run in ball and/or roller bearings and the weight of the motor shall be
carried by thrust bearings incorporated in the motor body.
(12) The efficiency and power factor of the motors shall be high over a wide range of load
conditions and the motors shall be designed, manufactured and tested in accordance
with IEC 34 for continuously rated industrial electric motors with Class F insulation but
limited to Class B temperature rise. The maximum continuous rating (MCR) of each
motor shall be as set out below and shall be rated and designed for operation in
ambient temperatures up to 45°C and capable of prolonged operation in sand laden
atmospheres.

MCR RATINGS
Application Up to 75 kW drive Above 75 kW drive
All pump motors 10% above that 5% above that
(excluding positive required under all required under all
displacement type) conditions of conditions of
operation operation
NOTE:
(a) The reserve power requirements shall be added to the calculated power prior to any other
adjustments, e.g. high ambient temperatures at site.
(b) All motors shall have Classification “F” insulation but Classification “B” temperature rise limitations
shall apply. It should be noted, however, that this requirement is in addition to any adjustments
necessary for high ambient temperatures at site.

(13) All motors shall be capable of starting 15 times per hour.

(14) The motors shall be commercially silent in operation and run free from vibration and the
rotors shall be perfectly balanced both statically and dynamically and shall be tested
and adjusted for dynamic balance in an approved manner.
(15) Terminal boxes shall be provided with glands suitable for XLPE or PVC armoured
cable. The motor stool base where appropriate shall be drilled at works vertically blew
the terminal box gland for the passage of the cables and the edges of the hole slightly
countersunk or the hole bushed.
(16) Electric motors shall be fitted with anti-condensation heaters embedded in the motor
windings and the terminal boxes shall be labelled with “Traffolyte” type labels white
letters on red back-ground, to read in English:
WARNING LIVE HEATER TERMINALS - ISOLATE BEFORE REMOVING COVER
(17) All motor drives shall be labelled to correspond with their respective starters.
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(18) All submersible pump motors shall be provided with slot temperature detection
(resistance thermometers) embedded in each phase of the stator winding, the leads of
which shall be brought to the terminal box.
(19) Out of these measurements, at least one maximum temperature contact shall be
derived either thermostatically or electronically and this thermal contact shall give alarm
and or trip its associated motor starter circuit breaker when the motor winding
temperature reaches its maximum allowable value.
(20) Motors with sleeve bearings shall be fitted with one dial type thermometer on each
bearing for local control and either thermo-couple or resistance thermometer for remote
indication, with oil level indicators marked for running and stand-still., oil flow indicators.
(21) Arrangements shall be made with the manufacturer so that the Engineer may witness
tests.
1.17 Reactive Power Compensation
(1) A "capacitor bank" for central reactive power compensation according to IEC
publication No. 70 shall be incorporated in each switchboard or MCC. The capacitor
bank shall consist of a definite number of parallel operated 400 V capacitors and their
associated feeders of individual fuse switch combinations.
(2) All this equipment shall be readily mounted inside suitable 400 V panels and shall be
connected ready for operation.
(3) Individual capacitor banks shall not exceed 150kVAr in rating. If a larger capacity
capacitor bank is required it shall comprise a number of banks of equal rating, each
bank not exceeding 150kVAr in rating.
(3) The power factor correction shall be permanently connected in circuit via the
associated fuse switch and shall be such as to keep the power factor to a figure not
more than 0.97 lagging.
(4) When dimensioning the total capacitance, as well as the number of parallel operated
capacitors, a design analysis shall be carried out based on the actual power factors of
motors as given by the manufacturer.
(5) Over compensation, i.e. self-excitation of the circuits shall be avoided in all cases.
1.18 Distribution Boards
(1) All distribution boards shall be of the totally enclosed metal clad pattern manufactured
in accordance with IEC standard publication No 28A5, 157,158,185,337,439,144 and
529.
(2) Fuses, MCB’s and MCCB’s as incorporated in distribution boards shall comply with the
relevant IEC standard and be fitted with thermal overload and instantaneous magnetic
short circuit protection. Earth leakage protection, when specified, shall be current
operated.
(3) The enclosure shall be made from zinc coated mild sheet steel formed to a clean line
and complete with a lockable hinged cover with gasket. Covers shall be fitted with
gaskets and shall be easily removable to preserve the finish and simplify installation.
Each distribution board shall be arranged for top and bottom cable entry and shall be
provided with an ample cable termination plate and chamber to enable cables to be
neatly glanded with tails grouped and terminated onto appropriate internal terminations.

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(4) Distribution boards shall be wall or floor mounted and shall incorporate load break fault
make incoming isolators which shall be front of panel operated with “ON/OFF” indicator
and capable of being padlocked in the “OFF” position. Distribution boards shall
incorporate HRC cartridge fuses or combinations of single pole and neutral and triple
pole miniature circuit breakers (MCB) as specified. For DC circuits and power outlets
double pole shall be used.
(5) Each bank of MCB/fuses shall be clearly identified with its appropriate phase colour
code and the mounting framework for the banks of MCB/fuses shall be easily
removable to simplify installation. Adequate phase barriers and shields shall be fitted to
ensure that after installation and wiring, all bare terminals and wires are covered to
prevent accidental contact with live conductors during the normal procedure of fuse
changing and resetting of MCB.
(6) All fuse distribution boards shall be complete with HRC fuse cartridges manufactured in
accordance with IEC standards with fusing factor of 1.5 to afford ‘close’ overcurrent
protection to circuits as defined in the IEC No. 408.
(7) All neutral bars shall have a separate terminal for each fuse / MCB way within the
distribution boards.
(8) The termination of circuit cables at distribution boards shall be neat and slack left at
each fuse / MCB bank or neutral bar to enable the complete assembly to be removed
for inspection without disconnection. Neutral conductors shall be connected to the bar
in the same order as the phase conductor to the fuse / MCB way.
(9) Each distribution board shall be complete with a permanent circuit identification chart
preferably mounted within the front door. This chart shall be permanently and legibly
filled in as circuits are completed the circuit description including the fuse mcb rating.
The chart shall be in English.
1.19 Remote Control Push Button Station
(1) Adjacent to all motors and in the positions specified there shall be supplied, installed
and mounted on a suitable structure, a metal, weatherproof, heavy duty remote control
station.
(2) The support structure shall be a robust floor mounted mild steel hot dip galvanised
structure, comprising a tube mounted to a base plate with a mounting plate for the
remote controls positioned 1500mm above floor level. The base plate shall be
designed for bolting down to a concrete foundation and the tube shall provide the
conduit for the control cables from ground level to the position of the remote controls.
(3) Each control station shall have an Emergency stop push button actuator of the auto
latch-turn to release type. The actuator head shall be red, mushroom shaped and
clearly labelled STOP in English. The Emergency stop button shall work in all modes of
control.
(4) Each control station shall have two, 2 position, rotary switch units. One switch unit shall
effect the manual operation of the associated drive and shall be labelled START and
STOP. The other switch unit shall effect the selection of automatic or manual control
and shall be labelled AUTO and MANUAL. In auto the function of the local start stop
switch shall be disabled.
(5) It is the responsibility of the Contractor to ensure that the pushbutton stations provided
are all from the same manufacturer.

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1.20 Cables
(1) All cables shall comply with the requirements of the relevant BS/VDE standard for the
type of cable supplied.
(2) All cables shall be of a suitable voltage grade and stranded copper cored.
Manufacturer’s test certificates shall be submitted for all armoured cables 600/1000 V
and above to the Engineer, before the cables are despatched.
(3) The Contractor shall ensure that each cable is of sufficient rating for its normal and
fault conditions. To assess the rating and cross section required for each cable the
following factors shall be considered:
 Fault level
 Conditions of ambient temperature relevant to method of laying
 Voltage drop
 Voltage drop in motor circuits due to starting
 Overcurrent settings of circuit breakers
 Disposition of cabling whether in air ducts or ground
(4) The Contractor shall state the cable sizes in his quotation. The cable sizes are to be
approved by the Engineer before ordering. Cable rating shall be calculated in
accordance with VDE 0271 and IEC standards 502 and 228.
(5) The selection of cables shall be based on the following conditions:
 Ground temperature 25°C
 Air temperature 35°C
 Thermal Resistivity 4.2.5°C m/w
 For PVC insulated cables, circuit protection will normally be “Close” with fusing or
tripping at 1.5 times the cable rating within 4 hours.
(6) The Contractor shall prepare Technical Schedules showing all principal power and
control cables/wires to be supplied. All such cables and wires shall be numbered in the
Schedule, the same reference numbers being used in the contract drawings and
Specification. The following data shall be included for all cables in the schedule:
 Cable identification number
 Route from/to
 Type of cable
 Derating factor used
 Cross sectional area (mm2)
 Length (meters)
 No. of cores (excluding earth conductor)
 Number of spare cores
(7) All cables necessary for the complete operational installation shall be included.

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(8) The Contractor shall be responsible for measuring from the contract drawings the
length of cables required. The cable size are to be approved by the Engineer before
ordering.
(9) Each cable shall be supplied in a suitable length and be continuous through its run.
Through joints will not be permitted without written permission from the Engineer.
(10) The earthing conductor shall be of adequate cross sectional area and shall either be
one core of a multicore cable or on a separately run single core cable. The use of cable
armouring, conduit, water or other service pipes in any part of the earth continuity
conductor is strictly prohibited.
(11) The Contractor shall supply and install all necessary cable glands and sealing boxes
required to complete the installation. All materials used in the manufacture of the
glands etc. shall have no deleterious effect on the cable core or armouring and shall be
non-corrodible.
1.21 Plastic Insulated Wire-armoured Cable (PVC SWA PVC)
(1) Thermoplastic insulated cables shall be Cross linked Polythene (XLPE) type and
comply with VDE 0271 and IEC 502 and IEC 228 class 1 and 2 respectively. They shall
be 600/1000 V and comprise of stranded copper conductor, XLPE insulation, suitable
bedding, steel wire armoured and PVC sheath.
(2) The cables shall be of approved manufacture.
(3) Aluminium armour shall be provided on single core cables.
(4) All such cables shall be terminated with mechanical glands in accordance with IEC
standards 502 and 540 which shall be of a type to provide adequate mechanical
support by locking on the armour and shall at the same time give high earth continuity.
1.22 PVC Insulated Cables
PVC insulated cables shall comply with VDE 0271 and IEC 228 class 1 and 2 and IEC 502
and shall be 600/1000V grade. The cable used shall not be less than 1.5 mm 2 cross
sectional area.
1.23 Building Services Wiring
(1) In general wiring for plant machinery shall be carried out in XLPE SWA PVC while the
building services shall be executed in PVC cable enclosed in heavy gauge screwed
galvanised conduit. The minimum copper conductor size used shall not be less than
1.5 m2. The use of junction boxes between fittings shall be kept to a minimum and
where practicable all connections shall be made at the fitting. When used, junction
boxes shall be rectangular pattern and where possible their position shall be hidden
from immediate view but not made inaccessible. Circuit wiring shall not be connected
directly on to the terminals of lighting fittings but shall made off in point boxes
consisting of standard BESA box containing shrouded pinch screw connectors to which
connections shall be made to the light fittings by flexible cables.
(2) The Contractor must ensure that the installation is installed so that not more than one
phase shall occur at switch lighting of power outlets where these outlets are less than
2.5 m apart unless guarded by a wall partition or other barrier. If this is impracticable
the Contractor shall obtain the advice of the Engineer before proceeding.
(3) The scheme of wiring shall conform to the colour code requirements of the IEC
Regulations.
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(4) A minimum length of 250 mm tails shall be left on all cables at outlet positions for
connection of the lighting fittings or other apparatus fed by the outlet.
(5) The installation of multi-core and single core cables or bunching of cables in conduit is
to be carried out on the assumption that such cables will carry alternating current.
(6) The excessive bunching of small cables in large conduits will not be permitted and the
Contractor shall not exceed the requirements of the regulations.
(7) The Contractor shall include for terminating each cable in excess of 30A current
carrying capacity in a pressure operated mechanically crimped leg terminal or terminal
socket.
1.24 Cable Installations
The electrical works shall include all cables and wiring necessary for the equipment including
supply and installation of cables and accessories, e.g. fastenings and mountings, screw
connections, cable lugs etc.
Power cables shall be separate from control and measuring cables.
Non-corroding materials shall be used exclusively. All cables shall be marked permanently
on both ends and at all separating and measuring points by way of durable marker labels.
The shielding of measuring and control cables shall be separately and adequately grounded
at the switch box.
Cable laying shall be effected by way of cable tray on walls and ceilings and ducts and
trenches in the floor or ground, duly executed in orderly fashion and sufficiently spaced
(especially power cables) in order to provide adequate ventilation. All cable tray installation
techniques shall not be used in excess of 60 % of their capacity.
On all cable trays, power transmission cables shall be installed in single layers, signal,
measuring and control cables may be installed in multiple layers. Separate cable trays shall
be provided for power cables and measuring and control cables. Accumulations and
crossings of cables shall be avoided.
The Contractor shall install standardised components only. Certificates of type acceptance
test shall be presented. Fastenings of all kinds shall be effected by way of wall plugs, dowels
etc. according to the building authorities' regulations. All fixings and fastenings shall be
stainless steel.
Where there is a possibility of aggressive substances (solvents), cables shall be designed
and/or protected accordingly (solvent-resistant). Also, areas of high ambient temperatures
shall be duly taken into account when choosing cables and wires.
Adequate measures shall be taken in design and construction to prevent water from entering
dry chambers through empty ducts.
Each cable duct shall be equipped with a 4 mm polypropylene pull rope. Where cable routes
pass through building walls or floors, suitable arrangements shall be provided to make good
the aperture when the cables have been installed.
1.25 Cabling Methods
(1) Every cable shall be installed in accordance with the relevant IEC Standards
Specification.
(2) Every cable shall be neatly run vertically, horizontally or parallel to adjacent walls,
beams or structural members.

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(3) Suitable screens shall be provided to protect the cables, run on the external surface of
structures or above ground level, from the effect of the sun’s radiation. All screens used
to protect the cable shall be of an approved design, securely fixed to the structure or
ground and be fully ventilated.
(4) Where cables are terminated at a particular item of equipment care should 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) All necessary materials for cable jointing and junction boxes required to complete the
installation shall be included. Cable ends shall be sealed in suitable chambers bolted to
terminals of circuit breakers and other equipment. Every cable shall be supported
where necessary by an approved method. All cable glands shall have a non-corrodible
finish and shall be supplied complete with PVC shroud.
(6) XLPE insulated cables shall be terminated in mechanical glands in accordance with
IEC standards No. 502 and 540, which shall be of a type to provide adequate
mechanical support by locking on the armour and give good earth continuity.
(7) Paper insulated cables with lead or lead alloy sheath shall be terminated in a suitable
wiping gland.
(8) All cable conductors shall be terminated in a suitable copper lug.
(9) Paper insulated cables shall only be joined or terminated by staff fully qualified to work
on this classification of cable. Before proceeding with the joint or termination the ability
of the staff employed on the work shall be demonstrated on site by making trial joints to
the satisfaction of the Engineer.
(10) Where cables enter or leave buildings the ducts shall be sealed at the points of entry
into the building. Caulking shall be carried out in fiberglass followed by not less than 40
mm of bitumen compound or a weak sand/cement mixture as directed by the Engineer.
Care must be taken to ensure that the PVC sheathing of cables is not damaged during
caulking due to excessive temperature if heated bituminous compound is employed.
(11) Wherever it is necessary to remove the PVC sheath of a cable e.g. at a joint, the mini-
mum length necessary shall be removed and the exposed copper conductor, sheath or
armouring shall be adequately covered by a PVC tape or sleeve or other suitable
means.
(12) All cables shall be delivered on robust cable drums with cable ends treated to form an
effective seal. When a cable is cut from a drum the cable end left on the drum shall be
immediately sealed in an approved manner to prevent the ingress of moisture. All
cables once they have been cut shall be either terminated in their final position
immediately or effectively sealed, paper insulated lead sheathed cables by sweating,
thermoplastic by taping in an approved manner.
(13) Every cable shall be permanently identified at each end by its cable number. Cable
markers shall be of adequate size and of a style approved by the Engineer. Cable
markers shall be securely fixed to the cable.
(14) Cable route marker posts shall also be installed at entry and exit points of buried ducts,
exits from buildings (if necessary wall mounted) and in such other position as are
necessary to identify and trace the route of any cable. All power cables shall be
connected to the main switchboard and other items of plant so that the correct phase
sequence and phase colour coding are preserved throughout the system. All such
cables shall be identified with phase colours for 3 and 4 wire systems and blue and

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Part 4 Electrical Specifications

brown for single phase. On rotating plant where to achieve the required direction of
appropriately identified terminals then special core ferrules shall be fitted to identify
each core with the terminal to which it is finally connected.
(15) Control and instrument cables shall have individual cores identified by means of
suitable permanent ferrules bearing the same numbers or letters at both ends and
corresponding with terminals on equipment. Core identification shall be shown on the
wiring diagrams of the equipment at which the change is made.
(16) Numbering shall read from the terminals outwards on all cores. At those points of inter-
connection between wiring where a change of number can not be avoided, double
ferrules shall be provided on each wire. The change of numbering shall be shown on
the wiring diagrams of the equipment at which the change is made.
(17) If it is proposed to use junction boxes in auxiliary control cable circuits for the purpose
of marshalling a number of cables feeding to a common item of equipment full details
shall be given to the Engineer and he shall only proceed after receipt of the Engineer's
written approval. Any such junction box shall be the wall mounting pattern with double
terminal with cores ferruled and identified in accordance with the system schematic and
cable diagrams.
1.26 Cable Trench Work
(1) The Contractor shall prepare drawings showing his precise requirements for cable
trench work, detailing the width and depth of trenches utilising the road crossing cable
ducts shown in the Contract Drawings. These drawings shall be prepared in
consultation with the Engineer and be approved before issue and be based on Contract
Drawings showing proposed cable routes.
(2) The excavation and backfilling of trench work will be carried out by the Contractor.
(3) The Contractor shall be responsible for ensuring that the trench work is adequate for
his requirements and in accordance with his trench work drawings.
(4) The Contractor shall supply and lay the sand bedding, supply and lay the cables,
supply and lay sand blinding and supply and lay cable covers; he shall also supply and
lay cable route marker posts after the backfilling and top soiling has been carried out by
the Contractor.
(5) The sanding and laying of cables shall satisfy the following requirements:
(a) Cables shall be laid at a depth of 0.5 meter for LV and 1.0 meter for HV cables
according D1 of table A.52.3 of IEC 60364-5-52 . The depth shall be assessed
from finished ground level unless otherwise directed by the Engineer.
(b) Generally, LV and HV cables should not run in the same trench but should be
laid staggered. However, where necessary to pass through ducts it will be
necessary to lay one above the other and HV cables should be laid first and
cable cover tiles laid before laying the LV cables.
(c) Before laying cables the Contractor shall ensure that the bottom of each trench is
firm and of smooth contour and free from broken stones or rock.
(d) 75mm of sand shall be placed in the trench to form a bedding for the cables.
(e) Cables shall be laid with adequate separation and shall be gently ‘snaked’ to
avoid tension during backfilling and subsequent settlement.

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(f) The Contractor shall provide all necessary plant for the installation including
feeding rollers, winches, draw-in stockings, etc. and all the necessary labour.
(g) The Contractor shall deal with or dispose of water to prevent risk to cables and
flooding of interconnected buildings.
(h) To this end the Contractor shall not unduly delay laying of cables once a trench
has been opened and temporary sealing of building entries shall be provided by
the Contractor if all cables are not laid in one session.
(i) Before sanding and backfilling all laid cables shall be inspected by the Engineer.
(j) A second inspection following sanding and tiling shall be made by the Engineer
before backfilling.
(k) After cables have been laid they shall be covered with a further 75 mm of sand
which shall be well tamped around the cables. Mechanical means shall not be
used for this work.
(l) After sanding cable covers shall be placed in position to overlap the cables by a
minimum of 50 mm either side of the cables.
(m) The Contractor shall carry out backfilling and ensure that tiles are not disturbed
and that no large rocks or stones are dropped on tiles or included in the backfill
material.
(n) After backfilling the Contractor shall reinstate to finished ground level and provide
and lay topsoil.
(o) There may be interval between the backfilling and topsoiling, if so the Contractor
shall provide temporary wooden route markers and erect these as directed by the
Engineer.
(6) The Contractor shall supply cable cover tiles. These shall be of the pre-cast concrete
type and engraved Electricity or other suitable symbol.
(7) Cable route marker posts shall be to approval of the Engineer and fitted with
permanently engraved label showing legend Danger Electric Cables, the appropriate
voltage and danger symbol of lightening stroke, legend to be in both English
languages.
(8) The general routing of cables is indicated on the Contract Drawings, but the final routes
shall be agreed with the Engineer before any work in connection with the cable
installation is commenced. All cables shall be installed in strict accordance with the
requirements of the Specification.
(9) All single core cables of the same circuit shall be grouped in trefoil and secured.
1.27 Cable Tray Work
(1) The Contractor shall supply and erect all required cable tray work.
(2) The following points are to be taken into account in selecting routes:
(a) Number of drive power and control cables to be located on each cable tray;
(b) The avoidance of existing pipe work and pipe work required for future extensions;
(c) The avoidance of maintenance areas of machinery pipes etc.;
(d) The avoidance of installation areas for the future extension to the system;

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(e) The avoidance of unnecessarily long runs of cable.

(3) The cable trays should be designed to take all cables, including future extension.
(4) Cable tray shall be manufactured from not less than 2.0 mm thick perforated steel of
the heavy duty return flange type, hot dip galvanised after manufacture and shall be
complete with approved type fixings.
(5) Trays shall be supported by purpose made galvanised steel brackets or channel.
(6) Brackets shall be provided at a maximum of 1,200 mm centres.
(7) Bends and tees shall be prefabricated and have an inside radius of not less than 300
mm and where large cables are to be accommodated radius shall be sufficient to fully
support correct minimum cable radius.
(8) Cables shall be fixed to trays by means of purpose made fixing clamps. Cable ladder
as opposed to tray will be accepted for large cables subject to the Engineer’s approval.
(9) All cables shall be saddled or cleated in position as they are installed along the route.
(10) Single core cables of the same circuit shall be laid and mounted in purpose made
trefoil cleats.
(11) Particular care should be taken on vertical rise tray providing adequate cable fixings to
ensure distribution of load and security.
(12) All cut edges and damage caused to the galvanising shall be immediately treated with a
suitable protective paint.
1.28 Conduit Systems
(1) Approved conduit systems shall comply with BS 31 (for rigid steel conduit and fittings),
BS 4568 (for rigid steel conduits with metric threads) or BS 731 Part I (for flexible steel
conduit and adaptors), as appropriate. All conduit and fittings shall be hot dip
galvanised.
(2) Conduits shall be fixed to the surface of the wall or concealed in the floor screed when
they cross the floor.
(3) Non-metallic conduit systems shall not be used without the written permission of the
Engineer. Conduit shall be run on the surfaces or sunk as specified and be neatly
arranged and ways shall be provided for additional conduits at all distribution boards.
The sizes of conduits used shall be determined by the number of cables to be drawn in
as scheduled in the IEC regulations or as specified for a particular position but in no
case shall conduits smaller than 20 mm diameter be used. Sunk and concealed conduit
system shall support fittings independently of any false ceiling.
(4) All conduits shall be installed in an approved manner and arranged with adequate
ventilation and drainage where necessary. Where practicable, all bends or sets shall be
formed in the conduit itself. Inaccessible junction boxes shall not be used. The radius of
bends shall not be less than that given in the latest IEC wiring regulations.
(5) The whole of the conduit system shall be completely swabbed through to remove any
loose matter or dirt before cables are drawn in. Where conduits connect to switch
boxes, draw-in boxes, etc., the conduits must have a machined faced socket screwed
onto the end which when tightened is flush with the outside of the box. The conduit is
then to be secured to the apparatus by means of a hexagon smooth bore brass bush
screwed from the inside of the apparatus into the conduit socket, in order to make a
sound and tight mechanical joint.
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Part 4 Electrical Specifications

(6) Surface run conduits shall be supported at intervals in accordance with the following
schedule:

Size Interval
20 mm 1.2 m
25 mm 2.0 m
32 mm 2.5 m

(7) Where bends and sets occur in the conduit run, the conduit shall be securely fastened
at a distance of 225 mm either side of the diversion.
(8) Standard junction or adaptable boxes shall be provided at all junctions and at sharp
changes of direction in addition to any special positions where they are called for by the
Engineer.
(9) Only continuous lengths of buried conduit shall be installed between boxes, no joint
boxes being allowed in the floor screeds. Conduit crossing expansion joints shall be
fitted with couplings of approved manufacture with an earthing clip at each side of the
coupling connected by the correct size of tinned copper stranded wire.
(10) The ends of conduit laid or set in formwork prior to concreting shall be temporarily
sealed off with a coupler and a solid brass plug.
(11) No conduit shall be installed on the exterior surface of buildings without the written
approval of the Engineer. All exterior fittings shall be suitable for rear access.
(12) Fixing to surfaces of walls shall be by means of spacer bar saddles securely fixed by
screws. Where conduits are concealed or laid in construction floors, they shall be held
in position with substantial fixings of make and pattern to be approved by the Engineer.
(13) Conduit shall be of the screwed pattern galvanised by the hot process. All conduit fit-
tings not carrying accessories shall be supplied with flat covers fixed in position with
round head brass screws. Neoprene gaskets shall be supplied on all fittings.
(14) Adaptable boxes shall be constructed of minimum 3 millimetres sheet steel or best
quality cast iron finished as previously detailed for conduit bores and sized to prevent
the undue packing of cables in them.
(15) Weatherproof boxes and accessories shall be used outdoors and where indicated in
the Specifications or drawings.
(16) Conduit shall be installed such as to permit complete rewiring without the need to carry
out builders works.
(17) No Single conduit serving single phase socket outlets, lighting points and switches
shall contain more than one phase.
(18) Wiring shall be carried out on the looping-in system and no joints other than at looping-
in points will be allowed.
1.29 Flexible Conduit
(1) Where the conduit system terminates at any equipment requiring a non-rigid
connection, a flexible conduit shall be installed of the PVC or PVC sheathed metallic
type fully watertight with purpose made connection adaptors.

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(2) Each flexible connection shall include not less than 400 mm length of flexible conduit
and a separate earth conductor shall be run within the conduit connected to the earth
terminals in the equipment and the fixed conduit run. The flexible conduit shall not be
used as an earth continuity conductor.
1.30 Cable Trunking
(1) The trunking shall be manufactured from heavy duty rigid unplasticised PVC which
shall be self extinguishing and shall be unaffected by sunlight or water. The material
shall be suitable for continuous ambient temperatures of 65°C. Each length shall be
supplied with the necessary connection sleeves and shall have joggled sides to allow
flush fitting.
(2) Each length trunking shall be fitted with easily removable covers attached to the
trunking by an efficient screw type fixing.
(3) The trunking system shall be complete with purpose made angle and set accessories
designed to afford easy installation of and to avoid tight right angle bends in the circuit
cables installed in the trunking. All trunking accessories shall be complete with
removable covers. No site made mitred joints shall be allowed.
(4) Where cable trunking is installed in vertical runs, efficient circuit cable clamps are to be
installed at not greater than 500 mm intervals.
(5) A continuous earth conductor shall be installed throughout the trunking system, with
provision for the connection of local circuits as necessary.
(6) All trunking shall be of adequate size to suit the number of cables passing through it
but as a minimum the size should be 50 mm by 50 mm. All bends, tees and
intersections to be of the gusset type and manufactured by the maker of the trunking
and to similar standard. The trunking shall be fixed to the walls and ceilings by means
of a secure and permanent fastening to be approved by the Engineer.
1.31 Socket Outlets
Socket outlets for installation throughout the Works covered by this Specification shall all be
of the waterproof corrosion resistant type and shall generally be mounted 1.30 m above floor
level as follows:
(a) 25 Volt, 5 A, 3 pin socket outlets complying with IEC 309-2/81 colour coded and
complete with matching colour coded plugs.
(b) 230 Volt, 16 A, 2 pin CEE 7/4 socket outlets.
(c) 400 Volt, 30 A, TP & N and E switched and mechanically interlocked. Each
socket outlet shall be supplied via current operated earth leakage circuit breaker
mounted within the distribution section of local switchgear/motor
control/distribution panel.

1.32 Outdoor/External Lighting

(1) Outdoor lighting system shall be provided to illuminate all roadways, yards around all
structures within the site where indicated on the drawings and subject to the Engineer’s approval.
The design and installation of the Outdoor lighting system shall be in accordance with DIN/VDE
and relevant national standards.

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(3) The lighting systems shall comprise column mounted luminaries, typical fittings at hot dip
galvanized steel conical ribbed lighting pole 8m high.
(4) The lanterns shall incorporate changeable LED lamps ( Power : 100W, Lumen: 12000lm,
Light Efficiency: 120lm/W, IP Rating: IP66, Colour temperature: 3500K “Standard White” ,
Lifespan: 50,000 Hrs. Lantern shall be of the side entry inclined overhanging pattern with integral
lamp control gear, weatherproof die cast aluminium body, with hinged access cover and high
impact polycarbonate bowl.
(5) The columns shall be hot dipped galvanised steel with low level cable termination chamber
accessible through lockable front cover plates. The column cable terminations shall comprise a
fully insulated TP+N termination block for the loop-in termination of the main power cable
between columns, and insulated fused cut-out or MCB and neutral connection for the luminaries
circuit. Internal wiring shall be in PVC insulated and sheathed cable. Each column and lantern
shall be positively bonded to the main cable armour in an approved manner. Each column should
have its own earthing rod in addition to main earthing lead and earthing conductor
(6) The poles (columns) shall be mounted in concrete foundations with PVC lined cable entry
ducts.
(7) The lighting shall be fed on a single independent TP+N buried cable circuit, fed from the 400
V primary distribution switchboard located in the Administration building. The circuit shall be
controlled by a photo-cell switching circuit , timer circuit and manual control selector switch. The
photo-cell shall be wall mounted on the west face of Administration building.

1.33 Lighting Switches

(1) Surface switches shall be of the ironclad protected pattern heavily galvanised type.
Where appropriate they shall be of the “multiple phase” type and where possible shall
be arranged in multi-gang boxes.
(2) Exterior lighting switches shall be metal clad galvanised watertight, with rotary switch
action. Rear entry shall be provided to allow concealed conduit installations.
(3) Switches employed in Control Buildings shall be suitable for flush mounting and shall
comply with IEC 364-3-1. Moulded, white finish, rocker operated.
(4) Switches in damp areas or for external use shall be heavy duty surface pattern.
(5) Special care shall be taken to ensure that all switches are securely fixed truly vertical
and that flush mounted switches are flush with the wall finish so that the overlapping
cover plates seat on to the rims of the boxes.
(6) Switches shall be mounted at 1.50 m from floor level.
(7) Not more than 12 Nos. fluorescent light fittings (24 Nos. of tubes) shall be connected to
any 16 amp lighting switch. Lighting fittings shall be distributed evenly between phases
and throughout that loss of any one phase or contactor does not leave any area in total
darkness.
(8) Operating switches and contactor energising coils shall also be distributed between
phases.

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1.34 Lighting Fittings

(1) Lighting fittings for use inside shall be fluorescent batten type or equivalent illumination
LED and shall be complete with all supports, suspensions, flexible cables, pendants
and plugs. Generally they shall be mounted horizontally on the wall at 3.00 m above
floor level. They shall be connected to the main circuit wiring with heat resistant flexible
cables of a minimum conductor size of 1.5 mm2 insulated with silicon rubber.
(2) Pendant fittings or fluorescent or LED fittings suspended from the ceiling shall only be
allowed with the permission of the Engineer. Where fluorescent fittings are suspended
from the ceiling they shall have a minimum of two suspension points.
(3) Break joint rings shall be used in conjunction with batten holders ceiling roses or back
plates mounted onto a flush installation.
(4) The earthing of all pendant or semi-pendant fittings shall be by a separate core in the
connection flex or cable securely bonding the earth terminal on the fittings to the
glanded joint of interconnecting cables. In no case shall pendant chains or conduit
support tube be used as a means of earthing.
(5) All lamp holders for flexible pendants shall be of the all insulated shirted pattern with
cord grips and for batten or wall mounting shall be of similar pattern. All lamp holders
shall be the bayonet cap pattern.
(6) The point box suspensions and other parts of the lighting fittings shall be erected at
times to suit the building programme for decoration. The glassware diffusers, shades,
lamps and tubes shall not be fitted until all construction work is completed.
(7) All fittings shall be left clean inside and outside ready for use. All fluorescent fittings
shall be suitable for instant start irrespective of any catalogue or list numbers quoted.
(8) All fluorescent tubes shall be of an approved manufacture with metal coil filaments gas
filled pearl in all standard sizes with standard caps to suit the fittings in which they are
in-stalled.
(9) The Contractor shall supply and install all lamps for the entire lighting fittings
installation and shall replace all burned out lamps up to the time that the Purchaser
takes final acceptance of the Works.
(10) Construction of the fittings shall be suitable for the site climatic conditions.
1.35 Emergency Lighting
(1) Emergency light fittings shall be designed to provide a level of illumination under mains
failure in compliance with IEC 598-2-24.2.
(2) Emergency lighting fittings shall be self contained, incorporating lamp(s), battery,
charger and mains failure relay.
(3) The fittings shall be fully automatic in operation, providing instant illumination in the
event of mains failure. The battery shall be automatically recharged when the main
supply is re-stored.
1.36 Earthing General
The metal framework of all electrical and associated equipment, metal enclosures and
associated screenings, supports, any other metalwork that is not normally used to conduit
electricity shall be effectively earthed at all times. Particular care shall be taken where

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Part 4 Electrical Specifications

moving parts are involved that they are earthed in any normal position e.g. circuit breaker
carriage, cubicle or sub-station door.
1.37 Earthing Systems
(1) The earthing system shall comply with the requirements of IEC Publication 364-5-54.
Earth tapes on 11 kV plant shall comprise a minimum of 50 mm x 6 mm copper tape
and on 400 V equipment 38 mm x 5 mm copper tape.
(2) The non-current carrying metal of electrical equipment provided under the Contract
shall be securely bonded to earth. Earthing shall be effected by means of the metal
sheath of cables which shall be securely bonded to the metalwork of the apparatus
concerned at each end or a separate earth conductor. A separate earth conductor shall
be provided for all items of plant rated 20 kW or greater.
(3) Armour wires on main cables shall be solidly bonded as additional earth path but
cables from the standby generators shall be insulated from the main earth system.
Particular care shall be taken on cable termination boxes bonded to the associated
item of plant. If continuity is adequate copper connections shall be made between the
apparatus frame and the cable sheath.
(4) Where the cable sheath and armour is used as the earth path return then it shall be
established that the resistance is less than 1.0 Ω. If not, a separate copper earth
conductor shall be installed.
(5) Particular care shall be taken to ensure earth continuity across items of equipment
situated within a cable run and should the design of such equipment not give adequate
and lasting continuity through its structural body then additional earthing clips and
conductors shall be provided to independently bond the cable sheaths together.
Similarly, additional earthing clips shall be provided to bond the cable sheaths to any
piece of apparatus fitted with a special earth terminal should the earth connection of
the termination gland prove inadequate. Any additional earthing clips shall be
contained within the apparatus wherever possible.
(6) The earth tapes shall be protected against corrosion and be complete with test links
and be run on walls held in position by saddles fixed by rawl plugs and screws.
(7) Connection shall be sweated and rivetted and shall be electrically and mechanically
continuous. Joints between the main conductor and the earth electrodes shall be
readily accessible for periodic inspection and shall be protected against damage and
corrosion.
(8) Where rigid or flexible conduit and/or trunking is incorporated into the Works, a
separate internal earth conductor shall be run which shall be securely bonded to the
terminating apparatus by means of a special earth terminal.
(9) The earth electrode system shall consist of two electrode beds or nest independently
arranged and each comprising a system of vertically mounted rods.
(10) On completion of the earth installation the Contractor shall demonstrate to the Engineer
that the resistance of the electrodes and the earth network is within the specified limits.
Test equipment shall be supplied by the Contractor.
1.38 Earthing Nests
(1) Each nest shall comprise of a number of interconnected earth rods, 25 mm in diameter
by 4.2.0 m long, driven vertically into the ground at intervals of not less than 3.0 m
apart with heads located at a depth to suit disconnecting chamber position.
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Part 4 Electrical Specifications

(2) Earth rods shall be copper or steel cored with a metallic bonded copper outer surface.
Rods shall be provided with special hardened tips and caps, to avoid distortion when
connecting the rod to the copper strip.
(3) Leads from each electrode shall be brought to concrete disconnection chambers to
enable each electrode to be disconnected for testing purposes.
(4) Concrete disconnecting chambers with removable cover and disconnecting lid, for test
purposes, shall be provided over each earth rod. The top of chamber shall be at
finished ground level.
(5) The test link shall be of copper and not be less than the connecting cables cross
sectional area and have a generous contact area.
(6) Disconnecting bolts, nuts, locknuts and washers shall be made from phosphor bronze.
(7) The copper strip connecting the earth rods to the test link shall be exothermically
welded at the test link and sweated to the top of the earth rod.
(8) The earth rod interconnections shall be an electrically unbroken ring and
interconnections shall be PVC insulated stranded copper conductor earthing cable
sweated to the test links. The cable shall be of sufficient low resistance to carry the
maximum fault current for a period equivalent to the clearing time of the protective
equipment without undue temperature rise.
(9) Joints at the head of the earth rods shall be easily accessible for periodic inspection.
(10) Earth nests shall be connected to their station associated earthing system by 2 Nos.
PVC insulated stranded copper conductor earthing cables. The cable shall be sweated
to opposite ends of the earth nest and to two different spaced points on the station
earthing system.
(11) The earthing system shall be protected against damage by corrosion wherever
necessary.
1.39 Location of Nests
(1) An earth nest shall be installed at sub-stations where such forms part of this contract.
(2) Earth nests shall be located adjacent to the building housing the switchgear as
practical. Where two nests are specified, they shall be located at opposite ends of the
system.
1.40 Battery Units
(1) A battery and charger set shall be housed in a single sheet steel floor mounted
ventilated cabinet with batteries housed in the lower part of the cubicle.
(2) The unit shall be complete with a self adjusting constant potential trickle charger
suitable for operating from 230 Volt single phase AC supply. The charger shall be rated
to continuously energise relay coils and lamps as applicable. The charger shall be
designed to maintain a constant voltage with +/- 3% irrespective of mains voltage or
frequency variation. Booster charge facilities shall be included. The unit shall be fitted
with the following:
1 No. Supply “ON” Indicating Lamp
1 No “ON / OFF” Switch
1 No Charger Ammeter

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1 No “OFF / FLOAT / BOOST” Switch

1 No Charger failure alarm relay and lamp
1 Set Cable terminals and fuses.
(3) All battery cells shall be nickel cadmium structure with an alkaline electrolyte and a
metal or plastic case.
(4) Batteries shall be of suitable ampere hour capacity to operate the closing and tripping
coils or motor of the circuit breakers. Dual duty batteries i.e. engine starting and
tripping for circuit breakers will not be acceptable.
(5) Voltage of battery/charger sets shall be 48 V as appropriate to application. One set
shall only supply equipment at a single voltage.

2 Particular Electrical Specifications

2.1 General Requirements
The minimum standards for satisfying the general requirements for the installation of Plant
and Equipment at the WWTP are outlined in the following specification.
It shall be the responsibility of the Contractor to provide all detailed designs of the
installations and to ensure full coherence of all the equipment installed with any existing plant
components and to comply with the present minimum quality standards.
 The Contractor shall submit the PLC's I/Os list according to the equipment for review at
the bidding stage.
 The Contractor shall submit a table of contents for all his equipment and spare part list
for review.
 The contractor shall submit a specific original catalogue not general catalogue. The
Contractor shall specify the type and the tag number of any missing catalogue any non
specified catalogues will not be accepted it is the Contractor responsibility to provide
this information.
 The Contractor shall submit his scope of work according to specifications.
The works shall include all electrical equipment, instrumentation, building and site services,
ancillaries and accessories necessary for the performance and operational requirements
herein specified. There shall be included all items, components, connections and services to
make the whole installation electrically complete and perfect in every part and detail and
operational as a complete integrated installation. The Contractor shall include for all
interfaces with existing equipment and replacement of existing defective or out of date
equipment not suitable for interface.

2.2 MCCs and Switchboards

2.2.1 Scope of Works
The switchgears and local control panels (LCP) integrated in the mechanical equipment such
as the panels on the FST or grit chamber bridges are not described here. These “package
units” will be supplied electrically with cable feeders from the MCCs. For the SCADA
sufficient I/Os at the PLCs and sufficient data or control cables shall be provided for these
package units.

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Part 4 Electrical Specifications

The work includes the following items:

 Synchronization unit for three power sources (JEPCO power transformer, CHP
generators, and PV panels).
 Main Low Voltage Switchgear (MLVS) with Automatic Reactive Power Compensation.
 Motor Control Centre MCC1 for storm water pumping station, inlet works, mechanical
cleaning, primary sedimentation tank 2.
 Motor Control Centre MCC2A for activated sludge tanks1 (AST), primary
sedimentation tank 1.
 Motor Control Centre MCC2B for activated sludge tanks 2 (AST)
 Motor Control Centre MCC3 for the final sedimentation tanks (FST), the return
activated sludge (RAS), the Waste Activated Sludge (WAS) pumping stations, gravity
sludge thickener 2, filtration system, UV disinfection station, and service water
pumping station.
 Motor Control Centre MCC4 for the Gravity Thickener 1, anaerobic digesters, odour
control unit 2, boiler station, biogas handling and treatment, and digester and
desulphurization unit heat pumps.
 Motor Control Centre MCC5 for the WAS storage tank, mechanical thickening,
mechanical sludge dewatering, and return liquor pumping station.
All switchgears comprising the relevant PLC and instrumentation inverters and all necessary
auxiliary devices.
Local Control Panels (LCP) for each electrically driven equipment and each instrumentation
shall be provided. The LCPs shall be either fixed at a rigid galvanised steel pillar, fixed on
concrete or in the earth, or wall mounted, where applicable.
The Contractor shall submit the data for the different MCC feeders together with the
particular data sheets of the particular equipment manufacturer to the Engineer for approval.

2.2.2 General data

The electricity supply shall be at 400V, 3 phase+N.
The short circuit capacity of the switchgears shall be 50kA for 3 seconds and 150kA
dynamic.
Earthing system shall be TN-S, TN-C or TN-C-S in accordance with IEC 60364.
The control circuit voltage shall be 230V, 1 phase, 50Hz and 24V DC

2.2.3 Switchgear Enclosures

The IP (Ingress Protection) class in accordance to IEC 60529, specified in the Particular
Requirements, shall be IP65 for outdoor installation and IP54 for indoor installation. The
switchgears shall be divided into compartments in Form 3b in accordance to IEC 60439-1.
Designing these enclosure features the temperature inside the switchgears may not be more
than the maximum allowed temperature of the electrical equipment (according to its data
sheets) considering maximum losses of these equipment and maximum possible
environmental temperature.

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Part 4 Electrical Specifications

The unaffected maximum environmental temperature is 45ºC. The supplier shall install at
critical switchgear rooms a ventilation or air conditioning system.
The supplier shall certify that the switchgears and the controlgears are constructed and
tested according to IEC 60439. The supplier shall submit the heat dissipation and
temperature rise calculations for review and approval.

2.2.4 General Notes

In addition to the detailed specification, the following shall be included:
1) The selection for the motor starter shall be carried out in accordance with any
configuration for the “Typical variation of combination starter and protected starter” as per
IEC 60947-4-1 in sub-clauses 2.2.7 and sub-clauses 2.2.8 and the motor starter shall be
type-2 coordination.
2) All components in the Motor Starters (such as circuit breaker, contactor, overload and the
protection relay, etc.) shall be selected according to type-2 coordination as per the IEC
947-4-1 recommendations and shall be sized according to the specified duties and design
temperature. The following covers further details about the specification of type-2 co-
ordination.
3) All low voltage C.Bs greater than 100A shall have an Electronic Trip Unit
4) The certificate of type tests for the proposed switchgear panel shall be submitted for
approval, complying with IEC as follows:-
a. Short circuit withstands.
b. Temperature rise limit.
c. Dielectric properties.
d. Protection circuit efficiency.
e. Mechanical operation.
f. Degree of protection.
g. Clearances and creepage distances
5) The supplier of LV switchboards shall submit original catalogues of the panel. The
catalogues and certificates of type test, mentioned above, shall include all technical data
of the supplied equipment.
The catalogue of LV switchboards shall contain all details about bus bar, derating, tables and
configuration of arrangement inside the panels.

2.2.5 Colour
The colour for the internal and external surfaces of the metalwork of the panels shall be RAL
7032.
Backplates shall be white.

2.2.6 Motor Overload Relays

Motor starters shall be fitted with standard thermal overload and phasing fault protection
relays or these devices are integrated in the particular C.B.

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2.2.7 Drive Protective Devices

Where the starter schedule requires the provision of protective devices such as torque
switches, current or voltage sensing relays, seal or liquid sensing relays, pressure sensing,
temperature sensing, movement sensing, etc., these devices shall be hardwired into the
starter control circuit in addition to the automatic control PLC.
All relays or controllers associated with such protective devices shall be installed in the
control section of the respective MCC.

2.2.8 Incomer Interlocking

Where a MCC is equipped with 2 incomer switches an electrical and mechanical interlocking
arrangement shall be supplied such that only 1 switch can be closed at any time. To achieve
the mechanical interlocking each incomer switch shall be fitted with a castell key interlock (or
similar), but only one key shall be supplied.

2.2.9 Cubicle Arrangements

Where a MCC is equipped with 1 or 2 incomer switches and no bus-coupler switch the
incomer switches shall be located at the left hand end of the MCC as viewed from the front.
Where a MCC is equipped with 2 incomer switches and a bus-coupler switch, these switches
shall be positioned at the centre of the MCC, as viewed from the front and the starter and
other load circuits shall be arranged either side of the incomer arrangement to provide
approximately equal loading on each half of the MCC.
The control section shall always be at the right hand end of the MCC.

2.2.10 Spare Cubicles

In addition to the spare cubicles described in the following sections dealing with each MCC,
switchboard shall include one empty spare cubicle for some of each rating of starter
incorporated in the MCC.
Where all the starters in the MCC are the same rating then 2 empty cubicles shall be
included.

2.2.11 Reactive Power Compensation Unit

The reactive power compensation unit, installed at the main distribution switchgear, shall be
of the automatic kind with a minimum 12 steps automatic regulation. The Capacitor bank
shall be integrated in Separate cubicle for PFC, connected to the MLVS busbar via C.B. The
unit shall have a monitoring screen, showing the actual power factor. The voltage and degree
of compensation and number of steps. The maximum demand of capacitive reactive power
should be 800 kVAr.
The capacitors shall be in compliance with IEC 60831. They shall be detuned by suitable
filters avoiding harmonics and with discharge reactors for discharge of the capacitors when
disconnected. The power contactors for connecting the capacitors shall be specially
designed for damping inrush currents.

2.2.12 Signalling lamps

All signal lights shall be flush mounted at the switchgear front. They shall be equipped with
multi LED lamps for 24V DC. The colours shall be according to IEC:

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Part 4 Electrical Specifications

 Yellow for operation

 Red for danger, fault and malfunction
 Green for availability (no operation, no fault or malfunction)

2.2.13 Process Instruments

Process instruments, level, flow, temperature, pressure, quality, etc. shall be powered by
battery buffered (UPS) 24V DC volts from the respective MCC control section, both for panel
and field mounted instruments. Appropriate numbers of suitably rated MCBs shall be
provided for these supplies.

2.2.14 Circuit Breakers

All MCCB (Moulded Case Circuit Breaker) and Air Circuit Breaker shall have a fault rating not
less than 70kA.

2.2.15 Existing Electrical Equipment

All on the plant existing electrical equipment shall be dismantled and either stored or
removed from the plant according to the advice of the Engineer or the Client. The removal
shall be done according to the national regulations. The dismantling as well as the
construction, installation and commissioning shall be the subject of the general time
schedule.
Exception regarding dismantling is the supply transformer, which will be dismantled by
JEPCO, according to the instruction of the client and engineer.

2.2.16 Abbreviations regarding switchgears

Devices
C.B. Circuit Breaker
EPB Emergency Push Button
F.C. Frequency Converter (Variable SpeedDrive)
HMI Human Machine Interface
I&C Instrumentation & Control
IEC International Electrotechnical Commision
LCP Local Control Panel
LVS Low Voltage Switchgear
MCC Motor Control Centre, usually standarised acording to IEC 60439
MCCB Moulded Case Circuit Breaker
MCB Miniature Circuit Breaker
MLVS Main Low Voltage Switchgear(Main Distribution Board)
PLC Programmable Logic Controller
RTU Remote Terminal Unit, usually a PLC
SS (Static) Soft Starter
UPS Uninterruptible Power Supply

Starting Methods
DOL Starter with Motor Protection by C.B. and Contactor "Direct On Line"
SD Starter with Motor Protection by C.B. and Controlled Star Delta
Contactor Combination
SC Starter with Cable Protection by C.B. and Contactor (PLC controlled)
C Starter with Cable Protection by C.B.
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ROS Starter with Motor Protection by C.B. and two Contactors for "Reversible
Direct On Line" start
RS Starter with Motor Protection by C.B. and two Contactors, reverse only
for jogging application
SS Static (Thyristor controlled) SS with integrated Motor Protection (Short
Circuit SS Protection by special fuses)
SSB like SS, but with SS controlled Contactor bypass
VSD Static Controlled Variable Speed Drive by F.C. with integrated Motor
Prot. (Short Circuit F.C. Prot. by special fuses)
DS Starter with Motor Protection by C.B. and two Contactor for two different
motor windings and speeds

Special Protection Devices

THR Thermistor
TES Temperature sensor
HUM Humidity sensor (Water Intrusion Detection)
TOL Torque or power limitation
LS Level switch
PS Pressure switch
FS Flow switch

2.2.17 Main Low Voltage Switchgear

The MLVS shall be installed in the power station (that contain: main synchronization unit,
diesel generator, power factor correction capacitor banks, automatic transfer switch and High
Voltage switchgear), shall be supplied from the main synchronization unit through a copper
cable.
The reactive power compensation unit for the WWTP shall be provided in the same room of
MLVS.
The compensation shall be:
 with automatic regulation, controlled by the measured electrical data of the power
supply.
 with display which shows the actual power factor and number of active steps.
The compensation plant shall be recalculated and if needed, redesigned by the contractor
after knowing the exact data of all electrical consumers and loads.

MLVSB in the power building

Rated Data Starter
Feeders No. Pn(kW) In(A) Type
Incomer (at the left side) from ATS 1 3600/4000
Feeder for MCC1 1 150 250/400
Feeder for MCC2-A 1 665 1250/1600
Feeder for MCC2-B 1 645 1250/1600
Feeder for MCC3 1 445 1000/1250
Feeder for MCCB4 1 250 300/630
Feeder for MCCB5 1 160 300/630
Site Lighting 1 80/100
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Control & PLC 1 20/100

MLSB Building Power 1 20/100
Power Factor corrector 1 900/1250
Spare 1 400/630
Spare 1 20/100
Spare 1 160/250
Spare 1 100/160
Spare 1 32/100

Comprising an I&C cubicle at the right side.

The Incoming Feeders shall comprise each:
 Withdrawable air Circuit Breaker with auxiliary contacts for signalisation switch
position and tripping (2 signals) via PLC
 Digital power meter (Current, voltage, frequency, power, etc.).
 3 no Ammeters, one per phase, complete with CT’s.
 Voltmeter with phase and line selector switch complete with MCB protection
 3x Voltage, power and power factor measuring for registration via PLC (4-20mA)
 Mains Failure (Under voltage / Phase fault) relay with signalisation via PLC
 Surge protection resistor with fault signalisation via PLC (only for the transformer
feeder).
 The Diesel Gen-set feeder and the synchronization unit shall be connected to ATS
cubicles then the third cubicle has the outgoing circuit breaker for supply the MLVS
so the switching between the GEN and the synchronization unit is automatic
(uninterrupted changeover).

2.2.18 Automatic Synchronization Panel

Scope of work :
As Salt WWTP is going to be electrically supplied by three different power sources, which are
( 2X1.5MVA ,11:0.4Kv transformers) , CHP generators, and PV panels. As Salt WWTP has
three CHP generators (3 X 300 Kwe,400v) located in the Anaerobic Digester building . the
electrical voltage from each CHPs generator shall be connected to a sub synchronization
unit supplied from the CHP system vender to merge the power at one line this power
transmuted to the power room to synchronize it with the other sources.
PV panels supplied ready with their own inverter which produced synchronized voltage with
grid voltage.
The JEPCO power grid will connect to ATS panel with the standby diesel generator as
shown in the drawing No. AS_WWTP_610.
The three power sources (the output power from ATS panel, CHP generators, and PV
panels) shall be connected to main synchronization unit located in the power room.
The Automatic Synchronization panel shall be installed in the power station that contains:
 Three Incoming one circuit breaker is for the output power from ATS (3MVA, 400v),
one circuit breaker is for CHP generators (600kW, 400v) , and one is for PV Power.

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 All Synchronization instrument and control devices such as control unit, PLC, check
relays …etc which achieve Automatic Synchronization.
 All Measurements meters and devices such as : Digital power meter (Current,
voltage, frequency, power, Volt-phase angle .. etc.), analogue Ammeters , analogue
Voltmeter, Volt-phase and angle–frequency meters to can achieve Manual
Synchronization.

2.2.19 Motor Control Centre MCC1

The Contractor shall install the MCC1 in the MCC1 building in the screens building .
MCC1 near Screen Building
Rated Data Starter
Feeders No. Pn(kW) In(A) Type
Incomer (at the left side) from MLVSB 1 250/400
Storm Water pump 2 15 36/63
Inlet Works & Grit Classifiers Control Panel 1 16 32/63
Grit & Grease Removal Control Panel 2 3.5 7/32
Grit blowers station 1 7 32/63
Primary Sedimentation Tank 2 Control Panel 2 1 25/63
Sludge Pump 2 3 5 16/32
Scum Pump 2 2 5 16/32
Overhead Crane 1 1 16/32
Odour Control Unit (head work) 1 37.5 65/100
Auto Sampler 1 1 16/MCPL
PLC & Control 1 0.25 20/MCPL
MDB of Screening Building 1 32/63
Waterline Drainage Pumps 2 11 22/63
Spare 2 50/100

Comprising an I&C cubicle at the right side.

The screens, conveyors, the compactor and the classifier shall be automatically controlled
through the SCADA with local manually control.

2.2.20 MCC2A
The contractor shall install the MCC2A in the in MLVSB room.
MCC2-A in the MLVSB room
Rated Data Starter
Feeders No. Pn(kW) In(A) Type
Incomer (at the left side) from MLVSB 1 1250/1600
Aeration blowers 1 3 200 360/ 400 VFD
Ventilator 3 1.5 10/32
Anoxic mixer 1 4 1.5 20/32
Internal recirculation pumps 1 2 3.5 15/32 VFD
AST flow maker 1 4 5.5 20/32
Overhead crane in blowers room1 1 5.5 30/100
Overhead crane in generator room 1 3 30/100
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Blowers room1 Service panel 1 30/100

Power room service panel 1 30/100
Primary Sedimentation Tank 1 Control Panel 2 1 25/63
Sludge Pump 1 3 3 16/32
Scum Pump 1 2 3 16/32
Overhead Crane 1 1 16/32
PLC & Control 1 0.25 20/MCB
Spare 2 50/100

Comprising an I&C cubicle at the right side.

The aeration blowers, anoxic mixer, Internal recirculation pumps, AST flow maker , primary
sedimentation tank 1, and sludge pump , shall be automatically controlled through the
SCADA with local manually control.

2.2.21 MCC2-B
The contractor shall install the MCC2A in the blower room 2.

MCC2–B located in blowers room 2

Rated Data Starter
Feeders No. Pn(kW) In(A) Type
Incomer (at the left side) from MLVSB 1 1250/1600
Aeration blowers 2 3 200 360/ 400 VFD
Ventilator 2 1.5 10/32
Anoxic mixer 2 4 1.5 20/32
AST flow maker 2 4 5.5 20/32
Internal recirculation pumps 2 2 3.5 15/32
Overhead crane in blowers room 2 1 5.5 30/100
Blowers room 2 lighting and power panel 1 30/100
Admin DB 1 50/100
Workshop DB 1 50/100
PLC & Control 1 0.25 20/MCB
Spare 2 50/100

Comprising an I&C cubicle at the right side.

The aeration blowers, anoxic mixer, internal recirculation pumps, and AST flow maker, shall
be automatically controlled through the SCADA with local manually control.

2.2.22 MCC3
The contractor shall install the MCC3 in the building for the RAS and WAS pumping stations.
MCC3 near FSTs
Rated Data Starter
Feeders No. Pn(kW) In(A) Type
Incomer (at the left side) from MLVSB 1 1000/1250
RAS pumps (in RAS/WAS station 1) 3 18.5 63/100 VFD

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WAS pumps (in RAS/WAS station 1) 2 6 15/32

RAS pumps (in RAS/WAS station 2) 3 18.5 63/100 VFD
WAS pumps (in RAS/WAS station 2) 2 6 15/32
Motorized penstock (in RAS/WAS station 1) 2 1.1 6/MCPL
Motorized penstock (in RAS/WAS station 2) 2 1.1 6/MCPL
Ventilator (in RAS/WAS station 1) 1 1.5 10/32
Ventilator (in RAS/WAS station 2) 1 1.5 10/32
Final sedimentation tanks control panels 4 2 25/63
Filtration system control panel 1 130 250/400
UV control panel 1 60 110/125
Fire Pumps 1 4 10/32
Service Water Pump 4 25 64/100
PLC & Control 1 6/MCPL
RAS/WAS DB1 1 50/100
RAS/WAS DB2 1 50/100
Secondary Scum Pump Station pumps 2 5 16/32
Spare 2 50/100

comprising an I&C cubicle at the right side.

the final sedimentation tanks (FST), the return activated sludge (RAS), the Waste Activated
Sludge (WAS) pumping stations, gravity sludge thickener 2, filtration system, UV disinfection
station, and service water pumping station shall be automatically controlled through the
SCADA with local manually control.

2.2.23 MCC4
The contractor shall install the MCC4 in the building for the dewatering plants.
MCC4 in Digester Building
Rated Data Starter
Feeders No. Pn(kW) In(A) Type
Incomer (at the left side) from MLVSB 1 300/630
Gravity Thickener Control Panel 1 1 1 10/32
Gravity Thickener Control Panel 2 1 1 10/32
Thickened Prime Pump 3 4 10/32
Ventilator Thickened Prime 1 0.25 6/32
Scum pumps 2 2 6/32
Digester Feed Pumps 3 5.5 10/32
Gas Injection Compressor 2 30 40/63
Digester Circulation Pump 4 4 15/32
Digester Feed Macerator 3 2.2 10/32
Digester Building Lighting & Power 1 30/100
Building Power 1 32/63
Control & PLC 1 30/63
Odour Control Panel 1 37.5 40/100
Boiler Heat Pump 1 2.2 15/32
Boiler 1 3 15/32
Boiler Ventilator 2 1.5 15/32
Boiler Fuel pump 1 1.1 15/32
Condensate Pump 2 1.1 15/32
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Component 3 Salt WWTP Technical Specifications
Part 4 Electrical Specifications

Biogas Booster blower 2 3 15/32

Biogas Ventilator 2 1.5 15/32
Siloxane Removal System 1 6 32/63
Biogas Desulphurization System 1 6 32/63
CHP Control Panel 1 35 70/100
Digester Heating Pump 4 1.5 15/32
Desulphurization Heat Pump 1 0.55 15/32
Ventilator in Cogeneration station 2 3 20/32
Sludge Drying beds Pump stations 2 7.5 15/32
SPARE 2 50/100

Comprising an I&C cubicle at the right side.

the Gravity Thickener 1, anaerobic digesters, odour control unit 2, boiler station, biogas
handling and treatment, and digester and desulphurization unit heat pumps shall be
automatically controlled through the SCADA with local manually control.

2.2.24 MCC5
The contractor shall install the MCC5 in the building for the sand filters and UV disinfection
plants.
MCC5 in Sludge Treatment building
Rated Data Starter
Feeders No. Pn(kW) In(A) Type
Incomer (at the left side) from MLVSB 1 300/630
WAS Tank mixer 2 3 10/32
Ventilator 2 1.5 10/32
Overhead crane 1 5.5 30/63
Mechanical Thickening Control Panel 1 34 210/400 VFD+DOL
Polymer Preparation Unit 1 5 20/32
Building Power 1 30/63
Control & PLC 1 10/32
Mechanical Sludge Dewatering Control Panel 1 44 290/400
Ventilator 2 1.5 10/32
Overhead crane 1 5.5 30/63
Polymer Preparation Unit 1 5 20/32
Return Liquor Pump 3 15 25/63
SPARE 2 50/100

comprising an I&C cubicle at the right side.

WAS storage tank, mechanical thickening, mechanical sludge dewatering, and return liquor
pumping station shall be automatically controlled through the SCADA with local manually
control.

2.2.25 Descriptions of the MCC feeders and starters

The Incoming Feeder shall comprise:
 3-pole Circuit Breaker with auxiliary contacts for signalisation switch position and
tripping (2 signals) via PLC.

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Part 4 Electrical Specifications

 Digital power meter (Current, voltage, frequency, power, etc.).

 3 no Ammeters, one per phase, complete with CT’s.
 Voltmeter with phase and line selector switch complete with MCB protection.
 3x Voltage, power and power factor measuring for registration via PLC (4-20mA).
 Mains Failure (Under voltage / Phase fault) relay with signalisation via PLC.
 Surge protection resistor with fault signalisation via PLC.
The Cable feeder “C” shall comprise:
 Moulded Case Circuit Breaker adjusted to the regarding cable (copper conductor)
cross section.
Cable feeders are supplying low voltage subdistributions (i.e. for electrical house
installations) or the switch- and controlgears separate control units (package units). Cable
feeders supply the “automatic” valve actuators.
The controlled (or switchable) Cable feeder “SC” shall comprise:
 Moulded Case Circuit Breaker adjusted to the suite the cable cross section.
 PLC controlled power contactor with auxiliary contacts for confirmation and
signalisation via the PLC.
The control is needed for Restarting Programs according to the Diesel Emergency Generator
and for central manual control.
The “DOL” starter is the standard motor starter with
 Moulded Case Circuit Breaker adjusted to the rated electrical data of the motor with
auxiliary contacts for signalisation switch positions and tripping 3 signals: ON, OFF
and Tripped via PLC
 Power contactor adjusted to the motor rating according to AC3 or AC4, if especially
required controlled via PLC, manual control, hardwired controlled by EPB circuits
and if required to other hard wired protective circuits i.e. dry run protection.
 Local ammeter with adjusted scale for starting current.
 Local operation hour meter.
 Available (green), operation (yellow) and fault (red) signalling lamps.
 Manual control with MANU-0-AUTO selection switch and ON and OFF pushbuttons.
The position MANU and 0 shall be signalled via PLC with one signal. Some drives
shall not be controlled at the switchgear then there would be no selection switch and
pushbuttons refer to MCC descriptions.
The “SD” starter is a DOL starter with a star-delta-contactor-combination. The C.B. of the
SD starter is according to overload adjusted to “Delta” operation. Special SD starter have, if
required, two different overcurrent protections: one for “Delta” and one for “Star” connected
operation.
The “DS” starter is a DOL starter for motors with two speeds realised by two windings.
The “ROS” starter is a DOL starter for motors, which shall be run in both directions.
The “RS” starter is a ROS starter which shall allow the reverse direction only for manual
checking by a nudging pushbutton.
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Part 4 Electrical Specifications

The “SS” starter is a static (thyristor controlled) Soft Starter with integrated Motor Protection
and with
 Short Circuit SS Protection by special very fast fuses
 Integrated monitoring and password protected manual control at the switchgear front
 Interface to the PLC point-to-point or data-bus for monitoring, control and
parameterisation.
The soft starter shall have the features:
 adjustable for the particular motor rating current.
 adjustable current limitation.
 Filters according to the EMC regulations Directive 2004/108/EC or equivalent
national regulations.
 Voltage fault monitoring and tripping.
 separately adjustable start and stop ramp using two time parameter.
 temperature sensor with signalisation using two limits: alarm and tripping.
 terminal for the EPB circuits for immediate stopping.
The “SSB” starter is a SS with contactor bypass for minimising temperature and losses of
the SS. The contactor shall be dimensioned minimum for the rated motor current, automatic
controlled by the SS electronic and direct by EPB circuits.
The “VSD(VFD)” starter is a starter for variable speed control by frequency converting
(F.C.) with integrated Motor Protection and with;
 Short Circuit F.C. Protection by special very fast fuses.
 Integrated monitoring and password protected manual control at the switchgear
front.
 Interface to the PLC with point-to-point or data-bus for monitoring, control and
parameterisation.
The F.C. shall have the features:
 adjustable for the particular motor rating current.
 adjustable current limitation.
 filters according to the EMC regulations Directive 2004/108/EC or equivalent
national regulations.
 cable filters for long outgoing cables, if required.
 voltage fault monitoring and tripping.
 separately adjustable start and stop ramp with two time parameter.
 possibility of adjusting the speed regulation by several regulating parameters.
 temperature sensor with signalisation with two limits: alarm and tripping.
 internal automatic controlled cooling system, if required.
 terminal for the EPB circuits for immediate stopping.

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Part 4 Electrical Specifications

2.2.26 PLC and Instrumentation components at the MCCs

The tasks of the PLCs at the MLVS and the MCCs are automation, management of manual
control, and as RTU data acquisition for SCADA. They shall also be enabled for central and
local setting and changing of control parameters.
The local HMI are as required for monitoring only. The manual control at the switchgear
where required should be conventional.

2.2.27 The I & C cubicle and auxiliary equipment

The I&C cubicle shall contain, as a minimum, the following features:
 UPS suitable for the PLC and the instrumentation connected to the particular MCC
for 30 mints power failure.
 The UPS shall be suitable for 24V DC output. If some of instrumentation needs AC
supply, the contractor shall supply an additional UPS for the particular AC supply.
 PLC with all needed I/O cards, CPU with RAM for program and data, 24V DC power
supply unit, interface to SCADA (RTU function) and required interfaces to data bus
connected equipment like the F.C.s and some of the instrumentation.
 Door mounted LCD operator touch screen interface unit (HMI) where required.
Internal data bus connection between PLC and HMI. The particular operational
Software.
 All required inverters of measuring sensors, if not local implemented.
 All other components, terminals, MCBs, interposing relays, surge arrestors for
power supply and surge arrestors for the different signal lines for surge protected
monitoring and control.

2.2.28 Standard LCP for drives

The most drives shall be equipped with LCP described as follow:
 Selection Switch MANUAL – 0FF – AUTO key lockable switch.
 Pushbutton ON.
 Pushbutton OFF.
Some are additionally equipped with an Emergency Pushbutton (EPB), whereas at other
drives this EPB should be installed separately.

2.2.29 Standard LCP for Actuators

For the actuators of the valves and the movable weirs the regarding LCP is:
 Selection Switch MANUAL – 0FF – AUTO key lockable switch.
 Pushbutton CLOSE / DOWN.
 Pushbutton STOP.
 Pushbutton OPEN / UP.
Integrated LCPs shall not be applied.

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Part 4 Electrical Specifications

2.2.30 Emergency push buttons (EPB)

Each EPB has to two contacts: one Normally Closed (NC) for disconnecting the main
contactor circuit; one Normally Open (NO) for signalling its pushing (switching) via the
relevant PLC.
The EPBs shall act individually on each motor or on a group of motors.
Each EPB shall get its own PLC input, so that a operation can be easily located,.

2.2.31 LCPs, EMP and Maintenance Switches at the Screens

Each of the four screens shall be manually controlled by the switches and pushbuttons:
 Selection Switch MANUAL – 0FF – TIME AUTO – LEVEL AUTO key lockable
switch.
 Pushbutton ON.
 Pushbutton OFF.
 Nudging Pushbutton RETURN.
The conveyors and compactors shall be equipped with standard LCPs.
But all these switches and pushbuttons shall be installed at a common panel together with
one general EPB.
In addition for each of the drives 1 EPB and 1 Maintenance Switch shall be installed adjacent
to the particular drive. The EPBs shall be installed considering safety and ergonomic
aspects, the Maintenance Switches can be arranged together with or as alternative to the
terminal box for the power cable.
Two EPBs for each of the compactors shall be installed, one at the screens and one down at
the drives.

2.2.32 LCPs, EMP and Maintenance Switches at the Grease Chambers

The Switchgear and LCP for the Grease Chambers shall be installed on the bridge as part of
the package unit. EPBs at both sides of the bridge shall operate direct on the bridge drive.
Two EPBs at both sides of the structure shall be provided operating on the feeder at the
MCC.

2.2.33 LCPs, EMP and Maintenance Switches at the Grit Chambers

The Switchgear and LCP for the Grit Chamber shall be installed on the bridge as part of the
package unit. EPBs at both sides of the bridge shall operate direct on the bridge drive. Two
EPBs at both sides of the structure shall be provided operating on the feeder at the MCC.

2.2.34 LCPs, EMP and Maintenance Switches for the Grit Classifiers
A standard LPC with EPB shall be provided for the Grit Classifiers at the concrete of the grit
chamber wall, where there is a good overview upon the Classifier. Another EPB shall be
provided down at the drive. The maintenance switch shall be installed near the drive too.

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Part 4 Electrical Specifications

2.2.35 LCPs, EMP and Maintenance Switches for the PSTs

The Switchgear and LCP for each PST shall be installed on the bridge as part of the package
unit. EPBs at both sides of the bridge shall operate direct on the bridge drive. Two EPBs at
two opposite sides of the structure shall be provided operating on the feeder at the MCC.
The modulating valve actuator for the sludge discharge shall be equipped with standard LCP
with EPB.

2.2.36 LCPs, EMP and Maintenance Switches for the ASTs

Standard LPCs with EPBs shall be provided for all drives and actuators at the ASTs. For the
mixers and aerators Maintenance Switches shall be provided.

2.2.37 LCPs, EMP and Maintenance Switches for the FSTs

The Switchgear and LCP for each FST shall be installed on the bridge as part of the package
unit. EPBs at both sides of the bridge shall operate direct on the bridge drive. Two EPBs at
two opposite sides of the structure shall be provided operating on the feeder at the MCC.
The modulating valve actuator for the sludge discharge shall be equipped with standard LCP
with EPB.

2.2.38 LCPs, EMP and Maintenance Switches for the RAS and WAS pumping
stations
The RAS and WAS pumps do not need LCPs because all manual control shall be installed
on the front of the adjacent MCC. EPBs and Maintenance Switches shall be installed
adjacent the particular pump.
The EPBs shall be installed considering safety and ergonomic aspects, the Maintenance
Switches can be arranged together with or as alternative to the terminal box for the power
cable. One additional EPB for all pumps shall be installed at the top of stair to the pumps
room.

2.2.39 LCPs, EMP and Maintenance Switches for the Sludge Thickeners
A standard LPC with EPB and a Maintenance Switch shall be provided for the thickener
drive. The maintenance switch shall be installed near the drive.

2.2.40 LCPs, EMP and Maintenance Switches for the Drainage Pumping
Stations
The switches and pushbuttons of the two pumps according to the standard LCP shall be
combined to one common LCP together with one common EPB.
The Maintenance Switches shall be installed as alternative to the terminal box for the power
cables of each drive.

2.3 Automation
The automatic control and the management of the manual control of each electromechanical
equipment of the plant shall be implemented in the associated PLC. The automation
programs shall be generally as described here and shall include any further relevant
operational item described and included by the supplier. The RTU tasks of the PLCs and
data acquisition for SCADA are not described in this section.

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Part 4 Electrical Specifications

The contractor shall submit a detailed program description and a PLC program flow chart for
the Engineers approval.
The contractor shall submit a complete I/O list for approval which shall include the SCADA
requirements.

2.3.1 General Control Philosophy

A: The plant shall normally be operated in automatic control.
B: Manual interface in the process is possible at the local LCP: If the local selection
switch is not in an AUTO position, no automation and no manual control action is possible at
the other locations (switchgear and SCADA). The hardwired safety interlocks shall still be
active and shall not operate not via PLCs.
C: Manual interface in the process is possible at the MCC if the local selection switch is
in an AUTO position. If the selection switch at the MCC is not in an AUTO position, no
automation and no manual control action is possible via the SCADA. The hardwired safety
interlocks shall still be active and shall not operate not via PLCs.
D: Manual Central Control as Supervisory Control (SCADA) shall be possible for some
equipment in emergency situations and in case the automatic control failed.
Some control parameters such as certain level limits, delays etc. shall be changeable under
the SCADA system.

2.3.2 Fault and Faulty Value Handling

The automation programs shall provide clearly defined reactions on any registered fault,
unexpected reactions or manual interference of or on the equipment. These are for example;
 Tripping of the electrical the C.B. or overload relays: alarming and starting of the
redundant drive.
 Failure of instrumentation: alarming, starting alternative program or stopping of
equipment.
 Unexpected or illogic data: alarming and depending on the logic, no action, stopping
or starting drives. This shall also be active in manual operation mode.
The effects of theses faults on other depending processes shall be considered in the
program.

2.3.3 Control of the screens station

The motors for screen station shall be explosion proof due to the gases that can be collected
inside the screen building.
Normal operation of the screens is with differential level control with the LCP selection switch
on LEVEL AUTO. On detecting a set maximum level difference of the levels up and down
stream of the screens the screen drive starts. The drive stops, if a set minimum level
difference is reached. If the operation time is too long the PLC sends an alarm to SCADA. If
the non-operation time is too long, the screen starts automatically for two cycles then it stops.
If one of level measuring devices are out of order he systems reverts automatically to TIME
AUTO operation. The level differentials are adjusted to suite site operational requirements.
If the selection switch is turned to TIME AUTO, the screen operates according to a operation
and pause program with the parameters operation time and pause time. Two different pairs
of parameters shall be provided, one for day time with a long operation and short pause time
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and the other for the night with a shorter operation and longer pause time. The clock time
from day to night and night to day is part of the operational parameters.
If the selection switch is set to the MANUAL position, the screen shall be enabled to be
turned ON and OFF and also be pulsed in the reverse direction for a short time, this shall be
provided to enable the operator to easily free the screen from a blockage.
The conveyor shall start automatically after the starting of either one of the screens and
stops after a delay when the last of the two screens stops.
The general EPB at the general LCP shall stop all four screens and the two conveyors.
The compactor starts automatically after the starting of the conveyor and it stops after a
delay when the last of the two conveyors stops.
Automatic programs shall be stopped by switching to MANUAL at the LCP or by EPB which
shall not be possible at the switchgear and at SCADA. The operation of the main night/day
clock shall not be suspended.

2.3.4 Control of the Return Pumping Station at the overflow tank

It shall not be programmed to operate on alternating duty/standby. One of the pumps shall
start pumping, if possible for both pumps to operate at the same time. They shall be the
water level in the overflow tank is above the low level and inflow of the WWTP is below
2,875m3/h (WWF). After starting the influence of the flow of the pumps on the measured
inflow shall be considered and if the inflow becomes too high the pump shall be stopped. The
alarm “too high inflow” shall be active in the manual operation mode. The operation shall be
stopped in automatic and manual mode, if level in overflow tank is low.
The automatic program will be stopped by switching to MANUAL at the LCP, at the
switchgear or at SCADA or by the EPB of the pumping station.

2.3.5 Control of the Grease and Grit Chambers

The automatic program of the Grease chamber is implemented at the Bridge Switchgear and
should be part of the package unit of the grit chamber manufacturer. The Bridge Switchgear
shall control the bridge drive and the two grease conveyors by automatic and manual control.
The bridge shall be operated on preset time intervals or by manual push button start, the grit
pumps shall operate whenever the bridge is in motion. It shall be also controlled by three
EPBs, installed at both ends of the bridge and at the Bridge Switchgear.
Additionally the power supply of the Bridge Switchgear shall be switched by contactor at the
MCC1, which is controlled manually at the switchgear and at SCADA, by other two EPBs at
the two ends of the grease chamber structure and automatically for the Emergency-Diesel-
Generator Starting Program.
The automatic program of the grit chamber is implemented at the Bridge Switchgear and
should be part of the package unit of the grit chamber manufacturer. The Bridge Switchgear
shall control the bridge drive and the two grit pumps by automatic and manual control. The
bridge shall be operated on preset time intervals or by manual push button start, the grit
pumps shall operate whenever the bridge is in motion. It shall be also controlled by three
EPBs, installed at both ends of the bridge and at the Bridge Switchgear.
Additionally the power supply of the Bridge Switchgear shall be switched by contactor at the
MCC1, which is controlled manually at the switchgear and at SCADA, by other two EPBs at
the two ends of the grit chamber structure and automatically for the Emergency-Diesel-
Generator Starting Program.

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The Grit Classifier shall start automatically after the starting of one of the two grit pumps. It
shall stop after a delay when the last of the two pumps stops. The two signals of the starting
of the pumps should be transmitted by wire from the Bridge Switchgear to the MCC1 PLC.
The automatic programs will be stopped by switching to MANUAL at the Classifier LCP
which shall not be possible at the switchgear and at SCADA or by the Classifier EPBs. The
two EPBs for the Grit Classifier shall be installed at the LCP and at the foot of the classifier
near the drive.

2.3.6 Control of the PSTs

The Bridges of the PSTs shall operate continuously in automatic mode. It shall be stopped by
three EPBs, installed at both ends of the bridge and at the Bridge Switchgear.
The PSTs shall be controlled by the starter at MCC1 & MCC2A, which is controlled manually
at the LCP, at the switchgear and at SCADA, by other two EPBs at opposite sides of the
structure and by the Emergency-Diesel-Generator Starting Program.
The position of the hydrostatic valves with modulating actuators at the sludge outflow of each
PST shall be automatically controlled by the separate sludge flow meters. The manual
control of the valve position shall be possible locally at the LCP and at SCADA.

2.3.7 Control of the ASTs

The mixers and flow makers of the four ASTs shall run continuously in the automatic mode
with low level protection. They shall be stopped by switching to MANUAL at the LCP, at the
switchgear and at SCADA, by the EPB or by the general EPBs for the selected tank. The
restart shall be done by switching the selector switches to AUTO, reset of the EPBs or
electrical faults or by the Emergency-Diesel-Generator Starting Program.
The aerators shall run continuously and be stopped by switching to MANUAL at the LCP, at
the switchgear and at SCADA, by the EPB or by the general EPBs for the selected tank. The
restart shall be done by switching the selector switches to AUTO, reset of the EPBs or
electrical faults or by the Emergency-Diesel-Generator Starting Program.
The oxygen concentration shall be monitored continuously and the blower motors speed
shall be changed, via VSD, automatically higher, if oxygen concentration is too low and
lower, if the oxygen concentration is too high according to PID regulator. If the oxygen
concentration remains high the program shall automatically switch off one aerator until the
concentration falls. An alarm shall be issued if the oxygen concentration falls below a preset
minimum value.
The blower motors speed is controlled automatically or manually at the LCP or at SCADA.
They shall be stopped by switching to MANUAL at the LCP and at SCADA, by the EPB. The
restart shall be done by switching the selector switches to AUTO or reset of the EPB or
electrical faults.

2.3.8 Controls of the FSTs

The Bridges of the FSTs shall operate continuously in automatic mode. It shall be stopped by
three EPBs, installed at both ends of the bridge and at the Bridge Switchgear.
The FSTs shall be controlled by the starter at the MCC3, which is controlled manually at the
LCP, at the switchgear and at SCADA, by other two EPBs at opposite sides of the structure
and by the Emergency-Diesel-Generator Starting Program.

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Part 4 Electrical Specifications

The position of the hydrostatic valves with modulating actuators at the sludge outflow of each
FST shall be automatically controlled by the separate sludge flow meters. The manual
control of the valve position shall be possible locally at the LCP and at SCADA.

2.3.9 Control of the Return Activated Sludge Pumping Station

The automatic program shall regulate the flow which shall be measured after the pumping
station which shall be dependent by the inflow of the WWTP by starting, stopping, increasing
and decreasing the speed of the pumps.
The automatic program will be stopped by switching to MANUAL at the LCP, at the
switchgear or at SCADA or by the EPB of the pump and the EPB of the station.
Additionally the Emergency-Diesel-Generator Starting Program shall control the starting or
restarting of the Pumping Station.

2.3.10 Control of the Waste Activated Sludge Pumping Station

The Waste Activated Sludge Pumps shall be automatically controlled on a daily time interval
and through the flowmeter to withdraw preset quantities of sludge. Manual control shall be
provided locally with only start and stop at the LCP and at SCADA. They shall run according
to a manually adjusted flow at SCADA. The program shall calculate the speed of the pump,
which shall adjust automatically the VSDs at MCC3.
Additionally the Emergency-Diesel-Generator Starting Program shall control the starting or
restarting of the Pumping Station.

2.3.11 Control of the Thickener

The Thickeners shall operate continuously in automation mode. It shall be stopped by two
EPBs, installed at both ends of the bridge and at the Bridge Switchgear.
The Thickener shall be controlled by the starter at the MCC5, which is controlled manually at
the LCP, at the switchgear and at SCADA, by two EPBs at opposite sides of the structure
and by the Emergency-Diesel-Generator Starting Program.

2.3.12 Control of the Mechanical Dewatering Station

The Mechanical Dewatering is a package unit, it shall operate in automatic control after
manual selection. The control shall be described by the manufacturer. Additionally the
Emergency-Diesel-Generator Starting Program shall control the starting or restarting of the
Mechanical Dewatering Station by a contactor at the MCC5 feeder.

2.3.13 Control of the Polymer Dosing

The Polymer Preparation is a package unit shall be automatically controlled for powder and
water delivery, storage and aging tanks after manual selection.
The polymer dosing pump shall be automatically controlled to operate whenever the
dewatering machines are in operation.

2.3.14 Control of the Thickened Sludge Pumping Station

The thickened sludge shall be manually controlled at the Mechanical Dewatering Station.
Additionally the Emergency-Diesel-Generator Starting Program shall control the starting or
restarting of the Pumping Station.

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2.3.15 Control of the Drainage Pumping Station

It shall be possible that both pumps operate at the same time if required. The two pumps
shall normally operate on alternating duty/standby. The operation of one or two pumps shall
depend on level and the speed of level descending when only one pump is operating. The
operation shall be stopped in automatic and manual mode, if the level in tank is low.
The automatic program shall be stopped by switching to MANUAL at the LCP, at the
switchgear or at SCADA or by the EPB of the pumping station.
Additionally the Emergency-Diesel-Generator Starting Program shall control the starting or
restarting of the Pumping Station.

2.3.16 Control of the Sand Filter Station

The Sand Filter Station is package unit. The control shall be described by the manufacturer.
Additionally the Emergency-Diesel-Generator Starting Program shall control the starting or
restarting of the Station Additionally the Emergency-Diesel-Generator Starting Program shall
control the starting or restarting of the Pumping Station.
Additionally the Emergency-Diesel-Generator Starting Program shall control the starting or
restarting of the Station.

2.3.17 Control of the UV Disinfection Station

The UV Disinfection Station is package unit it shall run continuously in automatic after being
selected by manual control. The power level of the UV unit shall be adjustable through the
SCADA as well as the UV control panel.

2.3.18 Wash water booster

The wash water booster shall be provided as a package unit complete with controls. The
control shall provide for maintaining the pressure and flow in the system and protection for
dry running of the pumps. All alarm signals shall be provided for the SCADA system.

2.4 Standby Stationary Diesel Generator

2.4.1 Scope of Works
The main items shall be included as follows:
 1 No. (400V,3Ph,50Hz) standby stationary diesel generator unit supply & installation
with all associated ancillary services, day tank, starting systems, cooling systems,
control panel, etc., to provide a complete operational system.
 1 No. air blast cooler system and engine cooler system.
 Control and auxiliary cabling.

2.4.2 Innovation
It is recognised that manufacturers will continue to develop new products, and improve
existing products, as part of the commercial and design processes. It is not the intention of
this specification to stifle improvement and innovation and new products incorporating
innovative features that enhance process performance and/or reduce whole life costs will be
considered. The generators shall be able to be practiced 8000 hours of operation within a 2-
year period without essential changes.
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2.4.3 Electricity Supply

The electricity supply provided by the new standby diesel generators and accompanying one
low voltage switchboard shall be at 400 volts, 3 phases, 4 wires, 50Hz.

2.4.4 Configurations
The diesel engine, generator, lubricating oil filters, fuel oil filter, lubrication oil strainers, fuel
oil strainers; lubrication oil coolers and other accessories deemed necessary by the
manufacturer shall be mounted on a common steel fabricated base. The common steel base
shall be sufficient strength to adequately support all equipment mounted on the base without
distortion either during operation or during shipment. If deemed necessary by the
manufacturer, the steel base shall be supported on steel spring vibration isolators or
sufficient size specifically designed for the weights and harmonics involved.
The isolators shall be furnished as part of the equipment. All spring connection from the
engine or accessories mounted on the steel base, such as air intake and exhaust, shall be
made by use of flexible connections. These flexible connectors shall be furnished as part of
the equipment.
All gauges shall be mounted in easily readable locations.

2.4.5 Generating Unit

The standby stationary diesel generating set shall be designed for 1100 kVA at maximum
load at power factor 0.8 for short time (starting of the greatest drive).

2.4.6 Ambient Temperature

The standby diesel generator set shall be suitable to operate at the ambient air temperature
in the generator room of 45oC and up to 500 meters altitude.

2.4.7 Generator
The alternator shall be a self-exciting, self-regulating brushless type to a degree of protection
not less than IP23, utilising CACA air cooling.
The excitation system shall be controlled by a semiconductor based automatic voltage
regulator (AVR) system and shall be self-exciting under all conditions, and capable of
producing at least twice full load machine current under short circuit conditions. The
machine’s output voltage shall remain stable when operating with all types of nonlinear
loads, such as large ac inverter variable speed drives.
The alternator and excitation equipment shall be of the quick response type suitable for the
starting of the largest load (ASTs).
The machine shall be constructed in accordance with BS 4999: Part 101, rated for type S8
duty, with loading requirements as detailed for each application.
Radio interference shall be suppressed to meet the requirements of BS 800.
The generator shall provide a 1100KVA, 400V, 3ph, 50Hz, 4-wire electrical output with power
factor of 0.8 lagging and the voltage shall be maintained within ± 2.5% at all load conditions
between no load and full load. When the generator operates at its full load, this ± 2.5%
tolerance shall apply with a power factor anyway between unity and 0.8 lagging.

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The generator shall be air cooled and the output voltage, measured at its terminal box, shall
not be less than 87% of design output under any transient condition, in the specified ambient
conditions.
The generator must be capable of running at 110% full load for 1 hour in every 12 hours at
maximum ambient temperature.
The generator output frequency shall not be less than 45Hz under any condition.
The alternator terminal box shall be suitable for the termination of XLPE insulated armoured
cables.

2.4.8 Prime Mover

The prime mover shall be a diesel powered internal combustion engine, and shall be
continuously rated in accordance with BS 5514, with governing as Table 2 Class A1.
The engine shall be provided with a flywheel to limit cyclic irregularities in accordance with
BS649.
The engine shall be fitted with a speed monitoring device suitable to provide an output signal
to terminate cranking, to provide engine speed indication and to provide an over-speed
signal.
The engine shall be suitable for battery starting.
The engine shall be provided with a remote mounted radiator cooling system.
The engine speed shall not exceed 1500 rpm.
The mean effective pressure inside the engine cylinder should not exceed 20kg/cm².

2.4.9 Engine Type

The engine shall be of four strokes, vertical, single acting solid injection, cold starting, turbo
charged, intercooler with prime mover using the exhaust energy system.

2.4.10 Engine Mounted Control Panel

The engine shall have a local control panel mounted on the engine in a position easily
observed by an operator standing on the floor beside the engine.
The engine control panel shall include as a minimum the following features:
 Engine speed indication
 Engine lub oil pressure
 Engine lub oil temperature
 Engine inlet cooling water temperature
 Engine outlet cooling water temperature
 Battery starting system
 Charge air pressure (for each cylinder bank)
 Local / remote selector switch
 Start button
 Stop button
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 Emergency stop button

This information may be presented by discrete instruments or in the form of a screen display,
as generally provided by the engine manufacturer. All information displayed at the engine
control panel shall provide electrical signal duplication for transmission to the Generator
Control panel.
In addition, mounted adjacent to the engine control panel, or forming part of the engine
control panel, there shall be an instrument capable of monitoring and displaying all the
cylinder head temperatures. This information is only required at the engine and does not
need to be transmitted to another location.

2.4.11 Engine Governor

The engine governor shall be of the electrically actuated type to enable automatic
incremental adjustment of engine speed. The governor system shall be capable of operating
either as a master or slave system. The governor shall be hold the engine speed to within
+0.25% of any selected speed at any constant load.

2.4.12 Engine Speed Characteristics

 Stability: 0.25% maximum frequency variation at any constant load from no load to
full load.
 Regulation: 1% maximum frequency deviation at constant loads between no-load and
full load at steady state.
 4% maximum frequency dip with application of 50% load with 50% load on generator.
 4% frequency rise with removal of 50% load with 50% load on the generator.
 Six seconds recovery time to return steady state.
 Provide externally adjustable speed and limit.
 Provide motor for remote speed adjustment.

2.4.13 Engine Lubrication

The engine shall be provided with a positive pressure oil lubrication system. The
arrangements may use either an engine driven system or an electric motor driven system.
However, the manufacturer shall ensure that the engine lubrication system is suitable for a
black start condition.
The details of the proposed system are included in the original copy of the employer's
specifications.
Lubrication oil filters and the means to drain and refill the engine lubrication system shall be
provided in a position readily accessible to an operator at floor level.
The lubrication oil filter shall be a twin element design and shall allow the changing of an
element while the engine is running.
The design of the engine shall provide adequate lubrication oil cooling via the engine cooling
system such that additional coolers for lubricating oil are not required.

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2.4.14 Cooling System

The engine shall be liquid cooled of a closed type system with liquid- to air radiator supplied
with blower fan to maintain desired operation conditions.

2.4.15 Jacket Water Expansion Tank

A jacket water expansion tank of adequate size shall be provided. The tank shall be
complete with all valves and fittings.
The tank shall be either mounted on the engine or remote mounted with all piping, fittings,
expansion of fill and vent, and visible level indicator.

2.4.16 Jacket Water Temperature Control Valves

The Jacket Water Temperature Control Valve shall be of the thermostatic type with 3 way
body and flanged connections. The suppliers design shall maintain the jacket water
temperature within the requirements. The valve shall be of the failsafe type to prevent engine
overheating due to valve failure.

2.4.17 Engine Starting System

The engine shall be equipped with a set of batteries with battery charger for starting of the
engine. A station battery shall be provided and to be of the nickel cadmium or lead calcium
material type and shall be rated at 24 volts and sized to start the engine efficiently.
The battery shall be supplied complete with inter-cell connectors and rack.
The battery charger shall have the capacity to recharge a fully discharge battery in 24hours.
The charge shall have provision for wall mounting. The charger shall be made of silicon
rectifier constant voltage, current limiting mag-amp type.
Each charger shall have it's own I/P and O/P fuse, also an ammeter and voltmeter are to be
installed in the front of each charger.

2.4.18 Engine Heater

The engine shall be fitted with a 230V, 50Hz heater for the water jacket in order to maintain
the set in a warm state for starting. This heater shall be thermostatically controlled and
disconnected automatically when the engine is running.

2.4.19 Generator Set Bedplate

The diesel engine and alternator shall be rigidly mounted on a robustly constructed mild steel
fabricated bedplate so that all alignment is carried out at the manufacturer’s workshop.
The combined unit together with its bedplate shall be mounted on to a prepared concrete
foundation using anti-vibration mountings.
The energy absorbent elements within the anti-vibration mounts shall be impervious to all
operation fluids associated with the prime mover.
In order to take into account the effects of the anti-vibration mounts, all connections to the
combined unit shall be flexible, and shall be terminated, where possible, nearest to the point
of least movement.
Where access is provided to rotating elements of the generator set then close mesh guards
shall be fitted at such locations which shall allow access to lubrication points only. These
guards shall be removable for routine maintenance requirements.
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To enable access to the highest parts of the engine for inspection and maintenance functions
a suitable access platform(s) and access ladder(s) shall be provided as fully integrated parts
of the generator set.

2.4.20 Spillages
Arrangements shall be provided to enable the collection of fuel and lubrication surpluses in
the form of a drip tray(s) or other discrete collection elements. Where such surpluses are
collected the collection point shall be in a position to enable the contents to be removed
easily by the operator.
Any interconnecting fuel or oil pipework which cannot be incorporated into the collection
elements shall be installed within a larger diameter pipe which shall only drain to a collection
element in the event of a spillage from the pipe.

2.4.21 Colour
The whole of the power unit comprising the engine, generator and bedplate is to be painted
the same colour. If no colour is specified for the application, the Supplier shall state in the
tender the standard colour normally supplied. The colour shall be approved in writing by the
Engineer.

2.4.22 Fuel System

The engine shall run on standard 35 second diesel fuel.
All fuel and oil stores required under the contract within shall be designed, constructed and
installed in compliance with prevailing local Regulations.
The capacity of the bulk tank shall be not less than 4 days continuous operating and shall be
Horizontal vertical steel tanks according to European or American international standard.
A day tank of sufficient capacity for 8 hours operation at full load shall be provided mounted
on a frame work to enable a gravity feed to the engine fuel pump. The day tank shall be
complete with all associated engine supply pipe work and fittings.
The day tank shall be of the double skin design with a drain cock provided to allow the
contents of the outer skin to be drained down. This drain point shall be piped to a point
common with the drain from the day tank itself and the drain from the dump tank.
Two electric pump and controls shall be provided, together with all interconnecting pipe work
and fittings to enable transfer of fuel from the existing bulk tank. These works shall also
include a connection into the supply pipe from the bulk tank at a suitable position. A semi-
rotary manually operated hand pump shall be installed within this system to allow the manual
transfer of fuel if necessary.
A suitable in line filter of the twin pot design shall be installed in the fuel line from the bulk
tank to the transfer pump. It shall be possible to remove and clean one filter while the fuel is
being transferred.
A suitable in line filter of the twin pot design or twin element design shall be installed in the
fuel line from the day tank to the engine. It shall be possible to remove and clean one filter or
filter element while the engine is running.
All electrical controls and monitoring instruments for the fuel transfer and supply system shall
be mounted in the Generator Control Panel.

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A dump tank shall be provided complete with all associated pipe work to receive surplus fuel
from the engine injection system. The drain pipe work from the dump tank shall be piped to a
point common with the drains from the day tank.
A fire valve of the dead weight type in the supply line to the engine shall be provided to
operate by fusible links above the engine, and shall be complete with an interconnecting wire
and pulley system.
A ladder and platform access arrangement shall be provided to enable access to all parts of
the day tank and engine fuel supply system.
The day tank shall be fitted with a mechanically operated contents gauge mounted so as to
be easily read by the operator standing at floor level.
The day tank shall be fitted with a level measuring system to enable automatic operation of
the electric fuel transfer pump and the monitoring of the tank contents.
The fuel supply line from the day tank to the engine shall be fitted with a mechanical fuel
meter calibrated in litres. This flow meter shall be fitted with an electronic sender unit such
that the signal can be transmitted to the generator control panel.
All instrumentation shall be mounted such that the instrument information can be read by the
operator standing at floor level.

2.4.23 Exhaust System

The exhaust position shall be as agreed.
The Supplier shall provide and install the complete exhaust system, suitably lagged to
prevent heat loss to the building. The exhaust system metalwork shall be aluminised to
prevent corrosion and shall be fitted with a bird guard at the discharge end. The exhaust
system inlet shall be stainless steel flexible connection to the engine exhaust outlet stub.
The exhaust silencer shall be mounted horizontally, complete with all necessary supports.
The silencing and exhaust system shall be bracketed from adjacent walls and/or supported
from the floor. Supports from the generator building roof or ceiling are not permitted.
The silencer design shall have flanged connections at each end of the silencer.

2.4.24 Warning Labels

The machine shall be fitted with a yellow triangular label with a black border and a black
exclamation mark, on each side of the generating set, with the wording:
DANGER
AUTOMATIC MACHINERY
STARTS WITHOUT WARNING
Warning notices shall be attached to each side of the generating set with the wording:-
INHIBIT AND ISOLATE STARTING SYSTEM
BEFORE COMMENCING MAINTENANCE WORK ON THE SET

2.4.25 Earthing
The generator sets shall be connected to the earthing arrangements at the generator
building.

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The Supplier shall be responsible for confirming the suitability of this earth for the connection
of the new generator set and for making recommendations for any necessary modifications.

2.4.26 Generator Operating Mode

The generator set shall be automatic starting through Automatic transfer switch connected
between the transformer and the generator to keep the generator as an emergency power
supply and manually starting / shutdown only for testing .

2.4.27 Generator Control Panel

The electricity supply to the generator control panel shall be:
 400V 3 phase 4 wire 50Hz to provide 3 phase and single phase power voltage
 24V DC for all control and instrument circuits.
The generator control panel shall receive a supply at 400V 3 phase 50Hz 4 wire from the LV
switchboard housed in the low voltage room. This supply shall be taken from the portion of
the LV switchboard fed by the transformer, so if the transformer fail the UPS will feed the
critical loads until the generator take its synchronisation speed and feed power to the low
voltage switchboard, so consequently feed the generator control panel again, so this 400V
supply is always available to the generator control panel. This 400V supply shall be used for
the power supply to electrically driven pumps and fans.
The generator control panel shall include a battery charger with boost and float charge
facilities to provide the 24V DC supply. The charger shall be sized to recharge a flat battery
to 80% capacity in 24 hours, and also be capable of supplying the standing load at the same
time. A 0-5 hour timer shall also be included to provide the boost facility in conjunction with
the Battery Charger Boost push button. A volt-meter and ammeter shall be provided on the
front of each charger.
The generator control panel shall comprise a wardrobe type enclosure containing as a
minimum controls for the following:
 Generators
 Fuel oil transfer pump
 Radiator air blast fans
 Control circuit battery and charger systems.
The generator control panel shall comply with the requirements of the General Electrical
Specification.
In addition to all the manufacturers standard features for engine start and stop control the
following shall also be included:
 Protection hold-off systems to inhibit high water temperature and low oil pressure
shutdowns until 15 seconds after running speed has been sensed.
 A stop sequence timer to allow the set 30 seconds to stop rotating.
 Circuitry to provide a maximum of 3 attempts to start the engine with crank and dwell
periods of 10 seconds, with a fail to start signal initiated at the end of the third crank
period if the engine fails to start.
 Safety devices shall be provided with an active audible and visual alarm system.

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The following components, as a minimum, shall be mounted on the front of the control panel:
 Charger isolator OFF/ON switch to simultaneously isolate the battery charger from
the 240V supply, and isolate the battery charger from the battery,
 Engine heater OFF/ON switch.
 Fuel oil transfer pump Man / Automatic
 Air blast cooler fan(s) Man / Automatic
 Switch for engine control
Pushbuttons:
 Battery charger boost
 Manual start
 Manual stop
 Emergency stop
 Alarm reset
 Lamp test
 Fuel oil transfer pump start
 Fuel oil transfer pump stop
 Air blast cooler fan start (for each fan)
 Air blast cooler fan stop (for each fan)
Indicators-Back lighted enunciators
 Mains failed Red
 Generator failed Red
 Engine heater on Yellow
 Engine control on Blue
 Boost charge in progress Red
 Low air start pressure Red
 Engine failed to start Red
 Over speed shutdown Red
 Earth leakage shutdown Red
 Generator over current shutdown Red
 High water temperature shutdown Red
 Low lub oil pressure shutdown Red
 High lub oil temperature shutdown Red
 High charge air temperature Red
 Low fuel level day tank Red

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 High fuel level Yellow

 Fuel transfer pump running Yellow
 Fuel transfer pump stopped
Yellow
 Fuel transfer pump failed
Red
 Air blast cooler fan running Yellow (for each fan)
 Air blast cooler fan stopped Green (for each fan)
 Air blast cooler fan failed Red (for each fan)
 Generator winding temperature high Red
 400V circuit breaker fault shutdown Red
Indicating Instruments:
 Generator output voltage with a red line at the line to line operating voltage, together
with a selector switch to monitor line and phase voltages
 Generator output current with a red line at the maximum operating current, 3 no 1 per
phase
 Generator output frequency calibrated 45 to 55 Hz. This shall not be a vibrating reed
instrument.
 Generator output power factor
 Generator hours run meter, non-resetting
 Engine speed
 Engine lub oil pressure
 Engine lub oil temperature
 Battery start system
 Engine inlet cooling water temperature
 Engine outlet cooling water temperature
 Fuel consumed
 Battery Voltage
 Battery Charge/Discharge Currents
 Wattmeter
In line with present technology, the generator set manufacturer is encouraged to consider the
use of composite electronic systems such as combined electronic generator protection relays
and LCD panel display units with touch screen facility, to provide the human interface with
the generator controls and displays, provided always that these systems shall operate with
long term reliability in the prevailing ambient conditions.
The Supplier shall indicate clearly in the offer the systems proposed.

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2.4.28 Construction Information

The generator set manufacturer shall be responsible for providing, with the offer, full details
in drawings and documents of all the civil engineering works required for the installation of
the generating set.
This shall include, but not be limited to, the engine/generator set foundation block and
foundations for day tank fuel system, cooling water system, battery charge system, starting
system and generator control panel. Details for cable and pipe work routes and any
associated ducts and trenches, wall and floor penetrations shall also form part of this
information.
Documentation to be supplied by the successful bidder shall be issued 2 weeks after the
offer is accepted in writing.

2.4.29 Protection relays

All Protection relays must be microprocessor based, numeric type, and includes disturbance
recorder.
The relay must have the capability to communicate with SCADA system through standard
bus. The design shall be in accordance with IEC regulations

2.5 Lightening Protection and Earthing Systems

2.5.1 Scope of Works
The Works includes the following main items:
 Supply and installation of Lightening Protection Systems.
 Supply and installation of Earthing Systems.

2.5.2 Earthing and Lightning Protection Standards

The Contractor shall establish in accordance to IEC 62305 Lightning Protection and in
accordance to IEC 60364 Earthing Systems at all buildings and structures of the As Salt
WWTP.

2.5.3 Earthing systems

The earthing systems shall comprise a system of earth rods connected together by stranded
copper conductors which surround each building or structure. These single earthing “circles”
shall be connected to each other by stranded copper conductors. Each circle shall be
connected minimum twice to the other circles.
Earthing bus bars at defined locations shall be connected to this multi circle earthing system.
As minimum requirement: at each of the switchgears two earthing bus bar shall be provided.
The earthing points of all equipment or its metallic housing shall be connected to one of
these Earthing bus bars.
At structures or in buildings without switchgear the number of to be provided bus bars shall
be optimised to minimise the cabling of the earthing conductors.

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2.5.4 Earth Value

The completed earth system at each designated building shall be tested by the Contractor in
the presence of the Engineer and demonstrated to have a resistance value less than 1 ohm.
The described systems are the minimum installations required. However, if the installation
fails to achieve the resistance value of less than 1 ohm, additional rods and copper
conductor shall be installed as necessary for the desired result to be obtained.

2.5.5 Earth Rods

Earth rods shall be of the type consisting of electrolytic copper bonded to a steel core.
Earth rods shall be minimum 1800mm long and approximately 20mm in diameter, treaded to
allow rods to be connected together using high copper content alloy threaded couplings.
Couplings shall not be commercial brass.

2.5.6 Earth Pits

Each earth rod shall be fitted with a concrete inspection pit to allow access for routine testing.

2.5.7 Earth Conductors

The conductors to be used for the interconnection of the earth rods and earth bars shall be
stranded copper 70mm2, laid directly in the ground with a minimum cover of 750mm, or PVC
GREEN/YELLOW insulated stranded copper 70mm2, if not laid under earth. For small
distances of the not insulated copper (i.e. for connection to earth bus bars) other materials
for protection than PVC could be used, i.e. butyl rubber ribbon.
Earth conductors between earth rods shall be continuous. All connections or junctions shall
be made at earth rods using a proprietary clamp arrangement from the manufacturer of the
earth rod materials.
The connections to the earth bars mounted inside the buildings shall be made at a
convenient point on the earth conductor. The connection at this point shall be made by
welding the cable to the earth conductor. The joint shall be covered with a heat shrink
protective boot or butyl rubber ribbon after the connection has been completed.

2.5.8 Equipotential Bonding

Each metallic part, which is not at normal operational condition connected to the operational
voltage, shall be connected to one busbar by PVC insulated stranded copper minimum
16mm2. This electrical connection can be done via other metallic parts which are also not at
normal operational condition connected to the operational voltage. The result shall be that all
these part are of the same electrical potential.

2.5.9 Earth Bars

2 no earth bars shall be provided for each transformer substation switch room or MCC room.
The earth bars shall be made from 50mm x 6mm hard drawn copper bar, hot dip tinned after
cutting and drilling.
The Contractor shall provide earth bars for the different applications with 6, 8, 10 or 12 holes
for M10x25 screws for the fixing of the cupper conductors.
Each earth bar shall be fitted with a bolted link connection at each end of the earth bar to
allow the earth bar to be disconnected from the earth conductor system for test purposes.
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Each earth bar shall be connected to the earth conductor installation by two separate cable
connections, one from each end of the earth bar.
The earth bars shall be positioned inside buildings in the rooms with switchgears and in
rooms with metallic equipment. Maximum one busbar for one room shall be provided.
Concerning the outside bus bars each machinery or plant or group of engines shall be
equipped with one bus bar.
The bus bars shall be protected with suitable cover of rigid plastic.
The exact location of the earth bars will be advised during installation.

2.5.10 Lightning Protection

The lightning protection system shall consists of suitable (according IEC 62305) Air-
Termination Rods, their proper whether (storm) proofed fixing equipment and their own
earthing rods. The connection to the earthing rods shall be disconnectable.

2.5.11 Acceptance Testing Earthing Systems

An independent qualified expert or certified organisation shall carry out acceptance tests of
the electrical equipment. All costs shall to be borne by the Contractor. Such testing shall be
carried out before commissioning tests. Tests shall be carried out according to pertinent
standards and regulations, and shall comprise at least the following:
 inspection of installation
 inspection of resistance of each earth rod installation
 inspection of resistance of earth system complete.
Test reports shall be drawn up and made available for the Engineer.

2.6 Supervisory Control and Data Acquisition (SCADA) System

2.6.1 Scope of Works
The Works includes the following main items:
 Supervisory Control and Data Acquisition SCADA System

2.6.2 Innovation
It is recognised that manufacturers will continue to develop new products, and improve
existing products, as part of the commercial and design processes. It is not the intention of
this specification to stifle improvement and innovation and new products incorporating
innovative features that enhance process performance and/or reduce whole life costs will be
considered.

2.6.3 General
A computer based Supervisory Control and Data Acquisition System (SCADA) shall be
provided for monitoring and controlling the operation of the WWTP.
The SCADA system shall be located in the WWTP control room in the new administration
building.
The SCADA system shall be configured as a distributed system with programmable Logic
Controllers (PLC’s) as RTU installed in each MCC carrying out all control and monitoring of

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the plant and equipment connected to the MCC. Each PLC shall work autonomously allowing
control to continue in the event of a communication network failure.
The system shall be designed to operate 24 hours a day without any necessity of attendance
from the personnel.

2.6.4 Functional Requirements

The SCADA system shall perform the following operations as a minimum:

• Supervision of the WWTP.

• Monitoring of alarms and status of the WWTP.
• Limited control operations such as stop and start certain pumps or other parts of the
WWTP equipment.
• Password protected changing of parameters such as level limits or timers for the
PLC programs.
• Management reports for operational management analysis and planning
preventative maintenance.
• Real-time handling and storing of data and alarms collected by the PLC’s.
The PLC’s shall perform the following operations as a minimum:
• Fully automatic control of the WWTP.
• Real-time collection of data and alarms.

2.6.5 Communication Network

The communication network between the RTUs and the SCADA system shall be based on a
system optical fiber based Ethernet LAN 1Gb minimum. The RTU may adopt also the PLC
tasks at the MCCs ( also called RTU/PLCs).
All transmissions shall be carried out with error detection capability and data shall be
retransmitted automatically in the event of a transmission error occurring.
Monitoring information and alarms generated at a RTU/PLCs shall be transmitted to the
SCADA system for registration and monitoring. In the event of a loss of transmission, the
SCADA system shall retain the last information received for display and logging purposes
and shall refresh all data as soon as transmission is reinstated.
The contractor shall submit his proposal for the Communication Network to be reviewed and
approved by the Engineer.

2.6.6 Electricity Supply

The electricity supply to the SCADA system, PC, printers, etc., shall be 230V AC single
phase from an uninterruptible power supply UPS rated to provide a minimum of 2 hours
support. All SCADA centre equipment shall be powered from this UPS including alarm printer
bur except the other printers and equipment not needed data transfer, registering and
monitoring. The Contractor shall submit a regarding power balance for approval.

2.6.7 Hardware
The server and operator workstations shall be of the Personal Computer type, of a reputable
make and in the firm's professional series to the approval of the Engineer.
As a minimum the computer shall fulfil with the following requirements:

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The Contractor shall design, supply, install and commission the SCADA centre with the
components:
 Double (redundant) router system for the connection of the SCADA centre to the local
components.
 DSL modem for connection to internet
 2x 1Gb Ethernet interface for fibre cable
 2 workstations (high quality standard PC).
 1 programmer workstation (high quality standard notebook).
 1 Alarm/Event printer
 1 colour ink jet printer (A3) and 1 laser printer (A4) or better
 Two (redundant) data recorder (may be incorporated in the workstations).
 interfaces for exchange of information with GIS, MIS and accounting computers
 Network (Ethernet LAN) for the interconnection of SCADA centre components
 Acoustic alarm and alarm reset push button
 Strip chart recorder for the five most important measured values (as redundancy)

2.6.8 Software General

All programs shall fulfil the following requirements:
• Be standard programs to the extent possible
• Be easy to modify and replace
• Be tested and free from faults.
• All software shall be in English versions

The operating system software for the server PCs shall be newest Microsoft Windows
version for Advanced Server and for the workstation PCs should be newest Windows
Professional version..
The PCs shall have installed newest Microsoft Office Professional version.
The PCs shall have an updated virus protection system. The virus protection system shall be
with subscription in order to keep the system updated all the times.
All the Programs and Software shall be delivered with its original CD and its license.

2.6.9 SCADA Program

The computers of the SCADA centre shall be furnished with high quality “water” process
controlling and monitoring software. The program shall base on the IEC 60830 standards.
The license shall be valid for the router and the two workstations.
They shall be programmed with the As Salt WWTP details as explained below. These details
shall be verified by the contractor after ordering.
The functional requirements for the SCADA programming system shall fulfil the following
requirements as a minimum:
• Collect data as real-time values

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• Store and handle the real-time data including performing arithmetic and logical
functions
• Undertake monitoring, alarm and fault handling
• Undertake self-diagnosis of the computer
The programming system shall collect, handle and store data while all other activities are on-
going.
A number of screen graphics to display the process shall be prepared. Each graphic shall
provide the facility, via overlay graphics, to select a number of detailed graphics which shall
include the composition and data of the parts of the process being viewed.
The following requirements are required for all mimics(graphics):
 The background colour for all mimics(graphics) shall be subject to the approval of the
Engineer.
 All flows shall be displayed in engineering units as specified in the I/O listing of the
agreed Functional Design Specification.
 Each mimic(graphic) shall have navigation 'pushbutton' to the process overview, the
geographical overview and associated process mimics(graphics) .
 The symbols used to describe the plant items shall be subject to the approval of the
Consultant.
 Mimics(graphics) shall display process lines as colour dynamic with arrow indication
of flow direction.
 Alarms indication shall be animated within the relevant mimic(graphic).
 Trend pages (including historic and current information) and the alarm summary page
shall be available from every mimic(graphic).
 The Contractor shall configure each on-site workstation such that a screen dump can
be printed by a single keyboard/on-screen action.
 Control pages for all plant that can be controlled, overridden or plant data entered
manually shall be available from every mimic(graphic).

2.6.10 Access Levels

The use of passwords shall limit the access to the control system for the operators. A
minimum of three levels shall be included.
Level 1: Will allow the operator to acknowledge alarms, initiate prints, monitoring of data and
screen pictures.
Level 2: As level 1 including changing of parameters, stop and start of motors.
Level 3: Administration access to allow changes to the SCADA program and access to PLC
programs.

2.6.11 Operator Interface

The SCADA system shall be easy to operate for persons with little or no knowledge of
computer systems.
Frequently used commands shall be operated from function keys or via the mouse.

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Operation of the system shall be based on an extensively use of the mouse to promote fast
and easy selections.
The operation shall be interactive and it shall be possible to display messages with
information that is helpful for the operator.
The internal clock shall be supplied with battery back-up or it shall automatically be adjusted.

2.6.12 Configuration
The SCADA software program shall allow the operator to extent and change the control and
monitoring, the reporting and the process configuration. The program shall be the interactive
type with explanatory messages to the operator.
The configuration shall be carried out via a well-documented standard program specifically
designed for configuration of the system (not via programming in a standard high level
programming language).
Changing or extension of the configuration shall include removing and/or adding of
components (motors, valves, instruments etc.), and it shall include all disciplines such as
addresses, conditions, alarms, reports, monitoring etc. Access shall be limited via password.
The program for configuration shall include a check program that will detect and disclose all
errors and allow only fault free configurations to be operational.
The contractor shall design following interactive pictures for the workstations.
The program to be installed at the routers and all workstations shall manage all acquired
data and shall enable the operator to monitor and control (supervisory control) the WWTP
and shall manage the automatic data storage and alarm printer output. The program shall be
a high quality standard program for waste water treatment plants.

2.6.13 Screen Graphics

Screen graphics shall be prepared to represent to the operator the entire process system for
the WWTP. The graphics shall be based primarily on the P & I drawings but shall also
incorporate additional features based on the plant and building layout drawings.
Sufficient pages shall be created to enable clear representation of all displayed items and
information, and where systems are required to be spread over a number of pages then
automatic links shall be provided between pages to enable the operator to move smoothly
through the system.
The graphics shall be configured to incorporate appropriate poke points/buttons to give
access to overlay screens for adjustments to set point parameters and for the HAND/AUTO
operation of individual items of plant.
In addition, graphics shall also be included to show relevant information from both upstream
and downstream sites.
Outlines of all the proposed graphics shall be supplied for approval prior to preparing the final
full colour graphics.
The graphical presentation shall be departed into many pictures, showing

 Overview of the whole WWTP

 Overview of the screens station and the stormwater overflow tank and PS
 Overview of the Grease removal and Grit chambers with grit classifier
 Overview of the 2 Primary Sedimentation tanks 1 and 2
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 Overview of the 2 aeration tanks 1 and 2

 Overview of the 2 final sedimentation tanks and water quality measuring
 Overview of the 2 RAS / WAS pumping stations
 Overview of the 3 mechanical thickeners and the drainage pumping station
 Overview of the 3 sludge dewatering station including sludge pumps
 Overview of the Sand Filters
 Overview of the disinfection stations and lagoon
 Overview of the main electrical power supplies and distribution including Diesel
 Overview of the CHP generation station, biogas handling and treatment.
 Overview of the 2 Gravity sludge thickeners
 Overview of the boiler station
 Overview of the service water pump station
 Overview of the PV panels all over the plant
 Detail pictures of each drive and each measuring station
These pictures shall give a vivid impression of flow, pressure and water resp. sludge levels.
All pictures with pull-down menus for the measured values and the equipment of these
pictures showing their available data.

 Possibility of system extension for additional 100 pictures

 Summary of all measuring points in data schedules
 Summary of all measurements in bar graphs
 Possibility to show histograms of each measuring point with zooming facilities
and min./max. function
 Possibility of system extension for additional 100 histograms
 Possibility to change easily from picture to picture without going back to
overview.
 Possibility to open a single measuring point by clicking into an overview
pictures.

2.6.14 Management Reporting

The SCADA system shall work together with the Microsoft Office suite of programs to
produce management reports as required. These reports shall comprise, but not be limited
to, the following:
 Flow reporting
 Quantity reporting
 Water quality reporting
 Stores stockholding
 Time based planned maintenance reporting
 Operating and maintenance schedules
It shall be possible for reports to be prepared at daily, weekly, monthly or yearly periods on
demand or other such time periods as required.

2.6.15 Graphical Standards:

Background Colours
All graphics backgrounds shall be light grey in colour.
Static Structures

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All static structures (including buildings and mechanical objects) shall be represented in
brown outlines of varying thicknesses.
Process Colours
All process pipelines and associated text displays will follow these colour codes:
Raw Sewage Blue
Settled Sewage Green
Primary Sludge Dark Brown
Waste Activated Sludge Light Brown
Water Light Blue
Grit and Scum Red

All Plant items (MCCB, Motors, actuated weirs, etc.) shall follow these colour codes:
On, Running, Open Plant symbol is shown in Yellow
Off, Stopped, Closed Plant symbol is shown in Green
Failed & Unacknowledged Plant symbol is shown in Flashing Red
Failed & Acknowledged Plant symbol is shown in Steady Red
Under Maintenance / Isolated Plant symbol is shown in Yellow inside a
white outline Box'
Auto Selected Word AUTO Word ‘AUTO’
appears appears
on the right ofon
thethe right (for all Motors)
plant symbol
Manual Selected Word MANUAL Word ‘AUTO’onappears
appears the rightonofthe
theright (for all Motors)
plant symbol
Position Word ‘AUTO’
A numerical display appears the
field alongside on the right (for all Motors)
plant
symbol shall display the actual position in
the relevant units

2.6.16 Analogue Values

All analogue displays, (temperature, flow, pressure, level, quality) shall be dynamic. A
bargraph representing the analogue value shall rise and fall in proportion to the analogue
value and will be displayed in Light Yellow.
When a 'High High Level' is reached a thick red bar will be displayed across the bargraph.
When a 'High Level' is reached a thick orange bar will be displayed across the bargraph.
When a 'Low Level' is reached a thick orange bar will be displayed across the bargraph.
When a 'Low Low Level' is reached a thick red bar will be displayed across the bargraph.
A numerical display field alongside the plant symbol shall display the actual contents in the
relevant units.
Textual Alarms
Alarm conditions will be displayed by textual dynamics located on the graphics.
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Point Status Display

Healthy condition Invisible (Graphic ground colour)
Alarm Condition Text message in Red
Analogue Values
Analogue values will be displayed in a white box with associated units located adjacent to the
box.

2.6.17 Alarms
Alarm Generation
All alarms shall be generated in the respective PLC's and transferred to the SCADA system
as a discrete bit. Alarms shall be generated in the PLC as described below:
 Discrete Digital Input - Generated by a field device i.e. pressure, level, temperature
switch and designated an alarm condition within the PLC.
 Analogue Derived - An alarm derived within the PLC by configuring a point or points
from an analogue input
 PLC Derived - An alarm derived from 2 or more discrete or derived signals
Alarm Display
All graphics shall have a three line banner at the bottom of the page which will display the
last three active alarms in descending order. The alarm banner shall be updated as new
alarms are generated, with the latest active alarm always being displayed on the top line.
The alarm summary page shall be accessed from any graphic via a function key or by
clicking on the screen poke point. The alarm summary page shall display all current alarms
and all cleared un-acknowledged alarms. The most recent alarm shall be shown at the top of
the display with date and time stamp.
An alarm condition shall be indicated on graphics by highlighting the equipment identification
label with a flashing border.
Alarm Processing
In the event of an alarm:
The relevant alarm message shall be inserted on the top line of both the graphic alarm
banner and the alarm summary page, an active alarm being indicated by a red square on the
left hand side of the alarm line.
The graphic symbol ID shall indicate an alarm.
An audible alarm shall be sounded.
An alarm message will be printed out on the dedicated alarm printer.
The alarm shall be muted via the dedicated function key.
The alarm shall be acknowledged at the alarm summary page, access to this page being
gained via the dedicated function key from any screen.
The alarm indicator square on the banner and the summary page shall change colour from
red to blue when the alarm is acknowledged.
The acknowledged message is printed out.

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When the alarm is returned to normal, i.e. the fault is cleared, the alarm message shall be
removed from the alarm banner and the summary page, the mimic(graphic)(graphic)
indicator shall clear and an alarm clear message shall be printed out.
If an alarm clears before it is acknowledged the alarm active condition shall be indicated on
the alarm banner and the summary page with a green square until it is acknowledged. When
acknowledged the alarm message shall be removed from the alarm banner and the summary
page.

2.6.18 Real Time and Historical Trending

The Trending task displays real time data collected by the database logger facility of the
SCADA software or Historical data previously stored in a database file as trending graphs.
Trends are plotted in amplitude - versus - time format with the most recent time value on the
right of the trend.
Each individual trend consists of:
 A chart containing the respective number of pens for each variable to be plotted.
Each pen operates independently of the other pens. Pens within a single chart must
use the same sample rate but can use different scales.
 A Vertical Scale
 A Horizontal time - base scale showing the start and end time/date of the trend.
 A movable value cursor that indicates the actual trend value of a variable at any point
on the variables trend line. The cursor is positioned using left and right scroll icons.
 Zoom In and Out on the historical record, thus expanding or contracting the length of
the record displayed in a trending chart.
 Pan horizontally through the historical record
The operator shall mouse 'click' on an individual process item that has associated trend
information (i.e. temperature, flow, pressure, level, quality, motor, etc.).
A pop - up window shall appear prompting the operator to display a trend in the following
formats:
Real - time displaying a window of 1 hour. Historical displaying the previous 1 hour. Historical
displaying the previous 8 hour. Historical displaying the previous 24 hour. Historical
displaying the previous one month
In real time mode all the above functions are available and the trend can be seen to scroll in
real time.
In historical mode all the above functions are available and the trend displays a snapshot of
the defined time period.
Trends can additionally be altered once the trend is displayed using the pan and zoom
facility.

2.6.19 PLC Program

The contractor shall supply an easy to apply program for automation systems, based on the
IEC 61131-3 standard.
The operating system software for the RTU/PLC's shall be individually loaded at the MCCs.

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It shall be possible to carry out changes to RTU/PLC programs and changes to program
parameters from the operator station in the SCADA centre under the password protected
access arrangements.
Changing of parameters shall be easy and by using interactive messages.

The license shall be valid for all RTUs and the SCADA workstations and laptop.
The system shall include two SCADA server and three SCADA client software licenses. The
system shall include an A3 colour printer Ink Jet or laser and a laser A4 printer. The
complete SCADA hardware and the two printers shall to be connected together with one high
speed LAN.

2.6.20 Software server specifications

The server shall include an unlimited number of internal and external tags. The server shall
include OPC server that are capable of communicating with the RTU/PLC. The SCADA and
OPC software shall be from the same PLC vendor for maximum compatibility of system
components. The SCADA server software shall be installed on hardware server from a
reputable server vendor. The server shall be equipped with raid hard-disk drive redundancy.
The server shall be state of the art configuration with at least one Gbyte RAM. The server
shall be equipped with backup and restore facility.

2.6.21 Software client specifications

The clients application shall be downloaded on a state of the art personal computer equipped
with at least one giga byte RAM. Two clients shall be equipped with a 21'' flat LCD monitor
and the other one a 40'' flat LCD monitor. The contractor shall submit his proposed hardware
for approval by the Engineer.

2.6.22 Visualization
The clients shall be able to view all of the WWTP parameters, status and commands. The
client shall include a hierarchy of security levels. All visualization screens shall be designed
in accordance to standard ISA symbols.

2.6.23 Historical data

All alarms and operator actions shall be stored in a historical database.
All analogue signals shall be stored in the historical data base and shall be able to be
trended. All data required for the purpose of maintenance or secures the safe operation of
the WWTP shall be stored and easily retrieved. Data related to the performance of the
process such as, but not limited to, inlet flow, outlet flow, quality measurements and power
consumption parameters etc. shall be stored and shall be easily retrieved and processed.

2.6.24 Reporting
Daily, weekly and monthly reports shall be printed automatically on the report printer. The
operator shall be able to select any historical period and request a report to be printed. All
trends shall be printed on the colour printer. The contractor is advised that a major
requirement of the SCADA system is the ability to produce maintenance reports and facility
performance monitoring reports. The contractor shall submit his proposal to the Engineer for
approval while noting that the contractor is obliged to deliver the reports required by the
Engineer.

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2.6.25 Equipment
One portable PC (laptop) shall be provided for easily programming in the site and shall be
latest version and international brand name type to be approved by the Engineer.
The SCADA system shall be equipped with all suitable furniture (desks) for use and
operation, separate stations shall be provided for each system.

3 Particular Photovoltaic (PV) Electrical Specifications

This section contains the technical requirements for the PV Plant installed at As-Salt WWTP.
The quality of all the proposed components shall reflect the expectations of the Employer to
reach a "best in class" photovoltaic plant.

3.1 Scope of work

The scope of work consists in the turnkey construction of a photovoltaic plant with a total
power of 500 kW DC (420 to 450 kW AC) and its Operation Services for 2 years until the issue of
the Contract Completion Certificate. This document is to cover the technical requirements of
design, supply, installation, testing and commissioning of the Plant with all components,
instruments, fittings and accessories for efficient operation with uninterrupted availability.

The turnkey construction of the PV Plant and its Operation Services, shall briefly include:

EPC

 Complete PV System and Project Design and Construction. All work shall be in
accordance with the relevant local and international standards
 Mobilization
 Hydrogeological works
 Supply of all the components to be installed in the PV plant premises.
 Civil & Infrastructure Design & Construction
 Mechanical Design & installations
 Electrical Design & installations
 Supply and installation of the Monitoring and SCADA systems
 Supply and installation of the Security and CCTV systems
 Testing, Commissioning, Operation Service the PV System and Project as specified and
for the defined period as described herein in this contract.
 De-mobilization after completion of the Works as per the contract
.
OPERATION & MAINTENANCE SERVICES

The scope of work of the Operation Services will be the proper functioning of the system as a
whole during the Defect Notification Period, by ensuring:

 The guaranteed level of Production, Performance Ratio and Availability;

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 The preventive maintenance activities to be carried out in accordance with the Operation
& Maintenance plan;
 The corrective maintenance including all the necessary components and labour to repair
or replace any defective parts, and in general to ensure the correct operation of the PV
Plant according to the reaction plan;
 The supply of all the components necessary for the proper maintenance of the PV plant;
 The supervision and control of the system through remote monitoring and the reporting
activity;
 The landscaping maintenance;
 The cleaning of the PV modules, at least 18 times per year;
 The assistance to the Employer in relation to any possible insurance and warranty
claims.

IMPORTANT. The Contractor shall be responsible for the complete design, supply and
installation of the MV equipment (transformer station, MV cables) to be compliant with the
Jordanian Electric Power Company (JEPCO). No deviations from the requirements of the
Grid Operator will be accepted. In case the requirements of the Grid Operator shall differ
from the technical specification as defined in this section, the Grid Operator’s instructions
shall prevail. The Contractor shall prepare the documents, submit them to the Grid Operator
and obtain their validation in order to avoid any problem or delay to the commissioning.

3.2 Minimum Guaranteed PV Plant Performance

The plants shall be designed, built and operated in a way to achieve the maximum energy
production and the best performance and reliability.

The Contractor shall Guarantee:

Minimum Production Year 1 710,000 kWh
Minimum Production Year 2 705,000 kWh
Minimum PR at Provisional Acceptance Test 71%
Minimum PR Year 1 71%
Minimum PR Year 2 70.5%
Minimum Availability 99%
Maximum Yearly Degradation 0.7%

3.3 General site description

Refer to Section 1.2 “General Site Conditions” of volume 2.1.

3.4 Cable trenches

All electrical cables between the PV units, inverters, to the transformers and main WWTP
power control building shall be carried out as specified in Section ‎1.26 “Cable Trench Work”.

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3.5 PV Modules
General Requirements
It is required to select a module manufacturer between the recognised Tier 1 suppliers for, at
least, 5 consecutive years. without any restrictions on where the PV modules are
manufactured. In terms of quality and warranty, the selected PV modules must fulfil the
requirements, as described in the subsequent sections of this document. Furthermore, prior
to or during the process of a module manufacturer selection, a comprehensive technical due
diligence to assess the manufacturing practice and quality systems of the manufacturers
under consideration has to be provided.
Full details of the PV modules shall be submitted to confirm compliance with the
Specifications for approval by the Engineer.
The objective is to evaluate the ability of such manufacturers to produce PV modules of the
same quality to those that have been submitted and passed certification and compliance
tests. The Contractor will provide an attestation by an independent third party that such an
assessment is or was performed, at a maximum of 12 months prior to the prospective
delivery date of the modules.
The PV plant supply or purchase agreements (e.g. contract documents) shall contain
detailed technical specifications and agreed warranty terms and conditions. The Contractor
will be requested to provide evidence of such specifications and warranties. Upon delivery of
the modules to Site, the Contractor shall submit the flash data for each PV module at STC
(flash reports) in electronic format (Excel files). The Contractor shall provide a summary
spreadsheet, containing the summary of all the spreadsheets and the full installed capacity.
Modules are expected to be packed vertically to avoid micro-crack damage, during
transportation.

3.6 PV Modules Cleaning Systems

PV modules will be cleaned on a regular basis to prevent dust build‐up which could affect
their performance. Therefore, the selected PV modules should be designed to be cleaned
using dry-brush cleaning method.

3.7 Technical requirements

The minimum technical parameters for each PV module are:
 Technology: mono-crystalline or polycrystalline silicon cells, preferably with 4 bus bar
or more. Modules must have been designed and manufactured in accordance with EN
61215
 Module peak power: 60/72 cells modules with an output respectively ≥ 275/330 Wp at
STC (Standard Test Conditions).
 Tolerance: modules are required to have only a positive output tolerance.
 Operating temperature range: PV modules shall be capable of operating under
temperatures between -40°C and +85°C and from 15% to 95% of humidity.
 Fill Factor: ≥ 0.7
 Nominal Operating Cell Temperature (NOCT): maximum 45°C with a tolerance of ±2°C
 Temperature coefficient: power loss shall not exceed 0.45% per degrees Celsius (°C)
 Full current intensity - voltage characteristics (I-V curves): shall be provided at 25°C for
a minimum of four different levels of irradiance between 200 W/m2 and 1000 W/m2.

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 The active electrical components within each PV module shall be electrically insulated
from the frame, the rear cover, and the front glass surface. The insulation must
withstand 1000 Volts DC between the short-circuited module output leads, the metal
frame and the rear and front covers.
 Mechanical resistance: PV modules must be certified for resistance to a suction
pressure of 2400 Pa (Wind speed 140 km/h with safety factor 3) and an increased
distributed mechanical load of 5400 Pa on the front glass surface (wind and snow).
 Junction box: shall include 3 by-pass diodes to protect against partial shading and
module overheating. IP67 protection required.
 Cables: factory fitted module cables shall be long enough to allow the modules to be
interconnected electrically in series, to form strings and shall indicate clearly the
polarity. Connectors certified BS EN 62852:2015. compatible with MC4.
 Encapsulation: EVA-Solar Cells-EVA. Back material: Tedlar-Polyester-Tedlar, white
colour.
 Glass: front surface of the modules shall be protected with at least a 3.2 mm tempered
glass of low iron content and may have a manufacturer-applied anti-reflective coating.
The glass cover shall have strong resistance to heavy shocks, thermal stress and high
wind loads including wind with high content of particulates.
 Frame: the PV laminate (glass / encapsulant / solar cells / rear side) shall be
surrounded with a metal frame made of aluminium or aluminium alloy. The frame shall
be placed to protect the edges of the glass cover of the PV modules and to facilitate
support and mounting. The construction of the frame of each PV module shall be
adequate to allow for thermal contractions and expansions of the glass cover of the PV
module. To avoid galvanic corrosion due to electrolytic action between different
materials, any contact between different metals in the PV module frame, must be fully
electrically isolated.
 Dimensions: approximately 100x160 cm for the 60 cells modules and approximately
200x100 cm for the 72 cells modules
 Certifications: PV module components are only considered to be approved when they
are used to fabricate the modules that were submitted to and passed various standard
certification and compliance tests such as IEC. Therefore, as the manufacturer goes
through the process of qualifying new suppliers, the test certificates must continuously
be updated to include additional component providers. Therefore, as part of the module
agreement, the Contractor shall include a requirement that the PV modules intended
for the PV projects under consideration shall be made with only approved module
components.
 Nameplate: each module shall permanently display a technical characteristics
nameplate carrying the following information as a minimum:
- Name of manufacturer (or monogram or symbol)
- Type or model number
- Serial number
- Polarity of terminals or leads
- Max system voltage which module is suitable for
- Safety class
- Application class
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- For class A module the safety class II symbol

- Date and place of manufacturing on label, or traceable from serial number

3.8 Technical Due Diligence

The Employer requires that:
 PV module factory acceptance tests shall to be performed where the modules have
been manufactured or stored before their shipment to the Project site;
 these tests shall be carried out by an independent internationally recognized
accreditation body;
 These tests shall include: VIS, STC, EL, testing conducted on a randomly sampled
population of the delivered PV modules (test on 25 modules to be foreseen).
 The total costs of the tests to make this technical due diligence are charged to the
Contractor.

Brief explanation of module tests to be carried out:

Visual inspection (VIS)
 Brief Description of Test
Visual inspection of solar modules by trained personnel
 Damage typically detected
Yellowing, delamination, bubbles, deformation of encapsulate
 Reference to existing standards
VIS is described in IEC 61215
Output power measurement at Standard Test Conditions (STC)
 Brief Description of Test
Measurement procedure for determination of the output power of solar modules
 Damage typically detected
Deviation from name-plate power
 Reference to existing standards
STC is described in IEC 61215
Electro-luminescence imaging (EL)
 Brief Description of Test
Generate an EL-picture of the modules in question
 Damage typically detected
Damaged Cells

3.9 Installation of PV Modules

The following elements related to the fixing of the PV modules on the support structure are
specified in the “Technical Specifications Vol. 2.2 Civil, Structural and Building Works,
Section 1.15.3”. The support structure shall be designed and provided by the Contractor. The
PV module installation manual shall be provided. The manual shall contain all the necessary
requirements and specifications for proper module installations such as:

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 Types of mounting structures including physical requirements for securing mechanisms

(anti-theft screws, clamps, dimensions, tightening force, locations) and useful
information such as:
 recommended mounting types;
 recommended spacing to guarantee sufficient air circulation;
 restrictions to certain environments etc.
 Mechanical and electrical module configuration guidelines (landscape, portrait, string
and array sizing, grounding etc.).
 In case special requirements in inverter selection and PV array groundings are called
for, these requirements shall be clear in the installation manual.
The Contractor shall respect the specifications of the module’s manufacturer concerning the
installation as described in the installation manual.

3.10 Inverters
3.10.1 Determination of the inverter
The Contractor shall select and supply the photovoltaic inverters required to realize the PV
plants considering the PV installation design and functional requirements and including the
integration requirements into the PV system and the compatibility to the selected PV
modules for the installations.
The Contractor shall submit full details of the inverters to demonstrate compliance with the
Specifications mentioned in the following section, for approval by the Engineer.
There are no restrictions where the PV inverters are manufactured; however, it shall be
noted that the inverter specifications shall comply with all the requirements of the grid
operator, including the capability to produce the reactive power that the grid operator could
require.
Inverters shall be three-phase decentralised.
The string configuration defined for the Works needs to be verified with the specific software
provided by the inverter manufacturer.
Technical specifications of inverters
The minimum technical parameters for the inverters are:
 One (or more) MPP tracker;
 A system to allow performance control;
 Maximum efficiency at least 98,6%;
 Remote monitoring and control capabilities (PC connection…);
 Isolation fault detection;
 Ability to start and stop function automatically;
 The ratio of the input power over the output power has to be between 90% and 100%
and, in any case such to deliver the needed reactive power;
 The MPP voltages of the strings are to be verified to lie in the MPP voltage range of the
inverter for temperatures between -10°C and 70°C.
 IP protection class of at least 54 is required for outdoor inverters. Noting the possible
presence of dust in the selected areas, a boxed installation is recommended even for
outdoor inverters.

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 Even when the technical characteristics of the inverter clearly contemplate an outdoor
installation, a protection is to be designed in any case against direct sunlight and rain
(e.g. sunshield, beneath the arrays, etc.);
 The inverter requires a DC switch.
 Inverters have to be protected from overload and short-circuit internally and shall be
equipped with disconnection devices following the local requirements.
In some cases, special requirements for inverters (grounding, with or without transformer
etc.) are requested by the PV module manufacturers. If such a case occurs, the Contractor
shall be responsible to include these requirements in the design and carry out such
measures at his own cost. Inverters shall comply with international standards and safety
regulations or any other local requirement. Inverters can sustain a given temperature range
defined in the related datasheet; this range shall be respected by the Contractor. If the
inverters are positioned inside a shelter, it implies designing an adequate ventilation system.
A thermal study shall be carried out to verify the inverters temperature specifications will be
respected. The inverters’ shelters shall be waterproof. The compatibility with the transformer
size is to be safeguarded.

3.11 AC (DC) Combiner boxes

The combiner boxes shall house an over current protection and an AC (DC) disconnect. The
DC combiner boxes shall be able to monitor the performance of the modules at a string level.
In order to ensure a correct lifetime to the box, it must be paid particular attention to the
enclosure material and position. Mounting in the shade is compulsory, as direct sunlight can
significantly increase internal combiner temperatures, reducing reliability and life of internal
components. Size can also have an impact. The combiner in the larger enclosure allows the
larger air volume and surface area to assist in better cooling of internal components. Larger
enclosures also make field wiring easier by allowing more room to work during installation
and maintenance. Enclosure shall satisfy IP 65 requirements.

3.12 Monitoring System

The monitoring system shall provide constant and full evidence of the PV system
performance in order to optimize the energy output, detecting abnormal losses, and planning
the preventive maintenance actions. The Contractor shall provide a web-based monitoring
system, integrated with the WWTP SCADA that complies with the requirements set below.
The main standard applicable is the IEC 61724.
The Contractor shall design the monitoring system and provide full details for approval by the
Engineer, including P&I diagrams, details of all components and integration with the WWTP
SCADA.

3.13 General requirements

The monitoring system shall record meteorological and electrical parameters and status of
the PV plant components. Continuous monitoring is required. The norm specifies that the
sampling frequency has to be at least one minute for the parameters varying directly with the
sunlight; up to 10 minutes is allowed for other parameters (e.g. temperatures, wind). The
minimum data to be monitored are:
 DC current and voltage at string level
 Inverters behaviour for each inverter:
 DC current and voltage input
 Output active and reactive power
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 Phase voltage and current

 Energy output
 Alarms and faults
 Meteorological data
 Module temperature measured at least in 2 modules
 Ambient temperature
 Irradiation measured at least in 2 locations
 Wind speed
 Energy output at the meter
 Status of the equipment (protection devices, inverters)
 Any other information which would be required by the laws and norms and grid code
Irradiance sensors (pyranometer)
At least two pyranometers shall be installed in the plane of the modules. Irradiance in the
horizontal plane shall be measured as well with a pyranometer. The uncertainties on the
measurement (including signal treatment) shall be at maximum +/-3% for hourly values and
+/-2% for daily totals. The non-linearity error (sensitivity variation versus irradiation) shall not
exceed 0.2%. Only measurements using pyranometers are accepted as reference sources.
The pyranometers shall have at least the characteristics of the CMP11 model from Kipp &
Zonen (or any equivalent Secondary Standard device according to ISO 9060). The
Contractor shall provide the Employer with a calibration certificate from an independent
laboratory for each sensor (as part of the as-built files). If signal cables of more than 50
meters have to be used, an adequate IP66 signal amplifier is required. This amplifier shall
allow voltage input between -12 to +150 mV and current output between 4 to 20 mA. Signal
accuracy shall be at minimum +/- 10 μV. Pyranometers shall be secured with levelling
screws or mounting rod to a SS-metal support with a good earth connection (e.g. by using a
lightning conductor). The following minimal pyranometer’s parameters shall be respected:
 Spectral range: 285 to 2800 nm
 Sensitivity: 7 to 14 µV/W/m²
 Response time: < 5 s
 Directional error (up to 80 ° with 1000 W/m² beam): < 10 W/m²
 Temperature dependence of sensitivity (-10 ºC to +40 ºC): < 1 %
 Operating temperature range: -40 °C to +80 °C
 Field of view: 180 °
 Protection: IP67
 Non-linearity (sensitivity variation vs. irradiance): < 0.2%
 Non-stability (variation sensitivity/year): < 0.5%
Ambient and Module Temperature Measurement
Ambient air temperature shall be measured with a sensor having an accuracy of at least +/-
1K (including signal treatment). The sensor shall be protected from direct sunlight to avoid
over-heating effect that can influence the measurement accuracy. The sensor to measure
the PV modules temperature shall be located at the back of a module, complying with the
installation manual of the manufacturer. The uncertainties shall not be more than +/-1K
(signal treatment included). PT100 or PT1000 temperature sensors with a silicon body and
auto adhesive are recommended. Temperature range shall be -50°C to +150°C. The location
of the temperature sensors needs to comply with the installation manual of the manufacturer
and the data shall be transferred to the data logger. The installer shall provide the client with
a calibration certificate from an independent laboratory for each sensor (as part of the as-
built files).
Wind speed measurement
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Wind speed shall be measured by an anemometer. The uncertainties of the measurement

have to be less than 0.5m/s for wind speed up to 5m/s; for higher wind speeds, the
uncertainties are to be at maximum +/-10% of the reading. The anemometer shall be placed
in accordance with the installation manual of the manufacturer. The Contractor shall provide
the client with a calibration certificate from an independent laboratory (as part of the as-built
files).
Datalogger
The datalogger collects the data from the photovoltaic installation. Fixed IP address making
the datalogger permanently accessible from remote is required. In case of a dynamic IP
address, the monitoring system shall be combined with a Dynamic DNS (Domain Name
Service). The Contractor is responsible for the synchronisation between the permanently
accessible fixed domain and the updates of the network router. No land line is available on
site. Therefore, the monitoring system is to be connected using a satellite link or GPRS
connection. The Contractor shall provide a complete folder for approval containing all the
information and parameters such as proposed system schematic, technical characteristics
devices, tools, software, access frequency and duration, security protocols, etc.). Data shall
be accessible 24hour/7day all year around remotely via a server. There shall be redundancy
in terms of communication lines and server, one being used as a backup if the main one
fails. The data transmission has to be secured using a firewall or a SFTP server. The
datalogger memory shall allow the storage of 1 month of data. The format of the data shall
comply with the specifications provided by the Energy Management System manufacturer in
order to assure the complete integration of the PV Plant in the system.
Data Treatment
Data measured and calculated have to be sent every 10 to 15 minutes to an FTP or SFTP
server where they will be accessible. The time of the end of each period shall be available
and shall refer to the local or universal time rather than solar time. Data quality has to be
checked by comparing it to admissible maximum and minimum values. A variety of values
can be calculated from the measured parameters as described in the norm IEC 61724.
Log Book
Documents specifying any event, incident, component replacement, calibration, maintenance
actions, cleaning shall be kept updated. The logbook shall be kept electronically and shall be
remotely accessible from the Employer.
IT-Infrastructure
Contractor shall deliver, install and put in service any additional software, with open licences
for installation on the WWTP SCADA IT hardware required for the monitoring system to be
fully compatible with the SCADA system.

3.14 Cables
3.14.1 General
All cabling shall be installed in accordance with its manufacturer’s requirements and to meet
the design conditions used in the sizing calculations. The combined cable losses shall not
exceed 3% (DC and AC cable losses combined). A shop drawing will be prepared to define
in detail the arrangement of the cables in the trenches, the AC/DC boxes and the inverters.

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3.14.2 DC cables
The cables of the PV installation shall have the following characteristics:
 Solar cables shall be in copper with a minimum cross section of 6mm².
 Cables used outside shall be UV resistant (according to HD 605/A1) and ozone
protected
 Class II rating for insulation
 Rated for temperatures from -40°C to +90°C. This requirement is also applicable to all
materials used in the installation of PV (such as cable conduits).
 Made of double insulated component and shall have a minimal life span of 25 years.
 Cable bending radius shall be at minimum four times the cable diameter or as specified
by manufacturer, if different.
 Sized to allow a current up to 1.25 Isc and up to 1.2 Voc typically observed for
crystalline-silicon modules
 Installed in conduits and hooded cable trays. The cable return path shall follow the
same way to avoid induction loops.
Cables shall be dimensioned according to CEI 20-40 and CEI 20-67. Norm CEI 64-8 shall be
followed to prevent short-circuit-induced current. Norm CEI 82-25 shall be followed regarding
arrangement of cables and cables trays. In terms of certifications, DC cables shall be
compliant with the requirements described in 2Pfg 1169/08.07 (“Requirements for cables for
use in photovoltaic-systems”). Combined DC cable losses shall be less than 1% at 80% Isc.

3.14.3 DC connector type

The DC connectors shall be MC4 (or MC4 compatible), UV resistant and ozone protected.
They shall be rated for the same temperature range as the cables or better. They shall be at
least an IP-class of 65. The used connectors have to be equipped with a locking system to
avoid disconnection of the parts.

3.14.4 AC cables
All AC cables shall be suitable for direct buried or ducted installation. In case of direct buried
installation, the Contractor shall install armoured cables and add one spare conduit from
each AC box to the transformer.
The LV cables shall be compliant to the following standards:
 General Services: Steel Wire Armoured (SWA) on tray or ladder, NYM-J within steel
conduit/trunking.
 CT/VT secondary and control cables: NYCY
 Cables between generators and external unit substations: NYY-O (double insulated
and suitable for outdoor use), minimum Voltage rating 1000V and suitable for the
generating Voltage.
 LV cables shall be terminated using proprietary crimped lugs
The MV cables shall be XLPE or EPR insulated with aluminium or copper stranded wire
conductors and PE or PVC outer sheath. The cable construction shall be according to
IEC60502 and shall employ longitudinal water blocking. All joints and terminations shall be
completed and tested in accordance with the manufacturer’s recommendations. MV cables
shall have a cross section of at least 150 mm2.

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The combined AC (both LV as MV) power losses shall be below 2%. The MV cables shall
comply with the requirements of the Grid Operator.

3.14.5 Cable identification

All the cables shall be given a unique identification number. All cables shall be listed in a
cable schedule and shown on the substation schematic diagrams. All cables shall be
identified at each end using a robust and weatherproof identification tag indicating the cable
reference number. For multi-core cables, cores shall be given a unique identifier and labelled
accordingly. Spare cores shall be labelled as spare. All phase conductors shall be suitably
identified at each end. Where cables pass through draw pits, identification markers shall be
fitted to the cables at both ends of the pit.

3.14.6 Cable Arrangement

Cable entry to all external equipment shall be via weatherproof glands. All cable conductors
larger than 1.5mm² shall be stranded. All cables shall be adequately supported, restrained
and protected from mechanical and thermal damage. Segregation shall be maintained
between power cables and control cables. The minimum segregation shall be not less than
300 mm. All ducts shall be sealed after cable installation with suitable expanding material to
prevent ingress of water, dust and vermin. Any cable entries through substation walls shall
be via proprietary cable transits and sealed after installation. All buried cables have to follow
the local requirement in terms of depth, signalling and protections.

3.15 Signal List

The Contractor shall assume overall responsibility for the signals list for all interfaces
between the power plant and the local utility company. The Contractor shall liaise with the
relevant parties, including the Network Operator and WWTP operator, to ensure signal
requirements are clearly understood and communicated. Cables carrying analogue signals
shall have each pair individually screened and shall have an overall outer screen. Cables
carrying digital signals shall have an outer overall screen only.

3.16 Transformers
Refer to Section ‎1.8‎1.8 “Current Transformers” and Section ‎2.2.18 “Automatic
Synchronization Panel”.

3.17 Lightning Protection

It is mandatory to install a lightning protection system (LPS). Refer to Section ‎2.5 “Lightning
Protection and Earthing Systems”.

3.18 Training Requirements

The Contractor shall provide comprehensive training and technical support to the Employer’s
staff to allow him to adequately operate and maintain the PV Plant.
The courses shall be targeted at different levels of personnel, including plant operators and
specialist maintenance personnel. Dates for training shall take place prior to Performance
Test and every 4 months during the Defects Notification Period. The training programme
shall include:
 Theoretical introduction to commissioning and test programs.
 Practical introduction to the correct use of maintenance manuals.
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 Fault finding.
 Safety features of the power plant.
 Safe operation of power plant.
 Protection equipment.
 Theory and practice of electrical power system.
 Operational activity that is permissible by the Employer’s personnel, during the
warranty period.
 Safe methods of isolation of equipment for maintenance.
 Description of the electrical system including details of MV, LV and data cable
routes.
 Location of plant and equipment including points of isolation and earthing.
 Identification of protection relays and equipment.
 Review of protection relay settings.
 Description of interface with any existing substation equipment and with the utility
grid.
 Safe operation, safe access, maintenance of nominal and safe performance
where special procedures are required which would not be familiar to
experienced, qualified/registered personnel.

The Contractor shall provide comprehensive course notes and shall include ‘hands-on’
practical sessions on the Works. Operating and technical manuals, including drawings shall
also be provided to accompany the training. Training manuals shall be provided to all
delegates attending training courses. The manuals shall be developed specifically for the
Works and shall be specific to the level of training provided to the course delegate. The
training manuals shall be developed in sections, reflecting the course structure and shall be
developed in a manner that will provide the delegate with a quick reference guide to the
various aspects of the system following the course. The Contractor shall provide written
certification for personnel who complete the course to the required standard.

3.19 Component Warranties

The Works shall be designed to operate for a Design Life of at least twenty-five (25) years
without major repairs or retrofits and all components shall be designed for at least this
lifetime. The Equipment shall be designed with due consideration given to its eventual
decommissioning involving complete removal of all components of the PV Plant. The
Contractor shall provide the following warranties, with all costs included.

3.19.1 PV Modules
The PV module manufacturers at the present day, generally, offer two types of standard
warranties: product and power warranty.
Product warranty shall warrant that the modules are free from defects in materials or
workmanship. The definition of defects in materials or workmanships shall be clearly defined.
The compensation for defective products shall be clearly defined (replacement, repair or
financial compensations). The warranty shall also include the factory-assembled DC
connector and cables. A warranty period of at least 12 years is required. A longer warranty
period is preferred.

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Power warranties guarantee certain percentage of initial power output during certain period
of time. The definition of a reference output power must be clearly defined. The
measurement shall be conducted under Standard Test Conditions (25°C, 1000W sqm). A
power output warranty, being at least 90% after 12 years and 80% after 25 years with a
linear/yearly degradation. The warranties shall start from the certified date of Contractual
Handover.
The involvement of an independent test party such as Fraunhofer ISE (Freiburg, Germany),
TUV Rheinland (Cologne, Germany), or other international institution in case of technical
disputes during the warranty claim is required. The warranties offered by the module
manufacturers shall be in the name of the Employer. Other terms and conditions for
warranties transferability must be defined clearly. The contract sales agreement with the
module manufacturer is expected to define clearly the claiming procedure of defect modules,
the required additional specific independent party involvement and any other conditions that
might influence the honouring of the warranties. Finally, the conditions which void the
warranties shall be clearly stated (e.g. mishandling of modules, etc.) for approval by the
Engineer.

3.19.2 Inverters
Inverters shall have at least a 5 years standard warranty. The contract sales agreement with
the inverter manufacturer shall clearly define the claiming procedure of defected inverters or
parts, the required additional specific independent party involvement and any other
conditions that might influence the honouring of the warranties. Any extension and the full
scope of that extension to the standard limited warranty - included in the price - shall be
indicated. The Contractor must provide proof that the inverter manufacturers have sufficient
financial backup that covers manufacturers in case of bankruptcy or that are filing for Chapter
11 protection. Finally, the conditions which void the warranties shall be clearly stated (e.g.
mishandling of inverters, installation in extreme salt conditions etc.) for the Engineer.

3.19.3 Other components

The Contractor shall provide warranties for all the components provided and for the works.
Warranties required are:
 20 years for the metal structure
 20 years for solar cables
 5 years for the transformers
 2 years for the rest of the PV components
 2 years for the installation
The PV plant components manufacturer warranties, and particularly for the PV modules and
the inverters shall be in the name of the Employer; the Defects Notification Period must be
taken into account in the Contractor warranties period determination and will be responsibility
of the Contractor; the repair or replacement of any defective PV plant component(s) shall
reset the beginning of the Contractor warranty period for the specific component(s).

3.20 Yield Analysis

The Contractor shall provide a 1 year production calculation – hourly based - assuming an
exceedance probability of 95% in order to substantiate the guaranteed minimum production.
The meteo data source, must be a source with at least 10 years of relevant data for a
location not further than 50 km away from the site or with interpolated values specific to the
site. The accuracy of the meteo data source must be proven by literature. The meteo data
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source must be able to provide an average expected yearly irradiation value and the yearly
climate variation or year to year values. The system has to be simulated using software or a
method that are widely accepted in the photovoltaic industry (e.g. PVSyst, PVSOL).
The Contractor is requested to certificate the estimated production forecast for the first year
and for the 24 following years, taking into account degradation and availability (both) as
guaranteed in the Contract.
The following losses shall be taken into consideration for the Yield simulation:
Far shading loss (horizon line) -0.1%
Soiling losses -4.0%
Near shading losses (obstacles, buildings, trees, etc.) -1.6%
IAM factor on global -1.5%
Irradiance dependencies -0.1%
Quality related losses (related to product variance) +0.5%
Temperature dependencies -7.8%
AC Ohmic loss -0.8%
Mismatching -1.1%
Cabling (DC as well as AC) -1.4%
Inverter losses -1.8%
Transformer losses -0.7%

Additionally, in the Simulation a Cos(Phi) for the Reactive Power of 0.85 shall be considered.
The real value to be applied to the system will be defined by the Grid Operator. The analysis
shall contain also the calculation of the Performance Ratio (PR) of the PV plant. Production
and PR estimated for the first year shall be split by single months.

3.20.1 Degradation
The value of the degradation shall be not more than 0.7% per year.

3.21 GUARANTEED PV PLANT PERFORMANCE

3.21.1 Key Performance Indicators and Acceptance Procedure
The following sections include the definition of the Acceptance Procedure with the
parameters and the formulas that will be used for the measurement of the Performances of
the PV Plant and the calculation of the Liquidated Damages in case of Performance Shortfall.
The following Performance Indicators will be considered:

 Production
 Performance Ratio
 Availability

At any relevant test, possible Performance Shortfalls (SHFPROD, SHFPR, SHFAV) will be
calculated and will be >0 when an Effective Performance for any of the indicators will prove
lower than the related minimum guaranteed value. All performance shortfalls will initially be
expressed in kWh, resulting from the formulas described in the relevant paragraphs of this
chapter.
The value of the Liquidated Damages will be calculated considering only the highest between
SHFPROD, SHFPR, SHFAVL and associating an economic value to each kWh equal to the
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electricity tariff paid by the Employer at the moment of the test or the cost of generating the
same amount of energy with the diesel generator installed at site, depending which of these
2 sources will actually deliver the missing energy.

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3.21.2 Production
Definition
The Production is defined as the total amount of energy delivered to the grid/water facility in
1 year, expressed in kWh, as recorded by the “comparison” MV meter (after the
Transformer).

Minimum Guaranteed Production (PRODguarYn)

The Minimum Guaranteed Production in the Year N (1, 2) will be equivalent to the result of
the following formula:

PRODGUARYN = PRODYN -EXCL

Where:
N = Number of the reference year
EXCL = the hourly generation profile shall be used as reference for the calculation of
the kWh to be excluded per each hour of duration of the following:
 Restriction in grid connection in case the energy is not absorbed
instantaneously by the water facility (grid connection injection limitations,
failure of the grid, defaults in grid connection point)
 Force Majeure
Effective Production (PRODEFF)
Effective Production will be evaluated against Guaranteed Production at Intermediate
Acceptance Test 1 and 2 and at Performance Test, For the purpose of clarity, the evaluation
of the Effective Production against the Guaranteed Production (and consequent possible
Performance Shortfall damages) will NOT be implemented in the following case:
In the event that shading of the PV Plant occurs, caused by factors external to the Site
and not attributed to the Contractor and outside the control of the Contractor. In the
event of partial shading under the same circumstances, that fraction of shaded areas
versus the total PV Plant capacity will determine a proportional reduction of the
Guaranteed Production.
For the purpose of the Intermediate Performance Tests 1 and 2, the Effective Production is
defined as the total energy expressed in kWh that has been injected into the grid and or
supplied to the water facility, as recorded by the meter installed in the delivery station in the
year elapsing between Take Over Certificate and the Intermediate Performance Test and in
the year elapsing between the issuing of the Intermediate Performance Certificate 1 and the
Intermediate Performance Test 2.
For the purpose of the Performance Tests, the Effective Production is defined as the total
energy injected into the grid and or supplied to the water facility as recorded by the Grid
Operator meter in the year elapsing between Intermediate Performance Certificate 2 and the
Performance Test.

3.21.3 Performance Ratio

Definition
The performance ratio (PR) shall be calculated in a 15-minute resolution.
The performance ratio (PR) is defined as:
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YF
PR = YR
The value for Yf is calculated by the equation:

YF= E (kWh/kWp)
PN
where: =
YF = final PV System yield
E = System net AC energy output in kWh as measured by the MV meter after the
transformer (if this last is provided by the Contractor)
PN = System nominal power in kWp

and:
H
Yr =
where: = G
Yr = reference yield
H = total in-plane irradiance in kWh/m2 being the average of the solar irradiance as
measured by the pyranometers installed for each PV Plant.
G = reference irradiance (1 kW/m2)

PR guaranteed at Year 1 shall be not more than 1.5% less than the PR defined by the Yield
analysis

At any relevant PR Test, the Guaranteed Performance Ratio (PRguarYn) will be calculated
according to the following formula:

PRGUARYN = (PRGUAR*AV*(100-(D*N)) - EXCL

where:
EXCL = 0,00026% per each hour of duration of the following:
o Restriction in grid connection (grid connection injection limitations,
failure of the grid, defaults in grid connection point)
o Force Majeure
o AV = Guaranteed Availability
o D = Degradation
o N = Year number
Example;
PRGUARY2 = (78,7%-99%*(100%-(0,7%*2))-0 = (78,7%*99%*98,6%)-0=76,82%
Minimum Acceptable Performance Ratio (PRACC)
The Minimum Acceptable Performance Ratio is the minimum value that has to be achieved
at the PAC in order to avoid the rejection of the PV Plant. The value shall be calculated
deducting 3% from the reference monthly PR as evidenced in the PVSyst included in the
Contractor’s Tender.
Effective Performance Ratio at Trial Period (PREFFTP)
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During the Trial Period Tests, the effective PR will be measured during a period of
consecutive 14 days, subject to:
at least 9 out of the 14 days resulting in a daily irradiation level > 3000 Wh/m2
no interruption in the regular system functioning
Shall the above conditions not be satisfied; the period will be extended to the next days
satisfying the conditions until a total of 14 test days will be achieved. The PR at PAC will be
computed as follows:

Yf
PREFFPAC Yr (kWh/m2)/(kW/m2)
= the reference PR of the month when the test has been
The PREFFPAC must be higher than
performed, according to the PVSyst included in the Contractor’s Tender. In case the average
temperature during the test will differ more than 15% from the temperature of the
correspondent month as defined in PVSyst, a temperature coefficient to adjust the
PREFFPAC shall be introduced.
Effective PR at Intermediate 1, Intermediate 2 and Final Performance Tests (PREFFIAC
and PREFFFAC)
The effective PR at the Intermediate and Final Performance tests shall be calculated in a 15-
minute resolution.
The effective PR at the Intermediate and at Final Performance tests is defined as follows:

E
PN
PREFF =
IRRAVG
G
Where:
IRRAVG = the average value of the solar irradiation measured by the pyranometers
installed in each PV Plant during respectively the 1st, 2nd and 3rd year after Take
Over Certificate. If data from different pyranometers differ >3%, then only the
highest value will be considered.

3.21.4 Availability
Definition
An inverter is considered as not available when it shows no production, while irradiance is
higher than 50 W/m² at the same time.
Minimum Guaranteed Availability
The Minimum Guaranteed Availability shall be 99,0%.
Effective Availability
The effective PV Plant availability (AVeff) is calculated as follows:

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Where:
AVeff Technical availability of PV plant
Hm: Number of hours with a solar irradiance of >50 W/m²
Pc: Impaired installed power of the affected inverter/s [kWp,DC,STC]
Pt: Total installed power of PV plant [kWp,DC,STC]
Hi: Incident duration in hours when inverter power is equal to 0 kW. Excluding times
when:
 such inverter is not operative due to a Force Majeure Event;
 grid outages, continuous overvoltage or undervoltage incidents and
permanent or temporary limitation by DNO not attributable to the Contractor
or its Subcontractors or delays in supply of the following missing Component
Parts: Medium Voltage Components and whole inverter or parts leading to
downtime of a whole inverter, on the basis that the Contractor has placed the
order for the required component part;
 solar irradiance is below 50 W/m²;

Performance shortfall
Production shortfall (SHFPROD)
Possible performance shortfalls related to Production will be evaluated at the Intermediate
Performance Test 1 and 2 and at the Final Performance Test. The value of the Shortfall is
calculated in kWh according to the formula shown below:

SHFPROD = PRODGUARYN - PRODEFFYN

Performance Ratio shortfall (SHFPR)
Possible Performance Ratio shortfall is calculated according to the following formula:

SHFPRYN = (PRGUARYN - PREFFYN)* PRODAVGYN

where:
PRODAVG = the total amount of the energy output/PREFF
Availability shortfall (SHFAV)
Possible performance shortfalls are calculated in kWh according to the formula shown below:
SHFAVYN = (AVGUARYN – AVEFFYN)* PRODEFFYN
Liquidated Damages for Performance Shortfalls
Possible Performance Shortfalls related to Performance Ratio will be evaluated during the
Trial Period.
Possible Performance Shortfalls related to Production, Performance Ratio, Availability, will
be evaluated at the Intermediate Performance Test 1 and 2 and at the Performance Test.
In case of multiple Performance Shortfalls in the same Test session, liquidated damages will
only apply to the highest Shortfall value. The value of the highest Shortfall expressed in kWh
will be multiplied by the corresponding price of the electricity supplied by the local utility and
or price to produce the same amount of energy with the diesel generator installed at site.
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The formulas for the calculation of Liquidated Damages at Intermediate Performance Test 1
and 2 and at Performance Test is:

LD = SHFHI*EP
Where:
SHFHI = the highest SHF (PROD, PR, AV)
EP = Price of Electricity supplied by the local Utility in the reference period and/or price
of the energy produced by the diesel generator installed at site
In case of shortfalls in PR at the Provisional and at the Performance Tests (in this last
case as an additional liquidated damage), the formula below will apply:
At Provisional Performance Test:

LDPR25Y = SHFPR*EPAVG*25/2
At Performance Test:

LDPR22Y = SHFPR*EPAVG*22/2
Where:
EPAVG = Average of the Electricity Price in the remaining years to get 25 years from
Take Over Certificate, calculated with an inflation of 3% (starting from the actual
electricity price)
/2 = Actualization
As an alternative to the payment of these last Liquidated Damages, the Employer and the
Contractor may agree that additional capacity is installed – sized as deemed necessary to
cover the Performance Shortfall – at the expense of the Contractor.

End of Part 4: Electrical Specification

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Part 5 – General Instrument Specifications

TABLE OF CONTENTS

5. MEASUREMENT INSTRUMENTATION & CONTROL ............................................ 3

5.1. General Specifications Instrumentation ................................................................ 3
5.1.1. Innovation ........................................................................................................ 3
5.1.2. Units and Dimensions ...................................................................................... 3
5.1.3. General............................................................................................................ 4
5.1.4. Enclosures and Environment ........................................................................... 5
5.1.5. Performance .................................................................................................... 6
5.1.6. Identification .................................................................................................... 7
5.1.7. Design and Installation .................................................................................... 7
5.2. Flow Measurement – Regulatory .......................................................................... 7
5.3. Flow measurement - Closed pipe systems ........................................................... 8
5.3.1. Flow Meters - Electro-Magnetic ....................................................................... 8
5.3.2. Flow Meters – Turbine ................................................................................... 10
5.3.3. Weir Plates & Open Channel systems ........................................................... 11
5.3.4. Weirs and Flumes.......................................................................................... 11
5.3.5. Flow Metering – Ultrasonic ............................................................................ 12
5.4. Level Measurement and Detection ..................................................................... 13
5.4.1. Level Measurement – Ultrasonic ................................................................... 13
5.4.2. Level Measurement – Pressure ..................................................................... 14
5.4.3. Level Measurement – Capacitance................................................................ 15
5.4.4. Level Measurement – Boreholes ................................................................... 15
5.4.5. Level Detection – Point .................................................................................. 15
5.4.6. Level Control – Sewage pumping .................................................................. 16
5.4.7. Level Control – Water .................................................................................... 16
5.5. Pressure Measurement ...................................................................................... 16
5.6. Pressure Gauges ............................................................................................... 17
5.7. Suspended Solids and Sludge Density Meters ................................................... 17
5.8. Turbidity - Monitoring and Control ...................................................................... 18
5.9. pH Measurement and Control ............................................................................ 19
5.10. Nitrate Measurement – Water Treatment Works ................................................ 20

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5.11. Other Instruments and Devices .......................................................................... 20

5.12. Ammonia Monitors ............................................................................................. 22
5.13. Sampling Systems ............................................................................................. 22
5.14. Particular Instrument Specifications ................................................................... 24

List of Tables
Table 1: Measure values to be used for units and dimensions............................................... 3
Table 2: Measurement and indication of chemical parameters .............................................. 4
Table 3: Totalizer precision for regulatory purposes .............................................................. 4
Table 4: IP ratings and materials/coatings ............................................................................. 6
Table 5: Minimum time between maintenance....................................................................... 6
Table 6: Turbidity – application and performance requirements............................................18
Table 7: pH measurement and control types ........................................................................19
Table 8: Performance overview on other instruments and devices .......................................20

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Part 5 Instrument Specifications

5. MEASUREMENT INSTRUMENTATION & CONTROL

5.1. General Specifications Instrumentation

5.1.1.Innovation
It is recognised that manufacturers will continue to develop new products, and improve
existing products, as part of the commercial and design processes. It is not the intention of
this specification to stifle improvement and innovation and new products incorporating
innovative features that enhance process performance and/or reduce whole life costs will be
considered. However it is also recognised that standardisation on particular instruments or
manufacturer has operational and maintenance advantages. Staff training costs associated
with the introduction of new technology or equipment must be taken into account. The end
user must always be consulted and his/her agreement obtained before a new product is
specified or accepted.

5.1.2.Units and Dimensions

Measured values shall be indicated in units and dimensions as specified in the following
tables.

Table 1: Measure values to be used for units and dimensions

MEASURED VALUE UNITS AND DIMENSIONS

Plant Flow Litres/second (l/s)

Works input/output (WTW)/(STW) Megalitres/day or Cubic Metres/day (Ml/d)/(Cu m/day)

Water Pressure Metres Head Water Gauge (m)

Air Pressure Bar (bar)

Hydraulic Pressure Bar (bar)

Differential Level or Head Loss Metres (m)

Percentage (with 0% and 100% being

Level (in Contained Structure) (%)
defined)

Level (In Borehole) Metres (below a datum) (m)

Speed of rotating plant Revolutions per minute (rpm)

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Measurement and indication of chemical parameters shall be in accordance with the

following table:-

Table 2: Measurement and indication of chemical parameters

MEASURED VALUE UNITS AND DIMENSIONS

Chlorine Milligrams/litre (mg/l)

Turbidity Formazin turbidity unit (FTU)

Ammonia (as N) Milligrams/litre (mg/l)

Nitrate (as NO3) Milligrams/litre (mg/l)

Dissolved oxygen Milligrams/litre mg/l

iron Milligrams/litre (mg/l)

Conductivity Micro Siemens/cm at 20°C (µS/cm)

pH pH Units

Phosphate (as P) Milligrams/litre (mg/l)

Ozone Milligrams/litre (mg/l)

Table 3: Totalizer precision for regulatory purposes

Annual licensed quantity Units of measurement

10 to 99 m³ 10 litres
100 to 999 m³ 100 litres
1000 to 9999 m³ 1 m³ (1000 litres)
10 000 m³ (10 Ml) and above 10 m³

5.1.3.General

The design, construction, inspection and testing of the equipment and component(s) shall
comply with all relevant Statutory Regulations, and the latest editions (current at the time of
Tender) of all relevant British and Harmonised European Standards, including:
a) The Electrical Equipment (Safety) Regulations 1994;
b) The Electromagnetic Compatibility Regulations 1992/1994;
c) The Low Voltage and Electromagnetic Compatibility Directives;
d) BS EN 50081-1 1992 for emissions - EMC;
e) BS EN 50082-2 1995 for immunity – EMC;
f) BS EN 61010-1 1993 low voltage directive;
g) BS EN 60529 Specification for Degrees of Protection Provided by Enclosures (IP
rating);
h) Equipment shall be CE marked to demonstrate compliance with:

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- the Low Voltage Directive; and

- the essential requirements of the relevant British Standard

Electrical installation works shall generally comply with BS 7671 and Part 5 General
Electrical Specification.
Mechanical installation works shall generally comply with Part 2 General Mechanical
Specification.
The performance of instrumentation, shall not be affected by:
- Fouling of sensors and sampling systems with biological slimes along with organic
and mineral deposits.
- Ingress of moisture into sensitive electronic circuits
- Sensitivity to electrical interference
- Poor accuracy due to variability of sample or presence of interferents
- Sensors sensitive to variations in sample flow rate, pressure or other measured
parameters
- Long response times due either to the instrument or its installation
- Changing environmental factors
- Unrepresentative sample due to change occurring in the sampling system or
unsatisfactory sample point location
- Instruments shall be protected against unauthorised operations of all controls
- Instruments shall have readily available supplies of spares and consumables
including reagents and standard solution
- Instruments and their measuring capability shall be unaffected by changes in
ambient temperature or pressure.

5.1.4.Enclosures and Environment

a) Individual instrument cases and sensor enclosures shall have an IP rating (in
accordance with BS EN 60529) suitable for the intended location. Where instruments
are mounted on a control panel the IP rating of the panel shall not be compromised.
b) Individual instrument cases and sensor enclosures shall also be of a material resistant
to any degradation by any chemicals, materials and/or UV radiation likely to be
encountered within the surrounding operating environment or; be suitably protected or
be located elsewhere.
c) Instruments shall not be located externally in such position that they are likely to be
exposed to direct sunlight for long periods. Where this is unavoidable a suitable screen
shall be provided.
d) Where the individual instruments own enclosure or case is unsuitable for mounting in
the intended location it shall be installed within another enclosure suitable for the
surrounding operating environment and which shall be fitted with a viewing window to
enable any display to be read without opening the enclosure. An anti-condensation
heater, operating at 220V ac, shall also be fitted within the enclosure.
e) Enclosure IP ratings and materials/coatings shall normally be as specified in the below
table:
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Table 4: IP ratings and materials/coatings

Operating Environment IP Rating Approved materials/coatings

Internal, dry, industrial IP54 Galvanised, manufacturers
standard paint finish, GRP or
reinforced polycarbonate (RPC).
Internal use where water may be IP55 Galvanised, manufacturers
used for hosing down or as part standard paint finish, GRP or
of the process. reinforced polycarbonate (RPC).
Internal, dry, industrial IP65 Stainless steel, GRP or RPC
environment with the presence
of corrosive atmospheres: or
External use
Where potentially subject to IP67 Stainless steel, GRP or RPC
flooding
Where subject to flooding or IP68 to a depth of 10 Stainless steel, GRP or RPC
likely to be submerged metres for an
indefinite time.

f) All cable glands used shall have the same IP rating as the enclosure or greater and
any unused cable entry holes shall be sealed or be fitted with suitable blanking plugs to
maintain the IP rating.

g) Enclosures shall only be affixed to structures and supports by means of any integral
mounting facilities or special brackets provided by the manufacturer for the purpose.
Additional holes shall NOT be drilled in the enclosure.

h) Instruments shall not normally be installed in a Hazardous Area. Where this is

unavoidable individual sensors and/or instruments and enclosures shall have a
Hazardous Area classification appropriate to the particular zone.

5.1.5.Performance
a) ‘Warm up time’ or performance following a power failure shall not unduly affect the
operation of the instrument and its associated plant.
b) The instrument shall operate within the performance specification for periods detailed
below without manual calibration or scheduled maintenance.
c) Minimum Time Between Maintenance shall be as specified in the below table.

Table 5: Minimum time between maintenance

Conductivity 6 months
Turbidity, dissolved oxygen, pH Nitrate and 30 days
suspended solids Phosphate, Iron, ammonia
Other analytical instruments 7 days
All other instruments 6 months

d) Routine maintenance and re-calibration shall not require the instrument to be off-line
more than 1 hour with the exception of flowmeters.

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e) The instrument shall be designed for a minimum operating life of ten years providing it
has been maintained and operated according to the manufacturer’s instructions.
f) Instrumentation shall be in accordance with the relevant British Standard
Specifications.

5.1.6.Identification
g) Every instrument shall be clearly identified as to it’s purpose and function by means of
durable, permanently engraved label securely fixed on or immediately adjacent to the
instrument.
h) Where an instrument is contained within another enclosure the presence of the
instrument within that enclosure shall also be indicated by means of durable,
permanently engraved label securely fixed on or immediately adjacent to the enclosure.
i) Sample pumps shall be clearly identified. The label should also indicate the instrument
or meter with which it is associated.

5.1.7.Design and Installation

Power supplies to instruments, meters and sensing devices, shall not exceed 220v ac or 48v
dc.
a) The design, configuration and installation of the instrument or sensor/transducer shall
provide:
 The required accuracy to enable any associated process to be controlled reliably
and efficiently.
 High reliability and repeatability.
 Ease of on-site maintenance, calibration and verification.
 Minimum skilled technician involvement.
 A visible indication that the instrument or sensor is functioning correctly or is
faulty.
b) Volt-free form ‘C’ contacts intended for external alarm, indication and control purposes
shall be rated 5A at 220Vac 50Hz non-inductive.
c) Terminal blocks shall be capable of accepting wiring cables with a core conductor not
exceeding 1.5mm2.
d) Analogue output signals shall be 4-20mA dc isolated. The range of the analogue
output(s) from any instrument or meter shall be scaled to correspond to the scale of the
instrument or meter display. Input signals shall be fully isolated from output signals.

5.2. Flow Measurement – Regulatory

Any flow meter intended for regulatory data reporting and audit purposes shall comply with
the following:
a) All flow meter installations that are to be used for regulatory data reporting and audit
purposes must comply with the relevant regulatory authority’s requirements and
recommendations and be correctly installed and certified to ensure the accurate
recording of all flow data.

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b) A notice shall be displayed on or immediately adjacent to the flow recording

instrument/transmitter as follows:
Do not interfere with this installation or change any parameters without
authorisation. If any component is repaired or replaced or any changes made to
the installation re-calibration and re-certification by a responsible authority may
be required.
c) On completion of a Flow meter installation that is to be used for regulatory data
reporting the installation shall be checked, verified and certified by a competent,
independent authority for calibration, accuracy and compliance with the relevant
standards. Any defects found shall be rectified by the contractor and the installation
rechecked, verified and certified by the competent, independent authority.
d) Every flow meter shall be provided with a dedicated integral or separate totaliser in
accordance with the following requirements:
 Be properly identified as to it’s purpose and units of measurement displayed;
 Wiring between the meter and a separate totalizer shall be visibly and electrically
auditable;
 Mains powered totalizers shall be protected from interruptions in the power
supply;
 Battery powered totalizers shall have a minimum battery life of 5 years;
 The totalizer shall be non-resettable and sealed against unauthorised tampering;
 Electronic totalizers shall retain the last recorded reading and not reset to zero in
event of any power failure.

Totalizer precision shall be in accordance with the table in 6.1.

e) For abstraction meters the totalizer must:
 display the total forward flow. Where bi–directional meters are used Net flow i.e.
forward minus reverse is NOT acceptable;
 be capable of recording a minimum of 5 times the annual licensed abstraction
quantity without returning to zero.
f) Where the flow meter is connected to telemetry for central monitoring, data collection
and recording the flow meter installation referred to above includes the telemetry
connections and interface. The verification and certification required includes the
correct scaling and range of the appropriate telemetry analogue inputs and outputs
associated with the meter installation.
g) An alarm output contact shall be connected to telemetry to indicate a meter/sensor fault
or failure condition.

5.3. Flow measurement - Closed pipe systems

5.3.1.Flow Meters - Electro-Magnetic

Electro-magnetic flow meters shall comply with BS EN ISO 6817 and shall only be used in
full pipe systems.
Any components and materials that will come into contact with water intended for public
consumption shall comply with the appropriate Regulations.
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Certification and Documentation

Immediately upon receipt/delivery to site the original Calibration certificate (including any
computer diskettes, programs etc.) supplied with the meter shall be retained and kept safe by
a responsible person who shall photo copy the certificate for inclusion in any O&M manuals.
As soon as practicable the original Calibration certificate (including any computer diskettes,
programs etc.) shall be formally issued to the designated end user or the end users
representative and a signed receipt obtained.
Should any original documentation (including any computer diskettes, programs etc.) be lost
or mislaid the Contractor shall be responsible for obtaining replacements at his own expense.
Meter type
Electro-magnetic flow meters shall be of the pulsed dc field type and where there is a
likelihood of reverse flows in normal operation, bi-directional.
For difficult conditions i.e. very low conductivity materials or low flows, associated with
chemical dosing, ac pulse type meters may be used.
Sizing & location
The meter shall be sized so that the velocity of fluid passing through the meter is within the
limits specified by the manufacturer for accurate metering and the pressure drop across the
meter is minimised.
The system shall be designed to prevent air being entrained within the meter or adjacent
pipe work.
Electro-magnetic flow meters shall be positioned such that there is a minimum length of
straight pipe equivalent to 5 pipe diameters directly upstream before the inlet to the flow
meter and a minimum length of straight pipe equivalent to 2 pipe diameters immediately
downstream of the meter. Performance requirements and potential disturbances to the flow
may dictate an increased length of straight pipe upstream or downstream is required.
Where the size of the meter is smaller than the diameter of the pipe the reduction in diameter
shall be a minimum of 5 pipe diameters upstream and the return to the original bore a
minimum of 3 pipe diameters downstream. Reduction and expansion in pipe size shall be
effected via concentric tapered adaptors to provide a smooth transition.
The maximum included angle of reducing/increasing tapers, if required, shall not exceed 15.
Pipe and flow meter flanges shall be PN16.
Where isolation valves are fitted these shall be a minimum of 10 pipe diameters upstream
and 5 pipe diameters downstream of the meter.
Earthing
Earthing shall be in accordance with the meter manufacturer’s recommendation for the
particular installation and must comply with BS 7671.
Earthing rings must be fitted if the pipes upstream or downstream of the primary head feature
a corrosion resistant internal lining or coating, or are manufactured from a non-conducting
material unless there is clear documentation from the manufacturer that they are not required
or the sensor has an equivalent ‘built-in’ feature. Earthing rings, where fitted, must be
installed on both sides of the primary head.
Cathodic Protection
Where the meter is to be installed in a metallic pipeline that is, or will be, protected by a
Cathodic Protection system the following shall be provided:-
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Insulating gaskets shall be fitted between both meter flanges and the pipe flanges and all
flange connecting bolts shall be fitted with insulating sleeves and washers.
An insulated, adequately rated, bonding cable shall be connected between the outermost
pipeline flanges to maintain the electrical continuity of the pipeline. The bonding cable
connections and terminals shall be adequately protected against corrosion.
The body of the meter must be earthed in compliance with BS 7671.
Upon completion of the meter installation any existing Cathodic Protection system must be
tested to ascertain that it is functioning correctly. Ref BS 7367
Location underground
All below-ground meters shall be installed in a water tight chamber.
Where meters are installed in pipelines and within underground chambers or directly buried
in ground the precise location of the meter shall be indicated by means of marker posts and
indicator plates.
Environment & Accessibility
Where meters are installed in chambers or buried directly in ground remote mounted
transmitters shall be provided and which shall be mounted in readily accessible positions
without the need to enter confined spaces and the like.
All pipeline mounted electrical equipment enclosures including sensors, integral transmitters
and the like shall be IP68 suitable for continuous submergence to 10 metres head of water in
accordance with BS EN 60529.
Where meters are installed in readily accessible positions and without the need to enter
confined spaces and the like, transmitter units may be integral with the sensor.
Outputs
The transmitter shall provide, as a minimum, a 4-20mA dc analogue output scaled directly
proportional to flow, programmable pulsed outputs for forward and reverse flows and an
alarm contact to indicate a fault/failure condition.
Accuracy
The accuracy of the proposed flow meters and the flow range to which these accuracy
figures relate shall be provided by the Contractor to the Engineer for information and
acceptance.
Cabling & Termination
Where remote mounting transmitters are to be used the interconnecting cable is typically a
special type specified and supplied by the meter manufacturer and must be ordered to the
correct length. Where the sensor/transmitter combination is matched to the length of cable
supplied the length of cable shall not be reduced or extended under any circumstances, any
excess must be coiled neatly and properly secured at one or both ends. Intermediate joints in
the cable are not permitted.
Termination of the cable shall be carried out strictly in accordance with the meter
manufacturers’ instructions and recommendations.
Where the interconnecting cable is to be buried in ground and/or in ducts it shall be steel wire
armoured with a PVC oversheath.

5.3.2.Flow Meters – Turbine

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Turbine meters shall be constructed from stainless steel with carbon steel or stainless steel
flanges. Rotors shall generate pulses within pick-up coils fitted to the outside of the meter
housing. Rotor bearings shall be tungsten carbide construction.
Turndown ratio shall not exceed 10:1

5.3.3.Weir Plates & Open Channel systems

The uncertainty of the primary element shall not exceed ±8% and that of the secondary
element ±2%.
All primary devices will be permanently fixed.
Where appropriate and channels and chambers shall be covered with GMS open mesh
flooring
Weir plates shall be fabricated from either a plastic polymer (PTFE) or stainless steel and be
sufficiently rigid or supported so as not to deflect
Manually operated penstocks shall be fitted to both bottom baffles and weir plates to facilitate
flushing
The flow computer shall, where possible, be located adjacent to the primary device in either
a wall mounted or pedestal mounted enclosure.
A retractable weather resistant calibration reference plate system shall be provided for all
installations. This shall be set to mimic a reading at approximately 90% of maximum flow.
All key flow measurement calibration parameters including the reference point data shall be
recorded on a weather resistant plate and fixed adjacent to the primary device.
The Contractor shall issue, to the Engineer, for all compliant flow systems, a traceable
certificate. The Contractor shall issue two paper copies and one electronic version (in an
editable PDF format). Each system shall have a 20-point ‘look-up table’ showing:
 point number
 head (mm) – {for open channel flow systems}
 flow (l/s)
 uncertainty (± %)

5.3.4.Weirs and Flumes

a) New hydraulic structures for flow measurement and/or flow control shall be constructed
to the best tolerances that current engineering and construction practices allow and be
sufficiently stable to maintain their dimensions for a minimum of 20 years.
b) The overall system hydraulic design, construction and location of the flow measuring
structure shall be such as to ensure that flow measurement is not adversely affected by
any downstream conditions that may reasonably be anticipated to occur e.g. high river
levels resulting from storm conditions should not cause the structure to flood or be
drowned out.
c) Where an existing structure is intended to be used or reused a full and proper
evaluation of its condition and dimensional stability shall be conducted.
d) The design, construction and installation of the primary element shall fully comply with
BS 3680.

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e) Thin plate weirs shall be in accordance with BS3680 part 4A. Weir plates shall be fixed
in position, of sufficient thickness as to ensure rigidity under all flow conditions and
installed true vertical and horizontal. Plates shall be fabricated from either stainless
steel or a plastic polymer that is not affected or degraded by exposure to sunlight/UV.
f) For sewage applications flumes shall normally be flat bottomed rectangular or U-
throated in accordance with BS3680 Part 4C.
g) The flume primary element may be a factory built prefabricated assembly to be
incorporated and installed true and level without distortion into the overall hydraulic
structure.

5.3.5.Flow Metering – Ultrasonic

The measurement of flows utilising primary elements such as weir plates and flumes in open
channels and shall be effected using a non-contacting ultrasonic head/flow monitoring
device.
a) Head/flow measurement shall be a high frequency, ultrasonic non-contact system.
b) The transducer shall be temperature compensated and protected to IP68 BS EN
60529.
c) The type of transducer chosen shall be located such that the emitted beam covers an
area that avoids obstacles and reflections to prevent spurious readings.
d) Any separate temperature sensor shall be located adjacent to the transducer but shall
not be positioned such that it may receive direct sunlight.
e) The transducer shall be installed in an approved and serviceable position and/or
mounted such that it may be easily and readily replaced.
f) The control unit shall provide the following features:
 Digital alphanumeric display of settings and conditions using standard
engineering units. The display must be visible in low light conditions (e.g.
illuminated by means of a back light.
 Visual indication of loss of echo either by utilising the display or a separate
indication.
 Have user configurable password or code number protection to restrict access to
parameter and configuration settings to prevent unauthorised changes.
 Entry of operating parameters and calibration without the need to physically
measure the distance to water level or to remove the transducer head and the
facility to simulate the programmed operations.
 Integral non-volatile memory for retention of all parameter settings and data in
event of power failure.
 Integral real time clock for time related operations.
 Accuracy to within not more than 0.5% of the operating range
 Volt-free changeover (form ‘C’) relay contacts configurable to provide sufficient
control and alarm points to meet the requirements of the particular application.
 Isolated, 4-20mA analogue output scalable to the configured measured range.

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Part 5 Instrument Specifications

 Be suitable for rack, panel and/or wall mounted applications as required for the
particular application.
g) The control unit shall also automatically self-monitor for correct operation and provide a
common alarm for system faults, memory failure and loss of echo. This common alarm
shall be connected to telemetry.
h) A plate, mounted and set to simulate known head of water and corresponding flow rate
shall be provided such that it may readily be temporarily rotated under the transducer
to provide a reference level to aid calibration and routine checking. A latch or retaining
device shall be provided to enable the plate to be locked in either position.
i) For general process flow measurement applications the control unit shall be mounted
on the main control panel unless the distance between the transducer and the control
unit exceeds the maximum stated by the manufacturer. If the maximum distance would
be exceeded the control unit may be mounted externally within a vandal proof lockable
enclosure with viewing window and providing protection to IP55 BS EN 60529. Such
enclosure to have a anti-condensation heater operating at 220 volts.
j) Where the instrument is to be used for Regulatory purposes the control unit shall
either:
 be mounted externally within a vandal proof lockable enclosure with a viewing
window and providing protection to IP55 BS EN 60529 installed in such a position
as to be readily and safely accessible to the Regulatory Authority for flow reading
purposes without it’s staff requiring access to any building, control room etc.
or
 a remote readout be provided for such purpose.
k) Where the instrument is to be used both for Regulatory purposes and process control
particular care shall be taken to ensure that the there are no adverse effects upon the
correct functioning of the meter by the process control connections or interface. Signal
isolators shall be used in the analogue circuits.

5.4. Level Measurement and Detection

For general water and sewage applications the preferred method of continuous flow
measurement shall be a high frequency ultrasonic, non-contact system

5.4.1.Level Measurement – Ultrasonic

a) Level measurement shall be a high frequency, ultrasonic non-contact system.

b) The transducer shall be temperature compensated and protected to IP68 BS EN

60529.

c) The type of transducer chosen shall be located such that the emitted beam covers an
area that avoids obstacles and reflections to prevent spurious readings.

d) Any separate temperature sensor shall be located adjacent to the transducer but shall
not be positioned such that it may receive direct sunlight.

e) The transducer shall be installed in an approved and serviceable position and/or

mounted such that it may be easily and readily replaced without the need to enter any
confined space e.g. sewage P.S. wet well.
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Component 3 Salt WWTP
Part 5 Instrument Specifications

f) The control unit shall provide the following features:

 Digital alphanumeric display of settings and conditions using standard
engineering units. The display must be visible in low light conditions e.g.
illuminated by means of a back light;
 Visual indication of loss of echo either by utilising the display or a separate
indication;
 Have user configurable password or code number protection to restrict all access
to parameter and configuration settings to prevent unauthorised changes;
 Entry of operating parameters and calibration without the need to physically
measure the distance to water level or to remove the transducer head and the
facility to simulate the programmed operations;
 Integral non-volatile memory for retention of all parameter settings and data in
event of power failure;
 Integral real time clock for time related operations;
 Accuracy to within not more than 0.5% of the operating range;
 Volt-free changeover (form ‘C’) relay contacts configurable to provide sufficient
control and alarm points to meet the requirements of the particular application;
 Programmable agitator discrimination and damping;
 Isolated, 4-20mA analogue output scalable to the configured measured range;
 Be suitable for rack, panel and/or wall mounted applications as required for the
particular application.

g) Where required by the particular application e.g. pump control the controller shall
provide additional features e.g.:
 Be configurable to operate around at least two sets of time dependant control
set points to allow peak lopping event and one time related low level pump
down event;
 Provide volumetric conversion of tank/sump level into volume and the
capability to gather total pumped volume data.

h) The control unit shall also automatically self-monitor for correct operation and provide a
common alarm for system faults, memory failure and loss of echo. This common alarm
shall be connected to telemetry.

i) The control unit shall normally be mounted on the main control panel unless the
distance between the transducer and the control unit exceeds the maximum stated by
the manufacturer. If the maximum distance would be exceeded the control unit may be
mounted externally within a vandal proof lockable enclosure with viewing window and
providing protection to IP55 BS EN 60529. Such enclosure to have a anti-condensation
heater operating at 220 volts.

5.4.2.Level Measurement – Pressure

This shall be by the utilisation of suspended pressure transducers as detailed in
Clause 5.1.13

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Part 5 Instrument Specifications

5.4.3.Level Measurement – Capacitance

a) The capacitance probe shall be immersed directly and vertically into the water.
b) Changes in water level shall produce a linear change in a frequency signal.
c) The transducer shall be installed so that access to its transmitter can be achieved
without the need to enter the actual reservoir, tower, tank etc, or step onto a hatchway
ladder, and in any event access must be possible by one person without the need for
special safety precautions.
d) The transducer shall be capable of being powered locally or remotely.
e) For spans of greater than 1 metre discrimination shall be ± 0.1% or ± 3 mm whichever
is the greater.
f) Surge suppression shall be fitted.
g) Adjustments shall be provided for span, zero and output signal amplitude.
h) Calibration shall be possible by raising and lowering the transducer and sufficient slack
cable shall be available.
i) The transducer shall be coupled to a suitable receiver/power unit/re-transmitter having
surge protection and a 4-20 mA output proportional to level.
j) Where level probes, transducer cables etc. enter or travel through the roof, hatch or
covers of storage structures the cable entry points should be sealed to prevent ingress
of non potable water and/or other foreign object matter into the storage structure.

5.4.4.Level Measurement – Boreholes

a) The preferred method shall be by the utilisation of suspended pressure transducers as
detailed in Clause 5.12.
b) The transducer shall be located approximately 2 metres above the pump suction and
routed via a dip tube suspended from the head plate and covered to prevent ingress
and contamination. Particular care in component selection and installation shall be
exercised to ensure that the system cannot be affected by particularly humid conditions
experienced in borehole applications.
The system shall be reverse acting, i.e. shall indicate the distance between the water surface
and the head plate.

5.4.5.Level Detection – Point

a) For raw sewage applications the preferred device for single point level detection for
alarm, indication and control purposes is a float switch.
b) For potable water, raw water and final effluent applications the use of either float
switches or level probes is acceptable.
c) The maximum voltage applied to float switch circuits shall be 48V ac or dc.
d) Where a float switch is located in a hazardous zone it shall be connected via an
Intrinsically Safe barrier.
e) Where probes are located in a hazardous zone each individual probe and the earth
return path shall be connected via Intrinsically Safe barriers.

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Part 5 Instrument Specifications

5.4.6.Level Control – Sewage pumping

a) Level control shall normally be effected by means of an ultrasonic level measurement
system. Where an ultrasonic system is unsuitable pressure transducers with the
appropriate control unit may be used as an alternative.
b) If required by the application the controller shall also:
 Be configurable to operate around at least two sets of time dependant control set
points to allow peak lopping event and one time related low level pump down
event;
and/or
 Provide volumetric conversion of tank/sump level into volume and the capability to
gather total pumped volume data.
c) In the event of the level control unit being out of service or when the rising level is in
danger of immersing the face of the ultrasonic transducer, level control shall be taken
over by one control backup float switch. This float switch shall be mounted such that
the switching differential shall prevent excessive frequency of start/stop operation of
the pumps. If necessary the switching differential may be obtained by use of a suitable
timing device in conjunction with the float switch. The float switch signal shall be wired
to the main control panel where it shall be used to sequentially start all available duty
units.
d) An additional float switch shall be positioned at a level above the control backup float
switch. This float switch shall be wired back to the control section of panel to provide an
emergency high level alarm connected to telemetry.

5.4.7.Level Control – Water

a) Level control shall normally be effected by means of an ultrasonic level measurement
system. Where an ultrasonic sensor is unsuitable pressure transducers with the
appropriate control unit may be used as an alternative.
b) All materials in contact with potable water shall be approved.

5.5. Pressure Measurement

a) Pressure measurement shall be by means of pressure transducers that shall be either
of the resistance strain gauge or variable capacitance type. The diaphragm material
shall be suitably corrosion resistant to the fluid being measured. The transducer shall
be capable of withstanding transient surge pressure without affecting the accuracy of
the system.
b) The associated transmitter shall provide a linear 4-20mA dc output signal proportional
to the pressure measured over the normal operating range. The transmitter shall have
the facility to adjust span and zero.
c) The pressure transducer shall be mounted in a serviceable position complete with a
suitable isolating valve and be protected to IP68 BS EN 60529.
d) A suitable dc power supply shall be located within a control panel.
e) The power supply must fully comply with the specification/requirements of the
manufacturer of the pressure transducer.

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Part 5 Instrument Specifications

5.6. Pressure Gauges

f) Gauge connections complete with isolating cocks shall be provided on each pump
delivery branch and, with the exception of submersible units, on each pump suction
branch.
g) One set only of 150 mm diameter diaphragm type pressure gauges is required for each
different size of pump.
h) For injection water booster pumps (e.g. chlorine treatment) or sample water pumps,
50 mm gauges may be utilised.
i) In addition to the pressure gauge connections there shall be included in a suitable
position on common delivery pipework a tapped 1" BSP connection with a valve for
isolation purposes.
Pressure gauges for use on sewage applications containing solids shall be supplied with
diaphragms of the clean out type. It shall be possible for the diaphragm to be separated from
the housing for cleaning purposes without breaking into the sealed system. The pressure
shall be transmitted from the diaphragms to remote gauges. All necessary isolating valves
and connections shall be included and the gauge calibrated in metres head of water.

5.7. Suspended Solids and Sludge Density Meters

1. The measurement of suspended solids shall either be in mg/litre or percentage dry solids
depending on application.
2. Applications and Performance Requirements:-
Type I - Sewage Treatment : final effluent, activated sludge control
Type IIa - Sewage Treatment : settled sewage
Type IIb - Sewage Treatment : raw sewage (influent)
Type III -
a. Sewage Treatment : mixed liquor suspended solids, returned activated
sludge and waste activated sludge solids (low MLSS processes)
b. Water Treatment : sludge bleed from clarifier blankets
Type IV -
a. Sewage Treatment : returned activated sludge and waste activated sludge
solids (high MLSS processes)
b. Sludge Solids Content : desludging of settling tanks and monitoring input
of solids into digesters
c. Solids loading of sludge to land
d. Sludge dewatering
Water Treatment : thickened sludge

Inaccuracy Range
Type I + 5 mg/l or + 10% of 0-100 mg/l suspended solids
reading whichever is
greater

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Part 5 Instrument Specifications

Type IIa + 50 mg/l or + 10% of 0-1000 mg/l suspended solids

reading whichever is
greater
Type IIb + 50 mg/l or + 20% of 0-1000 mg/l suspended solids
reading whichever is
greater
Type III + 10% of reading 1000-15000 mg/l suspended solids
Type IV + 10% of reading 1%-10% dry solids

3. Sensors - For dip and insertion sensors, the sensor shall be safely and easily removed
from the process stream without shutting down the process. Self cleaning and integral
automatic calibration facilities shall be included

5.8. Turbidity - Monitoring and Control

a) The measurement units of turbidity shall be in formazin turbidity units (FTU), however
Nephelometric turbidity instruments may be used.
b) Applications and performance requirements:
Type I - Coagulation control, filtered water turbidity, filter backwash control,
backwash and supernatant return;
Type II - Raw water monitoring, final treated water monitoring including final effluents
for STW’s.

Table 6: Turbidity – application and performance requirements

Inaccuracy Response Time (T90)

+ 2% of full scale
Type I deflection or + 0.2 FTU Less than 2 minutes
whichever is greater
+ 2% of full scale
Type II deflection, or + 0.2 FTU Less than 15 minutes
whichever is greater

The total response time, including all sampling lags, shall not exceed 3 minutes (T 90) for type
I analysis
Range - The range shall be capable of selection by the user and shall be suitable for the
application.
Repeatability - Repeatability shall not exceed + 1% of span or + 0.1 FTU, whichever is
greater.
c) Sensor Cleaning – self-cleaning integral automatic calibration and manual cleaning
facilities shall be included if required to achieve the required time between
maintenance.. Incorporation of these systems shall not affect the availability of the
instrument for a period greater than 1 minute in any one hour for type I instruments and
15 minutes in any one hour (maximum aggregate of 2 hours in 24 hours). For type II
instruments

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Part 5 Instrument Specifications

d) Entrainment of Air - the instrument shall incorporate a facility for ensuring that
inaccurate readings due to entrained air will be minimised.
e) Sensors - For dip and insertion sensors, the sensor shall be safely and easily removed
from the process stream without shutting down the process.

f) Calibration shall be by the use of a Dry Secondary Calibration Standards designed and
supplied for the instrument. The standards shall be traceable to an FTU standard. One
number of standards appropriate for each specific model and range of instrument are
required on any one site.

5.9. pH Measurement and Control

a) Instrument - the instrument shall measure the pH value of natural water, partially
treated water or potable water over a range from pH2 to pH12. The output signal zero
selection shall be in increments of < 1pH over the range of the instrument.
The output signal span selection shall be in increments of < 1pH. Indicators shall have
a resolution of 0.01pH units.
b) Applications and performance requirements:
Type I - Raw water monitoring; aeration monitoring
Type II - Coagulation pH control
- Manganese removal
- Final water pH /monitoring ( No chemical dose control)
- Precipitation softening
- Recarbonation
- Aeration control
Type III - De-alkaliser waste control

Table 7: pH measurement and control types

Inaccuracy Repeatability Response Time

Type I + 0.1 + 0.05 3 mins
Type II + 0.1 + 0.05 15 secs
Type III + 0.3 + 0.1 15 secs

c) The instrument shall meet the performance requirements of this specification when
operated continuously and without manual intervention for a minimum period of
30days. Auto-calibration, auto-cleaning or multi-sensor techniques may be used to
maintain this stability.
If self-cleaning and/or auto-calibration is incorporated the accuracy of the instrument
shall not be affected for a period greater than 10 minutes in any 1 hour period. The
aggregate of the off-line periods shall not exceed 2 hours in a 24 hour period.
d) Sampling systems should make provision for:

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Part 5 Instrument Specifications

- Clean water flush and/or air purge (i.e. avoid deposition of suspended
material);
- Chemical cleaning with acids or biocides;
- Mechanical cleaning arrangements;
- Ultrasonic cleaners (NB: Control output to be inhibited during cleaning until
re-stabilisation achieved);
- Sample take-off point at a position that is representative;
- Care in avoidance of aeration of the sample on the release of dissolved
gases;
- Avoidance of change in temperature of the sample;
- Short sample time, achieved by fast bypass loops where necessary.

5.10. Nitrate Measurement – Water Treatment Works

Measurement shall be by the ultraviolet absorption method. The analyser shall: incorporate
automatic cleaning, Xenon flash tube and concave mirror diffraction grating. At each
measurement, a minimum of 15 flashes shall be analysed for errors and be used in
measurement calculations:
- A minimum of one high level alarm is required, rated at 220 volts, ac.
- A discrete termination section is may be supplied.
- The sensor and flow cell shall be designed to withstand a fault condition
pressure of up to 4 bar.

5.11. Other Instruments and Devices

Performance shall be equal to or exceed the values given in the following table.
Note: Span and Full Scale Deflection relate to the calibrated span of the instrument as
installed, not the maximum span.

Table 8: Performance overview on other instruments and devices

Operating
Inaccuracy:
Long Term range, all
Combined effect Temperature
Stability components
of non-linearity, effect all
Device unless
hysterisis and components 12 Months otherwise
repeatability % FSD/ C
0
% Span specified
% FSD 0
C

Signal conditioning devices ± 0.2 ± 0.02 ± 0.1 - 15 to +55

Pressure transducer ± 0.25 ± 0.025 ± 0.2 -15 to +55

Pressure Transmitter ± 0.5 ± ± 0.025 -15 to +55

Pressure transducer for level

± 0.25 ± 0.02 ± 0.02 -15 to +55
measurement

Pressure Transmitter for level ± 0.5 ± 0.02 ± 0.02 -15 to +55

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Part 5 Instrument Specifications

Operating
Inaccuracy:
Long Term range, all
Combined effect Temperature
Stability components
of non-linearity, effect all
Device unless
hysterisis and components 12 Months otherwise
repeatability % FSD/ C
0
% Span specified
% FSD 0
C

measurement

± 0.25 or 6mm,
Level Measurement by
which ever is - - -15 to +55
ultrasonic methods
greater

Pressure Gauge, 100mm and

To BS 1780 class 1
above

Pressure Gauge, below 100mm To BS 1780 class 2

Differential Pressure
± 0.5 ± 0.02 ± 0.02 -
Transmitter

Panel Indicator
±1 - - -15 to +55
(analogue)

Recorder ± 0.5 ± 0.02 ± 0.02 -15 to +55

Ammonia analyser ± 2.0 - - +5 to +45

Conductivity Analyser ± 1.5 - - -10 to +50

Fluoride analyser ± 2.0 - - +5 to +45

Flowmeter,
± 1.0 % of reading - - -15 to +50
Turbine

Flowmeter
± 5.0 - - -15 to +50
Variable Area

Gas Leak detectors ± 2.0 ± 0.075 - -15 to + 40

1 to 50 mg/l ±
1.0mg/l
Nitrate Analyser + 5 to +45
50 to 100 mg/l ± - -
2% of reading

Ozone in water analyser ± 1.0 - - -15 to +40

Organic Pollution
± 0.5 ± ± +0 to +40
analyser

Phosphate analyser ± 2.0 - - +5 to +45

-10 to +50,
o
Temperature transmitter ± 0.5 C ± 0.02 ± 0.02 transmitter
only

Weight by load cell ± 0.5 ± 0.03 ± -15 to +50

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Part 5 Instrument Specifications

5.12. Ammonia Monitors

Ammonia monitors shall be of the ion selective electrode type.

5.13. Sampling Systems

a) All sample take-off point(s) shall be chosen to ensure that the sample being taken is
truly representative of the source water/liquid being monitored. Take-off point(s) should
be avoided from long pipeline runs supplying hydrants, stilling basins or ‘dead legs’.
b) Sample take-off point(s) shall be located such distance downstream of any chemical
dosing point as to ensure that the chemical has adequately mixed with the water before
sampling.
c) The design of the sampling system shall be such as to ensure that the sample is not
contaminated by any material, chemical or reagent other than one intentionally
introduced as part of the ‘test’ procedure or process.
d) Sample pumps shall be located as close as possible to the sample point and where
they can be easily maintained. Pumps shall not be located in confined spaces within
underground chambers.
e) The pumps and sample lines shall be located and sized such that the sample transit
time, from sample point to monitor instrument is appropriate to the purpose of the
measurement being undertaken. Where the measurement is used for monitoring, or
monitoring and plant/works shutdown, the sample transit time shall not exceed
4 minutes.
f) Sample lines shall not be run in the same duct(s) as electric cables, and shall be non
metallic.
g) Where sample lines are connected to pipework, the connection shall be via a dip tube
and isolating valve. This connection shall preferably be taken from the side of the pipe
to prevent entrained air being drawn into the sample system.
h) When sample lines are exposed above ground they shall be lagged and trace heated
to maintain a temperature of 5 degrees Celsius when the ambient temperature falls to
minus 20 degrees Celsius.
i) Sampling systems, in particular those used in raw water and sewage applications, are
susceptible to fouling and blockages with biological slimes, organic and mineral
deposits, fats & greases. The design of the system shall be such as to readily facilitate
cleaning and flushing including dismantling when appropriate.
j) In any potable water installation samples shall always be discharged to a suitable
waste water drain and under no circumstances should any sample be returned to the
process flow or sample source.
k) Used samples, particularly where chemicals or reagents have been introduced as part
of the measurement process, shall not be discharged direct to a watercourse unless
such discharge complies with an appropriate discharge consent.
l) Where the measurement is used for monitoring, or monitoring and plant/works
shutdown duty/standby sample pump(s) shall be provided. Any other requirement for
duplicate or duty/standby sample pumps will be dependant upon the purpose of the
monitoring or measurement being carried out. For large works with multi-sampling &
monitoring the provision of boxed spare(s) may be appropriate.

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m) 13. Motors fitted to sample pumps shall operate at the most suitable voltage appropriate
to the installation and type/size of pump being utilised. Motors shall be capable of long
term continuous running without maintenance e.g. 3ph 400Vac 50Hz. Single phase
230V or 110V ac 50Hz motors shall be of the capacitor start/run type.

End of Part 5 General Instrument Specification

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Part 5 Instrument Specifications

5.14. Particular Instrument Specifications

The following table lists particular instruments of the WWTP. However, it excludes those included in vendor equipment packages. The Contractor shall thoroughly investigate all of the additional instruments
which are contained within all proposed vendor packages and add them to the list below:
# Tag Number Location Signal Type Measured Parameter Instrument Type Measuring Range EX Category
Inlet Works

1 110-IL-01 in the Inlet chamber Analogue (4-20 mA) Level Ultrasonic Acc. to installation Ex 2
2 121-IL-01 Coarse screen 1 channel Analogue (4-20 mA) Differantial Level Ultrasonic Acc. to installation Ex 2
3 121-IL-02 Coarse screen 2 channel Analogue (4-20 mA) Differantial Level Ultrasonic Acc. to installation Ex 2
4 122-IL-01 Fine screen 1 channel Analogue (4-20 mA) Differantial Level Ultrasonic Acc. to installation Ex 2
5 122-IL-02 Fine screen 2 channel Analogue (4-20 mA) Differantial Level Ultrasonic Acc. to installation Ex 2
6 120-IQ-01 in screening building Analogue (4-20 mA) Gas (CH4 & H2S) incl. visual and audible alarm 0-100% LEL and 0-50 ppm H2S Ex 2
7 120-IP-01 Service water supply pipe in screening building Digital Pressure Manometer + switch 0-10 bar Ex 2
8 121-IL-03 Coarse Wash press inlet hopper Digital Level 2x Point Acc. to installation Ex 2
9 122-IL-03 Fine Wash press inlet hopper Digital Level 2x Point Acc. to installation Ex 2
10 123-IP-01 outlet of the grit blower Digital Pressure Manometer + switch 0-500 mbar Ex 2
11 123-IQ-01 in the Inlet work's effluent chamber Analogue (4-20 mA) pH, Temp 1-14 Ex 2
12 123-IQ-02 in the Inlet work's effluent chamber Analogue (4-20 mA) conductivity 0-500 mS/m Ex 2

Stormwater Pump station

13 124-IL-01 stormwater pump sump Analogue (4-20 mA) Level Ultrasonic Acc. to installation -

Water Line drainage pumping station

14 126-IL-01 waterline drainaige pump sump Analogue (4-20 mA) Level Ultrasonic Acc. to installation -
15 126-IL-02 waterline drainaige pump sump Digital Level Float Sensor Acc. to installation -

Flow Meter

16 125-IF-01 in the flow metering chamber Analogue (4-20 mA) Flow Electromagnetic 0-3000 m3/h -

PST 1 Primary Sludge pump station

17 200-IT-01 in Primary sludge pump 1 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
18 200-IT-02 in Primary sludge pump 2 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
19 200-IT-03 in Primary sludge pump 3 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
20 200-IP-01 discharge pipe of Primary sludge pump 1 Digital Pressure Manometer + switch 0-10 bar -
21 200-IP-02 discharge pipe of Primary sludge pump 2 Digital Pressure Manometer + switch 0-10 bar -
22 200-IP-03 discharge pipe of Primary sludge pump 3 Digital Pressure Manometer + switch 0-10 bar -
23 200-IF-01 on the common discharge pipe of primary sludge pumps Analogue (4-20 mA) Flow Electromagnetic 0-40 m3/h -

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Part 5 Instrument Specifications

# Tag Number Location Signal Type Measured Parameter Instrument Type Measuring Range EX Category

PST 2 Primary Sludge pump station

24 200-IT-04 in Primary sludge pump 1 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
25 200-IT-05 in Primary sludge pump 2 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
26 200-IT-06 in Primary sludge pump 3 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
27 200-IP-04 discharge pipe of Primary sludge pump 1 Digital Pressure Manometer + switch 0-10 bar -
28 200-IP-05 discharge pipe of Primary sludge pump 2 Digital Pressure Manometer + switch 0-10 bar -
29 200-IP-06 discharge pipe of Primary sludge pump 3 Digital Pressure Manometer + switch 0-10 bar -
30 200-IF-02 on the common discharge pipe of primary sludge pumps Analogue (4-20 mA) Flow Electromagnetic 0-40 m3/h -

PST 1 Primary scum pump station

31 201-IL-01 in the pump station Analogue (4-20 mA) Level Ultrasonic Acc. to installation -
201-IL-03 in the pump station Digital Level Float Sensor Acc. to installation -

PST 2 Primary scum pump station

32 201-IL-02 in the pump station Analogue (4-20 mA) Level Ultrasonic Acc. to installation -
33 201-IL-04 in the pump station Digital Level Float Sensor Acc. to installation -

Gravity Sludge Thickener 1

34 210-IL-01 in the thickener tank Analogue (4-20 mA) Sludge-blanket level Ultrasonic Acc. to installation Ex 2

Gravity Sludge Thickener 2

35 210-IL-02 in the thickener tank Analogue (4-20 mA) Sludge-blanket level Ultrasonic Acc. to installation Ex 2

Gravity Thickener Scum Pump station

36 210-IL-03 in the scum pump station Analogue (4-20 mA) Level Ultrasonic Acc. to installation Ex 2
37 210-IL-04 in the scum pump station Digital Level Float Sensor Acc. to installation Ex 2

Gravity Thickener Sludge Pump station

38 210-IT-01 Temperature sensor for Primary sludge pump 1 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
39 210-IT-02 Temperature sensor for Primary sludge pump 2 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
40 210-IT-03 Temperature sensor for Primary sludge pump 3 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
41 210-IP-01 Pressure sensor on the pipe after Primary sludge pump 1 Digital Pressure Manometer + switch 0-10 bar -
42 210-IP-02 Pressure sensor on the pipe after Primary sludge pump 2 Digital Pressure Manometer + switch 0-10 bar -
43 210-IP-03 Pressure sensor on the pipe after Primary sludge pump 3 Digital Pressure Manometer + switch 0-10 bar -
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Component 3 Salt WWTP
Part 5 Instrument Specifications

# Tag Number Location Signal Type Measured Parameter Instrument Type Measuring Range EX Category

Activated Sludge Tank 1

44 140-IQ-01 in the anoxic zone 1.1 Analogue (4-20 mA) Nitrate (NO3-N) UV absorbtion 0-10 mg NO3-N/l -
45 140-IQ-04 in the anoxic zone 1.2 Analogue (4-20 mA) Nitrate (NO3-N) UV absorbtion 0-10 mg NO3-N/l -
46 140-IQ-02 in aeration tank 1.1 Analogue (4-20 mA) Redox -500 … +500 mV -
47 140-IQ-03 in aeration tank 1.1 Analogue (4-20 mA) Dissolved Oxygen Optical 0-10 mg O2/l -
48 140-IQ-05 in aeration tank 1.2 Analogue (4-20 mA) Redox -500 … +500 mV -
49 140-IQ-06 in aeration tank 1.2 Analogue (4-20 mA) Dissolved Oxygen Optical 0-10 mg O2/l -
50 140-IF-01 on air pipe to AST 1.1 Analogue (4-20 mA) Flow 0-6000 m3/h -
51 140-IF-02 on air pipe to AST 1.2 Analogue (4-20 mA) Flow 0-6000 m3/h -

Blower Station 1

52 142-IT-01 in blower room Analogue (4-20 mA) Temperature 0-50 oC -

53 142-IP-01 common pressure main of blowers Analogue (4-20 mA) Pressure Pressure transducer 0-1 bar -

Activated Sludge Tank 2

54 140-IQ-07 in the anoxic zone 2.1 Analogue (4-20 mA) Nitrate (NO3-N) UV absorbtion 0-10 mg NO3-N/l -
55 140-IQ-10 in the anoxic zone 2.2 Analogue (4-20 mA) Nitrate (NO3-N) UV absorbtion 0-10 mg NO3-N/l -
56 140-IQ-08 in aeration tank 2.1 Analogue (4-20 mA) Redox -500 - 500 mV -
57 140-IQ-09 in aeration tank 2.1 Analogue (4-20 mA) Dissolved Oxygen Optical 0-10 mg O2/l -
58 140-IQ-12 in aeration tank 2.2 Analogue (4-20 mA) Redox -500 … +500 mV -
59 140-IQ-11 in aeration tank 2.2 Analogue (4-20 mA) Dissolved Oxygen Optical 0-10 mg O2/l -
60 140-IF-03 on air pipe to AST 2.1 Analogue (4-20 mA) Flow 0-6000 m3/h -
61 140-IF-04 on air pipe to AST 2.2 Analogue (4-20 mA) Flow 0-6000 m3/h -

Blower Station 2

62 142-IT-02 in blower room Analogue (4-20 mA) Temperature 0-50 oC -

63 142-IP-02 common pressure main of blowers Analogue (4-20 mA) Pressure Pressure transducer 0-1 bar -

RAS/WAS Pumping station 1

64 205-IF-02 in the inlet chamber from FST 1.2 Analogue (4-20 mA) Flow Ultrasonic 0-700 m3/h -
65 205-IF-03 in the inlet chamber from FST 1.1 Analogue (4-20 mA) Flow Ultrasonic 0-700 m3/h -
66 205-IL-01 in the RAS/WAS pump chamber Analogue (4-20 mA) Level Ultrasonic Acc. to installation -
67 205-IL-02 in the RAS/WAS pump chamber Digital Level Float Sensor Acc. to installation -
68 205-IF-01 on common discharge main from RAS pumps Analogue (4-20 mA) Flow Electromagnetic 0-1200 m3/h -
69 205-IF-04 on common dischrage main from WAS pumps Analogue (4-20 mA) Flow Electromagnetic 0-80 m3/h -

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Sanitation Programme: NEXUS and Resource Protection Tender Documents – Vol.2
Component 3 Salt WWTP
Part 5 Instrument Specifications

# Tag Number Location Signal Type Measured Parameter Instrument Type Measuring Range EX Category
RAS/WAS Pumping station 2

70 205-IF-06 in the inlet chamber from FST 2.2 Analogue (4-20 mA) Flow Ultrasonic 0-700 m3/h -
71 205-IF-07 in the inlet chamber from FST 2.1 Analogue (4-20 mA) Flow Ultrasonic 0-700 m3/h -
72 205-IL-03 in the RAS/WAS pump chamber Analogue (4-20 mA) Level Ultrasonic Acc. to installation -
73 205-IL-04 in the RAS/WAS pump chamber Digital Level Float Sensor Acc. to installation -
74 205-IF-05 on common discharge main from RAS pumps Analogue (4-20 mA) Flow Electromagnetic 0-1200 m3/h -
75 205-IF-08 on common dischrage main from WAS pumps Analogue (4-20 mA) Flow Electromagnetic 0-80 m3/h -

FST Scum pump station

76 152-IL-01 in the scum pump station Analogue (4-20 mA) Level Ultrasonic Acc. to installation -
77 152-IL-01 in the scum pump station Digital Level Float Sensor Acc. to installation -

Sand Filter

78 160-IL-01 in the Inlet chamber of the sand filter Analogue (4-20 mA) Level Ultrasonic Acc. to installation -
79 160-IL-02 wash water pump sump Analogue (4-20 mA) Level Ultrasonic Acc. to installation -
80 160-IP-01 pressure main of air compressors Digital Pressure Manometer + switch 0-1 bar -

UV Disinfection

81 170-IL-01 in the UV channel after disinfection Analogue (4-20 mA) Level Ultrasonic Acc. to installation -
82 190-IP-01 on the common pressure main of service water pumps Analogue (4-20 mA) Pressure Pressure transducer 0-10 bar -

WAS storage tank

83 211-IL-01 in the WAS storage tank Analogue (4-20 mA) Level Ultrasonic Acc. to installation -

Gravity Belt Thickener (Mechanical Sludge Thickener)

84 212-IT-01 in GBT feed pump 1 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
85 212-IT-02 in GBT feed pump 2 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
86 212-IT-03 in GBT feed pump 3 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
87 212-IP-02 discharge pipe of GBT feed pump 1 Digital Pressure Manometer + switch 0-10 bar -
88 212-IP-03 discharge pipe of GBT feed pump 2 Digital Pressure Manometer + switch 0-10 bar -
89 212-IP-04 discharge pipe of GBT feed pump 3 Digital Pressure Manometer + switch 0-10 bar -
90 212-IF-01 discharge pipe of GBT feed pump 1 Analogue (4-20 mA) Flow Electromagnetic 0-100 m3/h -
91 212-IF-02 discharge pipe of GBT feed pump 2 Analogue (4-20 mA) Flow Electromagnetic 0-100 m3/h -
92 212-IF-03 discharge pipe of GBT feed pump 3 Analogue (4-20 mA) Flow Electromagnetic 0-100 m3/h -
93 212-IL-03 suction pipe of GBT 1 outlet pipe Digital Level 2x Point Acc. to installation -
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Component 3 Salt WWTP
Part 5 Instrument Specifications

# Tag Number Location Signal Type Measured Parameter Instrument Type Measuring Range EX Category
94 212-IL-04 suction pipe of GBT 2 outlet pipe Digital Level 2x Point Acc. to installation -
95 212-IL-05 suction pipe of GBT 3 outlet pipe Digital Level 2x Point Acc. to installation -
96 212-IT-07 in GBT 1 outlet pump Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
97 212-IT-08 in GBT 2 outlet pump Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
98 212-IT-09 in GBT 3 outlet pump Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
99 212-IP-12 discharge pipe of pump after GBT 1 Digital Pressure Manometer + switch 0-10 bar -
100 212-IP-13 discharge pipe of pump after GBT 2 Digital Pressure Manometer + switch 0-10 bar -
101 212-IP-14 discharge pipe of pump after GBT 1 Digital Pressure Manometer + switch 0-10 bar -
102 212-IP-01 Service water supply pipe in Sludge Treatment Building Digital Pressure Manometer + switch 0-10 bar -
103 212-IT-04 in Polymer Preperation unit pump 1 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
104 212-IT-05 in Polymer Preperation unit pump 2 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
105 212-IT-06 in Polymer Preperation unit pump 3 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
106 212-IP-07 Discharge pipe of Polymer Preperation unit pump 1 Digital Pressure Manometer + switch 0-10 bar -
107 212-IP-08 Discharge pipe of Polymer Preperation unit pump 2 Digital Pressure Manometer + switch 0-10 bar -
108 212-IP-09 Discharge pipe of Polymer Preperation unit pump 3 Digital Pressure Manometer + switch 0-10 bar -
109 212-IF-06 Discharge pipe of Polymer Preperation unit pump 1 Analogue (4-20 mA) Flow Electromagnetic 0-1 m3/h -
110 212-IF-07 Discharge pipe of Polymer Preperation unit pump 2 Analogue (4-20 mA) Flow Electromagnetic 0-1 m3/h -
111 212-IF-08 Discharge pipe of Polymer Preperation unit pump 3 Analogue (4-20 mA) Flow Electromagnetic 0-1 m3/h -
112 212-IP-05 service water pipe to PPU inline mixer 1 going to GBT 2 Digital Pressure Manometer + switch 0-10 bar -
113 212-IP-06 service water pipe to PPU inline mixer 2 going to GBT 3 Digital Pressure Manometer + switch 0-10 bar -
114 212-IP-10 service water pipe to PPU inline mixer 3 going to GBT 1 Digital Pressure Manometer + switch 0-10 bar -
115 212-IF-04 service water pipe to PPU inline mixer 1 going to GBT 2 Digital Flow Rotameter + 2x switch 0-3 m3/h -
116 212-IF-05 service water pipe to PPU inline mixer 2 going to GBT 3 Digital Flow Rotameter + 2x switch 0-3 m3/h -
117 212-IF-09 service water pipe to PPU inline mixer 3 going to GBT 1 Digital Flow Rotameter + 2x switch 0-3 m3/h -

Return Liquor Pumping station

118 270-IL-01 in the return liquor pump sump Analogue (4-20 mA) Level Ultrasonic Acc. to installation -
119 270-IL-02 in the return liquor pump sump Digital Level Float Sensor Acc. to installation -
120 270-IF-01 common discharge pipe of return liquor pumps Analogue (4-20 mA) Flow Electromagnetic 0-300 m3/h -

Sludge blending tank

121 215-IL-01 in the sludge blending tank Analogue (4-20 mA) Level Ultrasonic Acc. to installation Ex 2

Digester Building

122 220-IT-07 in the Digester feed pump 1 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
123 220-IT-08 in the Digester feed pump 2 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
124 220-IT-09 in the Digester feed pump 3 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
125 220-IP-09 discharge pipe of the Digester feed pump1 Digital Pressure Manometer + switch 0-10 bar -
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Component 3 Salt WWTP
Part 5 Instrument Specifications

# Tag Number Location Signal Type Measured Parameter Instrument Type Measuring Range EX Category
126 220-IP-10 discharge pipe of the Digester feed pump2 Digital Pressure Manometer + switch 0-10 bar -
127 220-IP-11 discharge pipe of the Digester feed pump3 Digital Pressure Manometer + switch 0-10 bar -
128 220-IF-01 on infeed sludge going to heat exchanger 1 Analogue (4-20 mA) Flow Electromagnetic 0-100 m3/h -
129 220-IF-02 on infeed sludge going to heat exchanger 2 Analogue (4-20 mA) Flow Electromagnetic 0-100 m3/h -
130 220-IQ-01 on inlet of reciprocation pumps 1&2 Analogue (4-20 mA) pH 1-14 -
131 220-IQ-02 on inlet of reciprocation pumps 3&4 Analogue (4-20 mA) pH 1-14 -
132 220-IT-01 at the bottom of digester 1 Analogue (4-20 mA) Temperature PT100 0-50 oC -
133 220-IL-01 at the bottom of digester 1 Analogue (4-20 mA) Level Hydrostatic 0-20 m -
o
134 220-IT-02 at the middle of digester 1 Analogue (4-20 mA) Temperature PT100 0-50 C -
135 220-IL-02 at the top of digester 1 Digital Level Point Acc. to installation Ex 1
136 220-IP-01 at the top of digester 1 Analogue (4-20 mA) Pressure Pressure transducer 0-100 mbar Ex 1
137 220-IT-03 at the top of digester 1 Analogue (4-20 mA) Temperature PT100 0-50 oC -
138 220-IT-06 at the bottom of digester 2 Analogue (4-20 mA) Temperature PT100 0-50 oC -
139 220-IL-04 at the bottom of digester 2 Analogue (4-20 mA) Level Hydrostatic 0-20 m -
140 220-IT-05 at the middle of digester 2 Analogue (4-20 mA) Temperature PT100 0-50 oC -
141 220-IL-03 at the top of digester 2 Digital Level Point Acc. to installation Ex 1
142 220-IP-02 at the top of digester 2 Analogue (4-20 mA) Pressure Pressure transducer 0-100 mbar Ex 1
143 220-IT-04 at the top of digester 2 Analogue (4-20 mA) Temperature PT100 0-50 oC -

Digested Sludge Tank

144 230-IL-01 in the digested sludge tank Analogue (4-20 mA) Level Ultrasonic Acc. to installation Ex 2

Belt Filter Press (Mechanical Dewatering)

145 240-IT-01 in BFP feed pump 1 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
146 240-IT-02 in BFP feed pump 2 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
147 240-IT-03 in BFP feed pump 3 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
148 240-IP-01 discharge pipe of BFP feed pump 1 Digital Pressure Manometer + switch 0-10 bar -
149 240-IP-02 discharge pipe of BFP feed pump 2 Digital Pressure Manometer + switch 0-10 bar -
150 240-IP-03 discharge pipe of BFP feed pump 3 Digital Pressure Manometer + switch 0-10 bar -
151 240-IF-03 discharge pipe of BFP feed pump 1 Analogue (4-20 mA) Flow Electromagnetic 0-40 m3/h -
152 240-IF-02 discharge pipe of BFP feed pump 2 Analogue (4-20 mA) Flow Electromagnetic 0-40 m3/h -
153 240-IF-01 discharge pipe of BFP feed pump 3 Analogue (4-20 mA) Flow Electromagnetic 0-40 m3/h -
154 240-IT-04 in Polymer Preperation unit pump 1 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
155 240-IT-05 in Polymer Preperation unit pump 2 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
156 240-IT-06 in Polymer Preperation unit pump 3 Analogue (4-20 mA) Temperature Acc. to pump manufacturer -
157 240-IP-13 discharge pipe of Polymer Preperation unit pump 1 Digital Pressure Manometer + switch 0-10 bar -
158 240-IP-14 discharge pipe of Polymer Preperation unit pump 2 Digital Pressure Manometer + switch 0-10 bar -
159 240-IP-15 discharge pipe of Polymer Preperation unit pump 3 Digital Pressure Manometer + switch 0-10 bar -
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Component 3 Salt WWTP
Part 5 Instrument Specifications

# Tag Number Location Signal Type Measured Parameter Instrument Type Measuring Range EX Category
160 240-IF-07 discharge pipe of Polymer Preperation unit pump 1 Analogue (4-20 mA) Flow Electromagnetic 0-1.5 m3/h -
161 240-IF-08 discharge pipe of Polymer Preperation unit pump 2 Analogue (4-20 mA) Flow Electromagnetic 0-1.5 m3/h -
162 240-IF-09 discharge pipe of Polymer Preperation unit pump 3 Analogue (4-20 mA) Flow Electromagnetic 0-1.5 m3/h -
163 240-IP-10 service water pipe to PPU inline mixer 1 going to BFP 3 Digital Pressure Manometer + switch 0-10 bar -
164 240-IP-11 service water pipe to PPU inline mixer 2 going to BFP 2 Digital Pressure Manometer + switch 0-10 bar -
165 240-IP-12 service water pipe to PPU inline mixer 3 going to BFP 1 Digital Pressure Manometer + switch 0-10 bar -
166 240-IF-04 service water pipe to PPU inline mixer 1 going to BFP 3 Digital Flow Rotameter + 2x switch 0-6 m3/h -
167 240-IF-05 service water pipe to PPU inline mixer 2 going to BFP 2 Digital Flow Rotameter + 2x switch 0-6 m3/h -
168 240-IF-06 service water pipe to PPU inline mixer 3 going to BFP 1 Digital Flow Rotameter + 2x switch 0-6 m3/h -
169 240-IQ-01 in the BFP room in sludge treatment building Analogue (4-20 mA) Gas (CH4 & H2S) incl. visual and audible alarm 0-100% LEL and 0-50 ppm H2S -

Sludge Drying Area Drainage Pump Station

170 250-IL-01 in the drying area pump station Analogue (4-20 mA) Level Ultrasonic Acc. to installation -
171 250-IL-02 in the drying area pump station Digital Level Float Sensor Acc. to installation -

Return Liquor Equalization Tank

172 241-IL-01 in the equalization tank Analogue (4-20 mA) Level Ultrasonic Acc. to installation -
173 241-IL-02 in the equalization tank Digital Level Float Sensor Acc. to installation -

Gas Holder

174 320-IL-02 in the condensate chamber Digital Level 2x Point Acc. to installation Ex 1
175 320-IQ-02 in the condensate chamber Analogue (4-20 mA) Gas (CH4 & H2S) incl. visual and audible alarm 0-100% LEL and 0-50 ppm H2S Ex 1

Gas treatment room

176 325-IF-01 discharge pipe of gravel filter 1 Analogue (4-20 mA) Flow Thermal mass 0-400 m3/h Ex 2
177 325-IF-02 discharge pipe of gravel filter 2 Analogue (4-20 mA) Flow Thermal mass 0-400 m3/h Ex 2
178 325-IP-09 common suction pipe of gas booster blowers Analogue (4-20 mA) Pressure Pressure transducer -50 … +50 mbar Ex 2
179 325-IT-01 discharge of biogas booster 1 Analogue (4-20 mA) Temperature PT100 0-100 oC Ex 2
180 325-IT-02 discharge of biogas booster 2 Analogue (4-20 mA) Temperature PT100 0-100 oC Ex 2
181 325-IP-10 common discharge pipe of gas booster blowers Analogue (4-20 mA) Pressure Pressure transducer 0-200 mbar Ex 2
182 325-IF-03 at the outlet to CHP units Analogue (4-20 mA) Flow Thermal mass 0-400 m3/h Ex 2
183 325-IF-04 at the outlet to Boiler units Analogue (4-20 mA) Flow Thermal mass 0-200 m3/h Ex 2
184 325-IQ-03 in Gas room Analogue (4-20 mA) Gas (CH4 & H2S) incl. visual and audible alarm 0-100% LEL and 0-50 ppm H2S Ex 2

CHP Room
185 340-IT-01 heating water return pipe heat exchanger 2 Analogue (4-20 mA) Temperature PT100 0-100 oC Ex 2

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Sanitation Programme: NEXUS and Resource Protection Tender Documents – Vol.2
Component 3 Salt WWTP
Part 5 Instrument Specifications

# Tag Number Location Signal Type Measured Parameter Instrument Type Measuring Range EX Category
o
186 340-IT-02 heating water return pipe heat exchanger 1 Analogue (4-20 mA) Temperature PT100 0-100 C Ex 2
o
187 221-IT-09 on the hydraulic switch Analogue (4-20 mA) Temperature PT100 0-100 C Ex 2
188 350-IL-01 in the Fuel oil tank Analogue (4-20 mA) Level Ultrasonic Acc. to installation Ex 2
189 340-IQ-01 in CHP room Analogue (4-20 mA) Gas (CH4 & H2S) incl. visual and audible alarm 0-100% LEL and 0-50 ppm H2S Ex 2
190 340-IT-01 in CHP room Analogue (4-20 mA) Temperature PT100 0-50 oC Ex 2

End of Part 5 Particular Instrument Specifications

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On behalf of JV Nexus
Sanitation Programme: NEXUS and Resource Protection Tender Documents – Vol.2
Component 3 Salt WWTP Technical Specifications
Part 6 Documentation

Part 6 - Documentation
Table of Contents
page

6 DOCUMENTATION .................................................................................................. 1
6.1 General............................................................................................................ 1
6.2 Tender documentation ..................................................................................... 1
6.3 Documentation after Award of Contract and before Employer's
Taking-Over ..................................................................................................... 1
6.3.1 General ..................................................................................................... 1
6.3.2 Obtaining of relevant approvals and certificates ........................................ 3
6.4 Final Documentation ........................................................................................ 3
6.4.1 As-Built Drawings ..................................................................................... 3
6.4.2 Operation, Maintenance and Repair Manuals ........................................... 3
ANNEX A: MODEL OF OPERATIONS MANUAL FOR WWTP................................... 6

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Sanitation Programme: NEXUS and Resource Protection Tender Documents – Vol.2
Component 3 Salt WWTP Technical Specifications
Part 6 Documentation

6 DOCUMENTATION
6.1 General
The documentation is divided into three categories:
 Tender documentation to be submitted as part of the tender
 Documentation after Award of Contract and before Tests on Completion (Working
documentation).
 Final documentation to be submitted at the Tests on Completion.

6.2 Tender documentation

The requirements for tender documentation are detailed in “Volume 1, Part 1 Bidding
Procedures, Section I Instructions to Bidders”.

6.3 Documentation after Award of Contract and before Employer's Taking-Over

6.3.1 General
Detailed drawings, descriptions and calculations required for the Contractor’s Temporary
Works and to provide additional details for the Contractor to construct the Permanent Works
as shown on the Contract Drawings and specified, shall be prepared by the Contractor and
submitted to Engineer for review. Drawings and calculations shall be submitted in four (4)
copies. Two (2) copies shall be returned to the Contractor with the Engineer's comments.
Drawings are to be submitted in time for incorporation of comments without delaying the
programme and the completion of the work. The Contractor shall within 2 weeks from the
Order to Commence submit a programme for submittal of all drawings and design
calculations requiring approval.
Any drawings and documents submitted for approval will be inspected, stamped and
protected for return to the Contractor normally within 14 days from receipt of the drawings by
the Engineer. When large quantities of documents are submitted at one time, the Engineer
may, at his discretion, advise the Contractor of the expected return date.
Drawings from sub-contractors shall be checked signed by the Contractor before being
forwarded to the Engineer, who shall deal in all respects exclusively with the Contractor.
When the Engineer has approved a working drawing, he shall return a copy marked
"Approved" to the Contractor, who shall then insert the date of approval on the tracing and
furnish the Engineer with three prints of the working drawings as approved.
Approval of a working drawing by the Engineer will only signify his general approval of the
design and shall not make him liable for any error of the Contractor in detail or lack of
strength or efficiency of any part. Where errors, deviations and / or omissions are discovered
later, they shall be made good by the Contractor irrespective of any approval by the
Engineer.
Any modifications to the approved drawings found necessary on the Site shall be agreed with
the Engineer and confirmed in writing as record, by Site Instruction or other means. If any
approved drawing needs to be amended later, the amended drawing shall be submitted for
approval in accordance with the aforesaid.

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Component 3 Salt WWTP Technical Specifications
Part 6 Documentation

The Engineer may require the Contractor to submit for approval drawings, samples, patterns,
models and technical details of items additional to those mentioned above to the extent
reasonably necessary for him to satisfy himself that the items are suitable for their intended
purpose.
During the construction period, the Contractor shall prepare a set of drawings marked with
changes and additions. Upon completion of the work, this set of drawings shall be submitted
to the Engineer for approval.
(1) Numbering system
The Contractor shall design a document numbering system for all documentation. The
system shall include all documents, manuals and drawings and shall be comprehensive.
Issue and submittal of all subcontractor’s documentation shall be in accordance with the
approved system.
The Contractor shall design the tag numbering system for all equipment, processes and
locations.
 All documents and manuals
 All drawings
 All electrical and mechanical components
 All cables
 All pipes.
The Engineer shall approve the numbering / tag systems.
(2) QA system
Not more than thirty (30) days after the Commencement Date, the Contractor shall submit
a detailed Quality Plan for review by the Engineer. The Plan shall cover the quality
assurance of all aspects of the Works, and contain, as a minimum, the following items:
 Organisation chart for quality control
 List of Contractor’s staff to be engaged in quality control and materials testing
together with de-tails of their relevant experience
 List of facilities which will be inspected and tested by the Contractor at stages during
implementation of the Works as part of his quality control, together with inspection
procedures and test types
 Welding Procedure Specifications (WPS)
 Welders Certificates
 Results of welds testing
 Certificates of materials
 Test results from pressure test on pressure pipes
 Documentation of surface treatment (corrosion protection)
 Test results of capacity tests
 Specifications of equipment and work
 Tests

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Component 3 Salt WWTP Technical Specifications
Part 6 Documentation

 Relevant certificates on supplied materials

 Detailed checklist for all installations. The checklist shall be for the Contractor's own
use, documenting the Contractor's own quality control of the installation.
The Plan may be supplemented with additional items from time to time as requested by
the Engineer.
The approved Quality Plan shall be followed throughout the performance of the Contract,
unless the Engineer issues specific approvals or instructions to the contrary. Any approval
of the Engineer shall not relieve the Contractor of his obligation to ensure that the Works
comply with the requirements of the Contract.
Quality assurance records, test certificates, reports and daily records of on-site testing
and inspection shall be kept on site during the works, and the results shall be certified by
the responsible member of the Contractor’s staff.
(3) Draft Operation and Maintenance Manuals
Four (4) draft copies of the operations, maintenance and installation manuals shall be
provided by the equipment manufacturer at least two weeks prior to the shipment of all major
equipment. Each manual shall be provided in an indexed binder and shall be for the specific
equipment provided rather than general equipment instruction.

6.3.2 Obtaining of relevant approvals and certificates

The Contractor shall obtain all relevant approvals and certificates from local Authorities
regarding construction and operation of the Plant.

6.4 Final Documentation

6.4.1 As-Built Drawings

The Contractor shall prepare and submit to the Engineer for approval, duly amended, four (4)
copies of the As-Built Drawings. These accurate record drawings shall be fully dimensioned
to show the locations, elevations, dimensions and other pertinent details of the work
executed under this Contract.
The Engineer shall return to the Contractor two (2) copies of the drawings showing the
amendments required by the Engineer. Within 21 days of receipt of the amended drawings
the Contractor shall issue to the Engineer the following number of copies of the amended
drawings:
(i) 3 no. sets of A1 size paper prints;
(ii) 3 no. sets of A3 size paper prints; and
(iii) 3 no. sets of electronic copies in Autocad / ArcView and pdf format
All final approved drawings shall also be submitted in an electronic version on CD ROM.

6.4.2 Operation, Maintenance and Repair Manuals

The Contractor shall submit four (4) draft copies and one digital copy, in English, of the
Standard Operation, Maintenance and Repair Manuals and any associated software to the
Engineer. Note that where software is submitted the licence and the product keys should be
submitted. Following approval of these documents Arabic translations shall be produced and
submitted for approval prior to training. The manuals shall be bound into suitable durable

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Component 3 Salt WWTP Technical Specifications
Part 6 Documentation

loose-leaf binders of DIN A4 size. Copies of these manuals shall be used during the training
courses for operation and maintenance.
For all installations, the manuals shall include:
 A general part comprising contents, description of the installation and relevant
addresses and phone numbers,
 Documentation - as built,
 Functional description,
 List of components indicating manufacturer, type, component numbers, ordering
numbers, other data and position,
 Maintenance instructions stating maintenance routines and intervals,
 Fault finding instructions,
 Calibration reports for analogue signal circuits,
 Data leaflets,
 Manufacturer’s recommended spare parts lists for 2 years, according to the O&M
manuals, and sources of supply for the parts.
 List of tools, and
 List of lubricants.
 Written explanations of all safety considerations relating to operation and
maintenance procedures.
For mechanical installations the manual shall further as a minimum contain:
 Machinery Type and Serial No. (all in one chart),
 Operating instructions,
 Lubrication charts and maintenance instructions (all equipment included in one
chart),
 Fault finding details for rectification of basic faults,
 List of spare parts giving part numbers in relation to a drawing preferably of the
exploded view type. The list shall be appropriate for correct reordering of the
complete component and its spare parts as well as repair kits,
 Brochures including all components accompanied with names and addresses of
suppliers,
 Performance curves, diagrams, test certificates etc.
 Specification of corrosion protection,
 Specifications for repair of all painted / coated surfaces, and
 Guidelines for repair.
For all electrical components the manual shall be divided into separate sections for the
following installations:
 Control panels,

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Part 6 Documentation

 Instruments,
 Control and measuring components (signalling system), and
 Other components.
For electrical equipment the manual shall further include but not be limited to:
 Layout drawings,
 Schematic and wiring diagrams,
 Detailed description,
 Specific operation instructions,
 Specific maintenance instructions,
 Component list for all equipment,
 Fault-finding chart,
 Emergency procedure,
 A transcription of each application program with explanatory comments (source text)
for sub stations and the master station, which explains the function and operation
mode, including all potential documentation presenting the programming software
(Cross reference schedules etc.)
 Manual for sub-station and master station
 Backup copy of data, application program and potential updated PLC program on
flash memory or similar.
All electrical drawings shall also be delivered in electronic version on CD-ROM together with
a licensed version of the standard software tools used for designing the plant.
All information in the manuals shall apply specifically to the equipment being supplied, and
shall be free from such irrelevant matters as might be contained in the manufacturer’s
general literature. Other types of machines and options not included in the Contract are not
allowed in the instructions.
Immediately after the Test on Completion, the suitable corrected manuals shall be compiled
into its final form and be submitted to the Engineer for approval.
The final version of the Operation, Maintenance and Repair Manuals shall be submitted with
six (6) copies in both English and Arabic. Each of the Operation Maintenance and Repair
Manuals shall be submitted in both hard copy and in electronic form as approved by the
Engineer.
Any additions, alterations or deletions, which may be required following the experience
gained during the Defects Notification Period shall be incorporated into the final versions in
the form of additional pages or complete replacement of sections as specified by the
Engineer. All costs of these amendments shall be deemed to be included in the Contract
Price.
The Taking-Over Certificate will not be issued until all copies of the final Operation,
Maintenance and Repair Manuals have been handed over.

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ANNEX A: MODEL OF OPERATIONS MANUAL FOR WWTP

The following is an outline of the contents of an Operations Manual which should be

prepared - in part - by the Designer for a WWTP, based on information supplied - in part - by
the Contractor. Parts of the manual will have to be prepared by the Operator with the
support of the Consultant responsible for the design i.e. the Designer. It is not the
responsibility of the Contractor to prepare the entire manual however he should be aware of
its structure and contents and prepare the Operations and Maintenance Manuals and his
other submittals accordingly.
The Operation Manual should provide an essential reference for the managers responsible
for operating the treatment plant. It shall provide a concise description of the basic operating
and control functions as foreseen in the original design; process, hydraulic, mechanical and
electrical, instrumentation and monitoring.
It shall provide a basis guide for dealing with exception events (Emergency Plan) and cross
reference to all other relevant documentation; Equipment O&M Manuals, Standard Operating
Procedures, and company policies.
A simple step-by-step approach is required to build up the information needed to operate the
treatment plants. The emphasis should be on the inclusion of information that is not overly
complicated but contains sufficient details and data to be of value to all persons who will
need to use it.
Draft Table of Contents
Operations Manual for Major Wastewater Treatment Plants
SECTION 1 – INRODUCTION
 General introduction and explanation of how to use the manual.
 Definition of the various responsibilities within the Operator for the plant and
details of the number of staff.
 General site layout plan.
 General schematic(s) or plan(s) of the area supplied by the treatment plant.
 Geographic/demographic information for example a location plan and
numbers of customers served.
 Overview of the plant design capacity and average daily outputs.
 Details of relevant safety information for visitors regarding known hazards.

SECTION 2 – PLANT DESCRIPTION – PROCESS OPERATIONS

 Overall targets for wastewater quality and quantity.
 List of the prescribed wastewater quality standards.
 Overall description of the treatment processes in use on the site.
 Individual description of each stage of the process, (not too detailed) but
including main design parameters, flow rates, velocities, retention times,
contact times etc.

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 Details of water quality sampling points and tabulated results of analysis.

 List of chemicals in use and the quantities held on site.
 Description of measurement points and works metering.
 List of SOP’s and local procedures in use.
 Details of operation of the CHP system.
 Details of operation of the PV system.
 Inclusion of any relevant drawings in existence.

SECTION 3 – PLANT DESCRIPTION – ASSETS - CIVIL, ELECTRICAL & MECHANICAL

PLANT
 List and details of all relevant site drawings, for example pipeline layouts,
HV/MV electrical system layout, civil assets and structures.
 Details of types of pumps, motors, valves in use and cross referenced to the
process.
 Details of instrumentation and dosing systems/equipment for chlorine and
aluminium sulphate.
 Details of general items in use, for example lifting equipment.
 Details of PV installation and associated equipment.
 Details of the CHP equipment.

SECTION 4 – SAFETY& HYGIENE ASPECTS

 Company safety policy and links to TSM.
 Company hygiene policy for employees working in direct contact with potable
water.
 Emergency procedures - for example handling a major incident such as a
significant failure of chlorine drum.

SECTION 5 – GENERAL INFORMATION, DATA and RECORDS

 References to company policies and other relevant procedures.
 References to legislation.
 Water production information, water quality compliance with standards, annual
chemical use and costs, electricity consumption and annual costs.
 Description of measurement points and works metering.
 Performance of CHP systems.
 Performance of PV system, power generated.
 List of SOP’s and local procedures in use.
 Inclusion of any relevant drawings in existence.

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SECTION 6 – Start Up Procedures

SECTION 7 – Emergency Plans
SECTION 8 – Reference Documents
 Equipment O&M Manuals
 SOPs
 Company Policies.

End of Part 6 - Documentation

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Part 7 Testing on Completion

Part 7 - Testing on Completion

Table of Contents
page

7 Testing..................................................................................................................... 1
7.1 General ................................................................................................................ 1
7.2 Testing Method Statement and Work Programme ................................................ 2
7.3 Inspection and Testing Requirements .................................................................. 2
7.4 Testing General.................................................................................................... 2
7.4.1 Provision of Equipment, Materials, Power and Consumables for
Testing ............................................................................................................ 2
7.4.2 Works Testing and Inspection Costs ................................................................ 2
7.4.3 Test Instruments .............................................................................................. 3
7.4.4 Test Certificates............................................................................................... 3
7.5 Works Hydraulic Test ........................................................................................... 3
7.6 Works Inspection Tests and Guarantees .............................................................. 4
7.7 Pumps .................................................................................................................. 4
7.8 Motors .................................................................................................................. 5
7.9 Control Panels...................................................................................................... 5
7.10 Pressure Switches and Gauges ........................................................................... 5
7.11 Mechanical ........................................................................................................... 5
7.12 Electrical and Automation ..................................................................................... 6
7.12.1 Electrical .......................................................................................................... 6
7.12.2 Automation ...................................................................................................... 6
7.13 Performance Testing of Specific Equipment ....................................................... 10
7.14 Civil and Builders Works .................................................................................... 10
7.14.1 Materials ........................................................................................................ 10
7.14.1.1 Samples.................................................................................................. 10
7.14.1.2 Tests....................................................................................................... 11
7.14.2 Test Certificates............................................................................................. 11
7.14.3 Testing and Inspection................................................................................... 11
7.14.3.1 General ................................................................................................... 11
7.14.3.2 Gravity Sewers ....................................................................................... 12
7.14.3.3 Pressure Mains ....................................................................................... 13
7.14.3.4 Manholes and Inspection Chambers ....................................................... 13

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7.14.4 Testing of Concrete ....................................................................................... 14

7.14.4.1 General ................................................................................................... 14
7.14.4.2 Testing of Fresh Concrete ...................................................................... 14
7.14.4.3 Testing of Hardened Concrete ................................................................ 14
7.14.4.4 Laboratory .............................................................................................. 17
7.14.5 Water Retaining Structure ............................................................................. 17
7.14.6 Roof Testing .................................................................................................. 18
7.15 Solar PV Inspection and Testing Requirements ................................................. 18
7.15.1 PV Modules ................................................................................................... 18
7.15.2 Inverters ........................................................................................................ 19
7.15.3 Circuit Breakers ............................................................................................. 19
7.15.4 VT’s ............................................................................................................... 19
7.15.5 CT’s ............................................................................................................... 20
7.15.6 Disconnect and Earthing Switches................................................................. 20
7.15.7 Surge Arresters ............................................................................................. 20
7.15.8 MV Switchboards & RMUs............................................................................. 20
7.15.9 Transformers ................................................................................................. 21
7.15.10 Unit Substation Transformers ........................................................................ 21
7.15.11 Auxiliary Transformers ................................................................................... 21
7.15.12 Distribution Boards ........................................................................................ 21
7.15.13 Tests on Completion ...................................................................................... 22
7.15.14 Pre commissioning Test ................................................................................ 22
7.15.15 Commissioning Test ...................................................................................... 22
7.15.16 Operational Tests following the energization of the PV Plant ......................... 22
7.15.17 Trial Operations ............................................................................................. 22
7.15.18 Tests after Completion................................................................................... 22
7.15.19 Intermediate Performance Test ..................................................................... 23
7.15.20 Performance Test .......................................................................................... 23

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7 Testing

7.1 General
The tests shall be carried out in accordance with the Conditions of Contract prior to hand
over of the Works on Completion as follows:
Tests before Taking Over
 Pre commissioning,
 Commissioning,
Tests after Taking Over
 Monitoring of performance parameters and other tests to be carried out after
Taking Over during the O&M period
This Part 7 covers testing before Taking Over. Tests after Taking Over are specified in
Specification Part 8.
The objective of the testing is to verify that all equipment and systems work in accordance
with the Contract and the detailed design so that the whole Works or Section of Works can
be put into operation immediately following Taking over. Wet tests before Taking Over shall
generally be done with clean water. Where it is approved by the Engineer to carry out such
tests with wastewater, then adequate measures shall be taken for environmentally sound
disposal of the test water and it shall not be considered as Taking Over.
All tests of equipment and of the complete system shall be performed in accordance with the
Contractor's approved Quality Assurance system.
All tests have to be documented in test forms defined as part of Quality Assurance system
covering:
 Date of test,
 Description of test,
 Actual method of test,
 Output of test,
 Remarks regarding deviations from the expected output,
 Accepted / rejected,
 Supervisor's signature,
 Comments.

Handling of Deviations
Before the report is completed and can be approved, all significant deviations have to be
corrected.
In case of deviations, the following issues have to be decided:
 What are the consequences of the deviation? Which part of the installations will
be influenced by a revision, and which tests already accepted will have to be
done over again (if any)?
 Date of a new test of the revised system included repetition of already accepted
tests.

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The acceptance test report shall be approved when significant deviations have been
corrected and tested.
All tests have to be planned so the Engineer has the possibility to comment on the tests
planned and to supervise the tests. That means that all tests shall be announced at least two
weeks in advance. This goes also for any repetition of tests.

7.2 Testing Method Statement and Work Programme

At least 6 weeks before commencement of testing, the Contractor shall provide a detailed
testing method statement and work programme for approval by the Engineer.

7.3 Inspection and Testing Requirements

The Contractor shall be responsible for the factory inspections of the Material and for the site
inspection of the Works supplied under the Contract. Upon request, Factory Inspection of the
components will be organized in presence of the Employer representative. An Inspection and
Testing Plan covering factory inspection and site Inspections and Testing shall be provided
by the Contractor detailing all the tests and inspections methodology and parameters.
Following each inspection, a report shall be provided confirming that it was successful and
fully detailing the inspection results. At the end of each inspection the Contractor will send a
Request For Inspection (RFI) to the Employer Representative inviting him to inspect
randomly the Works. The 3 possible results of the ER inspections are:
 Witnessed
 Commented
 Rejected
In case of comments or rejection the Works shall be remedied to the full satisfaction of the
Employer Representative requirements.

7.4 Testing General

7.4.1 Provision of Equipment, Materials, Power and Consumables for Testing

The Contractor shall provide all personnel, temporary equipment, materials, power and
consumables required for carrying out the test before Taking Over at no additional cost.

7.4.2 Works Testing and Inspection Costs

(1) The Engineer shall be provided with the necessary facilities to inspect all equipment
and material and shall be given adequate notice of the date such equipment or material
shall be ready for inspection or for works test.
(2) No equipment or material shall be dispatched from the manufacturer’s works, without
the written permission of the Engineer.
(3) Full details of the method of testing proposed for each item shall be submitted.
(4) The Contract price shall include the cost of witness testing and inspection works. The
Contractor shall without extra cost arrange for two Employer representatives and one
Engineer representative to witness the testing and inspection of the components
specified in the Particular Specification at the manufacturers’ works, this shall include
all travel and accommodation expenses.

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7.4.3 Test Instruments

(1) The manufacturer shall satisfy the Engineer of the accuracy of all instruments used for
the tests and, if required, shall produce recent calibration tests, or otherwise have them
calibrated at his own expense by an independent authority.
(2) KWh meters shall be checked for correct rotation, creep tests shall be carried out to
ensure that meters are inoperative with voltage alone, should the secondary of the
current transformers be left connected with the primary current interrupted.

7.4.4 Test Certificates

(1) The Contractor shall obtain test certificates from his suppliers and forward three copies of
such certificates to the Engineer with indication of the item number according to the Bill of
Quantities.
For the following items:
 Pipes and fittings
 Valves
 Manhole covers
(2) Such certificates shall certify that the materials or goods have been tested in accordance
with the specifications and BS standards and/or DIN, and shall give the results of the
tests which have been carried out. With regard to major project equipment, the
Contractor shall ensure that the tests are carried out in the presence of the Engineer's
representative.

(3) The Contractor shall provide adequate means on site to identify the materials or goods
with their respective test certificates.

(4) Test Certificates shall be provided giving detailed records of all electrical and
mechanical tests carried out on the equipment and material including lifting equipment,
tanks, pressure vessels, cables and cabling both in the manufacturer’s works and on
site.
(5) Copies of certificates for the hydraulic tests carried out in all works shall be provided.
(6) The Contractor shall obtain and submit to the Engineer and to other parties as may be
directed, test certificates for all items, certifying that they have been satisfactorily tested
and describing and giving full particulars of such tests.
(7) Copies of test certificates of major items shall be included in the operating and
maintenance instructions.

7.5 Works Hydraulic Test

(1) All equipment subject to water pressure including pumps, pipes, fittings and valves,
shall be hydraulically tested to the pressure specified or to at least 1.5 times the
maximum working pressure.

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7.6 Works Inspection Tests and Guarantees

(1) All the Schedules of Particulars shall be completed with the guaranteed particulars and
efficiencies of the equipment offered at the duties specified. These shall be binding and
may not be varied except with the written consent of the Engineer.
(2) All proving tests of electrical equipment shall be in accordance with guaranteed
technical data for an ambient temperature.
(3) Full witness testing to the relevant standards and to prove guarantees given shall be
required for the following items:
− All pumps;
− Electric Motors;
− Pressure Switches and Gauges.
(4) In addition, all other items of equipment, not subject to witness testing, shall be
temporarily erected at the Manufacturer’s works and tested for satisfactory operation
and shall be offered for inspection.
(5) Such inspection, examination, or testing, shall not release the Contractor, manufacturer
or supplier of any item, from any obligation.
(6) Certified copies of manufacturer’s test readings of all items shall be submitted to the
Engineer.
(7) Whilst the Engineer shall be provided with facilities for witness testing and/or inspection
of all items of equipment at the manufacturer’s works, he may, at his own discretion,
advise that the tests shall proceed in his absence. However, the tests shall be made as
if in his presence and duly certified copies of test readings shall be submitted.
(8) Where items of equipment are of identical size and duty, it may be required at the
Engineer’s discretion that a reduced number of the items shall be subject to witness
tests. However, this shall not relieve the manufacturer from the requirement of carrying
out the performance tests on all items prior to offering witness testing.
(9) If, during inspection, examination or testing of any material or equipment, such items,
or any parts thereof, are found to be defective or not in accordance with the
specifications of performance requirements, the Engineer may reject the said items or
part thereof, giving the manufacturer a reasonable period of notice in writing of such
rejection, stating the grounds upon which the said decision is based.

7.7 Pumps
(1) The witnessed test shall obtain the guarantees of pump delivery, head, kW input,
overall efficiency and other figures in accordance with the guarantees given in the
Schedule of Particulars and shall satisfy the inspector as to the mechanical reliability of
the plant and its capability of fulfilling the whole of the conditions.
(2) The guarantee duty is subject to a tolerance of ±5%.
(3) It is preferable that the pumps be tested with their own motors, but if this is not
attainable the pumps shall be tested in conjunction with the pump manufacturer’s
standard or calibrated motor, but the manufacturer shall satisfy the Engineer as to the
performance of the test motor so that the kW absorbed by the pumps may be
accurately determined.

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7.8 Motors
(1) All motors shall be subject to full performance tests on site, which shall be witnessed
by the Engineer. Motors > 100 kW and their associated equipment subject to factory
performance tests may be witnessed by the Engineer and Employer. The Engineer will
nominate which tests are to be witnessed.
(2) Motor tests shall be carried out in accordance with the requirements of British
Standards or DIN as applicable. Tests shall gauge the overall level of efficiency and
other figures in accordance with the guarantees given in the Schedule of Particulars.
Test Certificates shall be provided for all sized motors.

7.9 Control Panels

Testing shall be carried out on all control panels in accordance with the relevant British
Standard or DIN as applicable.

7.10 Pressure Switches and Gauges

(1) All pressure switches, vacuum and pressure gauges shall be subject to routine tests in
accordance with the relevant British Standard Specification or DIN as applicable.
(2) Test certificates shall be provided against each item of equipment.

7.11 Mechanical
Before Taking-Over can take place, the Contractor shall test - as installed - all mechanical
installations to prove that the capacity, power consumption and general efficiency and
functionality complies with the Employer's Requirements.
The tests shall be carried out in the presence of the Engineer.
The results of the testing shall be compiled in a report for approval by the Engineer.
For pumps the tests shall include:
 Flow (measured at operating levels).
 Pressure in pressure main, if applicable.
 Power consumption.
For other mechanical installations the tests shall include:
 Test of correct functions.
 Power consumption, if motor-operated.
The tests shall be carried out as well before as after the equipment has been put into normal
service (dry and wet testing).
The testing shall also include testing of all automatic functions as described in the Employer's
Requirements.

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7.12 Electrical and Automation

7.12.1 Electrical
The following electrical functions shall be tested, and shall be verified to be in accordance
with the Employer's Requirements:
 Earth resistance and boundary system.
 Function of all emergency stop circuits.
 Function of all safety circuits.
 Lightning systems.
 Emergency power supply system. The external power supply shall be switched
off and it shall be verified, that the emergency power supply system starts up
automatically. Furthermore it shall be verified, that all emergency control
functions start up automatically (automatically by-pass of waste water, handling
of alarms etc.).
 Signal test of all signals according to signal lists. All signals shall be tested from
source to software. For analogue signals range and scale shall be verified. For
level transmitters offset and range shall be related to fix points in the
construction.

7.12.2 Automation
The automation system covers the PLC system and the SCADA system. The test shall cover
a number of different issues:
 Usability (general operation of the automation and SCADA system).
 Efficiency (performance).
 Accuracy (correct handling of values and calculations).
 Security (protection against unauthorised use of the SCADA system).
 Flexibility (verification that the automation system is suitable for upgrading).
Below, each issue is described. At the end of each item, a number of criteria for passing test
are described.
(1) Usability
This section describes the tasks to be performed to test the usability of the program.
(2) Installation and start up
The purpose of this test is to make sure that the installation and start-up procedure
functions well and is described correctly in the Operation and Maintenance Manual.
The test shall:
 Perform an installation procedure in accordance with the O&M Manual.
 Check if the procedure is in accordance with instructions.
 Check if the program can start up normally.
 Perform a normal removal of program.

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 Make a subsequent reinstallation.

The criteria for passing the final test will be:
 No errors occur during the installation procedure.
 The procedure is in accordance with the instructions.
 The program is able to start up normally.
(3) Normal Operation
The purpose of the test of the normal operation of the SCADA system is to make sure
that it is possible to operate the program in a logical way and in accordance with the
specifications / documentation / O&M Manual.
During the test of the normal user operation, the test operator shall:
 Guide themselves through a large number of menus and dialog boxes and test a
large number of various commands.
 Print different kinds of reports.
The criteria for passing the final test will be:
 Every activity of normal operation leads to the expected result, and activating a
command leads to the expected dialog box.
 A printing command leads to printing of the correct output.
Handling of Errors
The purpose of this test is to verify correct and logical handling of errors.
The test operator shall:
 Provoke a number of errors and verify that the system responds to these errors
as described in the requirements.
 Report any unexpected error during all tests in order to verify robustness.
The criteria for passing the final test will be:
 Indications of errors must be reasonable, and the user shall be able to continue
the work on a well-defined basis.
Handling of Help functions
The purpose of the test of the handling of help functions (on-line or in manual) is to
make sure that the on-screen help function is adequate and works in accordance with
the requirements and the actual pro-gram. In particular, it shall be verified that terms
are used consistently.
The operator shall perform the following tests:
 The help system shall be consulted a large number of times in different
situations. The operator shall focus on the existence of relevant help, on clear
language, on relevant link(s) to more help and on consistent use of terms.
 The text in the on-line help shall be read and compared with relevant
specifications.
The criteria for passing the final acceptance test will be:

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 The on-line help function provides relevant help to the operator in most situations,
and the terminology is clear and consistent.
(4) Efficiency
The purpose of the efficiency test is to verify that the operation and response times are
at an acceptable level.
The verification of efficiency values shall be based on well-defined situations. The
operator shall perform different kind of situations:
 Changing a set-point / sending a command.
 Open a new diagram.
 Open a graph.
 Require a report based on historical data's.
Five different types of response times have to be taken into account:
 Response time for a transaction, which is the time interval from sending a
command until the result is visible and the user can send a new command.
Sending a command can be executed by the "Enter"-button, by a mouse click
etc. This type of transaction is defined as typing data in an input data field with no
calculations, change of diagram etc. related to the transaction.
 Response time for opening a new part of the program, such as a new diagram.
Opening a diagram for the first time after start of the program may take longer
time.
 Response time for opening a graph showing curves for 24 hours. In this case, the
response time is the time interval from sending an "open graph" command until
the result is visible.
 Response time for opening a report showing values for 1 month. In this case, the
response time is the time interval from sending an "open report" command until
the result is visible.
 Response time for creating a background job such as a printing command.
The criteria for passing the final acceptance test will be:
 The response time for sending a command is almost negligible (less than 1
second). Return of the value from the PLC shall be fulfilled within 2 seconds.
 The response time for opening a new diagram is less than 2 seconds.
 The response time for opening a graph is less than 10 seconds.
 The response time for opening a report is less than 20 seconds.
All tests shall take place from the secondary operator station (not the server).
(5) Accuracy
The purpose of the accuracy test is to verify that the system generates correct output
results.
Based on the detailed project for automation the functionality described here shall be
verified.

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All functions shall be simulated so electrical connections the software and correct
parameter settings can be verified.
The real check of the results will be done manually. A selection of output data will be
made, and manual recalculation of this output data will be performed. The
documentation will include all the intermediate results.
The system has to be designed in a structure with well-defined modules or classes.
The classes shall be defined with interfaces where inputs and outputs are available for
investigation. A complete test is divided into several accounts. The number of accounts
shall be sufficiently high to allow verification of the sequence between two accounts by
use of a pocket calculator.
The criteria for passing the final test will be:
 Manual calculation proving correct relations between all generated accounts.
(6) Security
The purpose of this test is to verify correct security functions in accordance with the
requirements. A number of security levels have been specified.
For each security level, the following has to be verified:
 A person at each level (if defined) shall be able to log into the system and have
access to the system in accordance with their status. It shall also be verified that
the user does not have access to part of the system not covered by their rights.
This test shall be performed for a person at each level.
 Each person defined shall be able to change their own password.
 The administrator shall be able to define and remove users and to change a
user's password. If specified, the administrator shall be able to look into database
structures, as well.
 The designer shall be able to look into database structures and source codes.
The test of access to source code can be carried out on the development system,
only.
The criteria for passing the final acceptance test will be:
 The number of users has been successfully defined at different levels.
 A user has successfully logged in and out.
 A user successfully changed their own password.
 The administrator has successfully changed the password of a user.
 The system has been successfully accessed at the different levels.
(7) Flexibility
The purpose of this task is to verify that the structure of the system is suitable for
upgrading to additional functionality. The source code and programmers'
documentation shall be investigated.
The test shall verify that:
 The program and database structure of the program developed have well defined
interfaces in order to add new modules and new technical solutions under
existing SCADA systems.

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 The source code is well documented with comments and descriptions in the code
and variables are described in a logical way.
 The compilation and installation of the software are well described.
The criteria for passing the final acceptance test will be:
 The structure of the documentation is in accordance with the specifications.
 Investigation of several classes, selected arbitrarily proves a comprehensive
amount of relevant code line comments so that the source code is
understandable.
 The compilation and installation of the software are adequately described in the
documentation.

7.13 Performance Testing of Specific Equipment

Performance testing of some specific equipment for compliance with the Specifications can
only be done under actual operating conditions. For these items, the Taking Over Tests shall
be done during the first 6 months of the Defects Notification Period, when the O&M will be
under the responsibility of the Contractor.
These tests shall be considered to be part of the Snagging List on Taking Over and 5% of
the BoQ prices for these items shall be retained until the Tests are satisfactorily completed
and approved.
The items covered by this provision shall include but may not be limited to the following:
- Mechanical thickeners: solids retention & thickening capacity
- Mechanical dewatering: solids retention & dewatering capacity, polymer consumption
- Digester gas treatment system
- CHP units
- Solar PV performance.

7.14 Civil and Builders Works

Before Taking-Over can take place, all permits, certificates and approvals from local
Authorities must be obtained.

7.14.1 Materials

7.14.1.1 Samples
(1) In addition to specific provisions in the specifications for sampling and testing of
materials, the Contractor shall submit to the Engineer, as he may require, samples of
all materials which he proposes to use in the works. When approved, these will be
retained by the Engineer.
(2) Samples to be submitted shall be accompanied by an approved form on which all
information about specifications, description, location of use, manufacturer etc. are
stated.

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(3) The Contractor shall submit a “Materials Procurement Programme” for all materials and
equipment which are deemed to be used in the permanent works indicating dates for
sampling, approval, ordering, and delivery to site.
(4) The Engineer may reject any materials or goods which in his opinion are inferior to the
samples submitted.
(5) The Engineer's approval of manufacturers or material for the works, whenever required
by the specifications, shall not relieve the Contractor of his responsibilities under the
Contract.

7.14.1.2 Tests
(1) The Engineer may examine and may require testing of any materials or goods to be
used in the works at any place inside or outside Jordan. The Contractor shall give the
Engineer unrestricted access to his sub-contractors' and suppliers' premises for such
purposes at all times.
(2) The Contractor shall afford the Engineer all facilities, assistance, labour and appliances
necessary for the convenient examination, testing, weighing or analysis of all materials
and goods. The Contractor shall prepare all test samples the Engineer may require.
(3) Tests carried out off the site shall not relieve the Contractor of the responsibility of
ensuring that the materials pass any required tests on site and when they are
incorporated in the permanent works.
(4) The costs for all tests as prescribed in the Specifications and as directed by the
Engineer shall be borne by the Contractor and are deemed to be included in his
contract prices.

7.14.2 Test Certificates

(1) The Contractor shall obtain test certificates from his suppliers and forward three copies
of such certificates to the Engineer with indication of the item number according to the
BoQ. Such certificates shall certify that the materials or goods have been tested in
accordance with the specifications and DIN standards, and shall give the results of the
tests which have been carried out. With regard to major project equipment, the
Contractor shall ensure that the tests are carried out in the presence of the Employer's
representative.
(2) The Contractor shall provide adequate means on site to identify the materials or goods
with their respective test certificates.

7.14.3 Testing and Inspection

7.14.3.1 General
(1) All pipelines and associated chambers shall be inspected and tested as described and
the Contractor shall include in his rates for all costs thus incurred. Any defects found
shall be made good and the test shall be repeated at the expense of the Contractor
until a satisfactory result is obtained.
(2) All tests shall be witnessed by the Engineer. Test results shall be recorded on an
approved test data sheet, countersigned by the Contractor and the Engineer, and
copies shall be provided for the Engineer's use.

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7.14.3.2 Gravity Sewers

(1) All lengths of sewers shall be tested for water tightness by means of a water test
according to DIN EN 1610.
(2) Water tests shall be applied after partial backfilling leaving the joints exposed.
(3) Testing shall be carried out from manhole to manhole, short branch connections to a
main sewer between manholes being tested as a single system with the main sewer.
Long branches and manholes shall be separately tested.
(4) Tests shall be carried out as follows:
(a) The sewers shall be subjected to an internal pressure of 3.5 m head of water
above the crown of the pipe at the upper end of each section, subject to the
limitation that the maximum head at the lower end shall be 6.0 m. Steeply graded
sewers shall be tested in stages as instructed by the Engineer.
(b) The test shall be carried out by inserting suitably strutted expanding plugs in the
lower end of the section of sewer, and if necessary at appropriate positions within
any connections, and by filling the system with clean water. For small pipes a
knuckle bend may be temporarily jointed to the upper end of the section together
with a suitable length of vertical pipe to enable the required test head to be
attained. Mortar plugs shall not be used. The expandable plugs shall be
approved by the Engineer before testing commences.
(c) During the initial period, water may be added to maintain the test head in order to
allow for absorption and the displacement of trapped air from the system but the
test proper shall be commenced within one hour of the initial filling of the system.
(d) The loss of water over a period of 30 minutes shall be measured by adding water
from a measuring vessel at regular intervals of 10 minutes and noting the
quantities required to maintain the original water level in the stand pipe. For the
purpose of this test, the quantity added shall not exceed 1.25 litres per 25 mm
diameter of pipe per 100 m of pipe length.
(e) The pipeline shall be immediately backfilled on completion and approval of the
test to a minimum of 300 mm above the pipe. If the pipeline is not backfilled
within 24 hours, the water test shall be repeated.
(5) The following limits of infiltration shall not be exceeded when backfilling is completed
and all inlets to the length of sewer under test have been effectively sealed: For sewers
not exceeding 750 mm nominal internal diameter, 0.05 litre per hour per 100 linear
metres per mm of nominal bore sewer.
(6) Test for line, level and freedom from obstructions, shall be applied by means of a lamp
and mirror or by a laser beam. The Contractor shall ensure that no naked lights are
used in existing sewers and manholes, or in any new sewers connected to existing
sewers and in which there is a risk of explosion due to the presence of gases.
(7) A final inspection by CCTV shall be carried out on completion, prior to Taking Over of
each section of sewer. The CCTV inspection shall be carried out using a closed circuit
television sewer inspection unit approved by the Engineer. The inspection unit shall
comprise either a self propelled or winched television camera unit specifically designed
for pipe diameters to be surveyed. The camera unit shall be fitted with a swivel lens
capable of viewing through a total angle of at least 90o from the axis of the pipeline in
any direction, remote controlled from the monitoring unit. The inspection shall be
carried out for the full length of each sewer, manhole to manhole and shall be recorded

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as video, either on VHS tape or digital format. If the recording is provided in digital
format, then the viewing software shall be provided for the use of the Engineer.
(8) An inspection report shall be prepared, stating the date of inspection, sections
inspected, description of the inspection equipment, procedures and problems
encountered, inspector’s report sheets for each section and a summary of defects
observed.
(9) The inspection video record and report shall be submitted to the Engineer in two copies
before final Taking Over.

7.14.3.3 Pressure Mains

(1) Pressure pipelines shall be subjected to an internal pressure test according to
DIN 19630. Pressure pipelines and networks shall be tested in accordance with
DIN 4279, care being taken to anchor the pipeline during the test. Tests shall be
carried out in two phases:
(a) Phase one: sections of 500 to 1,500 m length, strictly in accordance with
DIN 4279; Test pressure 15 bar, duration 3 hours up to DN 200, 6 hours for
DN 200 to DIN 400.
(b) Phase two: overall pressure test under operation pressure plus 2 bar, as
approved by the Engineer.
(2) The Contractor shall provide all tools, labour and materials (also needed clean water)
for the testing of pipelines including calibrated pressure gauges, all of which shall be
subject to the Engineer's approval.
(3) As soon as practical, after sections of pipelines are completed and partially backfilled,
joints being exposed, and after any thrust blocks and the section have sufficiently
hardened, the pipelines shall be subjected to a test for water tightness as described.
Tests shall be carried out by the Contractor under the supervision of the Engineer.
(4) Pipelines without self-anchoring joints have to be anchored at pipe ends, bends,
branches and reducers against thrust forces caused by internal pressure. The
dimensioning of the concrete anchor blocks is shown in the drawings. Test pressure
shall not be applied against closed valves.
(5) The overall pressure test shall be executed leaving the connection pieces between the
test sections exposed.
(6) Upon satisfactory final test results the Engineer shall issue to the Contractor a
certificate stating that the mains have been tested satisfactorily. The issue of such a
certificate shall not be construed as relieving the Contractor of his contractual
obligations for remedying defects which may subsequently occur.

7.14.3.4 Manholes and Inspection Chambers

Manholes and inspection chambers shall be visually inspected for water tightness against
infiltration after backfilling operations have been completed and when the water table is at its
highest. Under these conditions no infiltration flow shall be admissible.

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7.14.4 Testing of Concrete

7.14.4.1 General
(1) The approval of the Engineer of any materials, proportions or results given under this
section shall not relieve the Contractor from his obligations in connection with the
requirements for permanent works concrete.
(2) Concrete for testing shall be taken from the point of placing. Sampling shall be carried
out and tests made in accordance with an approved procedure.
(3) The Contractor is responsible for the provision of the moulds and assisting the
Engineer in taking concrete samples for the execution of the tests and for taking into
account the results of such tests in the execution of the Works.

7.14.4.2 Testing of Fresh Concrete

(1) Compacting Factor Test. This test shall be carried out at the preliminary testing stage
and whenever a concrete sample is taken for the making of works test cubes. Values
for acceptable factors are indicated in the table following "Slump Test".
(2) Slump Test. This test shall be carried out regularly as an aid to maintaining uniform
consistency of concrete during the progress of the Works. Acceptable values of the
slump are indicated in the following table:
Compaction Slump
Purpose
Factor [mm]
High-strength concrete sections, pavings and mass
concrete compacted by vibration 0.78 – 0.85 50 – 75
Normally reinforced concrete sections compacted by
vibration. Hand-compacted mass concrete 0.85 – 0.92 75 – 100
Heavily reinforced concrete sections compacted by
vibration. Hand-compacted concrete in normally
reinforced slabs, beams, columns and walls 0.92 – 0.95 100 – 130
Heavily reinforced concrete sections compacted without
vibration and work where compaction is particularly
difficult over 0.95 100 – 130

7.14.4.3 Testing of Hardened Concrete

(1) General:
(a) Concrete test cube results shall be used to determine the suitability from strength
considerations of concrete to be incorporated in the permanent works. Hardened
concrete shall be deemed to be unacceptable for the Works should the
corresponding test cube results fail to meet the Specification and in this event the
Contractor shall take all necessary remedial measures as directed by the
Engineer.
(b) For the making of test cubes the Contractor shall provide a sufficient number but
at least 12 nos. of 200 mm standard steel moulds. The costs of assisting the
Engineer in taking samples and providing the moulds shall be included in the

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Contractor's rates for concrete and no additional payment for such assistance
shall be made.
(2) Preliminary Test Cubes shall be taken from the proposed mixes as follows:
(a) For each class a set of 6 cubes shall be made from each of 3 consecutive trial
batches. 3 from each set of 6 shall be tested at an age of 7 days and 3 at an age
of 28 days.
(b) The cubes shall be made, cured, stored, transported, and tested in accordance
with approved standards.
(c) At each age of test no cube strength shall fall below the appropriate specified
minimum for preliminary strength tests.
(3) Works Test Cubes:
(a) These cubes shall be made from works concrete samples taken from the point of
placing as and when directed by the Engineer. Normally for each grade of
concrete, 6 cubes shall be made from concrete taken at random, 3 cubes from
each set shall be tested at an age of 7 days and 3 at an age of 28 days.
(b) Cubes will generally be required at least as follows:
− For every 25 m3 of concrete placed;
− For each important structural member;
− As otherwise directed by the Engineer.
(c) The cubes shall be made, cured, stored, transported, and tested as specified.
(d) A record of such tests identifying the test cubes with the part of the work
executed shall be kept on the Site by the Engineer and made available to the
Contractor.
(e) The appropriate strength requirement shall be considered to be satisfactory if
none of the strengths of the three cubes tested at each age is below the specified
cube strength, or if the average strength of the three cubes is not less than the
specified cube strength and the difference between the greatest and the least
strengths is not more than 20 % of that average.
(f) If the expected 28 day cube strength ßw28 is to be estimated from the 7 day cube
strength ßw7 in preliminary tests and quality control tests, this may in general be
done by applying the factors given in the table below, to the values of the 7 day
cube strength:

28-Day Cube
Cement Strength
Compressive
Class
Strength ßw28
Z 25 1.4 x ßw7
Z 35 L 1.3 x ßw7
Z 35 F; Z 45 L 1.2 x ßw7
Z 45 F; Z 55 1.1 x ßw7
(according to DIN 1045 Section 7.4.3)
or:

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Cement Compressive Strength

Strength [N/mm²]
Class 2 days 7 days 28 days
32,5 N ---  16
 32,5  52,5
R  10 ---
42,5 N  10 ---
 42,5  62,5
R  20 ---
52,5 N  20 ---
 52,5 ---
R  30 ---
(according to DIN EN 197-1)

(g) The hardening test gives an indication of the strength of the concrete in the
structure at a particular time and thus also gives guidance as to the formwork
stripping time as determined in the following table extracted from DIN 1045,
Clause 12.3:
For the For Lateral
Lateral Formwork For the
Formwork of Formwork of
of Beams and Formwork
Cement Beams, Frames Walls for Water
Formwork of Walls of Ceiling
Strength Class and Wide Spread Retaining
and Columns Slabs
Slabs Structures *
[days] [days]
[days] [days]
Z 25 4 10 28 28
Z 35 L 3 8 20 20
Z 35 F, Z 45 L 2 5 10 10
Z 45 F, Z 55 1 3 6 6
* For design requirement, walls of closed tanks should not be subjected to any
lateral forces before the final hardening of the roof slab due to the propping
action induced by the slab.
(h) The hardening can be determined, in accordance with approved standards, on
test specimens or by non-destructive means.
(i) The specimens for these tests shall be made from the concrete intended for the
structural components in question and be stored directly beside or on these
components and be cured in the same manner (influence of temperature and
humidity). At least three specimens shall be made for the hardening test, but it is
advisable to make more specimens so that if the strength determined in the test
is found to be inadequate the test can be repeated.
(j) Components whose dimensions vary significantly from those of the test
specimens may attain a different degree of hardening from that of the specimens,
e.g. due to differences in heat evolution in the concrete. Due account should be
taken of such factors when assessing test results.
(k) If, due to lack of compressive strength test results, or in the event that there is
reason to doubt the strength of concrete in any particular section, it may be

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necessary to determine the compressive strength of the concrete by taking

specimens from the structure or, if authorised by the Engineer, by non destructive
testing performed on the finished component or by both methods. In connection
with such tests the age and the conditions of hardening (temperature, humidity)
of the concrete in the structure shall be taken into account.

7.14.4.4 Laboratory
(1) The Contractor shall provide and maintain on site for the duration of the Contract a
concrete testing laboratory. It shall be equipped with at least one concrete cube
crushing machine, weighing scales, a set of sieves for determining particle size
distribution of aggregate, apparatus for testing the chemical content of cement provided
for the Works, all equipment required to perform all concrete tests, staffed by personnel
experienced in the use of such equipment who will be employed by the Contractor to
work under the direction of the Engineer when required. The equipment described
above will remain the property of the Contractor, also after conclusion of the works.
(2) The Contractor shall provide a locked and insulated curing tank for concrete test cubes.
(3) All equipment to be provided shall be tested, calibrated and certificates provided to
confirm its suitability for the required tests.
(4) The Contractor shall supply, install and maintain testing equipment and material
required to perform soil tests and quality control of asphalt.
(5) With the Engineer’s approval the Contractor may use testing laboratories / facilities
established elsewhere in the Employer’s country, provided that these laboratories /
facilities are recognized by the responsible Government Authorities. All costs involved
using these laboratories / facilities shall be borne by the Contractor.

7.14.5 Water Retaining Structure

(1) On completion, the structures shall be proved watertight by testing in the manner
specified below, to the satisfaction of the Engineer. Testing shall be completed before
backfilling (if any) to the walls is carried out unless otherwise directed by the Engineer.
(2) The test shall be carried out by filling the structures to overflow level (with clean, water
obtained from an approved source for the water supply structures).
(3) The water shall be left to stand for 7 days, during which period visual examination and
readings of water levels shall be taken. To allow for absorption, in concrete structures
only, the level shall be maintained by topping up as necessary for the first 4 days. To
allow for evaporation, an approved "evaporation tank" of minimum depth 1 m shall be
provided by the Contractor and supported inside the structure with its open top above
overflow level.
(4) The evaporation tank shall be partially filled with water, to approximately the same level
as the structure and the levels monitored during the test period.
(5) After the first 4 days, no topping up to the structure (in the case of a concrete structure)
or the evaporation tank shall be carried out, and after a further 3 days the level in the
structure and the evaporation tank shall be noted. During this period, the outer faces of
the structure shall be carefully examined for signs of damp patches. If, after allowance
has been made for evaporation, the level in the structure has dropped during 3 days or
there is evidence of damp on the outer faces, then the structure shall be deemed to
have failed the test. If, after allowance for evaporation, the level has not dropped and

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no damp patches are visible, then the structure shall be deemed to have passed the
test.
(6) Should the structure be deemed by the Engineer to have failed the test, the Contractor
shall be responsible for and bear the expense of locating the source of leakage and
carrying out all necessary remedial work as required by the Engineer to make the
structure water tight. A further test shall then be carried out as before and the
procedure shall be repeated until the structure is deemed by the Engineer to have
passed the test.
(7) Incidental expenses to cover all the costs associated with carrying out this test to the
satisfaction of the Engineer are to be included in the respective Items. Payment will be
made for the successful structure only, and the rates entered by the Contractor shall be
deemed to cover all costs incurred in complying with the requirements of this Clause
including the cost of labour, equipment, supply and disposal of the water used in
testing.

7.14.6 Roof Testing

(1) The roofs of structures shall be water-tight.
(2) The roofs shall be tested for water-tightness by covering it with clean water to a
minimum thickness of 25 mm for a period of 3 days. Where this, in the opinion of the
Engineer, is impractical because of roof falls or otherwise, the roof shall be thoroughly
wetted by continuous hosing for a period of six hours. On completion of the wetting the
roof shall be inspected and shall be regarded as satisfactory if no leaks or damp
patches show in the soffit.

7.15 Solar PV Inspection and Testing Requirements

Once the installation is achieved, Pre-Commissioning Test will be carried out. Positive
outcome of this initial phase will allow to proceed with the Commissioning Tests (including
the PV Plant connection to the Grid and its energisation) and subsequently with the Trial
Operations. This last will be organized as per the guidelines of IEC 62446 and will include a
Performance Ratio test for a period of at least 14 days. Tests after Completion procedure
also will follow the IEC 62446 and will be divided in 2 stages: (i) Intermediate Performance
Test and (ii) Performance Test. The intermediate Performance Test will include checking of
the module reliability and defects, as well as an analysis of the Guaranteed Performance
data (Production, Performance Ratio, Availability) of the first 12 months after Taking Over
Certificate. The Performance Test will be implemented 12 months after the conclusion of the
Intermediate Test. The Performance Test will include a verification of the Guaranteed
Performance data on top of any contractual aspect required for an orderly conclusion of the
contract. The next paragraphs describe the specific requirements for each of the above tests.

7.15.1 PV Modules
For each PV module delivered for the project, a comprehensive IV flash test data collected
during the module fabrication (in excel format) must be provided. The data must have the
following information:
 Serial number of the tested module, including which modules are in which shipping
containers and pallets.
 Power at maximum power point (Pmpp).
 Voltage at MPP (Vmpp).

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 Current at MPP (Impp).

 Open circuit voltage (Voc).
 Short circuit current (Isc).

This information shall be provided the latest 2 weeks prior to the arrival of PV modules on the
site, in order to enable the Contractor to plan or change the program development and
assembly based on the type and quantity of modules, in the containers they are delivered in.

7.15.2 Inverters
The Factory Acceptance test for the inverters shall include as a minimum the following tests:
 Ingress protection (IP) testing. The test shall detect the ability of the inverter casing and
seal to prevent moisture, dust ingress and foreign particles from entering and harming
the electrical components.
 Built quality check. During this procedure the build quality of the inverters is checked.
This basically involves an assessment of the quality and assembly of the
components on the electrical circuit board (resistors, diodes, capacitors, transistors
etc.) and wiring used in the system.
 Hot spots and temperature distribution. During this test procedure, the temperature
inside an inverter and its distribution is checked.
 Functions test. The functions test assesses the operational functioning and power
conversion characteristics of the particular inverter with a simulated PV array.

7.15.3 Circuit Breakers

Factory testing on circuit-breakers shall include:
 Pressure and tightness test
 Functional check of wiring and auxiliaries
 Adjustment of set points and auxiliaries
 Lowest operating voltage of close and trip coils
 Resistance of the main circuit
 Power frequency withstand test
 Overpressure test on each pole
 Tightness test on each pole
 Mechanical operations test
 Timing test of the main contacts
 Timing test of the auxiliary contacts

7.15.4 VT’s
Factory testing on VTs shall include:
 Pressure and tightness test
 Power frequency withstand test
 Partial discharge test (<5pC)
 Verification of terminal marking
 Determination of Errors

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7.15.5 CT’s
Factory testing on CTs shall include:
 Pressure and tightness test
 Power frequency withstand test
 Partial discharge test (<5pC)
 Capacitance Measurement on Capacitive Tap
 Measurement of Dielectric Dissipation Factor
 Secondary Resistance Measurement
 Inter-turn Overvoltage test
 Verification of terminal marking and turns ratio test
 Determination of Errors
 Verification of secondary EMF
 Secondary magnetizing current characteristic

7.15.6 Disconnect and Earthing Switches

Factory testing on outdoor disconnects and earthing switches shall include:
 Functional check of wiring and auxiliaries
 Adjustment of set points and auxiliaries
 Lowest operating voltage of close and open coils
 Resistance of the main circuit
 Power frequency withstand test
 Mechanical operations test

7.15.7 Surge Arresters

Factory testing on outdoor surge arresters shall include:
 Measurement of the reference Voltage
 Residual Voltage test
 Partial Discharge test (<5pC)
 Leakage test
 Current distribution test
 Measurement of the continuous current at continuous operating Voltage

7.15.8 MV Switchboards & RMUs

Factory testing on Switchgear and RMUs shall include:
 Mechanical functional test of all components including mechanical interlocks.
 Electrical functional test of all control and protection wiring against the approved
switchgear schematics.
 Power frequency overvoltage test on the switchgear including circuit-breakers in the
test circuit.
 Low resistance conductor test on the switchgear including circuit-breakers in the test
circuit.
 Secondary injection test on all protection relays to confirm satisfactory operation of the
protection scheme.

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 Routine tests for all CTs and VTs including confirmation that ratio and errors are within
IEC tolerances.
 Primary injection of all CTs and VTs to confirm ratio and polarity.
 Magnetisation curve tests for all CTs.
 The overvoltage and secondary injection tests shall be repeated once the switchboard
has been installed at site.

7.15.9 Transformers
The following factory tests shall be undertaken on each of the following type of transformers
supplied by the Contractor as part of the Works:

7.15.10 Unit Substation Transformers

The testing described below shall be performed, as a minimum. (The Employer may waive
the requirement to conduct non-routine tests if the Contractor can provide independently
witnessed type test certificates for the exact same tests conducted on an identical design.)
Routine tests as per IEC 60076 including applied and induced overvoltage tests,
measurement of no load and load losses, impedance and resistance of the windings,
confirmation of the vector group and megger testing (HV-E, LV-E and HV-LV).
Lightning Impulse Type Test, to be performed on each Grid transformer and on one unit
transformer per order. Test procedure to include half wave, 3 x full wave and chopped wave.
Temperature Rise Type Test.
Partial Discharge Type Test, to be performed on all units with the following limits (where Ur is
the rated voltage):
1.1 Voltage level 1.2 Duration (sec) 1.3 Max partial discharge
level (pC)
1.4 1.0*Ur 1.5 0 1.6 -
1.7 1.2*Ur 1.8 0 1.9 -
1.10 1.4*Ur 1.11 0 1.12 -
1.13 1.8*Ur 1.14 30 1.15 -
1.16 1.4*Ur 1.17 300 1.18 100
1.19 1.2*Ur 1.20 30 1.21 50
1.22 1.0*Ur 1.23 30 1.24 30

7.15.11 Auxiliary Transformers

Routine tests as per IEC 60076 including applied and induced overvoltage tests,
measurement of no load and load losses, impedance and resistance of the windings,
confirmation of the vector group and insulation resistance testing (HV-E, LV-E and HV-LV).

7.15.12 Distribution Boards

Factory testing on distribution boards shall include:
 Mechanical functional test of all components including mechanical interlocks.
 Electrical functional test of all control and protection wiring against the approved
switchgear schematics.
 Power frequency overvoltage test (flash test) on the switchgear including circuit-
breakers in the test circuit.

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Part 7 Testing on Completion

 Low resistance conductor test on the switchgear including circuit-breakers in the test
circuit.
 Visual inspection.

7.15.13 Tests on Completion

Tests on Completion are formed by:
 Pre-commissioning Tests
 Commissioning Tests
 Trial period

7.15.14 Pre commissioning Test

Pre-commissioning tests, which shall include the appropriate inspections and (“dry” or “cold”)
functional tests to demonstrate that each item of Plant is adequately installed in order to
allow the Plant to undertake to the next stage of commissioning tests.
Inspections and tests shall be undertaken on all systems and equipment installed as part of
the Works. The Contractor shall provide RFI’s for each item of equipment/system, for each
stage of testing. These RFI’s shall list all the inspections and tests to be undertaken and shall
record the results.

7.15.15 Commissioning Test

Commissioning Tests will be carried out to verify the capacity of the PV plant to inject the
energy produced into the grid under several conditions. The test procedure will also be
agreed with the local Utility.

7.15.16 Operational Tests following the energization of the PV Plant

Operational Tests following the plant energization will follow IEC 62446 Edition 1.0 2009-05
(“Grid connected photovoltaic systems – Minimum requirements for system documentation,
acceptance tests and inspection”) this. This standard is based on:
 IEC60364;
 IEC/TR 60755:2008;
 IEC 61557 (all parts);
 IEC 61730-1.

7.15.17 Trial Operations

Once the commissioning tests are complete and the facility is energised from the Grid, a Trial
Period of 14 days will start for the verification of the Performance Ratio and its compliance
with the contractually guaranteed PR value (see par. 9.3.3 for Performance Ratio
measurement and acceptance procedures). Upon positive completion of the Trial Period a
Take Over Certificate is released.

7.15.18 Tests after Completion

Tests after Completion are formed by:
 Intermediate Performance Test
 Performance Test

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Once the Taking Over Certificate has been issued, the Defects Notification Period starts. The
period ends with the issue of the Performance Certificate. During this period 2 different Tests
will be carried out:
 The Intermediate Performance Test will start after the issue of the Taking Over
Certificate and will end 12 months after (see par. 8 for performance measurement
and acceptance procedures). Upon positive completion, an Intermediate
Performance Certificate is released by the Employer.
 The Performance Test will start after the issue of the Intermediate Performance
Certificate and will end 12 months after (see par. 8 for performance measurement
and acceptance procedures). Upon positive completion, a final Performance
Certificate is released by the Employer.

7.15.19 Intermediate Performance Test

Production, Performance Ratio and Availability verifications will be performed according to
the procedure specified in Chapter 8 at the end of a period of 1 year from the Take-Over
Certificate.
A visual inspection of the modules is executed to check for any defects.
A thermal analysis is made for at least 10% of the modules to check for hot spots. If this
analysis shows that more than 1% of the panels have an error (non working cell (s) and/or
cell(s) with a hot spot), then the Contractor will organise a new flash test carried out on a
number of panels for each type. It is up to the Contractor to determine this number of flash
tested panels but the outcome of the statistical sampling must have to demonstrate that the
probability of a type I error (the probability to accept the panels on basis of a statistical trial
despite that the mean value of the power of the population is lower than the peak power of
the panel type) is less than 5%. The peak power will be determined by taking into account a
decrease of the power of 0,6%/y. If it appears that the population will not pass the statistical
test, the manufacturer will verify by measurement the declared flash value of all panels and
non-conforming panels will be replaced at his expenses.

7.15.20 Performance Test

The Performance Test period will start after the issue of the Intermediate Performance
Certificate. During the final Performance tests, all remarks made during Provisional and
Intermediate Performance tests are verified for the full implementation of the respective
corrective actions.
Production, Performance Ratio and Availability verifications as described in the subsequent
Chapter 8 will be performed after a period of 1 year from the Intermediate Performance
Certificate.
Minimum requirements for Performance Certificate
The Performance Certificate will not be issued until all of the minimum requirements listed in
below have been met:
 Training of Employer’s Personnel is completed
 Tests After Completion have been successfully done meeting the minimum
Guaranteed Production, Performance Ratio and Availability over the periods of
analysis.

End of Part 7 - Testing on Completion

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Part 8 O&M

Part 8 – Operation and Maintenance by the Contractor

Table of Contents

8 Operations and Maintenance by The Contractor .................................................. 1

8.1 Objectives of the O&M ......................................................................................... 1
8.2 Wastewater Quality and Effluent Standards ......................................................... 2
8.3 Scope of the Facilities Covered by the O&M ........................................................ 2
8.4 Operations Staffing .............................................................................................. 3
8.4.1 Contractor’s Operations Staffing ...................................................................... 5
8.4.2 24 hour, 7 days per Week Contractor’s Operations Staffing............................. 6
8.4.3 WAJ Operations Staffing on Temporary Release to the Contractor ................. 6
8.5 Phasing ................................................................................................................ 6
8.6 Contractor’s Obligations ....................................................................................... 7
8.6.1 Contractor’s Operation Staff ............................................................................ 7
8.6.2 Electricity, Water, Utilities, Filters and Lubricants ............................................. 8
8.6.3 Changes in Personnel ..................................................................................... 9
8.6.4 Replenishment of Spare Parts ......................................................................... 9
8.6.5 Suppliers and Subcontractors .......................................................................... 9
8.7 Obligations of the Employer ................................................................................. 9
8.8 Contractors Operations Deliverables .................................................................. 10
8.8.1 Operational Management Plan ...................................................................... 10
8.8.2 Maintenance Management System (MMS) .................................................... 11
8.8.3 WAJ Staff Training Plan................................................................................. 12
8.8.4 Emergency Operating Plan ............................................................................ 12
8.8.5 Health & Safety Plan...................................................................................... 13
8.8.6 Quality Assurance System ............................................................................. 13
8.8.7 Environmental Management System ............................................................. 13
8.8.8 Reporting to the Engineer .............................................................................. 14
8.8.8.1 Monthly Reports ................................................................................... 14
8.8.8.2 Phase Completion Reports ................................................................... 15
8.9 Operations Management, Personnel and Training ............................................. 15
8.9.1 General.......................................................................................................... 15
8.9.2 Qualifications, Experience and Training ......................................................... 16
8.10 Monitoring, Sampling and Analysis..................................................................... 17

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8.10.1 General.......................................................................................................... 17
8.10.2 Sampling Equipment........................................................................................ 1
8.10.3 Laboratory and Analytical Equipment .............................................................. 1
8.10.4 Laboratory Information Management System .................................................. 1
8.10.5 Analytical Methodology .................................................................................... 1
8.10.6 Independent Analysis ...................................................................................... 1
8.10.7 Remedy on Compliance Failure ....................................................................... 1
8.10.8 Sampling by the Engineer ................................................................................ 1
8.10.9 Weather Data .................................................................................................. 2
8.11 Tests after Take Over........................................................................................... 2
8.12 Solid Waste Management .................................................................................... 3
8.12.1 Sludge Management........................................................................................ 3
8.12.2 Screenings, Grit and other Wastes .................................................................. 3
8.13 Third Party Discharges ......................................................................................... 3
8.13.1 Continuous Discharges to Sewer ..................................................................... 3
8.13.2 Intermittent Imported Discharges ..................................................................... 4
8.13.3 Procedures for Management of Third Party Discharges ................................... 4
8.13.4 Right to Refuse Third Party Discharges ........................................................... 4
8.14 Odour Control ...................................................................................................... 5
8.15 Noise Control ....................................................................................................... 5
8.16 Vermin Control ..................................................................................................... 5
8.17 Failure to Comply with the Environmental Requirements ..................................... 5
8.18 Management of Consumables.............................................................................. 6
8.18.1 Chemicals Management .................................................................................. 6
8.18.2 Energy Management ....................................................................................... 6
8.19 Maintenance of the Works .................................................................................... 6
8.19.1 General............................................................................................................ 6
8.19.2 Maintenance Programme ................................................................................ 6
8.19.3 Maintenance Outsourcing ................................................................................ 7
8.19.4 Building Maintenance ...................................................................................... 7
8.19.5 Site Infrastructural Maintenance ...................................................................... 8
8.19.6 Lifting Mechanisms .......................................................................................... 8
8.19.7 Tank and Pump Sump Inspection .................................................................... 8
8.19.8 Spare Parts ..................................................................................................... 9
8.19.9 Auditing of the Maintenance Programme ......................................................... 9

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8.20 Innovation and Efficiency Improvements .............................................................. 9

8.21 Health and Safety............................................................................................... 10
8.21.1 General.......................................................................................................... 10
8.21.2 Safe Working Procedures .............................................................................. 10
8.21.3 Personnel Vaccination ................................................................................... 10
8.21.4 Health and Safety Audits ............................................................................... 10
8.22 Unusual or Abnormal Situations ......................................................................... 10
8.22.1 Changes in Wastewater Characteristics ........................................................ 10
8.22.2 “No Flow” Occurrence.................................................................................... 10
8.22.3 Recording of Unusual or Abnormal Situations................................................ 11
8.22.4 Notification of Unusual or Abnormal Situations .............................................. 11
8.22.5 Public Complaints and Grievance Procedure ................................................. 11
8.23 Supervision and Auditing .................................................................................... 11
8.23.1 Supervision of the Operation and Maintenance Works .................................. 11
8.23.2 Auditing the Operation and Maintenance Works ............................................ 12
8.23.3 Auditing of the Maintenance Programme ....................................................... 12
8.23.4 Auditing of Effluent Standards ....................................................................... 12
8.23.5 Invoicing of the Operation and Maintenance Works ....................................... 13
8.23.6 Failure to Meet KPIs and Maintenance Requirements ................................... 13
8.24 Handing Back ..................................................................................................... 13
8.25 Training .............................................................................................................. 14

List of Tables
Table 1: Wastewater Influent Quality ...................................................................................... 2
Table 2: Treated Effluent Standard [Ref. JS 893/2006]........................................................... 2
Table 2: Staffing list for As Salt WWTP .................................................................................. 5
Table 3: O&M Staff Minimum Experience & Qualifications ..................................................... 8
Table 4: Sampling and Analysis Programme – Wastewater Treatment ................................ 19
Table 5: Sampling and Analysis Programme – Sludge Treatment ........................................ 20
Table 6: Sampling and Analysis Programme – Power Management..................................... 20

List of Figures
Figure 1: Organisation of Operations Staff.............................................................................. 4

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Part 8 O&M

8 OPERATIONS AND MAINTENANCE BY THE

CONTRACTOR

8.1 Objectives of the O&M

The Contractor shall provide a programme of full Operations and Maintenance including
training of WAJ operations personnel to operate and maintain the works following testing and
Taking Over of the Works. This shall be Section 3 “Part 2 Operations” of the Contract which
hereinafter shall be referred to as “O&M” in this document. The final 6 months of the O&M
shall be organised to provide additional training and to ensure a smooth transition of
operations responsibility.
The Contractor shall monitor the inlet wastewater characteristics to confirm compliance with
the design parameters specified below and shall report any anomalies. The prime objective
of the O&M shall be to operate the Salt WWTP to achieve the specified effluent standards.
The O&M will commence on Line 1 of the WWTP, including the sludge treatment, CHP and
all their associated works, once the Taking-Over Certificate for the Section 1 “Part 1
Construction Stage 1” has been issued and shall include start up and commissioning of Line
1. Once the Taking-over Certificate has been issued for Section 2 “Part 1 Construction Stage
2”, the Contractor shall commence the O&M on Line 2 of the WWTP, including start up and
commissioning and its associated works while continuing O&M on Line 1. In case there are
insufficient flows to operate both lines, then Line 1 or parts of Line 1 may be shut down to
optimise operating costs.
The total duration of the O&M Operations” shall be for a minimum of 24 months. This should
include a period of O&M for Line 2 for 15 months. If, however, the Taking-over of Section 2
“Part 1 Construction Stage 2” is delayed by more than 3 months the total duration of O&M
would extend beyond 24 months so as to enable a minimum of 12 months of O&M to be
provided for Line 2. The cost of any extension of the O&M due to delay in Taking Over of
Section 2 shall be borne by the Contractor.
The O&M shall be carried out in phases to provide an orderly transfer of responsibility and
capability, and is to ensure that management of the works shall be carried out in an efficient
and cost effective manner in accordance with the Specification and with the following
objectives:
1. Carry out operational trials as specified to demonstrate the capabilities of the WWTP
for both Line 1 and 2 and their associated works and to train the WAJ staff;
2. Ensure that the WAJ operations staff is fully involved in the testing, start up and initial
operation of the Works both for Line 1 and 2;
3. Make full use of the opportunity for hands on training of the WAJ staff in association
with the Contractor’s personnel during the operations period;
4. Provide a phased handover of responsibility for operations during the final 6 months of
the O&M period from the Contractor to WAJ;
5. Ensure that the WWTP is fully operational under WAJ responsibility at completion of
the O&M period;
6. Achieve design operational performance to comply with effluent discharge
requirements;

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7. Achieve satisfactory sanitary handling and disposal of screenings, grit and sludge; and
8. Minimise the generation of obnoxious odours and mitigate potential complaints due to
odours.
Training of WAJ staff shall be integrated into the O&M, commencing with the Tests on
Completion for both Section 1 and Section 2, as specified.

8.2 Wastewater Quality and Effluent Standards

The effluent quality shall comply with the following standards, based on 24 hour flow
proportional composite samples. Automatic sampling equipment is provided under the
Construction for this purpose to be analysed in the WWTP laboratory. However, WAJ may, in
addition, arrange for separate samples to be taken for independent analysis. The waste
water quality and effluent standards are shown in Table 1 and Table 2 below.

Parameter Unit Average inlet concentrations Peak inlet concentrations

COD (mg/l) 1100 1414

BOD5 (mg/l) 600 719
TSS (mg/l) 475 620
TKN (mg/l 96 96
NH4+ as N (mg/l) 71 71
TP as P (mg/l) 13 13

Table 1: Wastewater Influent Quality

Parameter Unit Cooked Vegetable, Parks, & Playgrounds (A

BOD5 (mg/l) 30

COD (mg/l) 100

DO (mg/l) >2

TSS (mg/l 50

NO3 as NO3 (mg/l) 30

NH4+ (mg/l) -

Total-N (mg/l) 45

PO4 as PO4 (mg/l) 30

FOG (mg/l 8

E.Coli MPN per 100

100 mL
Nematodes eggs/L ≤1

Table 2: Treated Effluent Standard [Ref. JS 893/2006]

8.3 Scope of the Facilities Covered by the O&M

The O&M shall be mobilised during the Tests on Completion for Section 1 and shall be fully
mobilised as a condition for Taking Over of the Works for both Section 1 and Section 2. The

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Contractor’s Operations Staff shall be assigned to the works as specified until completion of
the O&M i.e. Section 3, and WAJ has assumed full operations responsibility and the Defects
Notification Period for both Section 1 and Section 2 is completed.
The O&M shall include all civil, mechanical, electrical, telemetry, SCADA and infrastructure
items comprising the complete project operating unit, including but not necessarily limited to
the following:
- Salt WWTP in its entirety, from the Inlet Manhole in the adjacent road to the effluent
discharge downstream of the lagoon and dam.
- Sludge treatment, from removal of sludge from the settling tanks to removal of treated
sludge from the WWTP at minimum 50% ds, including the digesters, gas treatment &
handling and CHP units.
- Solar PV installation.
- Complete smart power system, integrating power from the following sources:
 Main power connection.
 Power generation from digestor sludge gas at Salt WWTP.
 Solar PV installation at Salt WWTP.
- All off site support or ancillary services needed for the functioning of the Salt WWTP as
an operating entity.

8.4 Operations Staffing

The operation of the Project will be under responsibility of the Contractor for the duration of
the O&M. The daily management and operation tasks will be under the control of the Plant
Manager provided by the Contractor, reporting to the Engineer. The WWTP staff will be
organised into following basic functions:
 General administration, planning and organisation
 Laboratory for plant self-monitoring
 Process control
 Power management and generation
 Treatment processes: mechanical, biological, sludge treatment
 Maintenance / workshop
 Ground keeping
 Security
The staff schedule is proposed to be organised according to these functions, as shown in
Figure 1 below.

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Figure 1: Organisation of Operations Staff

Operations Manager

Process Control Planning

Maintenance Laboratory Power Organisation
Management Administration

Biological Sludge MV Power

Mechanical
Treatment Treatment Mngmt
Treatment
Blowers

Security

The Plant Manager will be responsible for the overall day to day management of the project,
including the operation and control of the different units for power supply, wastewater
treatment and sludge handling. Reporting directly to the Employer, the Plant Manager should
have a good technical background, with a sound understanding of operation and
management of wastewater treatment plants. Suitable candidates should have at least 15
years appropriate experience, with an international background.
A chemist/biologist/chemical engineer will be in charge of the laboratory and the monitoring
of wastewater and sludge quality. He will advise the Plant Manager on the operation of
treatment processes to achieve the optimum performance and compliance with proposed
wastewater standards. Concerning treatment efficiency, he will report independently to WAJ.
He will be assisted by several lab assistants and will be nominated as Deputy Plant
Manager.
An Electrical Engineer will be responsible for the “Smart Power System” to ensure adequate
power for the project at all times from the three main supply sources; mains power, digester
gas generation and solar PV, including the emergency standby diesel generators. Suitable
candidates should have at least 10 years appropriate experience, preferably with an
international background.
An IT/SCADA Engineer will be responsible for the SCADA, PLCs and all instrumentation
included in the controls at the WWTP to ensure proper monitoring and control facilities and to
carry out any programming needed for the SCADA system. Suitable candidates should have
at least 10 years appropriate experience, preferably with an international background.
It is proposed that a total of about 36 employees work at the plant as shown in Table 3
below.

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Category Grade Shift Nos. Nos. Cat 1 Nos. Cat 2 Nos. Cat 3 Nos. Cat 4 Nos. Cat 5 Nos. Cat 6
Management
Plant Manager 1 1 shift 1 1
Planning/Process Control/Administration
Engineers 2 2 shift 1 1
Technicians 3 1 shift 1 1
Secretary 4 1 shift 1 1
Stores & Inventory 4 1 shift 1 1
O&M Power Supply/SCADA
Electrical Engineers 2 1 shift 1 1
IT/Instrumentation Engineers 2 1 shift 1 1
Technicians 3 2 shift 2 2
Skilled Workers 4 2 shift 2 2
O&M Water Treatment
Engineers 2 2 shift 2 2
Technicians 3 2 shift 2 2
Skilled Workers 4 2 shift 3 3
Unskilled Workers 5 1 shift 2 2
O&M Sludge Treatment & Gas Utilisation
Engineers 2 1 shift 1 1
Technicians 3 2 shift 2 2
Skilled Workers 4 2 shift 2 2
Unskilled Workers 5 1 shift 4 4
Laboratory
Manager/Deputy Plant Manager 1 1 shift 1 1
Technicians 3 1 shift 1 1
Skilled Workers 4 1 shift 1 1
Security
Security staff 6 2 shift 4 4

Total Staff 36 2 6 8 10 6 4
Category 1: plant manager Category 4: skilled workers
Category 2: Engineers Category 5: unskilled workers
Note:
1. If handover of the Works is delayed at the Contractor’s responsibility, Phase 1 manmonths shall be extended at no
additional cost.
2. If Defects Notification completion is delayed at the Contractor’s responsibility, Phase 3 manmonths shall be extended
at no additional cost.
Table 3: Staffing list for As Salt WWTP

8.4.1 Contractor’s Operations Staffing

The Contractor shall submit a proposed a final Staffing Plan to the Engineer, to be approved
by the Employer at least 3 months prior to commencement of final testing and Taking Over of
Line 1, see below.
The Contractor shall provide the full complement of operations staff according to the Staffing
Plan approved by the Engineer. Payment will be made according to actual inputs against
approved timesheets for all staff listed in Table 2 above. If the Contractor requires additional
staff to fully undertake the scope of the O&M specified herein, then the costs of these
additional staff shall be considered included in the rates.

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8.4.2 24 hour, 7 days per Week Contractor’s Operations Staffing

The WWTP shall be manned 24 hours per day, 7 hours per week. Each sift shall include at
least the following:
- One engineer or manager
- One technician or operator
- One labourer
- One security guard
The Contractor shall determine the shift working structure (number, duration and hours of
each sift) and the staffing roster according to his experience and shall submit this to the
Engineer for approval.
The Contractor shall also establish clear standby and emergency call procedures to enable
the shift workers to call in additional support in case of need.
For similar purposes, the Contractor shall designate a point of contact who shall be
contactable 24 hours per day. The default person for this shall be the plant managers unless
alternatives are notified, either from time to time or on a rota. These contact persons shall be
notified to the designated contacts in WAJ and the Engineer.

8.4.3 WAJ Operations Staffing on Temporary Release to the Contractor

The Contractor is encouraged to take on the existing operations staff from As Salt WWTP as
part of the O&M team under the full responsibility of the Contractor and the Contractor shall
pay the full costs of these staff. WAJ undertakes to allow these staff leave of absence for the
period of employment with the Contractor.
However, the Contractor is free to choose his O&M staff, provided they meet the qualification
requirements of the specification.
WAJ will support and coordinate with the Contractor to identify WAJ operations staff to be
released for working with the Contractor.
The Contractor shall be fully responsible to agree terms and conditions of employment with
the WAJ staff on temporary release.

8.5 Phasing
The O&M shall be provided in three phases as follows:
Phase 1 Prior to Taking Over of Section 1
For a period of at least 2 months during testing and commissioning of the Works
Section 1 Line 1 until formal Taking Over
Phase 1 shall apply to both Line 1 and Line 2. In the case of Line 2, the staff already
mobilised for the O&M and who are working on O&M shall provide these Phase 1 services.
Phase 2 After Taking Over of Section 1
For a period of at least eighteen calendar months from the date of takeover of the
works for Section 1“Part 1 Construction Stage 1”

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The Contractor’s staff shall then carry out full operations and maintenance of the WWTP Line
1 and associated works until end of the Contractor’s O&M period. These staff shall work
initially on Line 1 and then concurrently on WWTP Line 2 once the Taking–Over Certificate
for Section 2 “Part 1 Construction Stage 2” has been issued.
Phase 3 Prior to Completion of the O&M
For the final 6 months of the O&M until issue of the Performance Certificate at the completion
of the O&M Period, the Contractor shall provide the ongoing services of the specified
operations staff.
The Contractor shall arrange that at least 50% of his staff will transfer to employment with the
organisation designated by the Employer to take over operation of the WWTP.
The staff that will transfer shall sign a letter of intent confirming that they will work at least 12
months with the new operator. The content of the letter of Intent shall be submitted to the
Engineer for approval. Against signing of this letter of intent, the transferred staff will be paid
a bonus equivalent to 10% of their net salary (after deduction of tax and social security) for
the first 12 months following completion of the Contractor’s O&M and transfer to the new
operator. This bonus shall be paid from the Provisional Sum provided in Bill No. 7
Operations.
The Contractor shall provide full and comprehensive training during the 6 months of Phase 3
for the additional operations staff that will be assigned to take over on completion of the
Contractor’s O&M services. If 100% of the Contractor’s O&M staff agree to transfer to the
incoming operator, then no training will be required.
Phase 4 After Completion of the O&M
The Contractor shall provide a bank guarantee in value of 10% of the last year of the O&M.
This guarantee shall be valid for 12 months following completion of the O&M services and
shall guarantee that the Contractor shall rectify any defects in the Works caused by the O&M
services notified during the 12 month period.

8.6 Contractor’s Obligations

8.6.1 Contractor’s Operation Staff

The Contractor’s O&M Staff shall be fully integrated into the organisation for the WWTP. The
Contractor shall determine the staffing and organisation required during each phase of the
O&M. This shall be submitted the Engineer prior to commencement of start-up testing and
shall be approved prior to Taking-Over. The full time staffing during these Phases shall
include at least the staffing specified in Table 3 above.
The Contractor’s O&M staff shall be based at As Salt WWTP, using the working
accommodation which will be provided within the permanent facilities which already exist or
which will be constructed under the Contract at the sites (Administration Building, Workshop,
etc.) at no cost to the Contractor.
The Contractor’s staff shall include adequate English and Arabic skills and shall include a
minimum of 80% Jordanian nationals.
The Contractor shall provide support and backstopping as required for the site staff to meet
the O&M obligations and shall provide such other staff as are required to complete all other
deliverables as specified below.

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Provisional sums are provided for spare parts and expert support. These may be used at any
time during the O&M for services outside the Contractor’s specified scope, subject to the
approval of the Engineer.
The Contractor’s staff shall have the experience and background specified in Table 4 below.
Position Experience Qualifications
Operations Manager 15 years relevant experience in wastewater BSc or equivalent in
(Chief of Party) treatment, including 5 years responsible as engineering or process
manager in charge of the operation of a science.
WWTP of comparable size.
Process / Operations 10 years relevant experience in wastewater BSc or equivalent in
Engineer treatment operations, including 5 years in engineering or process
operation of a WWTP of comparable size. science.
Mechanical Engineer 10 years relevant experience in wastewater BSc or equivalent in
treatment operations, including sludge mechanical engineering
digestion.
Electrical Engineer 10 years relevant experience in operation of BSc or equivalent in
low and medium voltage power systems, electrical engineering
including generation, synchronisation and
networks
Laboratory Technician 5 years relevant experience in wastewater BSc in chemistry,
sampling and analysis. biochemistry or equivalent
Operations Technician 5 years relevant experience in wastewater Relevant vocational training
treatment and diploma or equivalent
certification
Mechanical 5 years relevant experience in wastewater Relevant vocational training
Technician treatment and diploma or equivalent
certification
Electrical Technician 5 years relevant experience in wastewater Relevant vocational training
treatment and diploma or equivalent
certification

Table 4: O&M Staff Minimum Experience & Qualifications

The CVs of each of the above staff shall be submitted to the Engineer for approval at least
one month before the start of assignment. The Engineer will require that the Operations
Manager and Process / Operations engineer attend an interview in Jordan prior to giving
approval. These interviews shall be done at no additional cost.
In the event that any proposed staff member is rejected, it shall be the Contractor’s
responsibility to propose a replacement for approval within the Contract Programme.

8.6.2 Electricity, Water, Utilities, Filters and Lubricants

For the duration of the O&M of the Contract the Contractor shall pay the cost of all electricity,
water and other utilities required for the O&M of the WWTP. The Contractor shall also pay
the cost for all chemicals, lubricants, filters etc. and other consumable items necessary for
the O&M of the WWTP.
The Contractor shall also pay for all sampling and testing relating to the O&M.
The Contractor shall be responsible for transporting liquid sludge to Ain Ghazal and
dewatered sludge to AlEkeider or other approved disposal sites within similar distances from
the WWTP. The Contractor shall not be responsible for paying for discharge permits or for
the payment of tipping fees for sludge etc.

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Electricity costs will be paid for according to the items provided in the Contract O&M Bill for
the WWTP is based on the Tariff Rate in effect at the time of tender.
Escalation of the electricity costs will be paid according to the actual tariff rates at the time of
consumption and the actual metered consumption based on the following formula:
EE=Pc x Ta x 1.1 / Tt
Where:
EE = Electricity escalation to be paid quarterly in addition to the BoQ rate
Pc = Actual power consumption over the invoiced period in kWhr
Ta = Actual electricity tariff applicable over the invoice period
Tt = Electricity tariff applicable at the time of tender

The escalation costs will be paid from Provisional Sum included in Contract O&M Bills.

8.6.3 Changes in Personnel

The Engineer shall be informed, with at least two weeks’ notice, of any proposed change to
personnel engaged in the management and operation of the works. The Contractor shall
ensure that there is a suitable level of continuity of staff.
Any new personnel, or personnel reallocated to different duties, shall be supervised by
experienced staff until they are properly trained and have a level of experience deemed
necessary for the tasks being undertaken. The Contractor shall provide details, as part of the
Operational Management Plan, of the measures to be taken to cater for these changes.

8.6.4 Replenishment of Spare Parts

Spare Parts are supplied as part of the Construction Works. The Contractor may use these
spare parts for the O&M. However, all spare parts used shall be replenished at no additional
cost. This means that a full complement of spare parts shall be handed over to the Employer
on completion of the O&M.
The provisional sum provided in the BoQ for Spare Parts shall not be used for this purpose.

8.6.5 Suppliers and Subcontractors

The Contractor shall provide details, as part of the OMP, of all contracts or arrangements
that may be entered into for the supply of goods or services relevant to the Operation and
Maintenance of the works. Before entering into such arrangements, the Contractor shall
submit details of the suppliers and sub-contractors he proposes to use to the Engineer.

8.7 Obligations of the Employer

The Employer shall, at no obligation to the Contractor, for the duration of the O&M:
- Provide all permits, permissions and authorities required for the normal operations of
the Works.
- Provide the qualified operating staff of the WAJ to work with the Contractors staff as
specified herein. The normal salary and salary costs of these staff shall be paid by
the Employer.
- Pay the costs of independent laboratory analyses legally required to confirm sludge
and effluent compliance.

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- Provide all authorisations and payment of tipping charges for screenings, grit and
sludge from the WWTP. Transport to the place of disposal shall be the responsibility
of the Contractor.
- Provide temporary release of WAJ staff as agreed to work with the Contractor
All other obligations shall be the responsibility of the Contractor and the associated costs
shall be included in the Contract rates.

8.8 Contractors Operations Deliverables

The Contractor shall provide the following deliverables, specifically prepared for the Project
and its operations and maintenance. These shall also take into account the planned future
stages and phases for extension of the project.
All plans, reports and other deliverables listed in Section ‎8.8 which follows - with the
exception of the Monthly Reports - shall be delivered as both draft and final reports. In each
case, for both the draft and the final reports, the Contractor shall submit three copies in
electronic format and three copies in paper format. With the exception of the Monthly and
Phase Completion Reports, the final reports shall be submitted with an Arabic translation.
Submission of the Monthly Reports shall be in accordance with Section ‎8.8.8.1 below.

8.8.1 Operational Management Plan

The Contractor shall, no later than three months before takeover of the Works for Section 1
“Part 1 Construction Stage 1”, produce an Operational Management Plan (OMP) for the
Project. The OMP shall be submitted to the Engineer for approval.
Approval of the OMP shall be a condition for issuing of the Taking Over Certificate for
Section 1 “Part 1 Construction Stage 1”.
The OMP shall cover the whole Project to ensure that it functions as single operating entity.
The OMP shall become a central point of reference for the Contractor and WAJ in the
operation of the works. A copy of the OMP shall be held at the works at all times and
controlled copies shall be provided to the Engineer and any other relevant personnel. All
copies of the OMP shall be kept up to date and re-issued on a regular basis by the
Contractor. The OMP shall be periodically reviewed by the Engineer, at intervals not greater
than six months.
The OMP shall include, but not be limited to, the following:
 Details of the works, to include its location; operational hours; design data; water
quality standards; emergency contacts.
 Facility management, to include details of the management structure for the
Operation and Maintenance of the works; all appropriate information relating to the
personnel employed on the Contract.
 Detailed description of the works to be operated and maintained, including all
infrastructure contained within its boundaries. Infrastructure shall include the
drainage system; water supply; external lighting; heating and lighting services to
buildings; roads; fencing and gates; landscapes; telecommunications.
 A complete and up to date inventory of all plant and equipment used in the
pumping and treatment of wastewater and sludge, and whatever provided to
support the infrastructure.

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 Process schematic diagrams of all pumping and treatment plant.

 A complete and up to date list of as-built drawings for the works and a written
record of all modifications carried out. Drawings shall be held separately at the
works and shall be kept updated by the Contractor.
 Procedures for the operation of the works, to include a detailed control philosophy
for each process stage.
 Procedures for the maintenance of the works, to include a procedure and
inspection check list for each item of plant; detailed maintenance schedule;
complete and up to date maintenance record; hours run record; record of all plant
and equipment replacements.
 Procedures for the maintenance and upkeep of infrastructure.
 Procedures for the management and regulation of third party wastewater
discharges made at the works. The Contractor shall incorporate, in his OMP, any
procedures, regulations, or stipulations that the local authority may issue in respect
of such discharges.
 Procedures and records for the treatment and disposal of screenings, sludge, and
any other solid waste produced at the works.
 Procedures for the monitoring, sampling, and analysis of wastewater and sludge at
various stages through the pumping and treatment process.
 Details of all contracts being entered into by the Contractor for the supply of goods
or services relevant to the O&M of the works.
 Records of chemical, energy (electricity / gas), and water usage.
 Health and safety plan and safe working procedures for the works.
 Emergency operating plan.
 Procedures for the monitoring and control of noise, odour, vermin, and litter.
 Quality Assurance System.
 Environmental Management System.
 Procedures for recording and reporting.
As part of the OMP, the Contractor shall provide detailed procedure for the operation of the
works. A detailed control philosophy shall be provided for each process stage and shall be
accompanied by a procedure for each individual item of plant. The operating manuals for the
works shall be used in the development of the operating procedures and shall be referenced
as annexes to the OMP. The OMP shall fully comply with the requirements of the Project
Area Environmental and Social Management Plan (PA-ESMP).

8.8.2 Maintenance Management System (MMS)

The Contractor shall provide, install and then operate a maintenance management system.
The Contractor shall propose 3 possible software packages for the Engineer’s selection and
approval. The system shall be based on industry standard software and the Contractor shall
provide the necessary licences needed to operate and update the software for at least the
duration of the O&M plus 12 months afterwards.
The MMS shall meet at least the following requirements:

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- Installed on at least 3 PCs with Windows operating system, located in the Control
Room, in the maintenance workshop and the Operations Manger’s Office.
- Track, schedule and document predictive, preventive and corrective maintenance
activities.
- Identify any potential maintenance problems.
- Issue of work orders.
- Show the status of spare parts inventory.
- Issue of Periodic status report.
The Contractor shall provide any special training required in the MMS use to his and WAJ
staff and shall ensure that all relevant data is regularly feed and updated into the system.

8.8.3 WAJ Staff Training Plan

The Contractor shall submit, with the OMP, a preliminary Training Plan for the WAJ staff.
This shall provide a detailed and comprehensive plan for on-site training and
recommendations for off-site training. During the first two months of the O&M, the capabilities
of the WAJ staff shall be assessed and the Training Plan shall be updated to take into
account the actual needs of the staff. The final Training Plan shall then be resubmitted to the
Engineer for approval. The Contractor shall implement the approved on-site training plan.
The training objectives shall be:
 Achieving an adequate human resource base through recognised practices, skills,
and incentives
 Training of the WAJ staff working with the Contractor on temporary release
throughout the O&M period
 Training during the final 3 months of the O&M of WAJ staff who will replace the
Contractor’s staff on final Taking Over.
 Improving the skills base of the staff in the required areas of expertise
 Achieving good operational performance through better management activity,
scheduling, and resource planning
 Achieving reliable operation through scheduled procedures for:
- Preventive maintenance and monitoring
- Reactive maintenance
- Emergency procedures
 Provide a basis to respond to organisational change
 Establish procedures for procurement and stores handling for spares and
consumables.
 Establish good laboratory sampling and analysis procedures according to agreed
standards for wastewater treatment monitoring and control.

8.8.4 Emergency Operating Plan

As part of the OMP, the Contractor shall provide an Emergency Operating Plan (EOP) for the
works.

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The plan shall identify the hazards that could have consequential impacts on human and
animal health and the surrounding environment resulting in an emergency response. It shall
also specify methods and procedures for:
 Dealing with emergencies
 Testing of the EOP
 The training for dealing with emergencies at the works, which shall be provided to
personnel.
 Notifying the Engineer, his representative, other relevant public and private bodies,
and the general public
 Dealing with the consequential impacts of the emergency
 Communication with those notified regarding plans for remediation of any damage
done and actions to minimise re-occurrence.
The EOP should extend to tasks related to the operation and maintenance that may be
carried out beyond the boundaries of the Site. These may include sludge, screenings, and
solid waste disposal, chemical deliveries, and transportation of plant and equipment to and
from the works. The Contractor shall issue a copy of his EOP to all personnel, contractors,
and subcontractors, and shall ensure that they comply with its conditions at all times.

8.8.5 Health & Safety Plan

As part of the OMP, the Contractor shall provide a health and safety plan, including training
and vaccination for personnel engaged in the management, operation, and maintenance of
the works. The health and safety plan shall fully comply with the requirements of the Project
Area Environmental and Social Management Plan (PA-ESMP).
A Safety Statement shall be included to specify the manner in which the health, safety, and
welfare of employees, contractors, and visitors to the works shall be protected. In the
provision of the Safety Statement, the Contractor shall carry out a Hazard and Operability
Review (HAZOP) to assess the risks and identify any hazards on all of the operational
activities to be undertaken at the Plant. The effects that these risks and hazards might have
on the operability of the Plant, and the actions for their resolution shall be identified by the
Contractor. Any impacts that these risks or hazards may have on the surrounding
environment shall also be identified and addressed.
The Safety Statement shall be revised on an annual basis.

8.8.6 Quality Assurance System

The Contractor shall during Phase 2 of the O&M establish and operate the works within a
quality assurance system that complies with, and is accredited to, EN ISO 9000 or its
equivalent. This system shall then be handed over to WAJ in Phase 3 of the O&M.

8.8.7 Environmental Management System

The Contractor shall establish an Environmental Management System (EMS) for the works
including required mitigation measures for approval prior to Taking Over of Section 1. The
Contractor shall then review and update the EMS within 6 months of the Commencement
Date Phase 2 of the O&M. The EMS shall be audited by the Engineer on a date to be agreed
with the Contractor during Phase 2 of the O&M. The audit shall be carried out to verify that

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the EMS is fully in place and operating to the satisfaction of the Engineer. The Contractor
shall not be responsible for auditing the EMS for certification purposes; this may be arranged
by the WAJ within the duration of the O&M.
The EMS shall include the following:
 Environmental policy;
 Schedule of Environmental Objectives and Targets;
 Environmental Management Programme;
 The Operational Management Plan (as described in Clause ‎8.8.1);
 Environmental review and audit procedures.
 Protection of the Archaeological Site.

8.8.8 Reporting to the Engineer

The Contractor shall provide to the Engineer the following reports:
 Monthly reports
 Phase completion reports
 Special reports as ordered by the Engineer or otherwise specified herein.

8.8.8.1 Monthly Reports

The monthly reports shall include, but not be limited to:
 General commentary on the performance of the Plant
 Status of the 8 objectives listed in Clause ‎8.1, noting any unusual or abnormal
situations that have prevented the objectives from being achieved.
 Details of failures, breakdowns, and non-routine maintenance
 Tables of analytical data, including graphical representations and a discussion of
the results
 Records of sludge management and disposal activities
 Manpower (Contractor & WAJ) records
 Details of any complaints
 Schedule of hours run of all operational plants
 Record of any third party waste discharged at the Plant (when and if they become
appropriate to include)
 Record of any accidents
 Records of chemical and energy usage
 Details of targets met as specified in the EMS
 Summary of weather records
 Any other records or information that may be considered relevant by the
Contractor.

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The report shall be submitted to the Engineer, one copy in electronic format and three copies
in paper format, within the first 14 days of each month following the month covered in the
Report.
The Engineer may request information, relating to the operation and maintenance of the
Plant, from the Contractor at any stage during the O&M.

8.8.8.2 Phase Completion Reports

The Phase Completion Reports shall be submitted within one calendar month of the
completion of each phase of the O&M and shall be prepared jointly with the WAJ staff. They
shall include, but not be limited to:
 General commentary on the performance of the Plant over the period of the Phase
 Details of failures, breakdowns, and non-routine maintenance, with
recommendations to avoid or reduce future risks of recurrence
 Tables of analytical data, including graphical representations and a discussion of
the results
 Assessment of actual flows and loads, trends and recommendations for staging
and programming of additional capacity
 Records of sludge management and disposal activities
 Recommendations for improvements to the OMP and Maintenance Programme
 Summary of Health & Safety Audits
 Recommendations for innovation / efficiency improvements
 Record of energy audits with recommendations for consumption optimisation
 Details of any complaints
 Record of any third party waste discharged at the Plant (when and if they become
appropriate to include)
 Details of targets met as specified in the EMS
 Assessment of the actual
 Any other records or information that may be considered relevant by the
Contractor.

8.9 Operations Management, Personnel and Training

8.9.1 General
The daily management and operation tasks will be under the control of the Operations
Manager (OM), reporting directly to the WAJ. The OM will be responsible for the overall day
to day management of the plant, including the operation and control of the different treatment
units for wastewater and sludge.
In Phase 2 of the O&M, the Contractor shall effectively manage operation of the works,
assisted by the WAJ personnel, on a continuous 24 hour, 7 day week basis. This will then be
taken over by WAJ in Phase 3 of the O&M.

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8.9.2 Qualifications, Experience and Training

All WAJ personnel shall be suitably qualified and have an appropriate level of training and
experience in the operation and maintenance of municipal Pumping Stations and
Wastewater Treatment Plants. The skills to be provided shall be in the areas of, but not
confined to:
 Operational management
 Maintenance management
 Works operation
 Analytical chemistry
 Plant and equipment maintenance
 Instrumentation and telemetry operation and maintenance
 Administration
 Quality systems implementation and management
 Health and safety planning and auditing.
The Contractor shall submit, as part of the OMP, details of his ongoing staff training
programme. This programme shall be updated and maintained regularly, and the Contractor
shall show evidence of the training carried out, if requested to do so by the Engineer.

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8.10 Monitoring, Sampling and Analysis

8.10.1 General
Regular sampling and analyses of the wastewater, effluent and sludge shall be commenced with the Tests at Completion and shall be
carried out throughout the O&M. The minimum parameters, locations and frequency of analyses for wastewater treatment are as
specified in
Outlet Outlet Sand
Parameter Unit Inlet WWTP Inlet AST AST FSTs RAS Filters Outlet UV Outlet WWTP
3
Flow m /hr online Online Online
pH Daily/FPS online Daily/FPS
Conductivity µS/cm Daily/FPS Daily/FPS
o
Temperature C online online
Turbidity l/m Daily/FPS Daily Daily/FPS
O2 mg/l Online Daily
RedOx V Online
COD mg/l Daily/FPS Daily/FPS Daily/FPS
BOD mg/l Daily/FPS Weekly/FPS Daily/FPS
TSS mg/l Daily/FPS Weekly/FPS Daily/FPS
NH4-N mg/l Weekly/FPS Weekly/FPS Weekly/FPS
NO3-N mg/l Weekly/FPS Weekly/FPS Weekly/FPS
TN-N mg/l Weekly/FPS Weekly/FPS Weekly/FPS
PO4 mg/l Weekly/FPS Weekly/FPS
H2S mg/l Handheld
Alkalinity mg/l Weekly/FPS Weekly/FPS
MLSS mg/l Daily/GS
MLVSS mg/l Daily/GS

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Outlet Outlet Sand

Parameter Unit Inlet WWTP Inlet AST AST FSTs RAS Filters Outlet UV Outlet WWTP
SV m(l) Daily/GS
ds % Daily/GS Daily/GS
E-coli Weekly/GS Weekly/GS
(1)
RCl2 Monthly/FPS

Table 5 below.
Outlet Outlet Sand
Parameter Unit Inlet WWTP Inlet AST AST FSTs RAS Filters Outlet UV Outlet WWTP
3
Flow m /hr online Online Online
pH Daily/FPS online Daily/FPS
Conductivity µS/cm Daily/FPS Daily/FPS
o
Temperature C online online
Turbidity l/m Daily/FPS Daily Daily/FPS
O2 mg/l Online Daily
RedOx V Online
COD mg/l Daily/FPS Daily/FPS Daily/FPS
BOD mg/l Daily/FPS Weekly/FPS Daily/FPS
TSS mg/l Daily/FPS Weekly/FPS Daily/FPS
NH4-N mg/l Weekly/FPS Weekly/FPS Weekly/FPS
NO3-N mg/l Weekly/FPS Weekly/FPS Weekly/FPS
TN-N mg/l Weekly/FPS Weekly/FPS Weekly/FPS
PO4 mg/l Weekly/FPS Weekly/FPS
H2S mg/l Handheld
Alkalinity mg/l Weekly/FPS Weekly/FPS
MLSS mg/l Daily/GS
MLVSS mg/l Daily/GS

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Outlet Outlet Sand

Parameter Unit Inlet WWTP Inlet AST AST FSTs RAS Filters Outlet UV Outlet WWTP
SV m(l) Daily/GS
ds % Daily/GS Daily/GS
E-coli Weekly/GS Weekly/GS
(1)
RCl2 Monthly/FPS

Table 5: Sampling and Analysis Programme – Wastewater Treatment

The minimum parameters, locations and frequency of analyses for sludge treatment are as specified in Table 6 below.
Sludge Sludge Dried
Dewateri. Dewateri. Gas
Parameter Unit WAS Thicken. Thickn. Digesters Sludge to Return PS
Inlet Outlet Treatment
inlet Outlet Disposal
Sludge Flow m3/hr Online Online Online Online Online
3
Decant Flow m /hr Online
3
Gas flow m /hr @ Online
atmos
Dried Sludge m3/d Daily
o
Temperature C Online
COD mg/l Daily/GS
BOD mg/l Daily/GS
TSS mg/l Daily/GS
TN-N mg/l Weekly/GS
Sludge acidity pH Daily
ds % Daily/GS Daily/GS Daily/GS Daily/GS Daily/GS Daily/GS Daily/GS
Arsenic (As) mg/kg Monthly
Cadmium (Cd) mg/kg Monthly
Chromium (Cr) mg/kg Monthly
Copper (Cu) mg/kg Monthly
Mercury (Hg) mg/kg Monthly

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Sludge Sludge Dried

Dewateri. Dewateri. Gas
Parameter Unit WAS Thicken. Thickn. Digesters Sludge to Return PS
Inlet Outlet Treatment
inlet Outlet Disposal
Molybdenum(Mb) mg/kg Monthly
Nickel(Ni) mg/kg Monthly
Selenium (Se) mg/kg Monthly
Lead (Pb) mg/kg Monthly
Zinc (Zn) mg/kg Monthly
(2) - Monthly
Moisture content

Total Fecal Coliform - Monthly

(3)
count

Salmonella - Monthly
(4) - Monthly
Helminthes eggs
(5) - Monthly
Viruses

Table 6: Sampling and Analysis Programme – Sludge Treatment

The minimum parameters, locations and frequency of analyses for power management are as specified in Table 7 below.
Parameter Unit Digesters Wastewater Sludge Treatment CHPs PV Diesel Generators
Treatment
Gas Flow @ atmos m3/hr Online Online
Power Production kWhr Daily Daily Daily
Power Consumption µS/cm Daily Daily
Diesel Fuel Consumption l/d Daily Daily

Table 7: Sampling and Analysis Programme – Power Management

Legend (
Outlet Outlet Sand
Parameter Unit Inlet WWTP Inlet AST AST FSTs RAS Filters Outlet UV Outlet WWTP
Flow m3/hr online Online Online
pH Daily/FPS online Daily/FPS

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Outlet Outlet Sand

Parameter Unit Inlet WWTP Inlet AST AST FSTs RAS Filters Outlet UV Outlet WWTP
Conductivity µS/cm Daily/FPS Daily/FPS
oC
Temperature online online
Turbidity l/m Daily/FPS Daily Daily/FPS
O2 mg/l Online Daily
RedOx V Online
COD mg/l Daily/FPS Daily/FPS Daily/FPS
BOD mg/l Daily/FPS Weekly/FPS Daily/FPS
TSS mg/l Daily/FPS Weekly/FPS Daily/FPS
NH4-N mg/l Weekly/FPS Weekly/FPS Weekly/FPS
NO3-N mg/l Weekly/FPS Weekly/FPS Weekly/FPS
TN-N mg/l Weekly/FPS Weekly/FPS Weekly/FPS
PO4 mg/l Weekly/FPS Weekly/FPS
H2S mg/l Handheld
Alkalinity mg/l Weekly/FPS Weekly/FPS
MLSS mg/l Daily/GS
MLVSS mg/l Daily/GS
SV m(l) Daily/GS
ds % Daily/GS Daily/GS
E-coli Weekly/GS Weekly/GS
(1)
RCl2 Monthly/FPS

Table 5, Table 6 and Table 7 above:

FPS: Flow Proportional Sample 24 h sample
GS: Grab Sample
*) Separate measurement in each Activated Sludge Tank

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Other sampling and analyses required, either on a regular or from time to time, for the proper
control of the process shall be defined by the Contractor or carried out in close cooperation
with the WAJ staff.
Analysis that is capable of being carried out with the analytical equipment provided under the
Contract shall be performed at the Plant by the operational staff. All other analysis shall be
carried out by a recognised independent laboratory, as agreed with the Engineer.
Procedures and methods for the monitoring, sampling, and analysis for the wastewater and
sludge shall be provided as part of the Contractor’s OMP.
The Contractor shall carry out monitoring, sampling, and analysis in accordance with all
relevant regulations.
The Contractor shall ensure that all on site analysis is carried out in a safe manner, and that
all waste chemicals and containers are disposed of in a proper fashion.
This sampling shall be separate from the control sampling that will be carried out with the
Engineer every quarter, refer Clause 8.23.

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8.10.2 Sampling Equipment

Automatic, refrigerated flow proportional samplers are required as defined in the Contract
Document.
The Contractor shall ensure that all samplers, including sample bottles and pipelines, are
cleaned regularly to avoid the build-up of grease, solid material, and bacterial growth.

8.10.3 Laboratory and Analytical Equipment

The Contractor shall ensure that the laboratory and analytical equipment is kept in good
repair. Analytical equipment shall be calibrated on a regular basis, and details of calibration
procedures and their frequency shall be detailed in the OMP.

8.10.4 Laboratory Information Management System

The contractor shall procure and implement a LIMS software system in each of the WWTP
laboratories, with authenticated licences to be hand over on completion of the Operations
and valid for at least 3 years.

8.10.5 Analytical Methodology

The Contractor shall also abide by the requirements of the most up to date edition of
“Standard Methods for the Examination of Water and Wastewater” produced by The
American Public Health Association (APHA); the American Water Works Association
(AWWA) and the Water Environment Federation (WEF).

8.10.6 Independent Analysis

Analyses for all parameters required in accordance with regulatory procedures to confirm
compliance shall be carried out by a recognised independent laboratory, approved by the
Engineer. A portion of the sample sent for independent analysis shall be kept on site and
analysed as normal. The results shall then be compared. Any unusual variance between the
results shall be brought to the attention of the Engineer for discussion. The Contractor shall
make any necessary adjustments to his analytical procedures to ensure that any errors,
considered to have occurred, are eliminated. The costs of these independent analyses shall
be paid by the Employer.

8.10.7 Remedy on Compliance Failure

In the event of any failure to comply with the treated wastewater discharge standards, the
Contractor shall inform the Engineer, in writing, immediately upon becoming aware of the
failure. The Contractor shall provide details of the reasons for failure and the remedies that
have been put into effect to ensure that the treatment plant can meet the standards.

8.10.8 Sampling by the Engineer

The Engineer reserves the right to enter the works to take samples at any location and at any
time without prior notice to the Contractor.

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8.10.9 Weather Data

Records of the continuous data measured at the station shall be kept at the works in
electronic and hard copy formats, and summary data shall be provided in the monthly report.

8.11 Tests after Take Over

The Contractor shall carry out tests after Taking Over during Phase 2 of the O&M to prove
the performance of the WWTP and the O&M. These tests shall then be repeated in Phase 3
of the O&M under the Contractor’s supervision to familiarise the WAJ staff with the
functioning of the plant and the process controls.
For each test, the Contractor shall submit a brief report documenting the following:
- Scope and objectives of the test
- Process units involved
- Results on the test
- Problems encountered
- Recommendations for improvement operationally
- Recommendations requiring modifications to the Works
Based on the recommendations, the Engineer may issue instructions to carry out
modifications to be carried out using the Provisional Sums provided in the Contract. In such
cases, the costs and workplan for executing the modifications will be agreed with the
Contractor.
The OMP shall include a detailed programme for the tests, which shall include but not
necessarily be limited to the following:
 Take out of service, emptying and inspecting at least one each of the following
units:
- Inlet screen
- Aerated grit channel
- Primary settling tank
- Aeration tank
- Final settling tank
- Sludge thickener
- Sludge holding tank
- Digester
- Power transformers; 11/0.40 kV
 Vary the MLSS in the activated sludge tanks by up to 15% of the design level to
determine the level for optimum treatment and energy efficiency, including
determination of the associated sludge age.
 Cycling the duty / standby functions of the following installations:
- Grit tank blowers
- Main blowers

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- RAS pumps
- Sludge pumps
- Dewatering units
- CHPs
 Operate the WWTP under emergency conditions on Diesel Generator power only
for 6 hours

8.12 Solid Waste Management

8.12.1 Sludge Management

The Contractor during O&M shall be responsible for the operation and maintenance of the
sludge treatment to ensure that the sludge is kept at an optimal quality to achieve the highest
possible standard of treated sludge cake and filtrate. A minimum of 20% dry solids shall be
achieved in the de-watered or dried sludge at all times.
The Contractor shall carry out trials to increase the dry solids in order to reduce the volume
of sludge to be transported to disposal and prepare and analysis of the additional polymer
costs against the saving in transport costs to determine the optimum for minimum cost.
The O&M shall coordinate transportation of the de-watered sludge for further treatment and
/or disposal off site. Transportation is included in the O&M BoQ and shall be provided by the
Contractor. The Contractor’s responsibility for sludge management shall be limited to
discharge at the disposal site.
The Contractor shall establish and produce the procedures for maintaining a record of all
movements of sludge to and from the Works.

8.12.2 Screenings, Grit and other Wastes

The O&M shall ensure that screenings, grit, and other wastes from the works is disposed of
or recycled in accordance with relevant legislation in force in Jordan.
Details of the licences, procedures, and records for managing such waste shall be provided
as part of the OMP.

8.13 Third Party Discharges

Third Party Discharges are considered to be any liquid wastes which are not domestic
wastewater in origin and septic sludge from emptying of domestic septic tanks.

8.13.1 Continuous Discharges to Sewer

Continuous discharges to sewer shall be construed to mean any discharges made under a
licence to discharge issued by the Water Authority of Jordan (WAJ) to any third party which
do not comply with the parameters for domestic wastewater.
Industries producing liquid waste may apply to the WAJ for a licence to discharge to sewer.
In this event, the Contractor during the O&M shall be consulted on the matter and provided
with all of the relevant data necessary to establish the likely impacts on the works. The
Contractor during the O&M shall, on the request of the Engineer, provide an impact report

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highlighting changes that may be necessary to the physical plant, any operational
adjustments, and associated additional costs.
The Contractor during O&M may also be required to carry out monitoring, sampling, and
analysis of the particular industrial discharge. The mechanism for this activity, and the costs
associated with it, would be agreed between the parties at the appropriate time.

8.13.2 Intermittent Imported Discharges

Intermittent Imported Discharges shall be construed to mean any wastewater or sludge
transported to the works by road tanker or other such vehicle for discharge and treatment.
The Contractor during O&M shall monitor the characteristics of all imported discharges to the
WWTP to ensure that no discharges are accepted that may disrupt the wastewater treatment
processes. This shall include, as a minimum, measurement of the following parameters:
- Volume
- COD
- TSS
- pH
A detailed inventory of all imported discharges shall be maintained.
The Contractor shall also provide for the progressive introduction of a manifest system for all
imported discharges, commencing with industrial wastewaters. Within 6 months of the
commencement of the O&M, imported industrial wastewater shall only be accepted against
manifests from registered industries. Within 12 months, communal imported wastewater
(septage) shall only be accepted against manifest from registered operators.

8.13.3 Procedures for Management of Third Party Discharges

Procedures for the management and regulation of continuous third party liquid discharges
made at the Wastewater Treatment Plant shall be provided by the Contractor. The
procedures shall include methods for:
 Review and examination of the wastewater prior to acceptance at the Plant
 Acceptance or non-acceptance of the wastewater
 Reporting and recording of third party wastewater management.
The Contractor shall also incorporate, in his OMP, any procedures, regulations, or
stipulations that the Engineer / WAJ may issue in respect of such discharges.

8.13.4 Right to Refuse Third Party Discharges

The Contractor during O&M shall have the right to refuse acceptance of third party
discharges at the works if it is proven that it would have a detrimental effect on the:
 Ability of the treatment plant to attain the required quality standards
 Plant, equipment, and structures at the treatment plant
 Health, safety, and welfare of personnel or the public
 Surrounding environment.

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8.14 Odour Control

An odour control system may be necessary as detailed in Contract Document. The
Contractor shall operate the odour control system to the standards set out in this clause.
The Contractor during O&M shall implement an odour monitoring regime. This shall include
measurement of ammonia and hydrogen sulphide at an appropriate point of the exhaust of
the odour treatment unit and the boundaries of the works.
No foul odour, originating from the works, shall be detectable beyond the boundary of the
works at any time. The boundary locations shall be determined during the preparation of the
OMP. The number of locations shall be limited to 4 at the works. Measurements at each
location shall be carried out on a once weekly basis, to establish performance trends. The
Engineer shall have discretion to require to increase or decrease the level of monitoring, if it
is considered necessary for any reason.
In the event of a complaint from any person concerning odour, the Contractor shall
investigate the complaint without delay and provide a solution to abate the odour if it is
considered to be present. The Contractor shall also document the complaint and the
solutions found and provide such information as part of the monthly report.

8.15 Noise Control

The Contractor during O&M shall ensure that noise from the works does not exceed the
limits given in the Contract Document.
The Contractor during O&M shall measure noise levels at the boundaries of the works on a
once weekly basis to establish performance trends. The Engineer shall have discretion to
require an increase or decrease in the level of monitoring, if it is considered necessary for
any reason.
In the event of a complaint from any person concerning noise, the Contractor shall
investigate the complaint without delay and provide a solution to abate the noise, if it is
considered to be present. The Contractor shall also document the complaint and the
solutions found and provide such information as part of the monthly report.

8.16 Vermin Control

The Contractor during O&M shall employ a recognised vermin control company to provide
and maintain bait points at the works.
The Contractor during O&M shall also ensure that the treatment plant is kept in good
condition and free of any organic waste material that could attract vermin.

8.17 Failure to Comply with the Environmental Requirements

Failure to comply with the environmental requirements concerning noise, nuisance, and
vermin as indicated above or other requirements set out in the Project Area Environmental
and Social Management Plan (PA-ESMP) shall be considered and handled as a defect.

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8.18 Management of Consumables

8.18.1 Chemicals Management

A record of all chemicals used for the treatment of wastewater or sludge shall be kept as part
of the OMP. The Contractor during O&M shall put procedures in place to ensure that the
treatment processes are optimised, so as to minimise the use of chemicals.

8.18.2 Energy Management

The Contractor during O&M shall keep records of the hours of operation of each item of
electrical plant and the total energy usage of the treatment plant. An energy audit of the
works shall be undertaken at the end of Phase 2 of the O&M and again at the end of Phase 3
to ensure that all electrical items of plant are operating to their maximum efficiency. The audit
shall be incorporated into the maintenance regime so that plant found to be operating
inefficiently can be scheduled for maintenance.

8.19 Maintenance of the Works

8.19.1 General
The Contractor during O&M shall provide for the routine, planned, breakdown, and repair
maintenance of all assets relating to civil, mechanical, electrical, and electronic plant,
equipment and infrastructure at the works.

8.19.2 Maintenance Programme

The Maintenance Programme to be put in place shall be based on a recognised
maintenance methodology. The Contractor shall provide a statement of the methodology he
proposes to adopt to the Engineer for approval, before developing it in detail.
The maintenance regime adopted by the Contractor shall include:
 Schedules for the maintenance of the treatment plant to include, but not be limited
to:
- a complete list of the assets to be maintained
- the frequency and type of routine and planned maintenance for each asset
- details of the calibration of all instrumentation
- a listing of all essential spare parts to be carried.
 Methods for dealing with breakdown and repair of assets to include:
- callout response times for each asset
- communication with the Engineer when breakdowns occur.
 Procedures for the maintenance of the assets incorporating manufacturer’s
instructions
 Methods for the planned replacement of assets at the works
 Records of all maintenance carried out at the works, to be kept up to date and held
electronically and in paper format at the works at all times.

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 Spare parts control and replenishment.

The Contractor during O&M shall ensure that the works are kept in a clean and tidy condition
at all times and shall incorporate a cleaning routine in the maintenance schedules.

8.19.3 Maintenance Outsourcing

The Contractor shall provide specific methodologies for maintenance of specialised
equipment covering periodic servicing and repairs in accordance with the O&M manuals
provided by the equipment suppliers. The Contractor shall either:
- Demonstrate in-house capabilities to carry out the maintenance in
accordance with the manufacturer’s requirements, or
- Assign the maintenance to a subcontractor (outsourcing) acceptable to the
equipment manufacturers
This Clause shall apply to the following equipment as a minimum:
 Aeration blowers
 Aeration diffusers
 Sand filters
 UV disinfection
 Diesel generators
 Mechanical sludge thickeners
 Sludge dewatering centrifuges
 Gas treatment systems
 CHP units
 Solar PV installation
The proposed methodology shall be submitted for approval by the Engineer.

8.19.4 Building Maintenance

The Contractor during O&M shall keep all buildings, contained within the works, in good re-
pair throughout the term of the Contract and shall be responsible for:
 Preparing maintenance schedules for painting of the buildings at regular intervals.
 Regular cleaning of all internal areas
 Repair or replacement of internal and external fixtures and fittings when they
become damaged
 Cleaning of roof guttering and drainage, windows and doors
 Maintenance of ventilation systems.
The Contractor during O&M shall be responsible for the replacement of any part of the
buildings that become damaged during the term of the Contract, excluding damage caused
by Force Majeure which cost shall be included within the Bill of Quantities of Operation and
Maintenance works. Replacements shall be made within a reasonable time after the damage

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occurs. The buildings shall be kept in such a state that they do not, in the opinion of the
Engineer, post any risk to the health, safety, and welfare of any person.

8.19.5 Site Infrastructural Maintenance

The Contractor during O&M shall keep all infrastructures within the works in good repair
throughout the term of the Contract and shall be responsible for:
 All road and path surfaces
 Gates and fences
 Water supply facilities
 Road and building drainage
 Landscaped and grassed areas.
The Contractor shall provide in the OMP procedures for maintenance of the infrastructure
listed above.
The Contractor during O&M shall be responsible for the replacement of any part of the
infrastructure that becomes damaged during the term of the Contract, excluding damage
caused by a Force Majeure event, which cost shall be included within the Schedule of
Payments of Operation and Maintenance works. Replacements shall be made within a
reasonable time after the damage occurs. The infrastructure shall be kept in such a state that
does not, in the opinion of the Engineer, pose any risk to the health, safety, and welfare of
any person.

8.19.6 Lifting Mechanisms

The Contractor during O&M shall be responsible for the certification of all mechanical lifting
mechanisms used at the works and shall ensure that they are in good repair and capable of
operating to the required standard at all times. The maintenance required for such
mechanisms shall be detailed in the Contractor’s maintenance schedules. Certificates for
lifting equipment shall be kept at the works as part of to O&M maintenance records.

8.19.7 Tank and Pump Sump Inspection

The Contractor during O&M shall empty, clean, and inspect all tanks and pumping sumps on
a planned basis at least every twelve months for the possibility of cracking and erosion. The
Contractor during O&M shall carry out any repairs that are deemed necessary, immediately
after the inspection, in consultation with the Engineer. The Contractor during O&M shall
record the findings of the inspection and the repairs (if any) that were carried out and keep
them on site as part of the maintenance records. The report shall act as a record of the work
having been carried out and shall be kept at the works.
Details of this procedure and the specific timing of inspection shall be included in the
Contractor's Maintenance Programme.
All tanks and pumping sumps to be confined spaces, and the Contractor during O&M shall
ensure that appropriate precautions are put in place to cater for these conditions.

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8.19.8 Spare Parts

The Contractor during O&M shall provide and maintain at all times sufficient spare parts to
ensure continuous operation of the Works. A provisional sum is provided for the supply and
replenishment of spare parts during the duration of the O&M by agreement and approval of
the Engineer.

8.19.9 Auditing of the Maintenance Programme

The management of the Maintenance Programme by the Contractor during O&M shall be
reviewed at each progress meeting, and any updates, changes or amendments shall be
made as required. The Engineer shall carry out an audit of the Maintenance Programme on
completion of Phase 2 of the O&M. The Contractor shall establish and produce procedures
for an annual audit programme. This audit shall include reviews of:
 The maintenance actually carried out, as detailed in the maintenance records,
against that required and stated in the maintenance schedules
 The maintenance procedures in the context of:
- a review of the frequency and extent of breakdown and repair maintenance
- a review of the methods used for scheduling and recording of maintenance
events.
The Engineer, in consultation with the Contractor, shall have the option to make
recommendations for improvement to the Maintenance Programme. Adjustments to the
programme shall then be made by the Contractor during O&M within an agreed time frame.
The Contractor during O&M shall continually assess the maintenance methodology, and
update or change it, in line with the most up to date thinking, to ensure that maintenance at
the Plant is carried out to the highest and most efficient standard.

8.20 Innovation and Efficiency Improvements

The Contractor shall be encouraged to introduce innovation and improved efficiency into the
operation and maintenance of the works during the O&M where it can be demonstrated to be
of benefit in terms of improved efficiency, reduced environmental impact or cost reduction.
When the Contractor wishes to introduce innovation, he shall put forward his proposal in
writing to the Engineer.
The proposal shall include the following:
 A detailed description of the innovation being proposed, including a work method
statement and a programme for its implementation
 Physical changes to the treatment plant (if any)
 Environmental impacts and abatement of any adverse impacts
 Environmental benefits
 Cost / benefit analysis
 Financial plan for proportioning of costs and savings between the parties.
The Engineer shall then review the proposal with the WAJ and discuss the issues with the
Contractor to reach a decision collectively.

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8.21 Health and Safety

8.21.1 General
The Contractor during O&M shall comply with all aspects of current International Safety
Standards. The O&M shall also fully comply with the requirements of “Volume 2.0, Part 2
Employer’s Requirements, Section VII. Works Requirements, 1. Specifications, b)
Specifications of Environmental, Social, Health and Safety Management (ESHS) of the
Works”. The Contractor during O&M shall maintain and update the Safety File on an ongoing
basis.

8.21.2 Safe Working Procedures

In conjunction with the development of the OMP, the Contractor shall prepare Safe Working
Procedures for the works.

8.21.3 Personnel Vaccination

Personnel shall be vaccinated against diseases associated with wastewater and shall carry
evidence of the vaccinations administered. Personnel vaccination cards shall show the type
of vaccine, the date of administration, the date of the boosters required, and the signature of
the vaccinator.
Personnel who do not show evidence of this training or vaccination will not be permitted to
work at the works.

8.21.4 Health and Safety Audits

The Contractor shall carry out periodic audits of the operation and implementation of the safe
working procedures and shall submit the audit reports to the Engineer. The Contractor shall
stipulate the time intervals for such audits and the manner in which they shall be carried out
in his / her Safe Working Procedures. The Engineer may, from time to time, carry out
independent audits of the Contractor’s compliance with current safety, health, and welfare
regulations.

8.22 Unusual or Abnormal Situations

8.22.1 Changes in Wastewater Characteristics

The Contractor during O&M shall, through the monitoring and analysis of influent samples,
give particular attention to any unusual changes in the wastewater characteristics that may
indicate the presence of material from an unknown industrial or commercial source. The
Contractor shall inform the Engineer of any such changes immediately, where they are likely
to pose a threat to the performance of the Plant.

8.22.2 “No Flow” Occurrence

A “no flow” occurrence is defined as any event where wastewater cannot be delivered to the
works for any reason, including essential maintenance or breakdown of the sewerage
system.

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The Contractor shall incorporate, into the OMP, procedures for the management, operation,
and maintenance of the works to be put in place in the event of a “no flow” occurrence. The
procedures shall cater for such an event should it occur without prior warning, i.e. as a result
of an emergency.

8.22.3 Recording of Unusual or Abnormal Situations

Unusual circumstances arising from industrial disputes, accidental spillage, mechanical
breakdown, power failure, stoppage for essential maintenance, or abnormal weather
conditions shall be noted by the Contractor in detail and taken into consideration when
interpreting the analytical data from the treatment plant.

8.22.4 Notification of Unusual or Abnormal Situations

The Contractor shall notify the Engineer of any unusual occurrence or incident in respect of
the provision of the Operation and Maintenance Works. Notification shall be made by
telephone with immediate effect and shall be followed by a written report of the occurrence or
incident. The Contractor shall incorporate a procedure for notification of such occurrences in
the OMP.

8.22.5 Public Complaints and Grievance Procedure

The Contractor shall nominate a point for public contact for the WWTP, normally the Plant
Managers, with a dedicated mobile phone number and email address. These contact details
shall be posted visibility and clearly on the project sign boards at the entrances to each
WWTP and at least one other public location associated with the WWTP.
Each complaint or grievance received from the public shall be logged in a register kept in the
WWTP control rooms. The Contractor shall take appropriate action for each and every
logged item and shall record the action taken in the log.
Any complaint or grievance involving public loss, damage or injury shall be notified to the
Engineer and WAJ as follows:
- Immediately in case of serious injury.
- Within one day in the case of lesser injuries or significant loss.
- Within one week in the case of lesser loss.
The log shall be available at all times for review by WAJ or the Engineer.

8.23 Supervision and Auditing

8.23.1 Supervision of the Operation and Maintenance Works

Routine supervision of the O&M Works will be carried out by the Employer.
In addition, audits of the O&M Works will be carried out every quarter by the Employer’s
designated agent, with the first audit three months following commencement of the O&M.
The purpose of the audits are as follows:
- Confirm that all key indicators, including effluent standards and energy efficiency, have
been achieved over the previous period.
- Assess the general standards of operations and general housekeeping at the WWTP.

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- Verify that all maintenance requirements are up to date and satisfactory.

- Evaluate any proposals by the Contractor for measures to improve the performance of
the WWTP.
- Review and comment on the Contractors progress reports and deliverables for the
previous three months.
- Check, adjust and certify the Contractor’s Interim Payment Statements for the previous
three months and to certify payment through issuing of the required IPC.
The Employer and the Engineer shall have full access to the works and shall be given
access to all relevant maintenance and operational data, held by the Contractor, at all
reasonable times.

8.23.2 Auditing the Operation and Maintenance Works

The Engineer shall, at their own discretion, audit the Contractor’s performance against the
performance indicators required under the Contract. Any improvements that are deemed
necessary shall be discussed with the Contractor and appropriate actions shall be agreed
and issued to him, in writing, by the Engineer. A specific time frame for the implementation of
such actions shall also be stipulated.

8.23.3 Auditing of the Maintenance Programme

The management of the Maintenance Programme by the Contractor during O&M shall be
reviewed at each progress meeting, and any updates, changes or amendments shall be
made as required. The Engineer shall carry out an audit of the Maintenance Programme on
completion of Phase 2 of the O&M. The Contractor shall establish and produce procedures
for an annual audit programme. This audit shall include reviews of:
 The maintenance actually carried out, as detailed in the maintenance records,
against that required and stated in the maintenance schedules
 The maintenance procedures in the context of:
- a review of the frequency and extent of breakdown and repair maintenance
- a review of the methods used for scheduling and recording of maintenance
events.
The Engineer, in consultation with the Contractor, shall have the option to make
recommendations for improvement to the Maintenance Programme. Adjustments to the
programme shall then be made by the Contractor during O&M within an agreed time frame.
The Contractor during O&M shall continually assess the maintenance methodology, and
update or change it, in line with the most up to date thinking, to ensure that maintenance at
the Plant is carried out to the highest and most efficient standard

8.23.4 Auditing of Effluent Standards

With each quarterly inspection, the Contractor and Engineer shall jointly take and witness
24hr flow proportional composite samples over 7 consecutive days. Each sample shall be
split, 50% retained by the Contactor for analysis and 50% retained by the Engineer for
independent analysis of the effluent parameters specified in Clause 8.2 to determine the
actual effluent KPIs.

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8.23.5 Invoicing of the Operation and Maintenance Works

The Contractor shall prepare its Interim Payment Requests for the Operation and
Maintenance Works quarterly during the O&M, to be submitted to the Engineer one week
prior to the planned quarterly audits.
The IPR will be reviewed with the Contractor during the audit inspection and any adjustments
made according to the Engineer’s observations of the actual status. The Engineer will then
issue he Interim Payment Certificate to the Employer in accordance with the Conditions of
Contract.

8.23.6 Failure to Meet KPIs and Maintenance Requirements

In the case that any of the KPIs are not being achieved or that the standard is maintenance
is not being achieved to recognised operations standards as specified, then the Engineer
shall make appropriate deductions from the Contractor’s interim payments.
In case of dispute, the standard of maintenance shall be assessed according to the
requirements needed to achieve TSM certification under the GIZ operations programme.
In the event that any of the effluent parameters analysed by the independent laboratory
according to Clause 8.23.4 above fail to meet the standards specified in Clause 8.2, then
Liquidated Damages will be deducted from the Contractor’s Interim Payment for each day of
failure in accordance with Clause 8.7 of the Conditions of Contract.

8.24 Handing Back

At the commencement of the O&M period the Contractor shall prepare an inventory of all the
work’s components, including structures, electrical works, mechanical works, computer
monitoring / control hardware, landscaping features, spares, and furniture. The inventory
shall be supplemented by photographs illustrating the appearance and quality of the works.
The itinerary has to be approved by the Engineer.
At the date of expiration of the O&M Period, the Work’s shall be in a good and maintained
condition, and the buildings and external works shall be well maintained.
As a guideline the Contractor shall, prior to completion of the Contract Defects Notification
Period and again prior to completion of the O&M, ensure that:
 All mechanical and electrical equipment and installations are well functioning and
well maintained. Any worn part which is due for replacement has been replaced,
and any overhaul which is due has been carried out
 All metal parts are free from rust and/or oxide
 All metal parts, except those made of stainless steel, have been inspected and
repainted where necessary
 All walls, windows, and doors of the buildings have been inspected and repainted
where necessary. Damaged tiles/brick stones have been replaced
 Concrete surfaces have been rehabilitated where damaged or worn
 Any damage to tarmac and paved surfaces has been repaired
 The treatment plant site is tidy and green areas well gardened
 Rooms in buildings and structures are tidy and clean.

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An inspection of the Plant, building structures, external works etc. shall be conducted jointly
by the Engineer at both times and the Contractor to establish the overall condition of the
facilities.
A functional test of all mechanical and electrical plant shall be carried out as part of the
inspection prior to completion of the Defects Notification Period. The tests shall be carried
out by the Contractor and witnessed by the Engineer.
A protocol shall be made containing all shortcomings found during the inspection and tests.
Responsibility for all shortcomings at the end of the Defects Notification Period shall be
determined in accordance with the Contract. The Contractor shall be required to remedy the
Defects under his liability within a predetermined time according to Conditions of Contract.
The Contractor shall, by the end of the Defects Notification Period, provide spare parts for
the Plant to an extent equivalent to the range of spare parts provided prior to Taking-Over
and agreed with the Engineer, paid from the Provisional Sum provided for this purpose.

8.25 Training
The Contractor shall be required to provide an on-site training programme in two phases.
Note that Phase 1 shall apply to both Section 1 “Part 1 Construction Stage 1” for Line 1 and
Section 2 “Part 1 Construction Stage 2” for Line 2. This training shall involve the following:
Phase 1: The Contractor shall be responsible for all dry and wet testing prior to Taking Over.
Phase 2: The Contractor shall be responsible for start-up, commissioning, performance
testing and operation of the WWTP over a period of 18 months. The date for commencement
of Stage 2 will normally be the date of Taking Over but may be delayed in agreement with
the Employer. During this Phase, the Contractor shall be responsible for any training needed
of his operations staff. However, no training of Waj staff is included in this Phase.
Phase 3: During the final 6 months of the O&M, the Contractor shall remain fully responsible
for the O&M of the WWTP as in Phase 2. In addition, the Employer shall assign O&M staff to
take over from the Contractor on completion of the O&M. During this period, the Employer’s
assigned staff shall be trained by the Contractor so that they will be able to take over
responsibility for operation of the plant at the end of the O&M.
The specified objectives shall be:
 Achieving for the Employer an adequate human resource base through recognised
practices, skills, and incentives
 Improving the skills base of the Employer’s assigned staff in the required areas of
expertise for the WWTP operations.
 Achieving good operational performance through better management activity,
scheduling, and resource planning
 Providing specific training in specialised equipment new to the Employer’s
assigned staff, including but not limited to the following:
- Aeration blowers
- Diffused air aeration systems
- Sludge digestion and gas production
- Gas storage and treatment
- CHP units

Dorsch International Consultants GmbH 14

On behalf of JV Nexus
 Sanitation Programme: NEXUS and Resource Protection Tender Documents – Vol.II
Component 3 Salt WWTP Technical Specifications
Part 8 O&M

- Solar PV
- Energy production and management
 Achieving reliable operation through scheduled procedures for:
- Preventive maintenance and monitoring
- Reactive maintenance
- Emergency procedures
 Provide a basis to respond to organisational change
 Establish procedures for procurement and stores handling for spares and
consumables.
Training programme:
Training shall be provided on site, both as formal instruction and “on the job” practice to
strengthen the following specific areas:
 Personnel management
 Wastewater treatment
 Wastewater monitoring
 Maintenance of pumps and mechanical equipment
 Electrical maintenance
 O&M Procedures
 SCADA systems
 Safe systems of work
 Budgeting
 Stores and handling
 Database development
This on-site training programme shall be coordinated with off-site training to be arranged
through the WAJ.

Dorsch International Consultants GmbH 15

On behalf of JV Nexus
 Sanitation Programme: NEXUS and Resource Protection Tender Documents – Vol.II
Component 3 Salt WWTP Technical Specifications
Part 8 O&M

Annex 1: Process Description, Power Consumer List and CHP

Calculations.

Dorsch International Consultants GmbH 16

On behalf of JV Nexus
 Sanitation Programme: NEXUS and Resource Protection Tender Documents – Vol.II
Component 3 Salt WWTP Technical Specifications
Part 8 O&M

End of Part 8 – Operation and Maintenance by the Contractor

Dorsch International Consultants GmbH 17

On behalf of JV Nexus
Sanitation Programme:
NEXUS and Resource Protection Annex 1: Process Description

1 As-Salt Wastewater Treatment Plant Process Description

1.1 General Process Design

1.1.1 Introduction
Process design is in accordance to the recommendations of German DWA/ATV representing leading
central European design and operation experiences, which makes sure compliance to effluent
requirements and operational requirements.

1.1.2 Design principles

The WWTP in As Salt is designed in accordance with the recommendations of the German Water
Association DWA. The following main directives are taken into account:

 DWA 118 (2006): for the consideration of Ingress water

 DWA 131 (2016): for the calculation of the primary settler, biological reactor, secondary settlers
 DWA 229 (2013): for the calculation of the air consumptions and design of the blowers
 DWA working group 2.5.1 "Grit Chambers", dated 03/98. For the calculation of the grit chambers
 DWA-A 199 Part 2-4E and general risk-based approaches for health and safety management.
In addition, and the recommendations of the wastewater hand book of Metcalf & Eddy (5 th edition) are also
taken into consideration, or at least referred to for internal comparison and quality control.

1.1.3 Process Overview

The conceptual design for the new As Salt WWTP mainly comprises the functional units of the WWTP for:
 Wastewater Treatment in accordance with the activated sludge process (Water line);
Water Line
Structure-No. Description
110 Inlet manhole
120 Inlet Works:
121 Coarse Screening Station
122 Fine Screening Station
123 Grit and Grease Removal Chambers
124 Storm Water Tank
125 Inlet Flow Measurement
126 Main PST distribution chamber
130 Primary Sedimentation Tank (PST)
140 Activated Sludge Tank (AST)
142 Blower Station, Power Station, and Standby Generator
142 Blower Room No.2
150 Final Settling Tank (FST)
151 FST distribution chamber
152 Secondary Scum PS
155 FeCl3 Dosing System
160 Sand filters
170 UV Disinfection

COMPONENT C3 – Rehabilitation and Upgrade of the WWTP in As Salt 1|9

Sanitation Programme:
NEXUS and Resource Protection Annex 1: Process Description

Water Line
Structure-No. Description
Irrigation Water Storage Tank (Former Chlorine Contact
171 Tank)
180 Odour control unit of Waterline
185 Chlorination system
190 Service Water Station

The treated wastewater will be either reused for irrigation purposes or discharged into the wadi.

 Sludge Treatment as anaerobic sludge digestion with mechanical sludge dewatering (sludge
line);

Sludge Line
Structure-No. Description
200 Primary Sludge Pumping Station
205 RAS/WAS Pumping Station
210 Gravity Sludge Thickener
211 WAS Storage Tank
212 Mechanical Thickening
215 Sludge blending tank
220 Anaerobic digester
230 Digested Sludge Tank
Sludge Treatment Building(Mechanical Thickening and
240 Dewatering)
241 Return Liquor Equalisation Tank
250 Sludge Drying Beds
260 Odour control unit for Sludge Treatment
270 Return Liquor Pumping Station

 Digester Gas treatment and utilization by combined heat power generation (CHP) (Power and
Gas lines);
Gas/ Power Line
Structure-No. Description
310 Desulphurisation Unit
320 Gas holder
330 Gas Flare
340 CHP Generator
350 Boiler
 Infrastructure with Public Utilities and Buildings.
Buildings
Structure-No. Description
400 Administration Building and Workshop
420 Standby Generator
430 Power Station

COMPONENT C3 – Rehabilitation and Upgrade of the WWTP in As Salt 2|9

Sanitation Programme:
NEXUS and Resource Protection Annex 1: Process Description

440 Guard House

450 Pedestrian/Pipe Gallery

1.1.3.1 Preliminary and Primary Treatment

Preliminary and primary (mechanical) wastewater treatment facilities for removal of coarse materials,
mineral materials and sand, floating matters and settleable organic materials from the wastewater will
comprise the following treatment units:
Preliminary Treatment includes:

 Coarse and Fine Screens

 Grit & Grease Chambers
 Flow & Influent Quality Measurement
 Storm water tank
 Primary Settling Tanks.
 And Odour Control
The screen house will include screenings treatment and handling equipment as well as auxiliary units for
the grit chambers and a control room for installation of the local MCC.The screen house will be connected
to a biological filter for odour control in order to prevent and reduce odour emissions.
All equipment and motors in the Screen Building will be specified to be explosion resistant against the
possible accumulation of gases if the ventilation / odour control system is not functioning. Mechanical
wastewater treatment with primary sedimentation will result in a reduction of COD and BOD to
concentrations of approx. 35%, with reduction of Total Suspended Solids (TSS) of about 60%. Nitrogen
and Phosphorous will be reduced by approx. 10 % only. The primary settling tanks are separated into 2
distinct lines, Line 1 and Line 2.

1.1.3.2 Biological Treatment

The biological wastewater treatment process is designed in accordance with the activated sludge process;
including the following treatment units and buildings:

 Activated sludge tanks for C and N removal

 Blower Stations
 Secondary Settling Tanks
 Return Sludge Pumping Station
The single stage activated sludge process comprises bioreactors (activated sludge tanks) with aeration
system (fine bubble membrane diffusers), the blower station [for compressed air generation and the
secondary settling tanks with the return sludge pumping station.
At this process stage, dissolved pollution content (BOD, COD) is oxidised in the aeration tanks and will be
removed to a large extend in the final settling tanks in order to comply with the effluent requirements of the
initial implementation stages. Moreover, compliance with the effluent requirements for Nitrogen will be
achieved using a combination of pre-Denitrification and Simultaneous Denitrification.
An overall treatment efficiency for BOD, COD, N and TSS of more than 90% will be achieved by
mechanical and biological wastewater treatment. The biological treatment is separated into 2 distinct lines,
Line 1 and Line 2.

1.1.3.1 Advanced Treatment (or tertiary treatment)

The advanced treatment at As Salt WWTP includes:

COMPONENT C3 – Rehabilitation and Upgrade of the WWTP in As Salt 3|9

Sanitation Programme:
NEXUS and Resource Protection Annex 1: Process Description

 Sand filters
 UV disinfection,Service Water Pumping Station
 Emergency chlorination dosing
The sand filters are required for the removal of fine suspended solids which would otherwise disturb the
process of disinfection. The treated effluent is then collected by the effluent control manhole for effluent
quality monitoring and finally discharged to the Storage Tank.

COMPONENT C3 – Rehabilitation and Upgrade of the WWTP in As Salt 4|9

Sanitation Programme:
NEXUS and Resource Protection Annex 1: Process Description

1.1.3.2 Sludge Treatment

Sludge treatment facilities include the main process steps of sludge thickening, anaerobic sludge
stabilization and mechanical sludge dewatering, comprising the following process units:
 Primary Sludge Pumping Station
 Return/Waste Activated Sludge Pumping Station
 Gravity Sludge Thickeners
 Mechanical Sludge Thickeners
 Thickened Sludge Pumping Station
 Anaerobic Digesters
 Sludge Storage Tanks
 Sludge Dewatering
 Sludge Liquor Equalisation Tank
 Sludge Liquor Pumping Station
 Sludge Drying/Storage Area
 Odour Treatment Unit
Sludge treatment targets further decomposition of the organic matter, by “mineralization”, in the process of
anaerobic sludge stabilization to reduce sludge quantity, i.e. total suspended solids. Sludge occurs in
different concentrations with generally high water content. Sludge thickening and sludge dewatering
reduces the final volume of the stabilized sludge with regard on transportation requirements.

1.1.3.3 Digester Gas Treatment

The anaerobic sludge digestion process continuously produces biogas, which requires further treatment
and storage in order to be utilized as fuel for digester heating and CHP-power generation.
 Gas Collection System
 Gas Treatment and Storage
 Power Generation and CHP
The gas collecting system includes facilities for mechanical gas purification and dehydration. A gasholder
balances the daily gas production, with gas flare for combustion of raw excess gas. Gas treatment
considers biological and physical purification of the biogas in order to meet the requirements for digester
gas utilization, which comprises generator sets for combined heat power production (CHP). Primary
digester heating shall be achieved by utilising the waste heat from the CHP.

1.1.3.4 Infrastructure and Buildings

Buildings, infrastructure and auxiliary systems for control and monitoring of the As Salt WWTP shall be
provided newly, including the following installations and buildings:
 Administration Building
 Trafo with MV/LV Distribution
 Administration Building and Workshop
 Screen House
 Blower Room
 Sludge Treatment Building
 Sludge Digestion Building
 Generator House (EPG)
 Guard House

COMPONENT C3 – Rehabilitation and Upgrade of the WWTP in As Salt 5|9

Sanitation Programme:
NEXUS and Resource Protection Annex 1: Process Description

 Roads &Exterior Works

 Interconnections & Yard Piping
 Interconnecting Cable Installations
Buildings willbe designed and completed in compliance with local building regulations under consideration
of the relevant structural and architectural requirements. Electrical and sanitary house installations (HAC),
anti-burglar surveillance, roof & rainwater drainage, furniture and equipment will be included for buildings,
accordingly. The drawings provided show the minimum requirements.

1.2 Hydraulic Design

Hydraulic calculations were carried out by the Consultant and resulted in a total head loss from the inlet
works to discharge chamber of about 12.5 m through the plant. This is relatively high but uses the natural
topography and fits well into the site layout. Hence, the Consultant decided to elevate the inlet works to
compensate for the headloss of 12.5 m.

The hydraulic calculations take into account the most unfavourable scenarios in each treatment unit:
 The night flow velocity is calculated in all units to check minimum velocities;
 The wet peak flow of at design horizon 2035isconsidered to check maximum velocities
 The emergency case (one of the parallel units is taken out of operation) is simulated, as this
increases the hydraulic load on the other lines. In that case, flooding is to be prevented.
In the start-up phase, minimum velocities in pipes and channel are expected to be in the range of 0.3 to
0.5 m/s for the night or average flow. These velocities are low but are in the range of acceptable velocities
and the hourly peak flow will assure that all potential deposits are carried away once a day, especially
between the mechanical units (screens, grit chamber and primary settling tanks).
At peak flow, maximum velocities will not exceed 1.8 m/s in pipes and channels, thus minimizing hydraulic
losses.Inemergency cases (if one unit is taken out of operation), velocities of up to 2 m/s are considered to
be acceptable. On the water line, the water flows per gravity from the inlet to the outlet of the WWTP. No
intermediate pumping station is required, except for the RAS recirculation and the nitrate internal
recirculation. Downstream of the inlet works, the primary settling tanks, activated sludge tanks and
secondary sedimentations tanks are implemented in 2 distinct lines (Line 1 and Line 2). The elevations of
all units in Line 2 are set approximately 50 cm higher than the elevations of the units of Line 2.

COMPONENT C3 – Rehabilitation and Upgrade of the WWTP in As Salt 6|9

Sanitation Programme:
NEXUS and Resource Protection Annex 1: Power Consumer List

2 Power Consumer List

COMPONENT C3 – Rehabilitation and Upgrade of the WWTP in As Salt 7|9

Consumer List
As Salt WWTP
Status: 28.03.2019 @ 100% Design Flows and Loads
Peak Operating Power Average Operating Power

Installed

Standby
Active
Rated power, Operating Operating Operating

Total

Duty
Active power Active power power
per unit factor factor hours
TAG Nr. Equipment consumption

No. No. No. kW - kW - kW h/a kWh/a

Inlet Chamber
Overhead crane 1 1 0 5.00 0.90 4.50 1.00 4.50 365 1,643

Motorised penstock 1 1 0 1.10 0.90 0.99 1.00 0.99 730 723

Stormwater Tank
Stormwater return pumps 2 1 1 15.00 0.90 13.50 1.00 13.50 720 9,720

Screening Plant

Coarse screen 2 2 0 1.10 0.90 1.98 1.00 1.98 2,920 5,782

Coarse screening conveyor 1 1 0 0.55 0.90 0.50 1.00 0.50 2,920 1,445

Washwater valve 1 1 0 0.01 0.90 0.01 1.00 0.01 365 3

Screenings wash press 2 2 0 2.20 0.90 3.96 1.00 3.96 2,920 11,563

Fine screen 2 2 0 1.10 0.90 1.98 1.00 1.98 4,380 8,672

Fine screen conveyor 1 1 0 0.55 0.90 0.50 1.00 0.50 4,380 2,168

Washwater valve 2 2 0 0.01 0.90 0.02 1.00 0.02 365 7

Screenings wash press 1 1 0 2.20 0.90 1.98 1.00 1.98 4,380 8,672

Ventilator (emergency) 2 2 0 0.75 0.90 1.35 1.00 1.35 360 486

Grit and Grease Removal Chambers 1 & 2

Grit and grease scraper 2 2 0 1.10 0.90 1.98 1.00 1.98 8,760 17,345

Grit pumps 2 2 0 1.00 0.90 1.80 1.00 1.80 2,920 5,256

Washwater valve 1 1 0 0.01 0.90 0.01 1.00 0.01 365 3

Grit classifier 2 1 1 3.00 0.90 2.70 1.00 2.70 2,920 7,884

Grease conveyor 2 2 0 1.10 0.90 1.98 1.00 1.98 730 1,445

Frequency converter 2 2 0 0.06 0.90 0.10 1.00 0.10 730 72

Grit Blower Station

Page 1 of 8 Printed on 5/6/2019

Consumer List
As Salt WWTP
Status: 28.03.2019 @ 100% Design Flows and Loads
Peak Operating Power Average Operating Power

Installed

Standby
Active
Rated power, Operating Operating Operating

Total

Duty
Active power Active power power
per unit factor factor hours
TAG Nr. Equipment consumption

No. No. No. kW - kW - kW h/a kWh/a

Grit blower 2 1 1 3.00 0.90 2.70 1.00 2.70 8,760 23,652

Frequency converter 2 1 1 0.15 0.90 0.14 1.00 0.14 8,760 1,183

Ventilator 1 1 0 0.37 0.90 0.33 1.00 0.33 8,760 2,917

Inlet Measurement
Automatic sampler 1 1 0 1.00 0.90 0.90 1.00 0.90 365 329

Primary Sedimentation Tanks 1-4

PST scraper 4 4 0 1.00 0.90 3.60 1.00 3.60 8,760 31,536

Primary Scum Pumping Stations 1 and 2

PST scum pump 2 1 1 3.00 0.90 2.70 1.00 2.70 730 1,971

PST scum pump 2 1 1 5.00 0.90 4.50 1.00 4.50 730 3,285

Page 2 of 8 Printed on 5/6/2019

Consumer List
As Salt WWTP
Status: 28.03.2019 @ 100% Design Flows and Loads
Peak Operating Power Average Operating Power

Installed

Standby
Active
Rated power, Operating Operating Operating

Total

Duty
Active power Active power power
per unit factor factor hours
TAG Nr. Equipment consumption

No. No. No. kW - kW - kW h/a kWh/a

Primary Sludge Pumping Stations 1 and 2

Primary sludge outlet valve 8 8 0 0.18 0.90 1.30 1.00 1.30 365 473

Primary sludge pump 3 2 1 3.00 0.90 5.40 1.00 5.40 1,460 7,884

Primary sludge pump 3 2 1 5.00 0.90 9.00 1.00 9.00 1,460 13,140

Ventilator 1 1 0 0.55 0.90 0.50 1.00 0.50 8,760 4,336

Activated Sludge Tanks 1 - 4

Anoxic tank mixer 8 8 0 1.50 0.90 10.80 1.00 10.80 8,760 94,608

AST flowmaker 8 8 0 5.50 0.90 39.60 1.00 39.60 8,760 346,896

İnternal recirculation pump 6 4 2 3.50 0.90 12.60 1.00 12.60 8,760 110,376

Frequency converter 4 4 0 0.18 0.90 0.63 1.00 0.63 8,760 5,519

AST Blower Stations 1 & 2

AST blower 6 4 2 200.00 0.90 720.00 0.70 504.00 8,760 4,415,040

Frequency converter 6 4 2 10.00 0.90 36.00 0.60 21.60 8,760 189,216

Modulating air control valve 4 4 0 0.37 0.90 1.33 1.00 1.33 730 972

Overhead crane 2 2 0 5.50 0.90 9.90 1.00 9.90 183 1,807

Ventilator 4 4 0 1.50 0.90 5.40 1.00 5.40 8,760 47,304

Final Sedimentation Tanks 1 - 4

FST scraper 4 4 0 1.10 0.90 3.96 1.00 3.96 8,760 34,690

FST channel cleaning brush 4 4 0 0.55 0.9 1.98 1 1.98 730 1,445

FST Scum Pumping Station

FST scum pump 2 1 1 5.00 0.90 4.50 1.00 4.50 730 3,285

Ferric Chloride Storage and Dosing Station

Ferric chloride dosing pumps 2 1 1 0.10 0.90 0.09 1.00 0.09 8,760 788

Filter Station

Filter inlet penstock 4 4 0 0.18 0.90 0.65 1.00 0.65 24 16

Sand filters 32 32 0 0.10 0.90 2.88 1.00 2.88 730 2,102

Filter backwash pumps 3 2 1 16.00 0.90 28.80 1.00 28.80 1,460 42,048

Air supply valve 4 4 0 0.25 0.90 0.90 1.00 0.90 730 657

Air compressors 2 1 1 37.00 0.90 33.30 1.00 33.30 1,460 48,618

UV Disinfection

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Consumer List
As Salt WWTP
Status: 28.03.2019 @ 100% Design Flows and Loads
Peak Operating Power Average Operating Power

Installed

Standby
Active
Rated power, Operating Operating Operating

Total

Duty
Active power Active power power
per unit factor factor hours
TAG Nr. Equipment consumption

No. No. No. kW - kW - kW h/a kWh/a

UV disinfection unit 1 1 0 60.00 0.90 54.00 1.00 54.00 8,760 473,040

Level control gate 3 3 0

0.25 0.90 0.68 1.00 0.68 2,190 1,478

Effluent Measurement
Automatic sampler 1 1 0 1.00 0.90 0.90 1.00 0.90 365 329

Service Water Pumping Station

Service water pumps 4 3 1 25.00 0.90 67.50 1.00 67.50 2,920 197,100

Frequency converter 4 3 1 1.25 0.90 3.38 1.00 3.38 4,380 14,783

Page 4 of 8 Printed on 5/6/2019

Consumer List
As Salt WWTP
Status: 28.03.2019 @ 100% Design Flows and Loads
Peak Operating Power Average Operating Power

Installed

Standby
Active
Rated power, Operating Operating Operating

Total

Duty
Active power Active power power
per unit factor factor hours
TAG Nr. Equipment consumption

No. No. No. kW - kW - kW h/a kWh/a

Odour Control Unit 1 (preliminary treatment)

Odour extraction fan 2 1 1 12.00 0.90 10.80 1.00 10.80 8,760 94,608

Odour Control Unit 1 (preliminary treatment) 1 1 0 0.75 0.90 0.68 1.00 0.68 8,760 5,913

Water circulation pumps 2 1 1 3.00 0.90 2.70 1.00 2.70 8,760 23,652

Water Line Drainage Pumping Station

Water line drainage pumps 2 1 1 11.00 0.90 9.90 1.00 9.90 2,920 28,908

RAS and SAS Pumping stations 1 & 2

Motorised penstock 4 4 0 1.10 0.90 3.96 1.00 3.96 730 2,891

RAS pumps 6 4 2 18.50 0.90 66.60 0.40 26.64 8,760 233,366

Frequency converter 6 4 2 0.93 0.90 3.33 0.40 1.33 8,760 11,668

WAS pumps 2 1 1 6.00 0.90 5.40 1.00 5.40 2,503 13,515

WAS pumps 2 1 1 6.00 0.90 5.40 1.00 5.40 2,503 13,515

Gravity Sludge Thickeners

Gravity thickener scraper 2 2 0 0.55 0.90 0.99 1.00 0.99 8,760 8,672

Gravity Thickner Scum Pumping Station

Gravity thickener scum pump 2 1 1 2.00 0.90 1.80 1.00 1.80 730 1,314

Thickened Primary Sludge Pumping Station

Thickened primary sludge pump 3 2 1 4.00 0.90 7.20 1.00 7.20 2,920 21,024

Ventilator 1 1 0 0.25 0.90 0.23 1.00 0.23 8,760 1,971

WAS Storage Tank

WAS tank mixer 2 2 0 3.00 0.90 5.40 1.00 5.40 8,760 47,304

Mechanical Sludge Thickener

GBT feed pump 3 2 1 7.50 0.90 13.50 1.00 13.50 2,503 33,789

Frequency converter 3 2 1 0.38 0.90 0.68 1.00 0.68 2,503 1,689

Gravity belt thickener 3 2 1 0.75 0.90 1.35 1.00 1.35 2,503 3,379

Washwater valve 3 2 1 0.01 0.90 0.02 1.00 0.02 156 3

Polymer preparation unit (mechanical thickening) 1 1 0 0.10 0.90 0.09 1.00 0.09 2,503 225

Page 5 of 8 Printed on 5/6/2019

Consumer List
As Salt WWTP
Status: 28.03.2019 @ 100% Design Flows and Loads
Peak Operating Power Average Operating Power

Installed

Standby
Active
Rated power, Operating Operating Operating

Total

Duty
Active power Active power power
per unit factor factor hours
TAG Nr. Equipment consumption

No. No. No. kW - kW - kW h/a kWh/a

Mixer 2 2 0 0.37 0.90 0.67 1.00 0.67 2,503 1,667

Polymer suction blower 1 1 0 0.55 0.90 0.50 1.00 0.50 313 155

Dilution water valve 1 1 0 0.01 0.90 0.01 1.00 0.01 156 1

Polymer dosing pump (mechanical thickening) 3 2 1 0.05 0.90 0.09 1.00 0.09 2,503 225

Frequency converter 3 2 1 0.00 0.90 0.00 1.00 0.00 2,503 11

Dilution water valve 1 1 0 0.01 0.90 0.01 1.00 0.01 156 1

Dilution water valve 3 2 1 0.01 0.90 0.02 1.00 0.02 156 3

Thickened WAS pump 3 2 1 3.00 0.90 5.40 1.00 5.40 2,503 13,515

Frequency converter 3 2 1 0.15 0.90 0.27 1.00 0.27 2,503 676

Ventilator 3 3 0 1.50 0.90 4.05 1.00 4.05 8,760 35,478

Crane 1 1 0 5.50 0.90 4.95 1.00 4.95 156 774

Thickened Sludge Blending Tank

Thickened sludge tank mixer 1 1 0 3.00 0.90 2.70 1.00 2.70 8,760 23,652

Anaerobic Digesters
Digester feed macerator 3 2 1 2.20 0.90 3.96 1.00 3.96 2,920 11,563

Digester feed pump 3 2 1 5.50 0.90 9.90 1.00 9.90 2,920 28,908

Digester mixing system 2 2 0 0.05 0.90 0.09 1.00 0.09 5,840 526

Gas injection compressors 4 2 2 30.00 0.90 54.00 1.00 54.00 5,840 315,360

Gas mixing valve 20 20 0 0.01 0.90 0.18 1.00 0.18 365 66

Digester recirculation pump 3 2 1 4.00 0.90 7.20 1.00 7.20 7,300 52,560

Foam water valve 2 2 0 0.01 0.90 0.02 1.00 0.02 365 7

Biogas Handling and Treatment

Biogas desulphurisation system 1 1 0 6.00 0.90 5.40 1.00 5.40 8,760 47,304

Gas flare 1 1 0 0.02 0.90 0.02 1.00 0.02 73 1

Condensate pump 3 2 1 1.10 0.90 1.98 1.00 1.98 730 1,445

Page 6 of 8 Printed on 5/6/2019

Consumer List
As Salt WWTP
Status: 28.03.2019 @ 100% Design Flows and Loads
Peak Operating Power Average Operating Power

Installed

Standby
Active
Rated power, Operating Operating Operating

Total

Duty
Active power Active power power
per unit factor factor hours
TAG Nr. Equipment consumption

No. No. No. kW - kW - kW h/a kWh/a

Gas holder 2 2 0 0.10 0.90 0.18 1.00 0.18 8,760 1,577

Biogas booster blower 2 1 1 3.00 0.90 2.70 1.00 2.70 8,760 23,652

Frequency converter 2 1 1 0.15 0.90 0.14 1.00 0.14 8,760 1,183

Siloxane removal system (future provision) 1 1 0 5.50 0.90 4.95 1.00 4.95 8,760 43,362

Ventilator 2 1 1 1.50 0.90 1.35 1.00 1.35 8,760 11,826

Cogeneration Station

Combined Heat & Power unit (CHP) 3 2 1 4.00 0.90 7.20 1.00 7.20 8,760 63,072

Emergency cooling fans 2 1 1 6.00 0.90 5.40 1.00 5.40 4,380 23,652

CHP heating pumps 3 2 1 2.20 0.90 3.96 1.00 3.96 8,760 34,690

Valve 3 2 1 0.37 0.90 0.67 1.00 0.67 730 486

Digester heating pumps 4 2 2 1.50 0.90 2.70 1.00 2.70 7,300 19,710

Valve 2 2 0 0.37 0.90 0.67 1.00 0.67 730 486

Desulphurisation heating pumps 1 1 0 0.55 0.90 0.50 1.00 0.50 1,460 723

Valve 2 2 0 0.25 0.90 0.45 1.00 0.45 730 329

Ventilator 2 1 1 3.00 0.90 2.70 1.00 2.70 8,760 23,652

Boiler Station

Boiler 1 1 0 3.00 0.90 2.70 1.00 2.70 365 986

Boiler heating pumps 1 1 0 2.20 0.90 1.98 1.00 1.98 365 723

Valve 2 2 0 0.37 0.90 0.67 1.00 0.67 365 243

Fuel pump 1 1 0 1.10 0.90 0.99 1.00 0.99 365 361

Ventilator 2 1 1 1.50 0.90 1.35 1.00 1.35 8,760 11,826

Digested Sludge Storage Tank

Digested sludge tank mixer 1 1 0 7.50 0.90 6.75 1.00 6.75 8,760 59,130

Mechanical Sludge Dewatering

BFP feed pump 3 2 1 5.50 0.90 9.90 1.00 9.90 2,920 28,908

Frequency converter 3 2 1 0.28 0.90 0.50 1.00 0.50 2,920 1,445

Belt filter press 3 2 1 4.00 0.90 7.20 1.00 7.20 2,920 21,024

Page 7 of 8 Printed on 5/6/2019

Consumer List
As Salt WWTP
Status: 28.03.2019 @ 100% Design Flows and Loads
Peak Operating Power Average Operating Power

Installed

Standby
Active
Rated power, Operating Operating Operating

Total

Duty
Active power Active power power
per unit factor factor hours
TAG Nr. Equipment consumption

No. No. No. kW - kW - kW h/a kWh/a

Washwater valve 3 2 1 0.02 0.90 0.04 1.00 0.04 730 26

Polymer preparation unit (mechanical dewatering) 2 1 1 0.20 0.90 0.18 1.00 0.18 2,920 526

Mixer 4 2 2 0.55 0.90 0.99 1.00 0.99 2,920 2,891

Polymer suction blower 2 1 1 1.10 0.90 0.99 1.00 0.99 730 723

Dilution water valve 2 1 1 0.01 0.90 0.01 1.00 0.01 2,920 26

Polymer dosing pump (mechanical dewatering) 3 2 1 0.25 0.90 0.45 1.00 0.45 2,920 1,314

Frequency converter 3 2 1 0.01 0.90 0.02 1.00 0.02 2,920 66

Dilution water valve 3 2 1 0.01 0.90 0.02 1.00 0.02 730 13

Sludge collection conveyor 1 1 0 5.50 0.90 4.95 1.00 4.95 2,920 14,454

Sludge distribution conveyor 1 1 0 5.50 0.90 4.95 1.00 4.95 2,920 14,454

Air compressor 2 1 1 2.20 0.90 1.98 1.00 1.98 730 1,445

Potable water booster pumps 2 1 1 4.50 0.90 4.05 1.00 4.05 2,920 11,826

Crane 1 1 0 5.50 0.90 4.95 1.00 4.95 365 1,807

Ventilator 3 2 1 1.50 0.90 2.70 1.00 2.70 8,760 23,652

Sludge Liquor Equalisation Tank

EQ sludge liquor pump 2 1 1 1.00 0.90 0.90 1.00 0.90 2,920 2,628

Return Liquor Pumping Station

Return liquor pump 3 2 1 15.00 0.90 27.00 1.00 27.00 4,380 118,260

Sludge Drying Drainage Pumping Station

Sludge drying drainage pumps 2 1 1 5.00 0.90 4.50 1.00 4.50 365 1,643

Odour Control Unit 2 (sludge treatment)

Odour extraction fan 2 1 1 15.00 0.90 13.50 1.00 13.50 8,760 118,260

Odour control unit 2 1 1 0 0.75 0.90 0.68 1.00 0.68 8,760 5,913

Water circulation pumps 2 1 1 3.00 0.90 2.70 1.00 2.70 8,760 23,652

Emergency Power Generation

Emergency power generator 1 1 0 2.00 0.90 1.80 1.00 1.80 48 86

Diesel pumps 2 1 1 0.55 0.90 0.50 1.00 0.50 48 24

Other Consumers 0.00

Online measuring intruments 1 1 0 5.00 0.90 4.50 1.00 4.50 8,760 39,420
PLC/SCADA/MCC/transformers 1 1 0 10.00 0.90 9.00 1.00 9.00 8,760 78,840
Air conditioners 1 1 0 50.00 0.90 45.00 1.00 45.00 2,920 131,400
Small power in buildings (plug sockets, indoor lighting) 1 1 0 80.00 0.90 72.00 1.00 72.00 3,650 262,800
Outdoor sockets 1 1 0 30.00 0.90 27.00 1.00 27.00 3,650 98,550
Outdoor lighting 1 1 0 40.00 0.90 36.00 1.00 36.00 3,650 131,400

1,684 1,411 8,743,796

Page 8 of 8 Printed on 5/6/2019

Sanitation Programme:
NEXUS and Resource Protection Annex 2: Effluent Standards

3 CHP Calculations
Biogas (64%
Average Peak
CHP system CH4)
Loads Loads
Medium
Daily calorific energy load kWh/d 27268 34156
Total number of CHP units units 3 3
Number of duty CHP units units 2 2
Electrical efficiency selected % 40 40
Required operation time h/d 24 24
Electrical capacity required kW elec. 227 285
Electrical capacity selected kW elec. 300 300
Effective operation time h/d 18 23
Total biogas flow to CHP units Nm3/h 234 234
Thermal efficiency % 45 45
Heat generated kW therm. 675 675

COMPONENT C3 – Rehabilitation and Upgrade of the WWTP in As Salt 8|9