GOVERNMENT OF PUNJAB
PUNJAB AAB-E-PAK AUTHORITY
VOLUME-II
TECHNICAL SPECIFICATIONS
FOR
SUPPLY, CONSTRUCTION, INSTALLATION OF WATER FILTRATION PLANTS & DIRECT SUPPLY IN LAHORE DIVISION
FEBRUARY 2021
PUNJAB AAB-E-PROJECT (PAPA) SUPPLY CONSTRUCTION, INSTALLATION OF WATER CONTRACT DOCUMENTS FILTRATION PLANTS & DIRECT SUPPLY IN LAHORE DIVISION TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS FOR SUPPLY, CONSTRUCTION, INSTALLATION OF WATER FILTRATION PLANTS LAHORE, PUNJAB
Contents 1 GENERAL PROJECT DESCRIPTION ...... 1
1.1 INTRODUCTION ...... 1
1.2 OBJECTIVES ...... 1
1.3 DESCRIPTION OF WORK ...... 2
1.4 CONTRACT AREA ...... 2
1.5 PROJECT DESCRIPTION ...... 4 2 GENERAL REQUIREMENTS ...... 17 2.1 General ...... 17 2.2 Responsibility for Information ...... 17 2.3 Workmanship ...... 17 2.4 Standards ...... 18 2.5 Contractor’s Staffing and Labor Force...... 18 2.6 Material and Equipment ...... 19 2.7 Accesses, Use of Land and Trespassing ...... 20 2.8 Contractor Activities on Private Property ...... 21 2.9 Safe Working Conditions ...... 21 2.10 Inspections and Tools ...... 25 2.11 Testing of Materials and Goods ...... 25 2.12 Report Preparation, Meeting and Taking Photographs ...... 26 2.13 Measurement and Payment ...... 27 2.14 Temporary Site Facilities ...... 28 2.15 Review of Technical Documents ...... 31 2.16 Review Procedure for Drawings ...... 31 2.17 Submittal of Documents ...... 31 2.18 System of Units ...... 35 3 CIVIL WORKS ...... 37 3.1 Excavation, Trenching and Backfilling ...... 37
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3.2 Concrete ...... 42 3.3 Brick and Cement Concrete Block Work ...... 56 3.4 Surface Rendering ...... 59 3.5 Damp Proofing ...... 60 3.6 Roof Insulation ...... 62 3.7 Flooring ...... 63 3.8 Painting Work ...... 64 3.9 Measurement and Payments ...... 66 4 MECHANICAL / PLUMBING WORKS ...... 68 4.1 Installation of Piping ...... 68 4.2 Skid Mounted Equipment Packages ...... 76 4.3 Fabrication and Assembly ...... 83 4.4 Water Supply Pipes, Pipe Laying and Appurtenances ...... 85 4.5 Installation ...... 87 5 CONSTRUCTION OF TUBEWELLS ...... 89 5.1 SCOPE ...... 89 5.2 GROUND WATER INVESTIGATION ...... 89 5.3 INSTALLATION OF WELL CASING ...... 91 5.4 GRAVEL SHROUDING ...... 95 5.5 GROUTING OF PUMP HOUSING CASING ...... 96 5.6 DEVELOPMENT AND TESTING ...... 97 5.7 MEASUREMENT AND PAYMENT ...... 105 6 TUBEWELL PUMPING FACILITIES ...... 106 6.1 SCOPE ...... 106 6.2 MATERIALS AND CONSTRUCTION REQUIREMENTS ...... 106 6.3 CIVIL WORKS ...... 106 6.4 MECHANICAL WORKS ...... 106 6.5 LIFTING GEAR (CHAIN PULLY) ...... 112 6.6 CHLORINATION EQUIPMENT ...... 113 6.7 GUARANTEE ...... 113 6.8 OPERATION AND MAINTENANCE MANUAL ...... 114 6.9 SPARES AND TOOLS ...... 114 6.10 MEASUREMENT AND PAYMENT ...... 114
TOC-II PUNJAB AAB-E-PROJECT (PAPA) SUPPLY CONSTRUCTION, INSTALLATION OF WATER CONTRACT DOCUMENTS FILTRATION PLANTS & DIRECT SUPPLY IN LAHORE DIVISION TECHNICAL SPECIFICATIONS
7 sUPPLY & INSTALLATION OF HIGH DENSITY POLYETHYENE PIPES ...... 115 7.1 Work Included ...... 115 7.2 Shop Drawings ...... 115 7.3 Marking ...... 116 7.4 Installation Requirements ...... 117 7.5 Pipe Laying and Protection ...... 119 7.6 PRODUCT HANDLING, DELIVERY AND STORAGE ...... 119 8 ELECTRICAL WORKS ...... 121 8.1 General ...... 121 8.2 Scope ...... 121 8.3 Building Electrical Works ...... 121 8.4 Electric Power Supply for the Filtration Room ...... 124 8.5 Low Voltage (LV) Distribution Boards ...... 125 8.6 LT Cables ...... 126 8.7 Lighting System, Wiring & Material ...... 127 8.8 Conduits & Pipes ...... 130 8.9 Earthing Protection ...... 130 9 FILTRATION PLANTS ...... 132 9.1 Treatment Plants ...... 132 9.2 WORKS TO BE INCLUDED ...... 132
9.3 BRIEF DESCRIPTION OF WORKS ...... 132
9.4 FILTRATION ...... 135 9.5 filtration Plants...... 135 9.6 Design Criteria ...... 135 9.7 Filtration Plants ...... 139 9.8 Granular Ferric Hydroxide for Arsenic Removal ...... 140 9.9 Activated Alumina (AA) absorbent for Fluoride Removal ...... 141
9.10 REVERS OSMOSIS PLANT ...... 142
9.11 CERTIFICATION ON THE PLANT COMPONENTS ...... 147
9.12 ACCEPTANCE CRITERIA AFTER INSTALLATION ...... 147
9.13 ACCEPTANCE CRITERIA FOR OPERATED AND MAINTAINED PLANTS ...... 147 10 PUMPING EQUIPMENT AND O&M INSTRUCTIONS ...... 149 10.1 General ...... 149
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10.2 Tests ...... 151 10.3 Products ...... 153 10.4 Execution ...... 154 10.5 Operation and Maintenance ...... 154 11 CONTROL AND MONITORING SYSTEM (CMS) ...... 156 11.1 SCOPE OF WORK ...... 156 11.2 KEY SYSTEM FEATURES AND ELEMENTS FOR CMS ...... 157 11.3 FACTORY TESTS: ...... 159 11.4 TESTS ON INSTALLATION COMPLETION ...... 160 11.5 GENERAL TECHNICAL REQUIREMENTS...... 161 11.6 Documentation ...... 165 11.7 Operation & Maintenance Instructions ...... 167 11.8 Program and Project Management ...... 167 12 TESTING, COMMISSIONING AND HAND-OVER ...... 170 12.1 General ...... 170 12.2 Prerequisites ...... 170 12.3 Test and Commissioning ...... 171 12.4 Start-up Operation ...... 171 12.5 Hand Over of the Site ...... 172 13 OPERATION AND MAINTENANCE PROCEDURES ...... 173 13.1 General ...... 173 13.2 Scope ...... 173 13.3 Aim of Operation and Maintenance ...... 174 13.4 Repair Time and Costs for O&M ...... 177 13.5 Performance Targets during the Operation Period ...... 177 13.6 Penalties ...... 178 13.7 Operation and Maintenance Manual ...... 179 13.8 Specific Requirements ...... 181 13.9 Operating Records and Reports ...... 183 13.10 Capacity Building Plans for O&M Personnel ...... 185 13.11 Plan for Providing Spares and Tools ...... 185 13.12 Approval ...... 186 13.13 Security and Safety ...... 186
TOC-IV PUNJAB AAB-E-PROJECT (PAPA) SUPPLY CONSTRUCTION, INSTALLATION OF WATER CONTRACT DOCUMENTS FILTRATION PLANTS & DIRECT SUPPLY IN LAHORE DIVISION TECHNICAL SPECIFICATIONS
13.14 Vehicles ...... 186 14 SAFETY ...... 187 14.1 Labor and Safety ...... 187 14.2 Safety Equipment ...... 188
TOC-V PUNJAB AAB-E-PROJECT (PAPA) SUPPLY CONSTRUCTION, INSTALLATION OF WATER CONTRACT DOCUMENTS FILTRATION PLANTS & DIRECT SUPPLY IN LAHORE DIVISION TECHNICAL SPECIFICATIONS
1 GENERAL PROJECT DESCRIPTION
1.1 INTRODUCTION
Drinking water is essential to sustain life. An adequate supply of safe drinking water is one of the major prerequisites for a healthy life, but waterborne diseases may be a major cause of death in many parts of Punjab and other provinces of Pakistan. A large number of children in Pakistan under the age of 5 years die every year due to water borne diseases.
The quality of drinking water and associated health risks vary from place to place with exhibiting presence of high levels of arsenic, fluoride, nitrate and total dissolved solids (TDS) or pathogens. Local standards, i.e., National Standards for Drinking Water Quality (NSDWQ) were established by Pakistan Environmental Protection Agency (EPA) explain guidelines for Pakistan along with latest WHO guidelines.
Punjab is the second largest province of Pakistan in terms of land mass, after Baluchistan, with an area of 205,344 km2 (79,284 sq. mi). It consists of 36 districts, 144 Tehsils, 3,464 union councils and 25,914 villages. Punjab is the most populous province of Pakistan, inhabited by over 98 million people i.e., it is home to 56% of the total population of Pakistan. Of the 98 million people living in the province, 38% reside in urban and 62% reside in rural areas. As per gender ratio, 48% are female and 52% are male. Government of the Punjab has made substantial efforts to improve water and sanitation in the province in last several years, but a lot remains to be done especially in terms of safe drinking water. According to the Pakistan Social Living Measurement (PSLM) Survey 2012-2013, 100% population of Punjab has access to drinking water from a variety of sources, including tap water 13%, 38% hand pump, 43% motor pump, 2% Dug Well & 4 % other sources but majority of these sources are susceptible to contamination.
Groundwater is the major source of drinking water in Punjab. Overall, around 30 % of groundwater can be stated as sweet, around 30% as mixed and the rest 40% as brackish. Pockets of various contaminants have also been identified all around Punjab i.e., Faisalabad, despite being highest in TDS is also contaminated with F, NO3 and Fe. Similarly, Rajanpur has the highest NO3 contamination, Lodharan is highest in Fluoride and arsenic is detected in Lahore, Bahawalpur and Khanewal.
It is essential that solution should be found to ameliorate these problem areas by undertaking crash program. The proposed project intends to provide water purification system combining many different types of water filters into complete turn-key drinking water system that provide a naturally pure and safe drinking water solution in different cities and rural areas of Punjab.
1.2 OBJECTIVES
The objective of “Punjab Aab-E-Pak Authority” is to provide safe and clean drinking water in accordance with the prescribed standards of WHO and Pakistan Standard for Drinking Water to the
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population living in rural and peri-urban areas of the Punjab with maximum coverage. Supply of safe water is essential to sustain a healthy life and prevent water-borne diseases. The program aims to construct water supply schemes with treatment plants and distribute water through dispensing centers called Aab e pak Markaz to be located near each settlement to facilitate daily water fetching.
1.3 DESCRIPTION OF WORK
The Contract includes the whole of the Works which are described or implied by the Bidding Documents. All matters omitted from the documents which may be inferred or are obviously necessary for the efficiency, stability, completion and entirely satisfactory operation of the Works shall be deemed to be included in the price and inserted in relative or additional Schedules. Omission of prices or details and Acceptance shall not be construed as acceptance of omission incurring additional costs. The Works shall include but not limited to:
The Punjab Aab-E-Pak Authority (PAPA) intends to install Pre-filtration & Reverse Osmosis water Treatment Plant in different areas of Lahore. For water Treatment Plant for drinking purpose, raw water will be supplied from bore hole pump to the Water Treatment Plant. Where the water will be treated in accordance with the water quality. The treated water will be pumped up to each low-level reservoir (LLR) at the Markaz e Aab centers. The Contract includes a minimum of One (01) year operation and maintenance (O&M) period extendable by mutual agreement with the Contractor.
The Contract will be on Procurement and Construction including O&M (minimum 01 year) basis where installation and construction of water Treatment plants shall be as per specifications of Bidding Documents.
The Contract mainly consist of but not limited to: i) construction of water treatment works (including tube well pumping facilities and WTP) and ii) construction of Markaz e Aab center, including civil and all related works; iii) full operation and maintenance of the schemes for One (01) year period (extendable) after satisfactory commissioning including training for Client’s personnel; and vi) remedying all defects during Defects Liability Period. Bidding is open to all pre-qualified firms for this particular Contract.
1.4 CONTRACT AREA
The target area for this contract is Lahore Division of the Punjab. The location of project within Lahore Division Area map is shown below.
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Figure 1: Location of Project Area
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1.5 PROJECT DESCRIPTION
The following tables show the summary of the plant to be constructed in the contract of Lahore Division Area.
Table 1.5-1 Summary of Plant
Sr. No. Type of Plant No. of Plants
1 Direct Supply / Pre-filtration Plant (Chlorination, 82 Sand & Activated Carbon Filter) Direct Supply / Pre-filtration Plant with Sand , 2 03 Activated Carbon & Arsenic removal Filter
Direct Supply / Pre-filtration Plant with Sand , 3 01 Activated Carbon & Fluoride removal Filter
(Dysfunctional Schemes)
4 Direct Supply Plant with Source development 16 (Chlorination, Sand & Activated Carbon Filter)
(Dysfunctional Schemes)
5 Direct Supply / Pre-filtration Plant with Source 02 development & Sand , Activated Carbon & Fluoride removal Filter
6 Reverse Osmosis 42
Total 146
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Table 1.5-2 Plant Location Details
Recommendations LATITUDE LONGITUDE Sr. District Tehsil Village Water Water Status No Source Source Capacity Type of Plant m3/hr
KASUR 1 DISTRICT Chunian Dhos 30.924292 73.963441 RO 2.00 RO PLANTS
KASUR Harse 2 DISTRICT Chunian 31.082711 74.061559 RO 2.00 Naushahra RO PLANTS
KASUR Kandu 3 DISTRICT Chunian 30.913786 73.890732 RO 2.00 Ranggar RO PLANTS
KASUR Lambe 4 DISTRICT Chunian 31.007571 74.118513 RO 2.00 Khalsa RO PLANTS
KASUR Kot Radha 5 DISTRICT Rawal Jageer 31.134423 74.164155 RO 2.00 Kishan RO PLANTS
KASUR Kot Radha 6 DISTRICT Azamabad 31.173621 74.121239 RO 2.00 Kishan RO PLANTS
KASUR Chak 39 7 DISTRICT Pattoki 31.045524 73.811077 RO 2.00 Awanwala RO PLANTS
KASUR 8 DISTRICT Pattoki Balair 31.120962 73.743774 RO 2.00 RO PLANTS
KASUR Chak No 20 9 DISTRICT Pattoki Wan Radha 30.959615 73.759994 RO 2.00 RO PLANTS Ram
KASUR 10 DISTRICT Pattoki Nauthe Jagir 31.276602 74.000675 RO 2.00 RO PLANTS
KASUR Bharwar 11 DISTRICT Pattoki 31.115561 73.853455 RO 2.00 Kalan RO PLANTS
KASUR Chak 41 12 DISTRICT Pattoki 31.087595 73.813672 RO 2.00 Khudian RO PLANTS
LAHORE 13 DISTRICT Lahore Dheerky 31.487778 74.556357 RO 2.00 RO PLANTS
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LATITUDE LONGITUDE Sr. District Tehsil Village Water Water Recommendations Status No Source Source
LAHORE 14 DISTRICT Raiwand Budduke 31.324338 74.182813 RO 2.00 RO PLANTS NANKANA SB 15 Nankana Kanwan Wali 31.410462 73.788528 RO 2.00 DISTRICT RO PLANTS NANKANA SB Bhuchoke 16 Nankana 31.343961 73.964369 RO 2.00 DISTRICT Pur RO PLANTS NANKANA SB 17 Nankana Pidd Pur 31.428941 73.771951 RO 2.00 DISTRICT RO PLANTS NANKANA Chak No SB 18 Nankana 16/Gb 31.4955 73.472255 RO 2.00 DISTRICT Budometa RO PLANTS NANKANA SB Chak No 41 19 Sangla Hill 31.657261 73.431725 RO 2.00 DISTRICT (Marar) RO PLANTS NANKANA Chak No SB 20 Sangla Hill 36/Rb 31.730095 73.420826 RO 2.00 DISTRICT (Baroy) RO PLANTS NANKANA Chak No SB 21 Sangla Hill 121/Rb(Hanj 31.772554 73.334999 RO 2.00 DISTRICT hli) RO PLANTS NANKANA SB Chak No 168 22 Shahkot 31.632336 73.587419 RO 2.00 DISTRICT Karkan RO PLANTS NANKANA SB Chak 82 ( 23 Shahkot 31.600966 73.499408 RO 2.00 DISTRICT Rasul Pura) RO PLANTS NANKANA SB Chak 33/Rb 24 Shahkot 31.635358 73.471003 RO 2.00 DISTRICT Darowali RO PLANTS SHEIKHUPU RA 25 Feroze Wala Kharin Wala 31.653072 73.932124 RO 2.00 DISTRICT RO PLANTS SHEIKHUPU RA Moman 26 Safdarabad 31.724555 73.474658 RO 2.00 DISTRICT Chak No 30 RO PLANTS
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LATITUDE LONGITUDE Sr. District Tehsil Village Water Water Recommendations Status No Source Source
SHEIKHUPU RA 27 Safdarabad Manght 31.801088 73.56132 RO 2.00 DISTRICT RO PLANTS SHEIKHUPU RA Rahmana 31.8178675 73.5710142 28 Safdarabad RO 2.00 DISTRICT Abad 10 8 1 RO PLANTS SHEIKHUPU RA Khambianwa 29 Sheikhupura 31.590836 73.713601 RO 2.00 DISTRICT ls RO PLANTS SHEIKHUPU RA Chah 30 Sheikhupura 31.641118 73.92133 RO 2.00 DISTRICT Chando RO PLANTS SHEIKHUPU RA 31 Sheikhupura Nawan Kot 31.606697 73.874153 RO 2.00 DISTRICT RO PLANTS DISTRICT Chlorination + KASUR Gehlan 32 Chunian 30.860469 74.038143 Sand + Activated 2.00 DIRECT Hithar CArbon Filter SUPPLY DISTRICT Chlorination + KASUR 33 Chunian Jodh Singh 30.941074 73.760316 Sand + Activated 2.00 DIRECT CArbon Filter SUPPLY DISTRICT Chlorination + KASUR 34 Chunian Talwandi 30.908649 74.134378 Sand + Activated 2.00 DIRECT CArbon Filter SUPPLY DISTRICT Chlorination + KASUR 35 Chunian Shaam Kot 30.823046 74.105751 Sand + Activated 2.00 DIRECT CArbon Filter SUPPLY DISTRICT KASUR Dysfunctio 36 Kasur Atheel Pur 31.163163 74.383599 Fluride Filter 2.00 DIRECT nal SUPPLY DISTRICT Chlorination + KASUR 37 Kasur Maan 31.074072 74.492144 Sand + Activated 2.00 DIRECT CArbon Filter SUPPLY DISTRICT KASUR 38 Kasur Naul Hithar 31.0371388 74.259903 RO 2.00 DIRECT SUPPLY
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LATITUDE LONGITUDE Sr. District Tehsil Village Water Water Recommendations Status No Source Source
DISTRICT Chlorination + KASUR 39 Kasur Nayyeke 31.033547 74.420966 Sand + Activated 2.00 DIRECT CArbon Filter SUPPLY DISTRICT Chlorination + KASUR Dysfunctio 40 Kasur Jaurra 31.012581 74.385455 Sand + Activated 2.00 DIRECT nal CArbon Filter SUPPLY DISTRICT Chlorination + KASUR Bhedian 41 Kasur 31.063022 74.527145 Sand + Activated 2.00 DIRECT Kalan CArbon Filter SUPPLY DISTRICT KASUR Rao Khan Dysfunctio 42 Kasur 31.191928 74.326055 RO 2.00 DIRECT Wala nal SUPPLY DISTRICT KASUR Rasool 43 Kasur 31.012441 74.49289 Fluride Filter 2.00 DIRECT Nager SUPPLY DISTRICT Chlorination + KASUR 44 Kasur Kaiser Gurh 31.105539 74.483032 Sand + Activated 2.00 DIRECT CArbon Filter SUPPLY DISTRICT Chlorination + KASUR 45 Kasur Patto Kalan 31.106763 74.511543 Sand + Activated 2.00 DIRECT CArbon Filter SUPPLY DISTRICT Chlorination + KASUR 46 Kasur Sanda Kalan 30.9457183 74.2804852 Sand + Activated 2.00 DIRECT CArbon Filter SUPPLY DISTRICT Chlorination + KASUR Lambay 47 Pattoki 31.222763 73.927585 Sand + Activated 2.00 DIRECT Jageer CArbon Filter SUPPLY DISTRICT R/W/S Chlorination + LAHORE 48 Lahore City Gulshan 31.494375 74.25798 Sand + Activated 2.00 DIRECT colony CArbon Filter SUPPLY DISTRICT LAHORE R/W/S Dysfunctio 49 Shalimar 31.469789 74.624547 Fluride Filter 2.00 DIRECT Padhana nal SUPPLY DISTRICT Chlorination + LAHORE R/W/S 50 Raiwind 31.43003 74.172346 Sand + Activated 2.00 DIRECT Chung CArbon Filter SUPPLY
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LATITUDE LONGITUDE Sr. District Tehsil Village Water Water Recommendations Status No Source Source
DISTRICT Chlorination + LAHORE R/W/S 51 Raiwind 31.33593 74.234116 Sand + Activated 2.00 DIRECT Arrian CArbon Filter SUPPLY DISTRICT Chlorination + NANKANA Nankana More 52 31.356383 73.688006 Sand + Activated 2.00 SB DIRECT Sahib Khunda CArbon Filter SUPPLY DISTRICT Chlorination + NANKANA Nankana Chak No 5 Dysfunctio 53 31.503697 73.582695 Sand + Activated 2.00 SB DIRECT Sahib G.B nal CArbon Filter SUPPLY DISTRICT Chlorination + NANKANA Nankana 54 Massu 31.313314 73.82344 Sand + Activated 2.00 SB DIRECT Sahib CArbon Filter SUPPLY DISTRICT Chlorination + NANKANA Nankana Chak No 6 55 31.496 73.4997 Sand + Activated 2.00 SB DIRECT Sahib G.B CArbon Filter SUPPLY DISTRICT NANKANA Nankana Chak 56 31.491718 73.516527 RO 2.00 SB DIRECT Sahib No.18GB SUPPLY DISTRICT Chlorination + NANKANA Chak No 46 57 Sangla Hill 31.689226 73.356308 Sand + Activated 2.00 SB DIRECT R.B CArbon Filter SUPPLY DISTRICT Chlorination + SHEIKHUPU RWSS Khan 58 Ferozewala 31.684311 74.104699 Sand + Activated 2.00 RA DIRECT pur Virkan CArbon Filter SUPPLY DISTRICT RWSS Chlorination + SHEIKHUPU 59 Ferozewala Amanpura & 31.70991 74.232969 Sand + Activated 2.00 RA DIRECT Shamke CArbon Filter SUPPLY
DISTRICT Rural Water Chlorination + SHEIKHUPU Supply 60 Sheikhupura 31.772359 73.899148 Sand + Activated 2.00 RA DIRECT Scheme CArbon Filter SUPPLY Kaloke
Rural Water DISTRICT Supply Chlorination + SHEIKHUPU 61 Sheikhupura Scheme 31.710955 74.060428 Sand + Activated 2.00 RA DIRECT Sahoki CArbon Filter SUPPLY Mallian DISTRICT Chlorination + KASUR Talwandi 62 Chunian 30.908649 74.134378 Sand + Activated 2.00 DIRECT Adda CArbon Filter SUPPLY
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LATITUDE LONGITUDE Sr. District Tehsil Village Water Water Recommendations Status No Source Source
DISTRICT Chlorination + KASUR Roshan 63 Kasur 31.089352 74.329651 Sand + Activated 2.00 DIRECT Bheela CArbon Filter SUPPLY DISTRICT Chlorination + KASUR Khereper 64 Kasur 31.001759 74.452482 Sand + Activated 2.00 DIRECT Hithar CArbon Filter SUPPLY DISTRICT Chlorination + KASUR 65 Kasur Kelo Kalan 31.04695 74.381804 Sand + Activated 2.00 DIRECT CArbon Filter SUPPLY DISTRICT Chlorination + KASUR Bahmani 66 Kasur 31.062777 74.47417 Sand + Activated 2.00 DIRECT Wala, CArbon Filter SUPPLY
Recommendation Sr. LATITUDE LONGITUDE District Tehsil Village Water Water Status No Source Source Capacity Type of Plant m3/hr
KASUR Kot Radha 1 DISTRICT RO Miroli Uttar 31.143069 74.186809 RO 2.00 Kishan PLANTS
KASUR Chak No 42 2 DISTRICT RO Pattoki 31.049677 73.790203 RO 2.00 Gopirai PLANTS Chlorination + KASUR Tara Garh Sand + 3 DISTRICT RO Pattoki 31.0960242 73.8172167 2.00 Chak 44 Activated PLANTS CArbon Filter SHEIKHUPURA 4 DISTRICT RO Safdarabad Chak 11 31.47125 73.537537 RO 2.00 PLANTS
SHEIKHUPURA Gurruanwal 5 DISTRICT RO Sheikhupura 31.60271 73.696488 RO 2.00 a Gharbi PLANTS
SHEIKHUPURA 6 DISTRICT RO Sheikhupura Keran 31.568489 73.701754 RO 2.00 PLANTS
SHEIKHUPURA Wara 7 DISTRICT RO Sheikhupura 31.602347 73.874982 RO 2.00 Ghulab Sing PLANTS
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Sr. LATITUDE LONGITUDE District Tehsil Village Water Water Recommendation Status No Source Source DISTRICT 8 KASUR DIRECT Chunian Muft Pura 30.920549 74.029432 Arsenic Fiter 2.00 SUPPLY Chlorination + DISTRICT Dholan Sand + 9 KASUR DIRECT Kasur 30.945978 74.275919 2.00 Hithar Activated SUPPLY CArbon Filter Chlorination + DISTRICT Hari Ke Sand + 10 KASUR DIRECT Kasur 31.023933 74.26297 2.00 Naual Activated SUPPLY CArbon Filter Chlorination + DISTRICT Bhadur Sand + 11 KASUR DIRECT Kasur 31.061623 74.401148 2.00 Pura Activated SUPPLY CArbon Filter DISTRICT R/W/S Niaz 12 LAHORE Lahore City 31.488898 74.235235 Arsenic Fiter 2.00 Baig DIRECT SUPPLY Chlorination + DISTRICT R/W/S Shah Sand + 13 LAHORE Lahore City 31.4591 74.205967 2.00 Pur Activated DIRECT SUPPLY CArbon Filter Chlorination + DISTRICT Rural Water Sand + 14 LAHORE Lahore City Supply 31.47313 74.224617 2.00 Activated DIRECT SUPPLY Gopi Rai CArbon Filter Chlorination + DISTRICT R/W/S Sand + 15 LAHORE Shalimar 31.610614 74.411004 2.00 Lakho Dhair Activated DIRECT SUPPLY CArbon Filter Chlorination + DISTRICT Sand + 16 LAHORE Shalimar Sharifpura 31.607327 74.418934 2.00 Activated DIRECT SUPPLY CArbon Filter Chlorination + DISTRICT Choor Kotly Sand + 17 NANKANA SB Sangla Hill 31.717922 73.372161 2.00 117 R.B Activated DIRECT SUPPLY CArbon Filter Chlorination + DISTRICT Sand + Dysfunctio 18 NANKANA SB Shah Kot Dala Naggal 31.610161 73.532257 2.00 Activated nal DIRECT SUPPLY CArbon Filter Chlorination + DISTRICT RWSS Faiz Sand + Dysfunctio 19 SHEIKHUPURA Ferozewala 31.594791 74.222195 2.00 Pur khurd Activated nal DIRECT SUPPLY CArbon Filter Chlorination + DISTRICT RWSS Sand + 20 SHEIKHUPURA Muridke Jandiala 31.8504 74.51617 2.00 Activated DIRECT SUPPLY Kalsan CArbon Filter
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Sr. LATITUDE LONGITUDE District Tehsil Village Water Water Recommendation Status No Source Source Chlorination + KASUR Kot Radha Sand + 21 DISTRICT RO Clarkabad 31.178228 74.151185 2.00 Kishan Activated PLANTS CArbon Filter SHEIKHUPURA 4 Chak 22 DISTRICT RO Sheikhupura 31.543358 73.963793 RO 2.00 Risala PLANTS Chlorination + DISTRICT Sand + 23 KASUR DIRECT Chunian Ellahabad 30.871683 74.059401 2.00 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sand + 24 KASUR DIRECT Chunian Rosa Tiba 30.999687 73.899896 2.00 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sand + 25 KASUR DIRECT Chunian Maukal 30.78107 74.188636 2.00 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sand + 26 KASUR DIRECT Chunian Chak 18 31.101072 74.053341 2.00 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Gohar Chak Sand + 27 KASUR DIRECT Chunian 30.95325 73.827389 2.00 No.8 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sand + 28 KASUR DIRECT Chunian Kot Lashkar 30.897915 74.032845 2.00 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Attari Jeet Sand + 29 KASUR DIRECT Chunian 31.15237 74.074564 2.00 Singh Activated SUPPLY CArbon Filter Chlorination + DISTRICT Mandi Sand + 30 KASUR DIRECT Kasur Usman 30.893027 74.234932 2.00 Activated SUPPLY Wala CArbon Filter Chlorination + DISTRICT Mhalam Sand + 31 KASUR DIRECT Kasur 31.054089 74.542145 2.00 Kalan Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sand + 32 KASUR DIRECT Kasur Gohar Jagir 30.885629 74.251647 2.00 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sand + 33 KASUR DIRECT Kasur Guggar 31.089355 74.329704 2.00 Activated SUPPLY CArbon Filter
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Sr. LATITUDE LONGITUDE District Tehsil Village Water Water Recommendation Status No Source Source Chlorination + DISTRICT Hussain Sand + 34 KASUR DIRECT Kasur 31.011229 74.414375 2.00 Khan wala Activated SUPPLY CArbon Filter Chlorination + DISTRICT Rajji Wala Sand + 35 KASUR DIRECT Kasur 31.06115 74.565269 2.00 Arayan Activated SUPPLY CArbon Filter Chlorination + DISTRICT Chah Aror Sand + 36 KASUR DIRECT Kasur 31.144311 74.352765 2.00 Sing Activated SUPPLY CArbon Filter Chlorination + DISTRICT Daulay Sand + 37 KASUR DIRECT Kasur 31.083138 74.452515 2.00 wala Activated SUPPLY CArbon Filter Chlorination + DISTRICT Gohar Sand + 38 KASUR DIRECT Kasur 30.99155 74.406578 2.00 Hithar Activated SUPPLY CArbon Filter Chlorination + DISTRICT Gehlan Sand + 39 KASUR DIRECT Pattoki 30.985699 73.815686 2.00 Chak 9 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Ghuman Sand + 40 KASUR DIRECT Pattoki 31.18327 73.978775 2.00 Kay Activated SUPPLY CArbon Filter Chlorination + DISTRICT Dholan Sand + 41 KASUR DIRECT Pattoki 31.002879 73.73605 2.00 Chak 7 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sand + 42 KASUR DIRECT Pattoki Chak#14 31.116223 74.0826398 2.00 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Cheela Chak Sand + 43 KASUR DIRECT Pattoki 31.082615 73.685646 2.00 No.49 Activated SUPPLY CArbon Filter Chlorination + DISTRICT R/W/S Sand + 44 LAHORE Lahore City Waris 31.49354 74.266766 2.00 Activated DIRECT SUPPLY colony CArbon Filter Rural Water Chlorination + DISTRICT Supply Sand + Dysfunctio 45 LAHORE Raiwind 31.40936 74.141282 2.00 Mohalanwa Activated nal DIRECT SUPPLY l CArbon Filter DISTRICT Nankana 46 NANKANA SB Burkhudar 31.356383 73.688006 Arsenic Fiter 2.00 Sahib DIRECT SUPPLY
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Sr. LATITUDE LONGITUDE District Tehsil Village Water Water Recommendation Status No Source Source Chlorination + DISTRICT RWSS Sand + Dysfunctio 47 SHEIKHUPURA Ferozewala 31.766195 74.11545 2.00 Sakhum Activated nal DIRECT SUPPLY CArbon Filter Chlorination + DISTRICT RWSSKot Sand + 48 SHEIKHUPURA Ferozewala 31.704807 74.181145 2.00 pindi das Activated DIRECT SUPPLY CArbon Filter Chlorination + DISTRICT RWSS Sand + 49 SHEIKHUPURA Ferozewala Javaid 31.638145 74.188516 2.00 Activated DIRECT SUPPLY Nagar CArbon Filter Rural Water Chlorination + DISTRICT Supply Sand + Dysfunctio 50 SHEIKHUPURA Muridke Scheme 31.767189 74.255671 2.00 Activated nal DIRECT SUPPLY Dhakam CArbon Filter pura Rural Water Chlorination + DISTRICT Supply Sand + Dysfunctio 51 SHEIKHUPURA Sheikhupura 31.85972 73.86279 2.00 Scheme Activated nal DIRECT SUPPLY Jhabran CArbon Filter SHEIKHUPURA 52 DISTRICT RO Safdarabad Bairwala 31.693691 73.57196 RO 2.00 PLANTS Chlorination + DISTRICT Sand + 53 KASUR DIRECT Chunian Saresar 30.849267 74.08958 2.00 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sand + 54 KASUR DIRECT Chunian Chak 17 31.082711 74.0615559 2.00 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Lukhney Sand + 55 KASUR DIRECT Kasur 31.200964 74.467962 2.00 Key Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sand + 56 KASUR DIRECT Kasur Rasool Pur 31.122414 74.425186 2.00 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Nand Ka Sand + 57 KASUR DIRECT Kasur 31.137936 74.379517 2.00 Takia Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sand + 58 KASUR DIRECT Kasur Said Pur 30.95587 74.166554 2.00 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Kotli Ray Sand + Dysfunctio 59 KASUR DIRECT Kasur 31.100277 74.276278 2.00 AbuBaker Activated nal SUPPLY CArbon Filter
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Sr. LATITUDE LONGITUDE District Tehsil Village Water Water Recommendation Status No Source Source Chlorination + DISTRICT Theh Sand + 60 KASUR DIRECT Kasur 31.150305 74.323198 2.00 Shaikham Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sand + 61 KASUR DIRECT Kasur Noori Wala 31.011227 74.414345 2.00 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sheikh Pura Sand + 62 KASUR DIRECT Kasur 31.075211 74.559021 2.00 Nau Activated SUPPLY CArbon Filter Chlorination + DISTRICT Noor Pur Sand + 63 KASUR DIRECT Kasur 31.029158 74.353775 2.00 Nehar Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sand + 64 KASUR DIRECT Kasur Bugri 31.086506 74.408359 2.00 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sand + 65 KASUR DIRECT Kasur Khai Hithar 30.974163 74.216536 2.00 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sand + 66 KASUR DIRECT Kasur Today Pur 31.036947 74.259903 2.00 Activated SUPPLY CArbon Filter Chlorination + DISTRICT Salamat Sand + 67 KASUR DIRECT Kasur 30.89623 74.239153 2.00 Pura Activated SUPPLY CArbon Filter Chlorination + DISTRICT Ratnay Sand + 68 KASUR DIRECT Kasur 30.958421 74.397749 2.00 Wala Activated SUPPLY CArbon Filter Chlorination + DISTRICT Sand + Dysfunctio 69 KASUR DIRECT Pattoki Bheo Asal 31.126846 74.027751 2.00 Activated nal SUPPLY CArbon Filter Chlorination + DISTRICT Ghandian Sand + 70 KASUR DIRECT Pattoki 31.108264 74.064796 2.00 Otar Activated SUPPLY CArbon Filter Chlorination + DISTRICT Aulakh Sand + 71 KASUR DIRECT Pattoki 31.20318 73.896987 2.00 Bhonga Activated SUPPLY CArbon Filter Chlorination + DISTRICT Kaween Sand + Dysfunctio 72 KASUR DIRECT Pattoki 31.13540833 74.08650167 2.00 Blaka Singh Activated nal SUPPLY CArbon Filter
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Sr. LATITUDE LONGITUDE District Tehsil Village Water Water Recommendation Status No Source Source Chlorination + DISTRICT R/W/S Sand + 73 LAHORE Model Town Yohanaaba 31.410357 74.364545 2.00 Activated DIRECT SUPPLY d CArbon Filter Chlorination + DISTRICT Rural Water Sand + Dysfunctio 74 LAHORE Model Town Supply 31.280491 74.358179 2.00 Activated nal DIRECT SUPPLY Pandoki CArbon Filter Chlorination + DISTRICT Rural Water Sand + Dysfunctio 75 LAHORE Raiwind Supply 31.356748 74.124433 2.00 Activated nal DIRECT SUPPLY Sundar CArbon Filter Chlorination + DISTRICT Nankana Sand + 76 NANKANA SB Bara Ghar 31.219919 73.628424 2.00 Sahib Activated DIRECT SUPPLY CArbon Filter Chlorination + DISTRICT Chak No. Sand + 77 NANKANA SB Shah Kot 31.643639 73.543936 2.00 81RB Activated DIRECT SUPPLY CArbon Filter Rural Water Chlorination + DISTRICT Supply Sand + Dysfunctio 78 SHEIKHUPURA Muridke 32.011468 74.536073 2.00 Scheme Kot Activated nal DIRECT SUPPLY Abdullah CArbon Filter Rural Water Chlorination + DISTRICT Shariq Supply Sand + Dysfunctio 79 SHEIKHUPURA 31.488325 74.111882 2.00 pur Scheme Activated nal DIRECT SUPPLY Ghazi pur CArbon Filter Rural Water Chlorination + DISTRICT Supply Sand + Dysfunctio 80 SHEIKHUPURA Sheikhupura 31.543392 73.963703 2.00 Scheme 4 Activated nal DIRECT SUPPLY Chak Rasala CArbon Filter
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2 GENERAL REQUIREMENTS
2.1 GENERAL
The General Specifications define the general requirements, materials and workmanship for the execution of the Works. The General Specifications also describe the framework under which the Contractual Works shall be executed and the general activities to be included in the rates for the Permanent and Temporary Works.
The Permanent Works comprise the contractual construction Works which shall be executed in accordance with the requirements of the General Specification and shall be quoted for the various sections of Works.
The testing of materials and equipment shall not be quoted separately and is deemed to be included in the remuneration for the Works unless where otherwise specified.
2.2 RESPONSIBILITY FOR INFORMATION
The Contractor shall be deemed to have inspected and examined the Site, to have verified the Site conditions and to have satisfied himself, before submitting the Bid and before the Commencement of the Works, as to all matters relative to the nature of the Site within the specified boundaries, details and levels of existing services and connections to be made, the quantity and nature of the work and materials necessary for the completion of the Works, the means of access to the Site along the formal protocols and permissions that are required, the accommodation he may require, the supply of water and electricity, the climatic, hydrological and geo-hydrological conditions, security and administration requirements or such contingencies which may influence or affect his Bid.
Any negligence or failure on the part of the Contractor to obtain reliable information on the Site or elsewhere concerning any matter affecting the Contract Agreement shall not relieve the Contractor from any of his obligations or liabilities arising from the Contract Agreement.
No claims shall be permitted with regard to meeting the full compliance associated with the Site conditions regarding the execution of the Works except as contains in the Conditions of Contract.
2.3 WORKMANSHIP
The Contractor to carry out all works as instructed by the Engineer in a thorough, diligent and workman-like manner, and up to current professional standards. The Contractor shall execute operations with due efficiency and dispatch in accordance with the terms of the contract and to the satisfaction of the Engineer. For this purpose, the Contractor shall employ suitable equipment, and competent staff demonstrated in certification and formal assessment.
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2.4 STANDARDS
The products and systems to be supplied and installed under this Contract shall conform to the requirements of the Technical Specifications and other associated documents, to the best accepted international practice and to the several requirements imposed by the service conditions. As a means of ensuring these objectives, the Contractor shall maintain a documented quality control and quality assurance system, which shall be generally in accordance with ISO 9001 or approved equivalent and so demonstrated
For the identification of the quality of materials and work reference has been made, where deemed necessary, to EN Standards, ISO or BS. The Contractor shall ensure that the same requirements are applied to products, systems, and services supplied by sub-contractors and suppliers.
In the event that any Standard referred to in these Technical Specifications has been superseded or replaced by another one, such other standard shall be deemed applicable. In any case always the most recent issue of any Standard referred to shall be applicable. The Standards referred to in this Technical Specifications shall not be deemed to be limitative, the Contractor shall justify compliance with the pertinent ISO, BS, EN or DIN Standards of any single element of the permanent Works when submitting for approval. The Engineer may reject any element not complying with the relevant standards.
The Contractor may, however, carry out the Works or provide materials in accordance to other International Standards, provided that the Contractor proves to the Engineer, prior to any execution that their requirements are superior or equivalent to the quality described by the Standards cited in these Specifications.
Should the Contractor desire to carry out Works or to substitute goods and materials in accordance with other than EN, BS, ISO or DIN Standards, he shall notify the Engineer thereof, and shall submit with his notice two (02) copies in English of the proposed Standard (latest version), and shall not order any material or perform any work unless he has obtained the Engineer’s approval of such Standard, together with any other information required by him.
Within 30 days of the signing of the Contract, the Contractor shall provide to the Engineer two (02) copies of all Standards (latest editions), which are to apply to materials and workmanship under the Contract, together with an index cross-referencing these Standards with the applicable aspects of the Works.
2.5 CONTRACTOR’S STAFFING AND LABOR FORCE
When nominating the representatives and the supervisors to whom the performance of the Works will be entrusted, the Contractor shall give full information on their educational and professional background in accordance with the minimum requirements given in the Tender Schedules. The replacement of ANY representatives and/or supervisors shall not be allowed without the written approval of the Engineer and shall be of equal or better demonstrable competence.
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Key staff responsible for the correct execution of the works must be available to the Engineer during working time.
Supervisors responsible for construction work must have a significant experience in work under the climatic circumstances and must be able to safeguard good workmanship so that the Works are executed according to the Standards. That is to demonstrate competence in this particular environment.
The Contractor shall also submit details of the labor force, which he proposes to employ. Such details shall include engineers and experts involved; senior staff and specialists, skilled and unskilled labor with indication of the local labor, which the Contractor envisages to employ and the variation in staff and labor levels and their distribution throughout the duration of the Contract. That is a manpower schedule and profile for monthly and annual allocation of manpower resources.
Child-labor shall not be permitted under any circumstances.
2.6 MATERIAL AND EQUIPMENT
2.6.1 Materials, Equipment and Plant to be Fit for Purpose
Notwithstanding more prescriptive or particular conditions in the specific parts of these Technical Specifications all material, equipment and plant to be incorporated in the Works shall be fit for its intended purpose. They should be new and unused, and shall be the current or most recent models available, from reputed manufactures\suppliers and incorporate all recent improvements in design and materials unless otherwise specified in this Specification. Materials used in the manufacture of the items required shall be of a grade sufficient to ensure long service life for the purpose of the equipment. The Contractor shall provide for approval by the Engineer copies of ISO or equivalent authorization from the manufacturers involved.
Second hand material, equipment and plant are not allowed under any circumstances and will be rejected.
2.6.2 Approval of Materials and Equipment
As soon as practicable and within 30 days after receipt of notice to proceed and before any material or equipment is purchased, the Contractor shall submit for approval by the Engineer a complete schedule, in triplicate, with the names and addresses of the manufacturers and their catalogue cuts, diagrams, drawings, test certificates and such other descriptive data as may be required by the Engineer. Samples of materials and equipment also to be submitted to be retained by the Engineer to allow visual comparison and approval of material and equipment delivered. No consideration will be given to partial lists submitted from time to time. Approval of materials and equipment under this provision shall not be considered as authorized, any deviation from the specifications unless the attention of the Engineer has been directed to the specific deviations.
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2.6.3 Origin and Identification of Material, Equipment and Plant
All plant and equipment shall bear distinct and easily legible plates of indestructible material showing manufacturer / brand, time of manufacturing, and all relevant technical data required by the standards or in the absence of standards, as generally indicated to describe the capacity of the plant or equipment in the English language.
2.7 ACCESSES, USE OF LAND AND TRESPASSING
2.7.1 Possession of the Site
In accordance with the Conditions of Contract the Employer will give the Contractor possession of land required for the construction of the Works. The limit of the Site will be the area of land occupied by the Works. No additional land will normally be made available by the Employer for access or construction purposes except as authorized by the Employer.
2.7.2 Access to the Site
The Contractor shall make arrangements with the owners or tenants in respect of access to the Site across their properties and shall pay all costs incurred in this regard.
The Contractor shall arrange to, construct, maintain, remove and reinstate on completion of the Contract any temporary access required for and relating to the execution of the Works. The Contractor shall immediately repair any damage done by him to fences, gateways, drains or
to any other structure in the execution of the Contract and shall leave everything in the same state as it was found by him.
The Contractor shall not harm or destroy any vegetation by fire or by any other means nor allow any practice which may have a detrimental effect on the environment. He shall be responsible for any damage whatsoever caused by his employees. The Contractor shall as far as possible confine his operations to within the limits of the Site or the land provided by the Employer, but if this is inadequate for his purpose, he shall make all arrangements for any further land he may require and shall pay all costs and charges in this connection.
The Contractor shall not use the land constituting the Site of the Works or a construction camp for any purposes whatsoever other than for the proper execution of the Contract, and shall be debarred specifically from any form of trading or bartering. The Contractor shall not sell any spirituous liquors or allow them to be sold or brought within the limits of the Works, and shall in every way discourage their use and distribution.
He shall erect and maintain suitable temporary fencing wherever necessary, and he will provide satisfactorily agreed compensation for all damage in respect of trespassing, and for all damage to the stock, crop or other property on the land, which may arise from the inefficiency or disrepair of such temporary fencing or from interference with existing fencing during the work.
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The Contractor's employees and those seeking employment shall be prohibited from trespassing on adjoining lands and from killing and disturbing any game, livestock or domestic animals.
2.8 CONTRACTOR ACTIVITIES ON PRIVATE PROPERTY
2.8.1 Action Required Prior to Entering Property
The Contractor shall not enter onto private property or property not belonging to the Employer for the purpose of carrying out any work in connection with the Contract without having completed the following formalities well ahead of his intended date for entering such property:
i. The Contractor shall give notice, in writing, to the owner, lessee or occupier, on a form approved by the Engineer, of his intention of entering upon the property, together with full details of the work he intends to carry out on the property and the intended dates and duration of occupation. ii. The Contractor shall arrange a meeting with the owner, lessee or occupier, to confirm that the owner, lessee or occupier has permitted the Contractor to enter upon the property for the said purpose; iii. obtain details from the owner, lessee or occupier, regarding any special precautions that should be taken by the Contractor during the execution of the Works; iv. record details, with photographs if necessary, of the condition of the property at that stage, including any defects in buildings, swimming pools, outbuildings, fences, etc. that may be affected by his activities and copies shall be submitted to the Engineer for record purpose v. Record in writing the details of the above; the form and substance of such records and agreements shall be subject to the Engineer's approval and a copy of the details as recorded shall be sent to the Engineer for his records and his approval. vi. In the event of the Contractor failing to reach agreement with the owner, lessee or occupier of the property on any of the matters referred to above, the matter shall be referred to the Engineer for further action. vii. Not less than three days before actually entering such property, the Contractor shall again give notice in writing to the owner, lessee or occupier of the exact date on which he intends to enter the property. If this date is not adhered to, he shall again give similar notice of his revised date.
2.9 SAFE WORKING CONDITIONS
2.9.1 General
The Contractor shall at all times observe adequate safety precautions on Site to ensure the safety of the public as well as of his own staff and other persons engaged in or about the Works. In this respect, he shall observe all laws, ordinances and regulations pertaining to his work.
When work is carried out within a road reserve, the road surfaces not affected by the work and which remain open to traffic, shall be kept clean at all times so that gravel and debris will not be thrown up by passing vehicles, causing possible injury to persons and damage to property and
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other vehicles. The Contractor's attention is specifically drawn to the fact that he should be in full compliance of all current acts and regulations in Pakistan in relation to Welfare and Working Regulations copies of which shall at all times be kept by the Contractor on the Site.
Should the work so require, the Contractor shall comply with all the safety requirements set out in Government Regulations and publications, copies of which shall also be kept by him on the Site.
2.9.2 Hygiene Requirements
Before commencing the work, the Contractor shall ensure that all his employees are instructed in the necessity for hygienic practices. The Contractor shall immediately dismiss and remove from the Site any employee or representative of the Contractor who has been polluting or fouling the Site and shall take appropriate remedial measures to prevent a repetition of the occurrence and to disinfect the areas concerned.
The hygiene requirements shall be in accordance with the Pakistan Labor Law.
2.9.3 Occupational Health and Safety Act
The Contractor shall comply with the Occupational Health and Safety Act and its Regulations. In particular, the Construction Regulations, shall be adhered to at all times. The Engineer and/or the Employer or his Agent shall inspect the works from time to time to monitor the Contractor’s compliance with the above legislation. Where any such investigations reveal, or where it comes to the Engineer’s attention that the Contractor is in any way in breach of the requirements of the above legislation, the engineer shall in accordance with the
Conditions of contract, be entitled to suspend construction of the works, or any part thereof, until such time as the breach has been rectified to the satisfaction of the Engineer, the Contractor will not be entitled to claim for any delay or disruption to the Contract due to the suspension of the works or the remedy practiced following the breach in this or any other associated legislation.
2.9.4 Health and Safety Plan
The health and safety plan required by the Act and supporting regulations shall include, but not limited to, the following:
• Occupational health and safety policy • Administrative requirements • Risk identification and assessment including maintenance of all registers • Training • Incident and accident reporting • Incident and accident investigation • First aid • Occupational health and safety representatives • Occupational health and safety committees • Permits
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• Certificates of competence and compliance Permits • Audits and inspections
2.9.5 Health and Safety File
Every Contractor shall ensure that a health and safety file, which shall include all documentation required in terms of the provisions of the Act and the relevant Regulations, is kept on site and made available to the Client, agent or inspectors on request. This document is a live document and should be updated on a continuous basis. A Principal Contractor shall hand over a consolidated Health and Safety File to the Client within 6 months of the completion of the construction work and shall, in addition to the documentation referred to in the regulations, include a record of all drawings, designs, materials used and other similar information concerning the completed works. A Principal Contractor shall ensure that in addition to the documentation required in the health and safety file as determined in the regulations, a comprehensive and updated list of all sub-contractors on site accountable to the principal contractor, the agreements between the parties and the type of work being done are included and available.
2.9.6 Safety Officer
The Contractor shall in accordance with the act and supporting regulations upon having considered the size of the project, the degree of risks likely to been countered or the accumulation of hazards or risks on the site, appoint a full-time Construction Safety Officer with the necessary competencies and resources to assist him in the control of all safety related aspects on the site. The appointment is subject to the Engineer’s approval.
2.9.7 Health and Safety Training
The Contractor shall provide employees with the necessary information and training or supervision that is necessary to enable them to perform their work safely and without risk to health, and shall ensure that every employee becomes familiar with work-related hazards and risks and the measures that must be taken to eliminate, control and minimize those hazards and risks.
2.9.8 Personal Protective Clothing and Equipment (PPE)
All employees employed on the construction site and visitors shall wear clothing and equipment as prescribed in the site hazard analysis. The Contractor shall identify tasks requiring protective
Clothing and equipment and issue the necessary to employees on site. Employees shall maintain all PPE in a safe, clean condition. Personnel not wearing PPE where PPE is prescribed will be disciplined in accordance with the general disciplinary code of conduct
2.9.9 Provision of Safety Fences, Signs and Barricades
The Contractor shall in accordance with the act and supporting regulations erect fences and/or barricades to protect the public passing by or entering the construction area. The Contractor shall,
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in accordance with the act and supporting regulations, erect Notices and Signs at entrances and along perimeters of the construction site indicating “No Unauthorized Entry” and “Visitors to report to Site Office”. Notices and Signs at the construction site entrance instructing visitors and non- employees what to do, where to go, and where to report to on entering the site shall also be erected. Where necessary, or as instructed by the Engineer, the Contractor shall employ security guards to safeguard safety fences, signs and barricades from theft or vandalism.
2.9.10 Environmental Protection of the Site
The Contractor shall undertake environmental protection measures to reduce the environmental impacts arising from execution of the Works. In particular, he shall arrange his method of working to minimize the effects on the air, noise, water quality as well as nuisance of waste within and outside the Site, on transport routes and at the stockpiling, loading, dredging and dumping areas.
The Contractor shall observe and comply with all the current enactments, relevant environmental protection and pollution control ordinances and regulations, and any additions or amendments thereto coming into effect before completion of the Works. The Contractor shall maintain on site legal copies of the relevant ordinances and their regulations, and provide one legal copy for the Engineer.
Where the activities on Site are found not in compliance with the requirements as specified or cause unacceptable environmental impacts, the Contractor shall be responsible, at its sole cost, for mitigating and cleaning up any environmental pollution, harm or damage arising from the performance of the Works, including all damage caused by the leakage, spillage or disposal of hazardous waste. Furthermore, he shall give strict instructions to all persons employed by him to use the sanitary facilities provided at Site.
If the Contractor fails to keep the Site clean, the Engineer shall instruct a third party to carry out the work at the cost of the Contractor.
2.9.11 Water Pollution Control
General: The Contractor shall carry out the Works in such a manner as to minimize adverse impacts on the water quality during execution of the Works. In particular, he shall arrange his method of working to minimize the adverse effects on the water quality within and outside the Site, on the transport routes and at the stockpiling, loading, dredging and dumping areas. The Contractor shall ensure that water flows in rivers, streams and other natural or irrigation channels are maintained and/or re-established where they are disrupted due to the execution of the Works.
Protection of Natural Streams/Rivers:
i. For the purpose of the Contract, a natural stream/river shall refer to a natural channel including the natural banks and riparian zones, with natural water fed from upper terrains with water flowing throughout the year or intermittent water-flow only during wet seasons, and any other water-carrying channels, ponds or the like and the extents are as defined on the Drawings. The Contractor shall keep on the Site records of photographs of the existing natural streams and
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rivers within the Site, and provide the Engineer with a copy of the same records before any works commence in or near natural streams/rivers. ii. Excavated or backfilling materials shall not be stored adjacent to natural streams/rivers unless permitted by the Engineer. iii. No excavated material, silt, debris, rubbish, cement slurry or such construction waste shall be deposited into natural streams/rivers. Should such deposits be found, the Contractor shall remove them, and restore the affected natural streams/rivers to their original state to the satisfaction of the Engineer. If the works site is inside or in the proximity of natural rivers/streams, the Contractor shall temporarily isolate the construction works with proper methods, such as by placing of sandbags or silt curtains with lead edge at bottom and properly supported props, to prevent adverse impacts on the water quality. iv. Without the prior consent of the Engineer, the Contractor shall not excavate boulders, gravel or sand or other substrata materials from the natural streams/rivers, whether these materials are for the purpose of temporary, long-term or off-site use as construction material, or for any other purposes.
2.10 INSPECTIONS AND TOOLS
Prior to packaging and transporting equipment/imported components of equipment, the Contractor shall inform to the Engineer and the Employer. In the case of the Employer accepts, the Contractor shall arrange the inspection for the Engineer and the Employer or his Representative to examine, inspect and mark products used in plant/works where, the equipment will be manufactured or installed completely. Duration of the inspection is at least 3 days excluding travel time. Equipment/specific tools: The Contractor shall supply sufficiently in terms of quantity and quality of compulsory equipment/specific tools at site during execution of requested items.
The Contractor is required to provide necessary equipment and tools to the Engineer and to the Employer during construction period for their duties and management. Such equipment and tools should be available at all time at site. The list of such equipment/tools shall be submitted to the Engineer for approval prior procurement. Upon issuing final acceptance, such equipment and tools shall be handed over to the Engineer.
2.11 TESTING OF MATERIALS AND GOODS
The Contractor shall provide at his expense all labor, materials and equipment necessary for sampling and testing of materials and goods supplied under this Contract. All measuring and metering equipment shall be certified by an approved authority.
A sampling protocol shall be agreed between the Engineer and the Contractor which shall define the extent of sampling, the methodology of sampling and testing, the relevant ranges of acceptable results and criteria of acceptance or rejection of the material or equipment.
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2.11.1 Samples
The Contractor shall submit to the Engineer as he may require, samples of all materials and goods, which he proposes to use or employ on or for the Works. Such samples, if approved, will be retained by the Engineer. It shall be the Contractor’s responsibility to ascertain from the Engineer which materials and articles are required for testing, and to ensure that they are submitted, sufficiently far in advance as to avoid delay in the Works.
2.11.2 Taking and Analysis of Sample
The Contractor shall take and analyze samples in compliance with existing relevant regulations standards and the agreed protocols. Taking samples shall be confirmed by Employer and the Engineer. Result of tests will be stored and preserved in accordance with technical requirements. At least one copy of the test results shall be submitted to the Engineer.
Without relieving the Contractor of his responsibilities under the Contract, the Contractor shall perform any additional tests which the Engineer may require and/or repeat tests the results of which, in the opinion of the Engineer are not representative.
2.11.3 Testing Facilities
As stated under item “2.14.4 Testing Facilities” of this specification
All current calibration records from a certified body for equipment testing shall be submitted to the Engineer for information.
2.12 REPORT PREPARATION, MEETING AND TAKING PHOTOGRAPHS
The Contractor shall submit reports and meet the deadline specified in the Bidding Document. All reports are presented in the A4 size and written in indelible ink. The Contractor will take Progress Photographs on a least a monthly basis to support his Progress Reports for execution of all Site Works
The Contractor cannot use his own standard forms without the Engineer’s Representative approval.
2.12.1 Progress Reports
The Contractor shall formally submit to the Engineer’s Representative no later than the first week of each month a Progress Report in such form that the That the monthly progress is charted against the formal Contract schedule showing either delay or an advance.
2.12.2 Meeting
The Contractor shall attend all meetings called for by the Engineer / Employer at the Site or in the Engineer’s / Employer’s office to discuss the progress of the Works and/or any problems related thereto, where adequate notice has been given.
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The Engineer will prepare Minutes of Meeting (MoM) and submit a copy for comments to both the Employer and the Contractor. Any comments must reach the Engineer within fourteen days after submission day. Beyond this period of time the MoM will be considered as accepted by all parties.
In the event that the Contractor fails or is unable to attend any meeting at which his presence has been requested, all matters arising shall be taken as if the Contractor had been present The opportunity for the Contractor to comment remains at 14 days.
2.12.3 Taking Photographs
The photographs, 3 Nos. copies shall be in color, minimum size 10x15 mm, and will be stored in the Site’s Office and be submitted following the requirement of the Employer and the Engineer’s Representative.
2.13 MEASUREMENT AND PAYMENT
2.13.1 Payment for the Works
The remuneration for various components of the Works shall be priced in the relevant items of the Bills of Quantities, which are deemed to include all obligations given notice in the Contract Documents
Unless provided by exception, the Technical Specifications, the Bills of Quantities and all the Contract provisions shall be deemed to be included at the Contractor’s cost and accounted in the Bill of Quantities
For the Permanent Works to be executed under the Contract, the Contractor shall supply all materials, equipment, temporary Works and labor necessary to perform, test and complete the Works and maintain the Works until issuance the Completion Certificate, General Conditions of Contract.
The Contractor shall also furnish all equipment’s, materials, specials and labor required to make connections to, to protect, to remove and to rearrange existing services and other structures so that the whole of Works is delivered to the Employer in perfect condition and working order.
2.13.2 Measurement of Works
The quantities shown in the Bill of Quantities (BoQ) are estimates only and they may vary during the course of the Works. Payment for these items shall be made on actual work done during construction and according to methods of measurement and payment, described in the Preamble to this document.
Measurement of Bill Items with a running total will be made for payment certificates shall be made by the Contractor for the Engineer. The Contractor’s measurement is always subject to the Engineer’s approval.
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The Contractor shall provide all assistance, drawings, schemes and all survey instruments and measuring equipment required. The cost for the measurement of works shall be deemed to be included in the respective prices for construction and installation of works.
If the Contractor does not assist or refuses to participate to the measurement of quantities, the quantities measured by the Engineer shall be considered valid.
Wherever levels, measurements, quantities, etc. of any work done cannot be checked at a later stage, the measurements made by the Engineer or approved by him shall be taken to be correct measurements of the work.
Any measurement of quantities taken during the progress of works is provisional and can be re visited if evidence demonstrates an error in identification or computation. In that case the Engineer and the Contractor shall proceed with new measurements.
2.14 TEMPORARY SITE FACILITIES
2.14.1 General
The temporary site facilities shall include any site infrastructure, temporary site offices and yards, site laboratory, safety provisions, accommodation and sanitary facilities, provisions for water, energy and access and the installation of signboards.
The maintenance of site facilities shall include at least but not be limited to water and energy supply, the operation and cleaning of Site offices, accommodation, sanitary facilities and all temporary Works, appropriate solid waste disposal. Access to and proper protection of construction sites including for security, lightening and traffic control must be ensured throughout all times of construction.
The costs of the site facilities shall be deemed to be included in the corresponding in the Bill of Quantities (BOQ).
Temporary facilities as outlined herein shall be installed prior to start of work and within (30) days of after the notice to commence work.
All offices, stores and testing laboratories shall be guarded and protected at all times of the day and night, and maintained throughout the duration of the Contract.
2.14.2 Water Supply
The Contractor shall provide suitable supplies of water for drinking, washing, sanitation and general cleaning in addition to any required for the construction, testing and commissioning of the Works.
Service water: The Contractor shall provide service water to the Employer via local suppliers in sufficient quantity and of quality during the contract implementation process.
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2.14.3 Power Supply
The Contractor shall install, operate, maintain and subsequently remove sufficient temporary supplies of electricity for air-conditioning, heating, lighting and ventilation for all offices, stores, laboratories and other temporary buildings used by the Contractor and those provided for the Engineer's use, in addition to any supplies he may require relating to the construction, testing and commissioning of the Works.
2.14.4 Testing Facilities
The Contractor shall arrange on site or nearby areas and maintain and remove when directed by the Engineer temporary facilities for testing and quality control. The testing facilities shall be i) equipped with material, suitable calibrated apparatus and tools needed for his own testing of materials and ii) staffed by sufficient competent technicians for the sampling and testing of materials and workmanship as required for verification of compliance with the Specification.
Testing that cannot be performed in the Contractor’s certified Site laboratory shall be carried out in other certified laboratories approved by the Engineer, prior the testing.
2.14.5 Contractor’s Accommodation
The Contractor shall erect, construct, and maintain and subsequently remove all temporary offices, sanitary conveniences, stores, workshops, compounds and parking areas and living accommodation as are necessary to ensure that he is able to conduct and supervise the construction of the Works effectively.
The Contractor must provide a legally and adequate standard of living accommodation for his work- force in any camp on or off the Site with sufficient safe, secure living space with adequate food, washing and sanitary arrangements.
Temporary toilet units: The Contractor shall provide and maintain self-contained single-occupant toilet units of the chemical, aerated recirculation, or combustion type, properly vented and fully enclosed with a glass fiber reinforced polyester shell or similar non-absorbent material for use by all Contractors and Subcontractors on the site. The number of units should be adequate to provide safe sanitary service for all on-site contractor personnel, and should meet any and all applicable code requirements.
All accommodation and welfare facilities are to be in accordance with the Pakistan Labor Law.
2.14.6 Demobilization from Site
The demobilization includes the removal of all Site facilities and temporary installations, the demobilization of all equipment from Site, the removal of all surplus materials, the reinstatement of all damaged or worn access roads and facilities used by the Contractor and the cleaning up of the Construction Site upon completion of the Works.
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The demobilization shall be in accordance with the Pakistan Labor, Health and Safety and Environmental Laws.
2.14.7 Contractor’s Toilet and First Aid Facilities
The Contractor shall set up, maintain and clean daily, toilet and washing facilities with adequate supplies of soap, disinfectant and the like and with suitable drainage arrangements, for the use of his employees. The Contractor shall provide adequate first-aid facilities for his staff at the Site. An adequate stock of sterile bandages, disinfectants, spray disinfectants, plasters, scissors, etc. shall be kept available, held in a dust proof cupboard accommodated in a clean room. The toilet and first aid facilities shall be ready for use within one week of commencement of work on Site.
The Contractor’s Toilet and First Aid Facilities shall be in accordance with the Pakistan Labor Law.
2.14.8 Assistance to the Engineer and Employer
The Contractor shall at all times during the duration of the Contract provide for the use of the Engineer and Employer all equipment, instruments and apparatus, all information and records and qualified chainmen and labourers required by the Engineer for inspecting and measuring the Works. Such equipment, instruments and apparatus shall include those listed in the Special Provisions.
2.14.9 Employer’s and Engineer’s Site Facilities
All facilities provided to the Employer and the Engineer by the Contractor shall be near the job site, where necessary and shall conform to the best standard for the required types. On completion of the Contract, the facilities provided by the Contractor including utilities and communication facilities shall revert to the Government including office equipment, apparatus, pieces of furniture, laboratory equipment etc., unless otherwise specified in the Contract documents.
2.14.10 Engineer’s and Employer Site office
The Contractor should provide an adequate fully equipped, static, prefabricated or mobile office with sufficient space and washing and sanitary facilities for the Engineer’s representative and Employer’s representative.
These offices shall have a minimum space of 25 m² for each, lockable entrances, operable windows and serviceable finishes. Each office shall be equipped at least but not limited to:
• Two office table, • Two office chairs (Swivel), • 4 sundry chairs, • 1 Computer incl. screen, mouse and keyboard and the current software, • A4 Colour Printer, • UPS Unit, • Air conditioning,
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• Lights, • Telecommunication, also International, • Internet, • Consumables & Stationary, • First Aid supplies. • Fire Extinguisher: hand-carried, portable, class “A” fire extinguisher for temporary offices and similar spaces all in accordance with prevailing building codes.
Temporary toilet units: The Contractor shall provide self-contained single-occupant toilet units of the chemical, aerated recirculation, or combustion type, properly vented and fully enclosed with a glass fiber reinforced polyester shell or similar non-absorbent material for use by the Engineer’s representative and Employer’s representative on the site. The number of units should be adequate to provide safe sanitary service for all on-site Engineer’s and Employer’s personnel, and should meet any and all applicable code requirements.
2.15 REVIEW OF TECHNICAL DOCUMENTS
The Contractor shall carefully review all technical documents included in the Contract before the start of the Works and the ordering of the required goods and report any conflicts or anomalies immediately.
The Contractor shall amend the initial lists, schedules and drawings as may be required and submit three copies to the Engineer.
2.16 REVIEW PROCEDURE FOR DRAWINGS
Items submitted by the Contractor will be returned after the Engineer’s Representative’s review either ‘Accepted’, ‘Accepted with reservations’ or ‘Returned for amendment’. Such acceptance shall mean that the Employer has no objection to the Contractor using, upon his own full responsibility, the design, plan or method of work proposed or furnishing the materials and equipment proposed.
2.17 SUBMITTAL OF DOCUMENTS
2.17.1 Cash Flow Program
Together with the Work Program the Contractor shall provide to the Engineer a detailed Cash Flow Program of all payments to which the Contractor shall be entitled under the Contract including O&M operation along with a 5-year asset replacement model. He shall update this Profile on a regular monthly basis based upon updates from the Program of works and Operation, which is a requirement of the Engineer.
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2.17.2 Construction Method
The Contractor shall submit details of all the plant, equipment and labour force, which he proposes to use and employ and shall describe in detail the proposed construction and operational methods for each element of the Works. The details of construction plant shall include the make, type, capacity or rating and the number of units, which the Contractor envisages to employ throughout the duration of the Contract.
Special attention shall be paid to:
i. the procedure of concrete mixing, transporting, vibrating and curing irrespective of the origin of the concrete; ii. procedure of grouting of any equipment and / or steel structure into box-outs of primary concrete after careful adjustment to line and grade and wrapping into plastic sheets against fouling during grouting; iii. on-site coating, painting and other works serving for corrosion protection; iv. General and particular safety measures to be maintained throughout implementation of the respective Works.
The Contractor shall furnish to the Engineer the formal approval of working methods he may be required to obtain from relevant authorities at least 14 days prior to the commencement of any new section of Works. Such approval of working methods shall in no way relive the Contractor from his obligations.
Such approvals of working methods shall be obtained, as applicable, e.g. for the maintaining of public traffic, the dealing with/crossing of other services, the diversion of flow and discharge of water from excavations, the reinstatement of excavated areas and the provisions to ensure public safety.
The Contractor shall maintain in both hard and soft copy records of construction and operational methods, their submission, approvals, modifications etc.
2.17.3 Method of Performing the Works & Services
The Bidder is required to submit a narrative outlining the method of performing the Works and Services. The narrative should indicate in detail and include but not be limited to:
i. The sequence and methods in which he proposes to carry out the Works/Services, including the number of hours per day, he expects to work. ii. A list of all major items of plant, tools and vehicles proposed to be used in carrying out the operation and maintenance, including number of each kind, make, type, capacity of all equipment, working condition, which shall be deployed by him in sufficient detail to demonstrate fully that the equipment will meet all the requirements of the Technical Provisions. iii. The procedure for transportation of materials to the site.
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iv. Details regarding mobilization in Pakistan, the type of facilities including personnel accommodation, office accommodation, provision for maintenance and for storage, communications, security and other services to be used. v. Organization chart indicating head office & field office personnel involved in management of the Works to be done and Services to be performed under the Contract.
2.17.4 Quality Assurance
The Contractor shall submit and have approved a Quality Management Plan within 30 days of signing of the Contract Agreement.
All material, equipment, plant and instruments to be supplied from outside Pakistan shall be manufactured and comply with application standards of Euro Countries, American or Japan. Bidders shall submit evidence that the equipment to be supplied from outside Pakistan will be manufactured and delivered to the requirements of ISO 9002 - Quality Systems -Model for Quality Assurance in Production, Installation and Servicing (or ISO 9001), and in accordance with the Technical Specification. This evidence shall be in the form of the following:
i. A certificate issued by an independent, internationally recognized Third Party Accreditation Agency that the proposed manufacturer of the materials operates quality assurance systems, which conform to the requirements of ISO 001 or 9002. The certificate shall clearly show the name of the certifying agency, the certificate number and the products or facilities certified. To be accepted as an internationally recognized independent third-party accreditation agency, the agency must have performed accreditation work of a similar nature in a minimum of two countries. As evidence of this, copies of relevant certificates issued by the agency or a statement from the agency or from an ISO Member Body, showing how the agency meets this criterion shall be provided. ii. A draft Quality Plan which demonstrates that the manufacturing, testing, production and delivery requirements of the Contract, and the standards to which the materials to be manufactured are understood, is to be submitted. The Quality Plan shall include the following as appropriate: - procurement of components and raw material; - calibration of test equipment; - sampling, destructive/non-destructive testing, frequencies of sampling and testing; - inspection procedures; - rectification of non-conformities; - record systems; - inventory control, packing; - Proposed production, transportation and delivery program.
2.17.5 Testing/Commissioning& Handover Schedules
Proposals for testing/commissioning, which shall include but not be limited to schedules of commissioning the civil structures, water pumping Filtration Plant, water treatment units and
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electrical equipment and cables. Schedules shall be submitted at least 4 weeks prior to the expected date of completion or earlier, if appropriate and agreed by the Engineer’s Representative.
2.17.6 As-Built Drawings
As the work proceeds, the Contractor shall prepare, at his own expense, record drawings based on the Contractor’s reviewed and updated working drawings as to portray the Works actually executed. These record drawings shall become As-Built Drawings upon completion of the Works. These drawings shall clearly show all portions of the Works, in plan, profile and sections and also all deviations from the original drawings.
The complete set of as-built drawings shall comprise, but is not limited to:
• General Layout • Layouts and profiles of pipelines • Pipe and Instrumentation Diagram (PID) • Actual drawings of any structures (plan and sections), showing built-in pipes and fittings. • Geo-tagged references and associated data.
Where the Works consist of plants, tanks etc., including hydraulic, mechanical and electrical works the complete set of as-built drawings shall comprise any civil, hydraulic, mechanical and electrical working drawing updated to reflect the Works as actually executed.
The Contractor shall use the metric international system of units (SI Units).
Draft versions of the records drawings shall be submitted to the Engineer for approval and then be completed with any amendments requested by him.
On completion of the individual Works the Contractor shall supply to the Engineer the complete set of originals and copies of the As-Built Drawings within 30 days. All this material shall be delivered in a legible and navigable manner in both hard and soft copy, well-structured and with a comprehensive list of contents. The structure is to be proposed by the Contractor in time provided the Engineer does not prescribe such structure in advance.
The material shall be delivered in the following formats:
i. As-built drawings: 1x dwg format, 1x pdf format; 2x hard copy full scale unfolded; 4x hard copy reduced scale
ii. Originals in A3 and original in A4: 1x pdf format; 3x hard copy full scale in folders A4
All Soft copies shall be delivered as a set of DVD high capacity and after approval stored on external drive.
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2.17.7 Shop Drawings
The shop drawings shall indicate the general assembly, components, dimensions, weights, clearances and methods of assembly. Draft versions drawings shall be submitted to the Engineer for approval and then be completed with any amendments requested by him.
The material shall be delivered in the following formats:
i. Shop-Drawings: 1x dwg format, 1x pdf format; 1x hard copy full scale unfolded; 2x hard copy reduced scale
ii. Originals in A3 and original in A4: 1x pdf format; 2x hard copy full scale in folders A4
2.17.8 Maintenance Instructions
For each element of plant and equipment, the Contractor shall provide the Manufacturer’s maintenance instructions. These instructions shall be in English language.
2.18 SYSTEM OF UNITS
This conversion table below shall be used if so required:
LINEAR MEASURE (LENGTH/DISTANCE) LINEAR MEASURE (LENGTH/DISTANCE) IMPERIAL METRIC METRIC IMPERIAL 1 inch 25.4 millimeters 1 Millimeters 0.0394 inch 1 foot (=12 inches) 0.3048 meter 1 centimeter (=10 mm) 0.3937 inch 1 yard (=3 feet) 0.9144 meter 1 meter (=100 cm) 1.0936 yards 1 kilometer (=1000 m) 0.6214 miles SQUARE MEASURE (AREA) SQUARE MEASURE (AREA) IMPERIAL METRIC METRIC IMPERIAL 1 square inch 6.4516 sq. centimeters 1 square centimeter 0.1550 sq. inch 1 square foot (=144 9.29 square decimeters 1 square meter (=10 000 1.1960 sq. yards square inches) sq. cm) 1 square yard (=9 square 0.8361 square meters 1 are (=100 sq. meters) 119.60 sq. yards feet) 1 acre (=4840 square 0.40469 hectare 1 hectare (=100 Ares) 2.4711 acres yards) 1 square mile (=640 259 hectares 1 square kilometer (=100 0.3861 sq. mile acres) hectares) CUBIC MEASURE (VOLUME) CUBIC MEASURE (VOLUME) IMPERIAL METRIC METRIC IMPERIAL 1 cubic inch 16.4 cubic centimeters 1 cubic centimeter 0.0610 cubic inch 1 cubic foot (=1728 cubic 0.0283 cubic meters 1 cubic meter (one 1.308 cubic yards inches) million cu. cm)
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CAPACITY MEASURE (VOLUME) CAPACITY MEASURE (VOLUME) IMPERIAL METRIC METRIC IMPERIAL 1 (imperial) fl. oz. (=1/20 28.41 ml 1 milliliter 0.002 (imperial) pint imperial pint) 1 (imperial) gallon (=4 4.546 liters 1 liter (=1000 ml) 1.76 pints quarts) 9.092 liters 1 deciliter (=10 l) 2.20 (imperial) gallons MASS (WEIGHT) MASS (WEIGHT) IMPERIAL METRIC METRIC IMPERIAL 1 ounce (=16 drams) 28.35 grams 1 milligram 0.015 grain 1 pound (=16 ounces 0.45359237 kilogram 1 gram (=1000 mg) 15.43 grain =7000 grains) 1 (long) ton (=2240 lbs) 1.016 tonnes 1 kilogram (=1000 g) 2.205 pounds 1 (short) ton (=2,000 lbs) 0.907 tonne 1 tonne (=1000 kg) 0.984 (long) ton
Temperature shall be in degrees Celsius (°C), power in Watts and irradiance in kWh/m² etc.
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3 CIVIL WORKS
3.1 EXCAVATION, TRENCHING AND BACKFILLING
3.1.1 Scope
The work covered by this section of the Technical Specifications consists of furnishing all plant, labor, equipment, appliances, and the materials for performing all operations in connection with excavation, trenching and back-filling for water supply, sewerage and structures including all incidental works necessary for excavation to the required depth and dimensions in accordance with the applicable drawings, or as directed by the Engineer. The work shall be carried out in complete conformity with the specifications, set forth hereunder.
3.1.2 Setting Out
The Contractor shall set out the works in accordance with the dimensions, lines and levels shown on the IFC Drawings. Where no precise positions or levels are shown on the drawings, the works shall be set out by the Contractor to the positions and levels determined by the Engineer's Representative as the work proceeds.
3.1.3 Clearing and Grubbing
The sites of all excavations shall be cleared of all shrubs, plants, bushes, large roots, rubbish and other objectionable materials. All such materials shall be removed from site of work or otherwise disposed of at no extra cost in a manner satisfactory to the Engineer. All trees and shrubs that are designated by the Engineer to remain shall be adequately protected and preserved in an approved manner.
3.1.4 Excavation
3.1.4.1 General
All excavation of whatever substance encountered shall be performed to the depths indicated or as otherwise specified. During excavation, material suitable for back-filling shall be stockpiled in an orderly manner at a sufficient distance from the banks of the excavation to avoid overloading and to prevent sides from caving. All excavated material unsuitable for backfill shall be removed and placed at a location approved by the Engineer. Grading shall be done as may be necessary to prevent surface water from flowing into the trenches or other excavations, and any water accumulated therein shall be removed by pumping or by other approved methods. Unless otherwise indicated or approved by the Engineer, excavation shall be open cut.
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3.1.4.2 Replaced Soil under Foundations
Material
Selected well graded granular material shall be used for filling beneath the structural foundations. This material should meet the requirements of A-2-4 & A-3 (AASHTO Soil Classification).
The suitability of the material shall be supported by adequate tests in the laboratory. Equipment and Procedure
Suitable equipment shall be selected by the Contractor on the basis of field trials for compaction. The Contractor shall indicate his planning to carry out compaction in his Method Statement for the Engineer's approval before undertaking actual compaction. A test section would be required to select the most suitable equipment, layer thickness, moisture content, No. of passes etc. Compaction Standard
The Contractor shall place the material to be compacted in layers. Each layer shall be of specified thickness and shall be compacted by the optimum number of passes as explained in above section. Compaction less than 75% of relative density or 95% of Modified Proctor Density shall not be acceptable. Quality Control
Every compacted layer shall be tested for quality of compaction by performing in-situ density tests. Sand replacement method of density measurement shall be used. The evaluation of 75% relative density or 95% Modified Proctor Density shall be based on measurement of maximum, minimum and maximum Modified Proctor Densities in the laboratory. The frequency of this testing shall be instructed by the Engineer at the site.
3.1.5 Precautionary and Remedial Measures
3.1.5.1 Protection of Existing Facilities and Structures
The Contractor shall take every necessary precaution not to endanger the safety, occupation or operation of any property, structures, installations or services in the vicinity of his operations and shall observe any restrictions imposed by the Authority concerned and the Engineer to this end. Should any such property, structures, installations or services be endangered or damaged as a result of the Contractor's operations, he shall immediately report any such danger or damage to the Engineer's Representative and any Authority concerned and shall forthwith undertake remedial measures to the satisfaction of the Engineer and the appropriate Authority without additional cost.
3.1.5.2 Planking and Strutting
The Contractor shall provide at his own expense to the satisfaction of the Engineer all timbering, poling, shoring, strutting and other approved supports to the sides of all excavations, trenches and
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all other works in such a way as will be sufficient to secure them from falling and to prevent any movement. All responsibilities connected with this part of the work shall rest with the Contractor.
In removing timbering, shoring and strutting and all other supports from excavation and trenches, special care shall be taken to avoid pressure on fresh concrete or any other work until it is sufficiently safe to resist such pressure.
3.1.5.3 Dewatering
The Contractor shall build all drains and do ditching, pumping, well pointing, bailing, and all other work necessary to keep the excavation clear of ground water, sewage and storm water during the progress of the work and until the finished work is safe from injury. All water pumped or drained from the work shall be disposed of in a manner satisfactory to the Engineer and necessary precautions against flooding shall be taken. The procedure for dewatering of subsoil water from excavation for the purpose of construction of sewer lines and other structures shall be in accordance with the method given below:
Dewatering of subsoil water from excavations of trenches and excavations for other structures shall be arranged by an adequate process of well-pointing, bailing and/or pumping or by any other suitable method approved by the Engineer on the basis of the method (statement to be submitted by the Contractor).
If well-points are used, then the following requirements shall be met with. Well-pointing shall consist of bore holes, provided with necessary strainers, blind pipes and pumping machinery, and these shall be of suitable size and depth and shall be located on both sides of the trench and along the periphery of water level to a sufficient depth to keep the excavations clear of subsoil water during the process of construction.
As a part of the work and at no extra cost, the Contractor shall provide all strainer pipes and other requisite material, and boring tools and plant, etc. for the well pointing and shall also provide pumping equipment as well as operating personnel, power, etc. Dewatering of subsoil water shall be continuous process round the clock during the progress of the work and until the finished work is safe, from injury to the complete satisfaction of the Engineer's representative and any interruption in continuous pumping and causing injury to the works done or under construction shall require the Contractor to repair or rebuild the works to the entire satisfaction of the Engineer's representative at no extra cost. No extra payment shall be made to the Contractor for the disposal of storm water and for dewatering in trenches and building structures less than 5 ft. depth.
3.1.5.4 Maintenance of Excavation
All excavation shall be properly maintained while open and exposed. Sufficient suitable barricades, warning lights, flood lights, reflective signs, and similar items shall be provided by the Contractor. The Contractor shall be responsible for any damage due to his negligence
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3.1.5.5 Surplus Materials
All surplus materials shall be disposed of at locations approved by the Engineer. The disposal of surplus material shall not interfere with other works and shall not damage or spoil other material. When it is necessary to haul earth or rock material over street or pavement, the Contractor shall prevent such material from falling on the street or pavement.
3.1.5.6 Cutting Pavement
In cutting or breaking street surfacing, the Contractor shall not use equipment which will damage the adjacent pavement. Existing paved surfaces shall be cut back beyond the edge of trenches to form neat square cuts. The road ballast, brick pavement, and other materials shall be placed on one side and shall be preserved for reinstatement when the trench is filled. Wherever necessary or required for the convenience of the public or individual residents, at street crossings and at private driveways, the Contractor shall provide suitable temporary bridges which shall be maintained in service until backfilling has been completed. The Contractor shall keep the road crossings manned 24 hours per day. During night time, enough red lights shall be provided to warn the traffic. If detour is necessary, the Contractor shall make proper detour for the traffic and shall install signs 3 ft. x 4 ft. in size indicating the detour.
3.1.6 Transportation of Material
All carts, trucks or other vehicles used by the Contractor for transportation of the material shall be suitably constructed or lined not to permit any leakage/spillage of soil while the vehicles are on the move. These would be so loaded and arranged as not to spill on the site and public roads. Whenever any vehicle so used is found leaking/spilling and unsuitable, it shall be immediately withdrawn from the work on notification by the Engineer.
3.1.7 Compacted Fill and Backfill
3.1.7.1 General
After the completion of water and sewer lines, foundations, walls and other structures below the elevation of the final grade, all voids shall be backfilled with suitable materials, as specified below.
3.1.7.2 Backfilling for Structures
It would comprise returning and filling the selected excavated material around foundations, and at back of walls etc., upto finished levels shown on the Drawings or as required in layers not exceeding 6 inches, carefully rammed and consolidated (with addition of water if required) so as to achieve a minimum relative density of 90% of modified proctor test at optimum moisture content. No fill shall be made until the concrete foundations and footings etc., have been inspected and approved by the Engineer. Earth to be used for filling must be free of all the organic impurities, debris or any other foreign matter. Earth which contains more than 1% of salts particularly sulphates will not be used in filling.
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3.1.7.3 Backfilling of Trenches
The trenches shall not be completely backfilled until all required pressure tests are performed and until the water lines as installed conform to the requirements of specifications. Where in the opinion of the Engineer, damage is likely to result from withdrawing sheeting, shoring; the same shall be left in place and cut off at a level 1 ft. below ground surface. Trenches shall be backfilled to the ground surface with selected excavated material or other material that is suitable for proper compaction. Trenches improperly backfilled shall be reopened to the depth required for proper compaction, then refilled and compacted to the specified density. The surface shall be restored to its original or better condition. Pavement and base course disturbed by trenching operations shall be replaced.
3.1.7.4 Lower Portion of Trench
Backfill material below and around pipe shall be deposited in 6 inch maximum thickness layers and compacted with suitable hand tampers to 90% of maximum density until there is a cover of not less than 1 ft. over the pipe. The backfill material in this portion of trench shall consist of sandy clay or other approved materials free from stones and lumps.
3.1.7.5 Remainder of Trench
The remainder of the trench portion above pipe shall be backfilled with material that is free from stones larger than 6 inch in any dimension. Backfill material shall be compacted to achieve a minimum relative density of 90% of modified proctor test at optimum moisture content for cohesive soils and 95 percent of maximum density for others.
3.1.8 Borrow
In case of insufficiency of excavated material and un-suitability of earth for backfilling, conforming to the above specifications, such material shall be brought from the source approved by the Engineer.
3.1.9 Grading
After the completion of all backfilling operations, the Contractor shall grade the work areas to the lines, grades and elevations shown on the drawings or as directed by the Engineer. Finished grading shall not be done until the installation of all utilities or appurtenance. All damage due to settlement shall be repaired by and at the expense of the Contractor.
3.1.10 Testing of Soil in Place
The Engineer will make tests using the calibrated cone method/core cutter method to determine the density of soil in place. If soil in place fails to meet the specified degree of compaction the areas represented by the failing tests shall be removed, replaced and compacted to the specified density in the manner directed by the Engineer and at no additional cost to the Owner.
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3.2 CONCRETE
3.2.1 Scope
This section covers the manufacture, forming, transporting, placing, stripping of forms, finishing and curing of plain and reinforced normal concrete in the structures included herein.
3.2.2 Specifications
Concrete work shall conform to all requirements of ACI 301-72, (Revised 1975), Specifications for Structural Concrete for Buildings, except as modified by supplemental requirements below. The Contractor shall submit, for the approval of the Engineer, before commencement of any work, his Method Statement which would provide complete details of the procedures and equipment to be used for the satisfactory execution of the work. The approval of such Method Statement shall not relieve the Contractor of any of his responsibilities under the Contract.
3.2.3 Composition and Quality
Concrete shall be composed of Portland cement, water, fine and coarse aggregates and any admixtures as and when specified. The concrete mixes will be designed by the Engineer who will determine the required quality of the concrete for the structures covered by these Specifications. The desired strength of concrete for various parts of the structures have been shown on the Drawings. Such concrete mixes shall not relieve the Contractor of the responsibilities to achieve the desired strength of concrete for various parts of structures as specified in the Technical Specifications or shown on the Drawing and to the full satisfaction of the Engineer.
3.2.4 Cement
3.2.4.1 General
Cement shall be furnished in sacks or in bulk form as approved by the Engineer.
Unless otherwise permitted, cement from not more than two plants shall be used and in general, the product from only one plant shall be used in any particular section of the work. No cement recovered through cleaning sacks shall be used.
3.2.4.2 Portland Cement
Portland cement shall be indigenous stuff unless otherwise approved by the Engineer. Portland cement shall conform to latest British Standard 12:1971, Specifications for Portland Cement or to ASTM Designation C150- 74, Standard Specifications for Portland Cement for Type I. Portland cement conforming to ASTM Designation C150-74, Type II or IV may also be used in certain parts of work as directed by the Engineer.
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3.2.4.3 Tests
Cement shall be sampled at storage site and tested from time to time at the discretion of the Engineer in accordance with the ASTM Designation C150-74 or its equivalent British Standards. Expenses for such tests shall be borne by the Contractor. If the tests prove that the cement has become unsatisfactory, it shall be discarded and thrown as rejection as directed and to the full satisfaction of the Engineer. Cement which has been in storage at the project site longer than four months, shall not be used until retesting proves it to be satisfactory.
3.2.4.4 Storage
Cement shall be stored in dry, weather tight and properly ventilated structure. All storage facilities shall be subject to approval and shall be such as to permit easy access for inspection and identification of each consignment. Sufficient cement from a single source shall be in storage at the work site to complete any lift of concrete stored. Adequate storage capacity shall be furnished to provide sufficient cement to meet the peak needs of the project. Cement in sacks shall be stored on a damp proof floor and shall not be piled to a height exceeding 6 feet.
The Contractor shall use cement in the approximate chronological order in which it is received at the site. All empty sacks shall be promptly disposed of as permitted and directed by the Engineer so as to avoid any confusion in use of quantity of cement.
Cement storage facilities shall be emptied and cleaned by the Contractor when so directed, however the interval between required cleaning normally will not be less than four months.
Suitable, accurate scale shall be provided by the Contractor for weighing the cement in stores and elsewhere on the work, if required, and he shall also furnish all necessary test weights.
3.2.4.5 Delivery and Usage Record
Accurate records of receipts of cement at site and its use in the work shall be kept by the Contractor. Copies of these records shall be supplied to the Engineer in such a form as he may require.
3.2.5 Aggregates
Materials used as aggregates shall be obtained from sources known e.g Margalla / Shaheen-Abad/ Sikhan-wali to produce satisfactory results for the different classes of concrete. The use of aggregates from sources which have not been approved by the Engineer shall not be permitted.
3.2.5.1 Fine Aggregate for Concrete
Fine aggregate for all the classes of concrete shall be well graded natural sand, stone screenings or other inert material of similar characteristics or a combination of these. The whole of it shall be perfectly clean, free from coagulated lumps, soft and flaky particles, shale alkali, organic matter, loam mica and injurious amount of other deleterious substances. Maximum allowable content of
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silt and other deleterious inert substances is 5 percent by washing. Material derived from stone unsuitable for coarse aggregate shall not be used as fine aggregate. Fine aggregate derived from stone screenings shall be sharp, cubical, hard, dense and durable and shall be stacked on a platform so as to adequately protect it from dust and other admixtures.
Grading for the above specified fine aggregate shall be within the following limits, as determined by the Owner:
Sieve Size Percentage Passing (Dry Weight)
3/8 inches 100 No. 4 95 to 100 No. 8 80 to 90 No. 16 50 to 85 No. 30 25 to 60 No. 50 10 to 30 No. 100 2 to 10
Fine aggregate for class D (1000 psi) concrete may be good quality bank run sand obtained from the River in vicinity. It shall be clean natural material graded from fine to coarse, free from lumps, clay, cinder, ashes, rubbish and other debris. It shall not contain more than 5 percent of material finer than No. 200 mesh screen, not more than 5 percent remaining on No. 4 sieve; all material shall pass through 3/8" screen.
3.2.5.2 Coarse Aggregate for Concrete
Coarse aggregate for the first 3 classes of concrete shall consist of quarried or crushed stone/river run gravel or inert material or a combination of these, with maximum size of 3/4 inch and shall be clean, hard durable, sound, cubical and well-shaped, free from soft or friable matter, or thin elongated pieces, alkali, organic matter or injurious amounts of other deleterious substances. Deleterious inert matter shall not exceed 3 percent.
Grading for above specified coarse aggregate shall be within the following limits:
Sieve Size Percentage Passing (Dry Weight)
1 inch 100 3/4inch 90 to 100 1/2 inch 20 to 55 3/8 inch 0 to 10 #-4 0 to 5
Coarse aggregates for Class D (1000 psi) concrete shall be broken stone or river run gravel from dense hard stone, or boulders. The stone or gravel should not be porous or slaty it must be free from earth, sand or other foreign matters. The broken aggregate or gravel shall be of the prescribed size for the class D (1000 psi). The broken aggregate or gravel shall be of max. Size 1 inch or 1 1/2 inches and not contain any thing which will pass through No.4 sieve.
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3.2.5.3 Storage of Aggregate
Each class of aggregate is to be stored separately and the Contractor is to provide means of ensuring that aggregates are stored on a suitable hard clean surface or platform to prevent contamination from the ground.
3.2.5.4 Proportions of Coarse and Fine Aggregates
The nominal ratio of the Volume of coarse aggregate to the volume of fine aggregate shall be decided by compression test of concrete cubes or cylinders to be furnished by the Contractor but the Owner may order these ratios to be varied slightly according to the grading of the aggregates by weight, if necessary, so as to produce required grading. The Engineer can get the tests carried out at the Contractor's cost.
At the beginning of the work and where there is any change in the coarse or fine aggregates or in their source of supply, the Contractor is to have a series of tests on cubes/cylinders made representative of and marked as to the aggregates and their grading and mix of concrete. Such cubes are to be tested in the laboratory under identical conditions, except for small variations in the relative proportions of the coarse and fine aggregates up and down from the best proportions derived from the sieve analysis. The cubes etc. are to be tested at 7 days.
3.2.5.5 Water
Water for washing aggregates and for mixing and curing concrete shall be clean and free from injurious amounts of oil, acid, alkali, salt, organic matter, or other deleterious substances as determined by standard tests selected by the Engineer. It shall meet the following chemical requirements:
Chlorides such as Sodium Chloride Max 3000 ppm Sulphates such as Sodium Sulphate Max 2000 ppm Impurities Max 2000 ppm Melted Salt Max 25000 ppm
The water for curing concrete should not have pH value lower than 5 and shall not contain impurities which cause discoloration of concrete.
3.2.6 Concrete Mix Requirements
3.2.6.1 Strength
The concrete shall be one of four different classes to be paid for at their respective unit prices designated. The numerical classifications refer to the approximate proportions of cement, fine aggregate and coarse aggregate, according to the common practice. However, the actual concrete mix requirement shall consist of proportioning and mixing for the following strengths when tested in the form 6" cubes, 3 for 7 days’ and 3 for 28 days’ test shall be made for each class of concrete.
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The cubes are to be made, cured, stored, transported and tests are to be carried out at a testing laboratory approved by the Engineer. All such tests shall be at the cost of the Contractor.
Cube (Min) Compressive Concrete Cylinder (Min) Compressive Strength Tentative Strength Ratio Class Tested at 7 days Tested at 28 days Tested at 28 days A 2000 psi 3000 psi 4000 psi 1:1-1/2:3 B 1600 psi 2400 psi 3000 psi 1:2:4 C 1000 psi 1600 psi 2000 psi 1:3:6 No strength D 800 psi 1000 psi 1:4:8 requirements
3.2.7 Water Cement Ratio
The water-cement ratio is the ratio of the weight of water in the mix to the weight of cement therein. Water content shall be sufficient to produce a workable mix of the specified strength but the total water content shall be governed by the following table:
Concrete Maximum Permissible Total Water Demand Class (Imperial) Gallons per 112 pounds of cement A 6.0 B 7.5 C 8.0 D No requirements
3.2.7.1 Consistency
Proportions of ingredients shall vary to achieve the desired concrete consistencies when tested, conforming to the following slump requirements or as desired by the Engineer:
Use of Concrete Minimum and Maximum Slump (inch) Normally reinforced sections compacted by vibration, hand 1 to 3 Compacted mass concrete. Heavily reinforced concrete sections compacted by vibration, hand Compacted concrete In normally 2 to 4 rein-forced slabs, beams, columns and walls.
Compacted concrete in normally rein-forced slabs, beams, columns and walls.
In all cases, the proportions of aggregates for concrete shall be such as to produce mixes which will work readily into the corners and angles of the forms and around the reinforcement without permitting the segregation of materials or liateance. Uniformity in concrete consisting from batch to batch shall be ensured.
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3.2.8 Mixing Methods
The concrete shall be mixed in an approved mechanically operated batch mixer. The mixer, its hopper and working platforms shall be protected from rain and wind.
The aggregates and cement shall be mixed together before adding water until the concrete is of even colour and consistency throughout. Dirt and other undesirable substances shall be excluded. Water shall not be added indiscriminately from a hose or can. All concrete shall be thoroughly mixed by a modern reliable batch mixer to produce maximum output of concrete necessary to complete the work within the specified time without reducing the required mixing time. Concrete shall be mixed in the concrete mixers for the duration required for uniform distribution of the ingredients to produce a homogeneous mass of consistent colour but for not less than 1 1/2 minutes. The mixer shall be operated by trained operators, who have previous experience of running and operation of concrete mixers.
At the conclusion of mixing, the mixer and all handling plants shall be thoroughly cleaned out before the concrete remaining in them has had time to set.
No concrete shall be mixed by hand without the Engineer's written consent, and such consent shall be given only for small quantities under special circumstances.
3.2.9 Test of Concrete
3.2.9.1 Strength Test during the Work
Strength tests of the concrete placed during the course of the work will be made by the Engineer in an approved laboratory at the Contractor's expenses. The Contractor shall assist the Engineer in obtaining, for control purposes, such number of cylinders or cubes as the Engineer may direct, but in general, three beams taken from each 2,650 ft³ or fraction thereof, or from each day’s pour, whichever is less, of each class of concrete placed, shall govern. Test specimen will be made and cured by the Engineer in accordance with the applicable requirement of ASTM Designation C31-69, Standard Method of Making and Curing Concrete Compressive and Flexural Test Specimens in the Field.
Cubes and beams will be tested by the Engineer in accordance with the applicable requirements of ASTM Designation C39-72, Standard Method of Test for Compressive Strength of Cubical Concrete Specimens and ASTM Designation C78-64, Standard Method of Test for Flexural Strength of concrete (Using Simple Beam with Third Point Loading). The test result will be based on the average of the strength of the test specimens except that if one specimen in a set of three shows manifest evidence of improper sampling, molding, or testing, the test result will be based on the average of the remaining two specimens. If two specimens out of a set of three show such defects, the results of the set will be discarded and average strength determined from test results of the other two sets. The standard age of test will be 28 days, but 7-day tests may be used at the discretion of the Engineer, based on the relation between the 7 days and 28 days’ strengths of the concrete as established by tests for the materials and proportions used. If the average of the strength test of three specimen cured under laboratory controls, for any portion of the work, falls below the
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minimum allowable compressive or flexural strength at 28 days required for the class of concrete used in that portion, the Engineer may change the proportions of the constituents of the concrete, as necessary to secure the required strength for the remaining portions of the work. If the average strength of the specimens cured under actual field conditions as specified herein before falls below the minimum allowable strength, the Engineer will make such changes in the conditions for temperature and moisture under which the concrete work is being placed and cured as may be necessary to secure the required strength.
3.2.10 Conveying of Concrete
Concrete shall be conveyed from mixer to the place of final deposit as rapidly as practicable, by methods which will prevent segregation or loss of ingredients and in accordance with latest edition of ACI Code Recommended Practice for Measuring, Mixing, Transporting and Placing Concrete.
Any wet batch hopper through which the concrete passes shall be conical in shape. There shall be no vertical drop greater than 5 ft. except where suitable equipment is provided to prevent segregation and where specifically authorized. Belt conveyers, chutes, or other similar equipment will not be permitted either for conveying concrete except where the use of such equipment is approved in writing by the Engineer, in advance of any use. Each type or class of concrete shall be visually identified by placing a coloured tag or marker on the bucket as it leaves the mixing plant so that the concrete may be positively identified and placed in the structure forms in the desired position.
3.2.11 Placing
3.2.11.1 General
Concrete placing shall follow the Recommended Practice for Measuring, Mixing, Transporting and Placing Concrete, latest ACI Code requirement. No concrete shall be placed until all formwork, reinforcement, installation of parts to be embedded, bracing of forms and preparation of surface involved in the placing and the method of placement have been approved by the Engineer. Approval of the method of placement proposed will not relieve the Contractor of his responsibility for its adequacy and he shall remain solely responsible for the satisfactory construction of all work under the Contract.
Before concrete is placed, all surfaces upon or against which concrete is to be placed shall be free from standing water, mud, debris or loose material. All surfaces of form and embedded material that have become encrusted with dried mortar or grout from concrete previously placed shall be cleaned of all such mortar or grout before the surrounding or adjacent concrete is placed. The surfaces of absorptive material against or upon which concrete is to be placed shall be moistened thoroughly so that the moisture will not be drawn from the freshly placed concrete. Concrete shall be worked into the corners and angles of the forms and around all reinforcement and embedded items without permitting the materials to its final position in the forms. The depositing of concrete shall be regulated so that the concrete may be effectively compacted with a minimum of lateral movement into horizontal layers approximately 1.5 ft. in thickness. No concrete that has partially
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been hardened or contaminated by foreign materials shall be deposited in the structure, nor shall retempered concrete be used unless approved by the Engineer. The surfaces of construction joints shall be kept continuously wet for at least eighteen hours during the twenty-four hours’ period prior to placing concrete except as otherwise directed by the Engineer. All free water shall be removed and the construction joint shall be completely surface dry prior to approval all concrete placing equipment and methods shall be subject to approval. Concrete placement will not be permitted, when in the opinion of the Engineer weather conditions prevent proper placement and consolidation.
3.2.12 Compacting Concrete
All concrete, except that in blinding layers and in- situ-concrete in very small sections, shall be compacted by vibration. After any necessary hand spading, working and ramming into place, each layer of concrete shall be compacted with mechanical immersion vibrators of types approved by the Engineer. The immersion vibrators shall produce a vibration frequency of not less than 6000 impulses per minute. Under no circumstances shall the immersion vibrators be allowed to come into contact with reinforcement or shuttering. Immersion vibrators shall penetrate vertically for a few inches into any previous unset layer in order to establish a satisfactory bond, but no concrete shall be vibrated in such a manner as to cause injury to concrete (already set or otherwise) in other parts of works. Care shall be taken to keep the vibrators vertical, to insert them at regular intervals and withdraw them slowly to prevent the formation of voids, so that the entire mass of the concrete is properly compacted. Haphazard or random penetration of the vibrators without sufficient depth of insertion shall be avoided. A sufficient number of vibrators shall be used to ensure compaction of each batch of concrete before the next batch is delivered. At least one extra vibrator shall be in hand for emergency use.
Vibration shall be supplemented by hand punning with approved small-diameter smooth steel rods with rounded ends in order to achieve complete compaction around reinforcement and other embedded fittings and a completely dense mortar finish against the shuttering.
Excessive vibration shall be avoided and vibration shall not be continued after a good surface finish, without free water, has been achieved. Vibration and punning shall be just sufficient to produce a dense, homogeneous concrete properly filling the moulds and free from air voids, segregation, bleeding, honey combing and other imperfections. Only highly skilled operators and workmen, subject to constant supervision, shall be employed in vibrating and punning concrete.
3.2.12.1 Time Interval between Mixing and Placing
Concrete mixed in stationary mixers and transported by non-agitating equipment shall be placed within thirty minutes after it has been mixed, unless otherwise authorized. When a truck mixer or agitator is used for transporting concrete, the concrete shall be delivered to the site of the work and discharge shall be completed within 1 1/2 hours after introduction of the cement to the aggregates. The concrete shall be placed within 20 minutes after it has been discharged. In all cases, concrete shall be placed and compacted well within the initial setting time.
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3.2.13 Concrete Finishes
Concrete fishes shall be made in accordance with the provision of ACI 301-8 or as directed by the Engineer
Workmanship in shuttering and concreting shall be such that concrete work shall normally require retouching and the surfaces being dense, watertight and where steel shuttering has been used, perfect and smooth. Should there be faults in these respects, the Contractor shall cut out and replace the whole of the lift concerned or such amount as the Engineer decides, or make good if permitted by the Engineer and to his approval. Concrete which is honey-combed or otherwise shows voids shall invariably be cut out and replaced in an approved manner as suggested by the Engineer.
Any making good shall be carried out immediately after striking the shuttering and shall be restricted to light rubbing down with wet carborundum or the approved correction of minor blemishes. In no circumstances shall surfaces be made good with cement or washes or rendering.
Exposed concrete surfacing not requiring shuttering and not subsequently to be given extra finishes shall be given perfectly dense smooth finish with a wooden float.
Where concrete slabs, ducts, bases or machine plinths will themselves form the finished floor surface the concrete shall be troweled immediately after the first laying process only just sufficiently to give a level surface. Thereafter, when the concrete has stiffened to a condition such that a hard compacted surface can be obtained without bringing up laitance, a final surface troweling shall be given with a steel float to produce a smooth finish.
3.2.14 Concrete and Weather
No concrete shall be placed when the atmospheric temperature is below 15 °C without the written permission of the Engineer. When directed by the Engineer the Contractor shall provide adequate means for maintaining a temperature of not less than 20 °C for 3 days or 15 °C for five days after placing the concrete.
If Rapid-Hardening Portland Cement is used, the period may be reduced as directed by the Engineer.
The Contractor shall supply such heating apparatus as stoves salamanders or steam equipment and the necessary fuel. When dry heat is used, means of maintaining atmospheric moisture shall be provided. All aggregates and mixing water shall be heated to temperature of at least 20 °C, but not more than 75 °C the aggregates may be heated by either steam or dry heat, if permitted by the Engineer the torch method of heating mixed aggregate shall be such as to heat the mass uniformly and avoid spots which will burn the materials. The temperature of the concrete shall be not less than 10 °C at time of placing in the forms.
In case of extremely low temperature, the Engineer may, at his discretion, raise the minimum limiting temperature of water, aggregates and mixed concrete. When the shade temperature is above 32 °C, special precautions shall be observed during concreting to the satisfaction of the
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Engineer. Concreting will be permitted when it is not raining. Thermometer shall be kept at the Site by the Contractor.
3.2.15 Curing of Concrete
Unless otherwise specified or ordered by the Engineer all concrete shall be cured by water. It shall be kept wet continuously for at least fourteen days after placement. It shall be covered with water saturated material like gunny bags, canvas, clean sand, matting, etc. or any other improved method duly approved by the Engineer.
In order that tensile stresses on the cooling of concrete shall be kept to a minimum, all materials shall be as cool as practicable when mixed and placed. To this end, aggregates shall be covered, coarse aggregates shall be cooled with water and mixing plant etc., water storage tanks and pipelines shall be covered or insulated from the effects of the sun. The temperature of concrete on placing shall in no case exceed 32 °C.
Concrete shall be placed only against surfaces which are damp and no such work shall be started until arrangements for keeping the shuttering continuously cool and wet are in place. Shuttering and exposed faces of concrete and mortar shall be covered by at least 3 thicknesses of approved stout hessian kept continuously cool and wet by an efficient and comprehensive system of sprinklers and diffused jets of water, with appropriate temporary drainage arrangements, for at least 14 days after placing.
As an alternative to continuous curing with water after stripping of shuttering a proprietary membranes method of curing may be used provided that it is used strictly in accordance with the manufacturer's instructions, is colored to show its presence, contains no bituminous substance, does not prejudice the appearance of permanently exposed concrete surfaces and is in all other respects to the approval of the Engineer. Wherever practicable, both faces of concrete structures shall be appropriately treated in order to prevent tensile stresses due to differential shrinkage or temperature across the section. Furthermore, the Contractor shall continue to provide facilities for covering and/or keeping wet such exposed surfaces of the Work as are, in the opinion of the Engineer liable at any time to be damaged by weather.
At no time shall any further work involving concrete proceed until the Contractor has satisfied the Engineer that all such work previously carried out is being protected and cured in accordance with this clause.
3.2.16 Concrete in Excavation and Filling
Before concrete is placed in or against any excavation or filling, the surface of such earthwork shall have been compacted and shall be free from running and standing water, oil and other deleterious matter. Loose earth and other material shall be removed. The excavation or filling shall be damp but not wet and special precautions shall be taken to prevent groundwater from damaging unset concrete or causing movement of the concrete.
Immediately after the excavation or filling has been trimmed and prepared as above, the exposed foundation shall be protected by a blinding layer or "No-fines" concrete or of cement mortar or
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other protection as shown on the Drawings or ordered by the Engineer. Such blinding layers and coatings shall be thoroughly cleaned and moistened before further concrete work is placed thereon.
Reinforced concrete shall not be cast against an unprotected face of earth or any other material liable to become loose or to slip; the greatest possible care shall be taken to avoid falls of material on to the concrete, by leaving the timbering in place (if permitted) or by removing the timbering in small depths and lengths at a time and by any other approved means. If any such falls occur, all soiled concrete shall be removed and replaced at Contractor's own cost.
3.2.17 Shuttering
The Contractor shall submit, for the approval of the Engineer full proposals and design calculations for all shuttering and proposals for the period of time to elapse before each item of the shuttering is struck. Notwithstanding the approval of the Engineer to any actual shuttering or proposals for its striking, the Contractor shall retain complete responsibility for its adequacy as to the provisions of this clause and for any consequences of the striking being premature or harmful. In general, the minimum time for the removal of form work shall be as under:
Form Work Removal Time Normal Weather above 15 oC
Formwork of Vertical Surfaces such as Beams a) side walls and columns 4 days 2 days b) Slabs, props left under 10 days 5 days c) Props to slab 14 days 10 days Beam soffits, prop left under 14 days 7 days c) Removal of props to Beams 21 days 21 days
Shuttering shall be designed with easily sealed access hatches for inspection purposes and for removal of water and deleterious materials, and with connections to facilitate striking without damaging the concrete. Shuttering for soffits of slabs shall be erected with an upward camber of 1/4" for each 10 feet of span. When props are to be left in position under slabs the shuttering shall be made and removed in such a way that the props are not disturbed in any way.
A tolerance of plus or minus 1/8 inch in line or level will normally be permitted after erection of the shuttering which shall nevertheless be sufficiently strong, stiff and rigidly braced against loads due to the wet concrete and vibration and against constructional loads, to remain true to the line and level accepted before concreting. It shall be sufficiently watertight to ensure that there shall occur no "fine" or escape of mortar at joints or of liquid from the concrete.
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All exterior angles for concrete work not permanently buried in the ground shall be given 3/4" x 3/4" chamfers unless otherwise indicated on the Drawings.
Timber for shuttering shall be well seasoned, free from loose knots, splits, projecting nails and the like and from any adhering foreign matter.
Steel shuttering shall be used to produce a fair face concrete with only a faint but consistent pattern of plate marks on exposed concrete surfaces. The shuttering shall be assembled from wrought tongued and grooved boarding, true and tightly fitted with joints as necessary, the whole surface and all edges being rendered smooth before and after oiling. Bearing in mind the quality of the finish required, wrought, plain-edged and butt-joint boarding may replace the tongued and grooved boarding or purpose-made steel- faced shutters of first-class quality may be used, solely at the discretion of the Engineer.
Rough shuttering shall be used for surfaces to be buried in the ground and shall be assembled from sawn boards with smooth and true edges or from approved steel shutters. In either case all joints shall be suitably filled.
The inside faces of all shuttering shall be treated with an approved material to prevent adhesion of the concrete, all such materials being kept clear of the reinforcement and other items to be embedded.
Shuttering shall be struck by static force alone without shock and vibration causing any damage to the concrete. Shuttering being reused shall be thoroughly repaired and cleaned before re-assembly.
3.2.18 Water Stopper's
3.2.18.1 Scope
The work to be done under this item consists of providing and installing PVC/Metal water stops as shown on the Drawings or as directed by the Engineer.
Polyvinylchloride Water Stopper
Polyvinylchloride water stops shall be extruded from an elastomeric plastic compound, the basic resin of which shall be polyvinylchloride (PVC) The compound shall contain such additional resins, plasticizers, stabilizers or other materials needed to ensure that when the material is compounded and extruded to the shapes and dimensions shown, it will have physical characteristics when tested by the U.S. Corps of Engineers Tested Method specified below:
No. of Specimens Tested Requirement USCE Test Method
5 1750 psi 568
5 350% 573
5 -35oF 570
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3 400 psi 571
Physical Characteristics Tensile strength using die III, not less than Ultimate elongation using die III, not less than Low temperature brittleness, no sign of failure such as cracking or chipping at Stiffness in flexure, 1/2- inch span, not less than Installation
The PVC Water stops shall be laid in continuous lengths. Splices in the continuity or at the intersections of runs of PVC water stops shall be performed by heat sealing the adjacent surfaces in accordance with the manufacturer's recommendations or as directed by the Engineer. A thermostatically controlled electric source of heat shall be used to make all splices. The correct temperature at which splices should be made will differ with the material used but should be sufficient to melt but not char the plastic. After splicing, a remolding iron with ribs and corrugations to match the pattern of the water stop shall be used to reform the ribs at the splice. The continuity of the characteristic components of the cross section of the water stop design (ribs, tubular center axis, protrusions, and the like) shall be maintained across the splice.
Metal Water stoppers
Copper, stainless steel and steel water-stoppers shall be installed in joints at the locations shown on the Drawings. The thickness, shape, dimensions and splicing of metal water-stoppers shall be as shown on the Drawings or as approved by the Engineer.
3.2.19 Steel Reinforcement
3.2.19.1 Scope
The work to be done under these items shall include furnish, cut, bend, and place all steel reinforcement as indicated on the Drawings or otherwise required. All reinforcement when surrounding concrete is placed shall be free from loose, flaky rust, and scale, and free from oil grease or other coating which might destroy or reduce its bond with the concrete. All placing shall be in accordance with Drawings furnished or approved. The use of reinforcement for the transmission of current for welding will not be permitted. All reinforcement, including dowels, remaining exposed in the work shall be suitably protected until embedded in concrete.
3.2.19.2 Cutting and Bending
Steel reinforcement may be mill or field cut and bent. All bending shall be in accordance with standard approved practice and by approved machine methods. When bending is required, it shall be performed prior to embedding the bars in the concrete. In all such cases, the bars shall be cold bent. Bending or straightening of bars partially embedded in set concrete shall not be permitted except in isolated cases where corrective action or a field change is required and is specifically approved by the Engineer.
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3.2.19.3 Quality
Concrete reinforcement bars shall be of following quality:
Intermediate grade Steel: It shall be deformed bars conforming to ASTM 615-81 (a,b) Grade 40/ Grade 60 or equivalent having a minimum yield strength of 40,000 psi/ 60,000 psi. The Contractor shall provide labor, materials, arrange measuring and testing facilities to ascertain quality, weight or quantity of steel at his own expense, no steel shall be incorporated in the Works without prior approval of the Engineer.
3.2.19.4 Spacing of Bars
The spacing of bars shall be as shown on the Drawings or as directed by the Engineer. The variation from indicated spacing, provided that the total area of reinforcement is in accordance with the Drawings, shall not be more than 1 inch.
3.2.19.5 Relation of Bars to Concrete Surface
The cover of all main reinforcement shall conform to the dimensions shown on the Drawings. The protective covering shall not be less than, and shall not exceed more than 1/4" from the values specified on the Drawings, indicate the clear distance from the edge of the main reinforcement to the concrete surface. The concrete covering of stirrups spacer bars, and similar secondary reinforcement may be reduced by the diameter of such bars.
3.2.19.6 Splicing
Except as otherwise shown on the Drawings or specified herein, all splices, lengths of laps, splice locations, placement and embedment of reinforcement shall conform to the applicable requirements of American Concrete Institute 318-77, Building Code Requirements for Reinforced Concrete. All splices and locations of laps in reinforcement shall be as shown on the Drawings or as directed by the Engineer. Additional bar splices shall be provided as required, subject to approval of the Engineer. Lapped ends of bars may be placed in contact and securely wired or may be separated sufficiently to permit the embedment of the entire surface of each bars by butt-welding or by approved mechanical methods such as the Cadweld splice or other type splice using positive connectors shall be adopted where indicated or directed by the Engineer. Butt welding of reinforcing bars, where indicated or directed shall conform to the requirements of American Welding Society's Recommended Practice for Welding Reinforcing Steel, Metal Inserts and Connections, D.12.1. Concrete shall be protected from heat during welding operations.
3.2.19.7 Supports
All reinforcement shall be secured in place by use of metal or concrete supports, spacers, or ties, as approved by the Engineer. Such supports shall be of sufficient strength to maintain the reinforcement in place throughout the concreting operation. The supports shall be used in such a
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manner that they will discoloration or deterioration of the concrete. Concrete supports shall be manufactured of the same concrete mix as used in the structure to be concreted.
3.3 BRICK AND CEMENT CONCRETE BLOCK WORK
3.3.1 Scope
This section consists of construction of brick/ cement concrete block work walls of any thickness with first class hand-mould and/or machine pressed bricks/cement concrete blocks with the specified ratio of cement mortar in foundation, plinth superstructure or for any other structure as directed by the Engineer, or shown in the Bid Schedule. The Contractor shall furnish all materials and all other requirements to produce finished brick/block work. Brick/block work and materials for brick/block work shall be in strict accordance with this section of the specifications and applicable drawings and subject to the terms and conditions of the Contract.
3.3.2 Materials
3.3.2.1 Portland Cement
Portland cement shall conform to the stipulations and requirements set forth in Section “CONCRETE”.
3.3.2.2 Mortar Sand
Sand for mortar used in construction of brickwork/blockwork required under these Specifications shall be furnished by the Contractor in accordance with the provisions and in conformity with the stipulations and requirements of ASTM Designation C144-70 or latest revision and shall have a fineness modulus between 1.6 and 2.5.
3.3.2.3 Water
The water used in the preparation of mortar shall be free from objectionable quantities of silt, organic matter, alkali salts and other impurities and it will be tested in accordance with BS-3148 and approved by the Engineer at the Contractor's cost.
3.3.2.4 Aggregate
Aggregates for mortar shall comply with the requirements of ASTM C144. Sand that has been in contact with seawater shall not be used unless it has been thoroughly washed to the satisfaction of the Engineer.
3.3.2.5 Additives
Additives where used, shall be proprietary products used in the proportions and manner recommended by the manufacturer. The additives shall in no way adversely affect the mortar
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strength or contain chemicals, which may e harmful to other building materials. To add gypsum to cement is strictly forbidden.
3.3.3 Mortar and Grout
Materials for mortar, sand binding agent and water shall be mixed by volume for at least 3 minutes with the minimum amount of water to produce a correctly mixed mortar or grout of workable consistency in a mechanical batch mixer. For small jobs, hand mixing may be permitted, the ingredients being mixed with sufficient water to produce a correctly mixed workable mortar. Mortar used in masonry construction shall conform to ASTM C-270 Standard.
Mortars shall be mixed in batches, which can be used within a period before the setting process commences. Once a mix begins drying off, it shall be rejected. No ingredients shall be added to it once the setting process has begun. Mortar shall not be retained for more than 30 minutes and shall be constantly worked over with hoe or shovel until used.
3.3.4 Mortar Batching
Methods or equipment used for mixing mortar shall be such as will accurately determine and control the amount of each separate ingredient entering into the mortar and shall be subject to the approval of the Engineer. If a mixer is used it shall be of approved design and the mixing time after the ingredients are in the mixer, except for the full amount of water, shall not be less than two minutes.
Mortar shall be mixed only in sufficient quantities for immediate use and all mortar not used within 30 minutes after addition of water to the mix shall be wasted. Retampering of mortar shall not be allowed. Mixing pans and troughs shall be thoroughly cleaned and washed at the end of each day's work.
3.3.5 Scaffolding
The Contractor shall provide safe scaffolding of adequate strength for use of workmen at all levels and heights at his own expense. Scaffolding which is unsafe in the opinion of the Engineer shall not be used until it has strengthened and made safe for use of workmen. Cost of scaffolding etc., shall be included by the Contractor in the unit rate for masonry items.
Damage to masonry from scaffolding or from any other object shall be repaired by the Contractor at his own cost.
3.3.6 Jointing
Jointing is the forming of joints as work proceeds. Joints shall be as follows:
a) Exterior exposed joints shall be tightly formed to a weather joint with the point of the trowel.
b) Interior exposed joints shall be tightly formed to a concave joint.
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Joints which are subsequently covered with plaster or other finish materials shall be struck flush.
3.3.7 Bricks
The bricks used shall be of standard size (9"x4.5"x3") first class well burnt, uniform in shape, size, texture and colour and should produce a ringing sound when struck. The bricks shall be free from flaws, cracks, chips, stone nodules of lime or kan-kar or any other blemishes. The brick shall not absorb more than one sixth of its weight when soaked in water for one hour. Compressive strength shall not be less than of 1,400 psi. Bricks over burnt, under burnt vitrified and irregular shall not be used. Bricks of uniform size shall be used throughout the work and source of supply shall not be diversified.
3.3.7.1 Soaking
Before use all bricks shall be soaked in clean water in tanks or pits for at-least two hours.
3.3.7.2 Laying of Bricks
All brickwork shall be skillfully laid with level courses, uniform joints, square corners, plumb verticals and true surfaces except when otherwise shown on the Drawings or directed by the Engineer. Brickwork will be of best standard of workmanship obtainable and objectionable offsets in the brickwork shall be avoided. Smoothest practicable finished surface of the brickwork shall be ensured. Unless otherwise specified bricks shall be laid in English Bond with frogs (Manufacturer's marks) upward.
All horizontal joints shall be parallel and truly level. Vertical joints in alternate courses shall come directly over one another. Thickness of joints unless otherwise specified shall not be less than 1/4 of an inch and not more than 3/8 of an inch. The height of 4 courses and 3 joints as laid shall not exceed by more than 1 inch the height of 4 bricks as piled one upon the other.
3.3.7.3 Curing
All brick work involving use of cement shall be cured by water curing or other acceptable methods. The Engineer shall approve all methods and operations of the Contractor in curing different portions of work.
When curing by water brickwork shall be kept wet for at least 14 days by covering with water saturated materials or by a system of perforated pipes, mechanical sprinklers, porous hose and ponding or by any other approved method which will keep all surfaces to be cured continuously wet. Water used for curing shall meet the requirements given in Clause 1.3.2 of these specifications.
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3.4 SURFACE RENDERING
3.4.1 Scope
The work covered by this part of the Specifications consists of supplying all materials, labour and equipment, appliances in performing all operations required for doing the work of cement plastering, pointing, and white washing in accordance with the herein stated requirements except when specifically modified by the Engineer.
3.4.2 Cement Plaster
3.4.2.1 General
The work to be carried out under this item shall consist of providing 1/2" thick plaster in grey cement as specified below. The work shall be carried out in accordance with applicable requirements of British Code of practice 211:1966 or latest revision.
3.4.2.2 Materials
• Cement
All cement required for incorporation in this Section shall conform to the applicable requirements of Section "CONCRETE"
• Sand
The sand shall be of medium to coarse grain and having a fineness modulus varying between 1.10 and 1.50 obtained from an approved quarry e.g. Lawrencepur/Local. The material shall be free from clay, vegetable matters and other impurities. Sand bearing clay shall be washed at the discretion of the Engineer.
• Water
Water required for cement sand paste and curing purposes shall conform to applicable requirements of Section "CONCRETE".
3.4.2.3 Mortar Composition
Mortar for plastering shall consist of one part of Portland cement to 3 parts of sand by volume.
3.4.2.4 Material Batching
Material batching for preparation of mortar shall conform to stipulations and requirements set for in the Section "BRICK AND CEMENT CONCRETE BLOCK WORK".
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3.4.2.5 Application of Plaster
The surface on which plaster is to be applied shall in case of brick work, be properly raked and wetted before application of plaster. Plaster shall be applied in a thickness of 1/2". If the specified thickness sis more than 1/2" then plaster shall be applied in two coats viz rendering coat and the final coat. Plaster shall be carried out to the full length of the wall or to the natural points. Vertical or horizontal joints which show themselves shall not be allowed. Rendering coat shall be roughened with waving lines drawn by wire brushes to provide bond for the final coat and it shall be properly moistened before application of subsequent coat. The final coat shall be finished with floats to provide smooth and uniform surface. All arises shall be straight and either truly horizontal or perpendicular and finished with 1/8" radius. Defective finishes if any shall be cut out and re- plastered at the expense of the Contractor. Plaster after finishes shall be kept moist for about 10 days to the satisfaction of the Engineer.
3.5 DAMP PROOFING
3.5.1 Scope
The work covered under this section shall consist of damp proofing concrete surface or brick/block masonry surface, in accordance with these specifications and at the locations shown on the Drawings or as directed by the Engineer.
3.5.2 General
The concrete surface shall be damp proofed with bitumen by the absorptive method whereas brick/block masonry surfaces shall be first treated with a horizontal layer of Portland cement concrete and then covered with bitumen damp proof cover with Hessian base. Vertical faces of walls likely to come in contact with earth shall be first.
Plastered with cement plaster and then treated with bitumen by the absorptive method. Damp proofing shall not be applied when the temperature is below 390 F and falling. The work shall be done by workmen experienced in the application of damp-proofing. Damp proofing shall be applied as shown on the Drawings.
3.5.3 Damp-Proofing Materials
All asphaltic materials shall be delivered in sealed containers bearing the manufacturer's original labels. Bituminized Kraft paper shall be delivered in rolls as per manufacturer's original packing. Other materials shall be delivered as provided under relevant clauses of these Specifications. All materials shall conform to the Specifications designated and be approved by the Engineer. Damp proofing materials shall conform to the following requirements along with the requirements shown on the Drawings.
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3.5.4 Asphalt Primer
The asphalt primer shall consist of an asphaltic base thinned to a suitable brushing consistency, with a volatile solvent, and shall conform to the requirements set forth under ASTM 41-73 or latest revision.
3.5.5 Asphalt
Asphalt for damp proofing shall meet the requirements of ASTM D 449-73, Type C or latest revision.
3.5.6 Bituminized Kraft Paper
3-ply brown Kraft paper (0.00113 lbs/ft² each ply) sandwiched with two layers of Bitumen (0.00083 lbs/ft² each layer) as manufactured by Messrs. Packages Ltd., Lahore or equivalent, as approved by the Engineer, shall be used.
3.5.7 Preparation of Surfaces
Surfaces to receive damp proofing shall be smooth, clean and dry. Holes, joints and cracks shall be painted flush with mortar and high spots ground level with the surrounding surface. Before damp proofing, surfaces shall be swept clean of all foreign matter and shall be inspected and approved.
3.5.8 Placement Procedures
The selection and combination of various waterproofing and damp proofing materials for different locations shall be as shown on the Drawings or as directed by the Engineer. Unless otherwise directed or approved by the Engineer, the following procedures shall be adopted.
3.5.9 Damp Proofing Under Brick Masonry Walls
The damp proofing shall comprise of:
a) 1 1/2" thick layer of plain cement concrete Class B shall be placed over the area to be damp proofed. b) A priming coat of asphalt primer confirming to BS specification 1097 October 1973 bore the application of asphalt coating. c) An asphalt coat using not less than 30 lbs/100 ft² and 2 layers of Bituminized Kraft paper or polythene sheet.
3.5.10 Quality Control
Sampling of asphalt for Specifications compliance shall be done in accordance with ASTM D 140-70. Samples shall be taken from each consignment, as directed by the Engineer.
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3.6 ROOF INSULATION
3.6.1 Scope
The work consists of insulation with brick tiles of sizes 9"x4" x 1 1/2" or any other approved size laid in cement mortar (1:3) over rammed mud laid to grade as shown on drawings after applying two coats of bitumen on the R.C.C. roof slab surface at 30/25 lbs, respectively for first and second coats at specified heat and laying 20 lbs. polythene sheet complete in all respects.
3.6.2 Materials
The brick tiles shall comply with the standards set in "Section Bricks" except for their thickness and strength. The cement, sand and water shall meet the requirements as given in Section “CONCRETE”.
Bitumen shall be PB3 or PB4.
The clay for making mud shall be clean, free of all organic and other injurious matters.
3.6.3 Application
3.6.3.1 Bitumen Painting
Bitumen heated to the specified temperature and applied on R.C.C. roof slab cleaned and dried surface including sanding at 1 1/2 ft³/100 ft² of surface.
3.6.3.2 Laying Mud
The clay shall be mixed with reasonable quantity of water and thoroughly kneaded to form a thick paste to which copped straw at the rate of 10 lbs./ft³of mud shall be added. It shall be laid and thumped with wooden trowels to form the slope as shown on the drawings.
3.6.3.3 Laying of Tiles
The brick tiles shall be laid in cement mortar (1:3) in fall/slope as shown on drawings.
3.6.3.4 Pointing
The brick tiles shall then be flush pointed in cement mortar (1:2)
3.6.3.5 Curing
The tiles laid shall be cured properly for ten days.
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3.6.4 Measurement and Payment
3.6.4.1 Roof Insulation
Measurement and payment for roof insulation shall be made in accordance with the provisions given hereafter.
3.7 FLOORING
3.7.1 Scope
The work covered in this Section consists of furnishing all plant, labour and material etc., and of performing all operations in connection with making cement concrete floor in conformity with lines and dimensions shown on the Drawings and in strict accordance with these specifications.
MATERIALS
Cement, sand and aggregate shall conform to the requirement of relevant clauses in section "CONCRETE"
3.7.2 Base for Flooring
The base for flooring shall be laid down when the earth filling has been done up to the specified level in a layer of 6 inches and has been properly watered and consolidated and correctly leveled.
A layer of sand about 4" thick shall be laid and rammed after having saturated so that a 4" layer is reduced to about 3" after compaction.
Portland cement concrete of Class C (2000 psi) shall be laid in one operation in a uniform layer of specified thickness, absolutely true and parallel to the required level of the finished surface. Concrete shall be cured for at least 7 days before any topping is laid. Before laying the surface shall be washed and scrubbed with wire brushes so that the concrete in the base and the topping are well bounded.
3.7.3 Cement Concrete Flooring
Before laying the topping, the surface of the base shall be divided into symmetrical panels by glass strips. The size of panels, unless otherwise specified, shall not exceed 3 ft. square and concrete shall be placed in alternative panels. The top of the glass strips shall be adjusted to the specified level of the finished floor surface.
Cement concrete floor shall consist of laying a topping of cement concrete of Class B (3000 psi) of specified thickness over the prepared and finished base as or roughed surface of floor slabs.
Placing operation shall be specifically timed. No sooner the concrete has been evenly spread in a panel, then it shall be beaten for about 5 to 10 minutes with "wooden thapies" (about 5 lbs. weight).
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Immediately after consolidation, the surface shall be leveled with a wooden trowel. Excessive trowelling in the early stages shall be avoided. The surface shall be tested with a straight edge to detect undulations, which, if found, shall be eliminated. The finer stuff in the concrete which has come to the surface with the stroking shall be quickly but carefully smoothen with the steel trowel. When the concrete has hardened sufficiently, trowelling shall be done with steel trowel. No dry cement or a mixture of dry cement shall be sprinkled on the surface for hardening the surface.
3.7.4 Brick Flooring
The work covered by this item consists of furnishing and laying 4-inch sand over prepared earth to required slope and grade. 3-inch-thick layer of Class D (1000 psi) concrete is laid over it and 4.5- inch-thick brick on edge are laid in 1:3 cement sand mortar. These joints of these bricks are struck at the top by flush pointing.
3.7.4.1 Method of Construction
The method consists of placing bricks on edge for flooring in 1:3 cement sand mortar over 4-inch sand and 3-inch Class D (1000 psi) concrete and striking the joints of bricks with flush pointing and laid over thoroughly consolidated bottom by ramming and watering before laying this floor.
3.7.5 Curing
The concrete flooring properly laid shall be cured for 7 days.
3.8 PAINTING WORK
The following codes and standards shall be followed wherever relevant and applicable and/or directed by the Engineer.
BS 242-66 Linseed Oil BS 245-76 Specification for mineral solvent (white and related hydrocarbon solvents) BS 2523-83 Lead –based priming paint BS 2569-64/45 Sprayed metal coatings. BS 2992-70 Painters and decorators’ brushes. BS CP 3012-72 Cleaning and preparation of metal surfaces. BS 4800-81 Paint colors for building purposes. BS 5082-74 Water-Thinned priming paints for wood. BS 5358-76 Specifications for low-lead solvent-thinned priming paint for wood work. BS 6150-82 Code of practice for painting of building.
The whitewash shall be made from pure fat lime brought to site of work in the form of un-slaked lime. Water shall be added to this lime in a container until the mixture is of consistency cream and allowed to rest until cracks shall appear on its surface (48-72 hours). After screening through coarse cloth, gum at the rate of 4 oz. boiled with 10 oz. of rice shall be added to each cubic feet of white wash. The color pigment if required shall be added and mixed with white wash and stirred to give
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the required shade. Enough quantity shall be prepared in one go so as to meet the requirement of one Complete room.
3.8.1 Weather Resistant Paint
3.8.1.1 Selection of paint
Cement based paints or one of the three common types of the exterior latex paints (polyvinyl acetate, styrene-butadiene and acrylic) of ICl/Burger make or equivalent shall be used whichever specified. Approved quality cement based or weather resistant emulsion paints shall be used as directed by the Engineer.
3.8.1.2 Primers
Boiled linseed oil or silicone water repellent primers ICl/Burger make or equivalent shall be used on concrete and masonry surfaces. Before application of paint, concrete and masonry surface should be allowed to dry for at least 3 weeks after cessation of curing
3.8.1.3 Fillers
Paste of Zinc Oxide and varnish thinned with turpentine shall be used as filler on masonry and concrete.
3.8.1.4 Sealers
Water insoluble and water-repellent substances dissolved in solvent such as petroleum naphtha or the special clear silicone compounds shall be used to seal masonry surfaces.
3.8.1.5 Thinner
Thinners such as turpentine, mineral spirit, water, xylene and linseed oil of approved quality shall only be used in accordance with the manufacturers' instructions and with prior approval of the Engineer.
3.8.1.6 Brushes
All brushes used for painting work shall conform to B.S 2992 or equivalent American Standards.
3.8.2 Preparation of Surface
All loose material and dirt on the surface shall be removed with a brush. Holes and irregularities of surface shall be repaired with lime putty, and the surface shall be allowed to dry before applying whitewash or color wash and weather resistant paint All greasy spots shall be given a coat of rice, water and sand. Surfaces discolored by smoke shall be washed with a mixture of wood ashes and water or yellow earth before being-white washed or painted.
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3.8.2.1 Application
Three coats of white or color wash shall be applied on the prepared surface with a brush. Paint or finish to any surface shall be applied when ambient temperature is 10 °C or above and less than 43 °C unless otherwise recommended by the manufacturer. No painting shall be done above 90% relative humidity. Drop cloths shall be placed to adequately protect all finished work.
All paint and coating materials shall be in thoroughly mixed condition at the time of application. All work shall be done in a workman-like manner, leaving the finished surface free from drips, ridges, waves, laps and brush marks. All paints shall be applied under dry and dust free conditions.
All primary paint shall be applied by brushing. The first coat of paint shall be applied immediately after cleaning.
3.9 MEASUREMENT AND PAYMENTS
3.9.1 Cement Plaster
Measurement and payment for cement plaster shall be made in accordance with the provisions given hereafter.
3.9.2 Method of Measurement
Measurement shall be made of cement plastering for the actual area in square foot in accordance with this section of Specification or as directed by the Engineer.
3.9.3 Basis of Payment
Payment shall be made for the number of square foot of surface area cement plastered at the contract unit price per square foot and shall constitute full compensation for furnishing all materials, equipment and labour including all incidentals necessary to complete the work in strict accordance with this Section of Specification.
Description Unit Provide and apply Y" thick 1:3 ft² Cement Sand Plaster for ceiling ft²
3.9.4 Painting
Measurement and payment for white washing and weather resistant paint shall be made in accordance with the provisions given hereafter.
3.9.5 Method of Measurement
The measurement shall be made in ft² of the actual surfaces completed and approved.
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3.9.6 Basis of Payment
Payment shall be made for number of square feet of the actual surface painted measured as provided above at the Contract unit price per square feet for the respective item and shall constitute full compensation for all materials, equipment, labor, including all incidentals necessary to complete the work.
Description Unit Provide and apply white wash ft² Provide and apply weather resistance paint ft² Provide and apply vinyl emulsion paint ft² Provide and apply enamel paint ft²
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4 MECHANICAL / PLUMBING WORKS
4.1 INSTALLATION OF PIPING
4.1.1 Applicable Codes and Specifications
Work shall be carried out according to the requirements of this specification and will conform to the technical specifications, data sheets and fabrication / installation drawings. Where specific details about the execution of any items of work are not included, work shall be carried out according to the requirements of the latest editions of the following standards and Engineering's general specifications described below:
• B 31.3 Process Piping (Latest Edition) • B. 1.20.1 Pipe Threads General Purpose (Inch).
4.1.2 Traceability, Storage and Handling
4.1.2.1 Storage
• All piping material shall be stored by the Contractor in areas demarcated for this purpose. • Pipes and fittings shall preferable be stored on dry wooden platforms. • Valves, control valves, instruments, bolts, small fittings and gaskets shall be stored in covered, locked premises. In no case shall the marking on the equipment be removed. Valves, steam traps and other equipment provided with protective caps shall be stored with the caps up to the moment they are installed. • The Contractor shall be entirely responsible for safekeeping of all the material and equipment. If any item is lost or damaged, the Contractor shall be required to replace it at his own expense. • The Contractor shall identify space for storage of material.
4.1.2.2 Handling
Handling of material shall be done with suitable mechanical equipment and safety of workers shall be given top priority.
4.1.2.3 Traceability
i. All piping material including line pipes, fittings, flanges, bolting etc. shall bear marking as per their relevant manufacturing codes and shall as well be traceable to the manufacturer supplied Material Test Certificates (MTCs). The Contractor shall have the Engineer’s approval for all such materials before commencement of fabrication / installation. All piping material which will be without embossed manufacturing information /details will not be acceptable.
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ii. All valves shall be new and have manufacturers tests certificates of pressure and leak lest, each traceable with its serial no.
4.1.3 Pipe Cutting
All Pipes shall be cut by pipe cutter only.
Cutting will only be acceptable, provided after cutting, the edges are prepared by grinding and machining.
After cutting, the pipe ends shall be beveled and prepared according to the dimensions and tolerances shown in the drawings and project specifications.
4.1.4 Piping Joints
4.1.4.1 Flanged Joints
All flanges, flanged fittings, bolting including stud bolts, nuts and washers as well as gaskets shall comply with the relevant piping specifications.
The flanges shall be welding neck with bore matching pipe internal diameter (I.D) unless otherwise specified and/or authorized.
All bolt holes shall straddle vertical and horizontal centerlines, unless otherwise directed for special or specific reasons. The correct length of bolts shall be used according to reference code. They shall be long enough to project a minimum of two threads out of the nuts when tightened up.
Flange bolts shall be tightened evenly and sequentially to impose equal pressure on the gasket and to avoid distortion or overstressing of equipment flanges. Bolts shall be tightened as per the manufactures recommended torque loads. Gaskets used with cast iron flanges shall cover the full face of the flanges. Torque wrench will be used for tightening the bolts.
4.1.4.2 Piping Installation
a. Piping connections to equipment nozzles shall be accurately aligned and the Contractor shall ensure that flange faces are parallel and correctly centered before bolting. Force shall not be used to attain alignment. b. Piping shall be aligned true and level. Where slope is specified, it shall be maintained without sags in the piping run. Misalignment in piping shall not exceed 5 mm. each flanged joints shall be offered to the Engineer’s representative to check stress-free prior to bolting. c. Piping supports should conform in all respects (construction and location) to the piping design. Location of sliding, guiding and fixing supports (pipe shoes, U Bolts, straps and other types of supports) should conform strictly to the location indicated in related piping drawing. It will be ensured that the pipe does not remain suspended above the pipe support and is fully resting on the support. There should not be any gap between pipe and its support. Erection of supports shall be by bolting and/or welding in accordance with the piping design.
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d. Erection of supports fabricated of pipes may also include cutting of ends to Suit the contour to which they have to be welded. In addition to the supports included in the piping design, certain supports may be indicated directly on field before the completion of the work. e. All pipe work shall be kept clean during construction by mechanical cleaning and swabbing out. f. Piping and equipment shall be adequately supported, rigid enough to prevent excessive vibration, and sufficiently anchored to prevent undue stresses and undue strains on the connected equipment and machinery. g. Hangers and supports shall be made of non-combustible material, and capable of sustaining the loads to which they will be subjected. h. During construction, pipes in trenches shall be sealed with tight caps at the termination of each day work or when working on a pipe section is temporarily discontinued. i. Hangers and supports shall be so installed as not to interfere with the free piping movements due to expansion or contraction due to temperature variations. j. All overhead piping shall be installed to provide at least two (2) meters headroom in all passageways. Valves and other equipment items shall be accessible for operation and maintenance. k. Over ground piping shall be grouped together on sleepers to form pipe racks and shall be run on supports to give the lines the same bottom of pipe elevations. l. All piping shall be installed in a neat workmanlike manner, properly painted, guided and supported. Making smart use of space and avoid haphazard look & aesthetics. m. In all cases care shall be taken, wherever possible, to avoid air or liquid pockets throughout the system. A sufficient and proper number of vents at the high points and drain connections at the low points shall be foreseen. n. Care shall be taken to avoid undue stresses of pipes and components during mechanical erection, offer flanged joints for inspection prior to bolting. o. Underground piping shall be carefully laid to levels shown in the drawings and shall have the minimum specified cover. p. Whenever possible, underground piping shall be laid so that it shall be drained on one end only. q. Pipes lying on sleepers shall be high enough to clear all flanges, valve bodies, etc. form grade. r. A clearance of 20 cm from grade shall be provided unless otherwise stated. s. Where pipe work is laid on pipe racks or in permanent trenches the arrangement and clearances shall allow the removal of any pipe, fitting, valve, etc. without the necessity to disturb adjacent pipe work. t. Lines shall be painted in colors in accordance with color coding scheme. u. In all cases, changes in direction for piping shall be performed by means of factory made butt welding/thermal fusion fittings. This will apply for pipes 2" in diameter and above.
4.1.4.3 Initial Backfill
This is the critical zone of embedment soil surrounding the pipe from the foundation to at least 6 inches over the pipe. The pipe’s ability to support loads and resist deflection is determined by the
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quality of the embedment material and the quality of its placement. Within the initial backfill zone are bedding, haunching, primary, and secondary zones.
4.1.4.4 Bedding
In addition to bringing the trench bottom to required grade, the bedding levels out any irregularities and ensures uniform support along the length of the pipe.
4.1.4.5 Haunching
The backfill under the lower half of the pipe (haunches) distributes the superimposed loadings.
4.1.4.6 Primary Initial Backfill
This zone of backfill provides the primary support against lateral pipe deformation. To ensure such support is available, this zone should extend from trench grade up to at least 75 percent of the pipe diameter.
4.1.4.7 Secondary Initial Backfill
The basic function of the material in this zone is to distribute overhead loads and to isolate the pipe from any adverse effects of the placement of the final backfill.
4.1.4.8 Final Backfill
The final backfill should be free of large rocks, organic material, and debris. The material and compaction requirements for the final backfill should reflect sound construction practices and satisfy local ordinances and sidewalk, road building, or other applicable regulations.
4.1.4.9 Simplified Installation Guidelines for Pressure Pipe
A quality job can be achieved for most installations following the simple steps that are listed below. These guidelines apply where the following conditions are met:
• Pipe Diameter of 24-inch or less • SDR equal to or less than 26 • Depth of Cover between 2. 5 feet and 16 feet • Groundwater elevation never higher than 2 feet below the surface • The route of the pipeline is through stable soil
The following are general guidelines for the installation of PE pipe according to the above conditions.
4.1.4.10 Simplified Step-by-Step Installation
Trenching
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The length of open trench required for fused pipe sections should be such that bending and lowering the pipe into the ditch does not exceed the manufacturer’s minimum recommended bend radius and result in kinking. The trench width at pipe grade should be equal to the pipe outer diameter (O. D.) plus 12 inches.
Bedding Bedding may be prepared from the excavated material if it is rock free and well broken up during excavation. The trench bottom should be relatively smooth and free of rock. When rocks, boulders, or large stones are encountered which may cause point loading on the pipe, they should be removed and the trench bottom padded with 4 to 6 inches of tamped bedding material. Bedding should consist of free-flowing material such as gravel, sand, silty sand, or clayey sand that is free of stones or hard particles larger than one-half inch.
Placing Pipe in Trench PE pressure pipe up to about 8” in diameter and weighing roughly 6 lbs per ft. or less can usually be placed in the trench by hand. Heavier, larger diameter pipe will require handling equipment to lift, move, and lower the pipe into the trench. Pipe must not be dumped, dropped, pushed, or rolled into the trench. Appropriate safety precautions must be observed whenever persons are in or near the trench.
Pipe Embedment The embedment material should be a coarse grained soil, such as gravel or sand, or a coarse grained soil containing fines, such as a silty sand or clayey sand. The particle size should not exceed one-half inch for 2 to 4-inch pipe, three-quarter inch for 6 to 8-inch pipe and one inch for all other sizes. Where the embedment is angular, crushed stone may be placed around the pipe by dumping and slicing with a shovel. Where the embedment is naturally occurring gravels, sands and mixtures with fines, the embedment should be placed in lifts, not exceeding 6 inches in thickness, and then tamped. Tamping should be accomplished by using a mechanical tamper. Compact to at least 85 percent Standard Proctor density as defined in ASTM D698.
Trench Backfill The final backfill may consist of the excavated material, provided it is free from unsuitable matter such as large lumps of clay, organic material, boulders or stones larger than 8 inches, or construction debris. Where the pipe is located beneath a road, place the final backfill in lifts as mentioned earlier and compact to 95 % Standard Proctor Density.
4.1.4.11 Classification and Supporting Strength of Pipe Embedment Materials
The burial of PE pipe for pressure flow applications is covered by ASTM 2774, “Standard Practice for Underground Installation of Thermoplastic Pressure Piping”.
4.1.4.12 Embedment Classification per ASTM D-2321
Pipe embedment materials have been grouped by ASTM D-2321, “Standard Practice for Underground Installation of Thermoplastic Pipe for Sewers and Other Gravity - Flow Applications” into five embedment classes according to their suitability for that use.
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4.1.4.13 Maximum Particle size
Maximum aggregate size of Class I and Class II materials when used next to the pipe (i.e. bedding, haunching and initial backfill) should not be larger than those given in Table 1 below.
TABLE 1: Maximum Particle Size vs. Pipe Size
Nominal Pipe Size (in.) Maximum Particle Size (in) 2 to 4 ½ 6 to 8 ¾ 10 to 15 1 16 and larger 1 ½
4.1.4.14 Trench Construction
Trenches should be excavated to line and grade as indicated by contract documents and in accordance with applicable safety standards. Excavation should proceed upgrade. Excessive runs of open trench should be avoided.
Trench Width
Trench width in firm, stable ground will generally be determined by the pipe size and the compacting equipment used. Table 2 below gives minimum trench width values.
TABLE 2: Minimum Trench Width in Stable Ground vs. Pipe Size
Nominal Pipe Size (in.) Minimum Trench Width (in.) < 3 12 3 - 24 Pipe O. D. + 12 > 24 - 63 Pipe O. D. + 24
Table 3 lists the recommended lengths of trench openings for each placement of continuous lengths of fused pipe, assembled above the trench. When the trench sidewalls are significantly sloped, somewhat shorter trench openings may be used. When space or ground conditions do not permit these suggested trench openings, the pipe lengths may be joined within the trench, using a joining machine or flanged couplings.
TABLE 3: Suggested Length of Minimum Trench Opening
For Installation of Joined Lengths of PE Pipe
Nominal Depth of Trench (Feet) Pipe Size (in.) 3 5 7 9 11 13
½ to 3 15 20 25 30 35 40 4 to 8 25 30 35 40 45 50
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Nominal Depth of Trench (Feet) 10 to 14 35 40 45 50 55 60
4.1.4.15 Sunlight Exposure
Placing pipe that has been in direct sunlight in a cooler trench will result in thermal contraction of the pipe’s length. This contraction can generate force which could result in pull-out at mechanical couplings or other buried structures. Allow pipe to cool before making connections to an anchored joint, flange, or a fitting that requires protection against excessive pull-out forces. Covering the pipe with embedment will facilitate cooling.
4.1.4.16 Cold (Field) Bending
Coiled lengths and long strings of PE fused pipe may be cold bent in the field. The allowable bend ratio is determined by the pipe diameter and the dimension ratio. (Figure2 and Table 4)
Figure 2: Bend Radius, R
TABLE 4: Minimum Bend Radius for PE Pipe Installed in Open Cut Trench
Dimension Ratio, DR Minimum Cold Bend Radius 7, 7.3, 9 20 x Pipe OD 11, 13.5 25 x Pipe OD 17, 21 27 x Pipe OD 26 34 x Pipe OD 32.5 42 x Pipe OD 41 52 x Pipe OD Fitting or flange present in bend 100 x Pipe OD
4.1.4.17 Installation of Pipe in Curves
Field bending involves excavating the trench to the desired bend radius, then sweeping or pulling the pipe string into the required bend and placing it in the trench.
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Temporary restraints may be required to bend the pipe, and to maintain the bend while placing the pipe in the trench and placing initial backfill. Temporary blocks or restraints must be removed before installing final backfill, and any voids must be filled with compacted initial backfill material. Considerable force may be required to field bend the pipe, and the pipe may spring back forcibly if the restraints slip or are inadvertently released while bending. Observe appropriate safety precautions during field bending.
4.1.4.18 Transition from PE Pressure Pipe to Gasket Jointed Pipe
It is necessary to anchor the ends of a PE pipeline that transitions into an unrestrained gasket jointed pipe system. If the gasket joints are restrained anchoring is unnecessary.
4.1.4.19 Proper Burial of Fabricated PE Fittings
Common fittings, elbows and equal tees normally require the same backfill as specified for the pipe. When service connections are made from PE water mains, no special compaction is required. When service connections are made under an active roadway, 95% Standard Proctor density is normally required around the pipe and the service connection.
As with all piping systems, proper compaction of the soil around pipe and fittings is important. In water systems, when in-situ embedment materials can be compacted to a Standard Proctor density of 85% for installation outside of roadways or 95% Standard Proctor density in roadways, these materials should be used. When in-situ materials do not provide proper support, then sand stabilized with cement or flow able fill should be used.
4.1.4.20 Inspection
The Engineer should provide inspection commensurate with the application. Good inspection would include some or all of the following:
o Verification that all embedment materials meet the specification and verification of pipe grade and alignment, o Verification that the correct pipe is installed (see numerical code printed on pipe), o Observation of pipe installation, placement of embedment and backfill materials, and trench excavation methods,
Verification that proper pipe storage and handling procedures are followed, that pipe placement in the trench, attachment of mechanical joints, fittings and appurtenances, and transitions to other pipes were done in accordance with recommended methods, that scratches or gouges do not exceed the permitted depth, and that the minimum bend radius was not exceeded.
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4.2 SKID MOUNTED EQUIPMENT PACKAGES
4.2.1 Codes and Standards
4.2.1.1 Codes, Standards and Regulations
The skid mounted packages covered by this specification shall be designed, manufactured and tested in accordance with the requirements of ITB Document and this specification, other referenced Project Specifications and the following Codes, Standards (latest edition) and Statutory Regulations (where applicable):
• AISC Standard American Institute of Steel Construction Specification for the design, fabrication and erection of structural steel for buildings. • ANSI/AWS-D1-I American Welding Society Code. • ASME IX Welding and Brazing Qualifications • ANSI B.16.5 Pipe Flanges and Flanged Fittings. • ANSI B.58.1 Building Code Requirements for Minimum Design Loads in Buildings and other Structures • ASME VIII DIV 1 Pressure Vessels
4.2.1.2 Drawing & Documents
The Vendor shall prepare the calculation sheets, fabrication drawings and fabrication procedure specifications including welding, inspection and testing.
Vendor must also provide the following documents
• Detail isometric drawing of skid piping • Detail P&ID’s • Quality control/quality assurance detail documents • Detailed drawing of each equipment mounted on the skid. • Detailed bill of material with part number/ identification numbers & specifications of all equipment and piping mounted on the skid
The form of fabrication drawings and documents may be as per the Vendor’s standards.
4.2.2 Scope of Supply
Each package shall be supplied as a self-contained unit mounted on a structural steel skid base, complete with the following as a minimum:
• All necessary interconnecting pipe work and valves, terminating at the edge of the skid, complete with any supports. • All necessary instrumentation and controls. • All necessary electric cabling and cable trays up to skid junction box. • All necessary start-up and commissioning spares.
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• All special tools required for maintenance of the package. • All necessary noise suppression equipment. • All relevant documentation and record. • Inspection and testing, as called for, in this specification and its attachments. • The Vendor shall be responsible for the complete design, engineering, co-ordination, inspection, testing, delivery and proper functioning of the equipment. • To enable the Contractor to offer performance and mechanical guarantees in accordance with the Project requirements, the Vendor, as a minimum, shall be responsible for: • Sizing of all equipment. • Selection of materials of construction together with design temperatures and pressures. • Layout of items of equipment within the specified skid dimensions. • Procurement and testing of individual items of equipment. • Assembly and testing of the skid mounted package. • Full compliance with the requirements of any nominated certifying authority and the supply of all documentation as required obtaining final acceptance certification. • Confirmation of the final weight, centre of gravity position and dimensions of the skid mounted assembly and its suitability for transportation.
The Contractor shall provide a detailed schedule and program of work for procurement and manufacturing phases of the contract.
All the valves mounted on the skid should be pressure/ leak tested. The Contractor to provide the tests certificates as an evidence.
Detail vibration/ pulsation and piping stress analysis should be performed for the complete skid, especially for the rotary/ reciprocating equipment skid.
4.2.3 Environmental Design Criteria
4.2.3.1 General
Unless otherwise approved by the Engineer, the package(s) will be located in an open exposed area. (This criterion is not for skid mounted treatment plants which will be installed in a building).
4.2.3.2 Site Environmental Data
Environmental conditions for the equipment can be seen in the relevant section of the ITB Document.
4.2.4 Design Requirements
4.2.4.1 General
The assembly shall be designed for high reliability and minimum downtime.
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Materials of construction shall be chosen with regard to previous operating experience on similar packages.
No cabling piping or instrument tubing shall be routed within the skid base.
All equipment shall be located within the package so as to afford easy access for maintenance and personnel safety. All piping/ cabling should also be laid appropriately as such it will not cause any hindrance in access & maintenance of any equipment or area of skid
No part of the equipment shall overhang the boundaries of the skid.
The skid base, associated steelwork and all equipment shall be designed for a basic wind speed of 50 m/s at 10 m above sea level. Wind pressure and stress analysis shall be computed in accordance with ANSI A58.1. (This criterion is not for skid mounted treatment plants which will be installed in a building).
4.2.5 Skid Base
Skids shall be designed in full accordance with sound structural engineering principles and the American Institute of Steel Construction (AISC) specifications, where applicable. Skids shall be of all welded construction.
The primary beams (longitudinal base members) shall be considered to be simply supported with the support locations occurring at the extreme ends of the beams. The maximum allowable deflection of any primary beam shall be 1/500 of the span between supports under conditions of dead, plus superimposed, loads.
Cross members shall be designed on a similar basis and sized such that the top faces are in line and flush with the top faces of the primary beams, whilst the lower faces shall be such so as to give a minimum of 40mm ground clearance.
The spacing of cross members shall not exceed the maximum allowable unbraced length of compression flange for the primary beams (defined in the AISC specification).
Slots shall be provided within the skid base members to allow retained liquids to drain away e.g. during wash-down.
The primary members shall be adequately cross-braced to prevent flexing or distortion of the skid during transportation and installation. Equipment mounted on the skid shall not be considered as contributing to the structural strength or bracing of the skid.
The underside of skid frames shall be left flat to provide a continuous bearing surface and bolt holes or bearing pads shall only be provided.
Where alignment of machinery is critical, the Contractor shall propose a point-mounted skid, using bearing pads, as an alternative to his standard. The position of the support parts shall be agreed with the Engineer. Where required all machinery shall have suitable anti-vibration mounts provided between the machine and the skid or between the skid and the deck.
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Where required, flexible bellows shall be fitted to prevent vibration, transmission through ducting or piping.
All other types of skids should be reviewed against the calculated or known deflection of the platform deck and the exciting forces.
Where the skid is too large for handling or transportation on land, it may be sub-divided into sections for re-joining and bolting together on site. In such cases, all equipment upon the skid, including interconnecting piping and cabling, shall be pre-assembled and match marked before disassembly to assist re-assembly on site.
Foundation bolts shall be supplied by others. The Contractor shall provide full details of the size and number required.
Skids shall have hot dipped galvanized steel bar floor grating covering the entire top surface with cutouts for supports and/or equipment. Floor grating shall not be used as a mounting surface for equipment or supports. Floor grating shall be fully located by side and end stops and suitably bolted or clipped. (This criterion is not for skid mounted treatment plants which will have stainless steel skids, as mentioned in the following sections)
Grating shall be in removable sections, each section and all cutouts to be completed with flat edging bars. Where grating sections are cutout around equipment and edging bars welded in to suit, complete section of flooring shall be re-galvanized to original specification. Cold galvanizing of re-worked areas is not acceptable.
The strength of the Grating should be adequate to hold the weight of equipment and personal during operation/ maintenance. Relevant code for grating may be consulted regarding strength of grating.
Metal thicknesses at the point of equipment bolting shall not be less than 10mm.
Pad-eye type lifting lugs shall be welded to the skid with full penetration welds. The pad-eyes shall be designed for a minimum load factor of 2.0, with no increase in AISC permissible stresses, on the calculated force and for all sling angles between 45 and 75 degrees to the horizontal, as obtained from a single point lift.
When a single lift point from the skid base is impractical due to location of on-skid equipment, the Contractor shall supply suitable spreader beams or lifting frame, complete with all slings and shackles. Spreader beams/lifting frames shall be of all welded construction using full penetration welds and shall be designed for the same load factor as skid lifting lugs.
Jacking screws, of robust design and construction shall be provided on all skids supporting heavy machinery in order to facilitate lateral and axial movement of each equipment during alignment.
Skid bases shall be provided with two earthing bosses welded to opposite ends of skid base frame.
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4.2.6 Ancillary Structures
All ancillary support structures shall be designed so as to withstand all superimposed loads, including wind loadings in accordance with the AISC specifications.
Access ways, handrails and ladders shall conform to the requirements of API RP 2A, and shall be provided for operating and maintenance access to all instruments, controls and valves when located more than 1.5m above the skid floor.
All piping and cabling shall be suitably supported for service and shipment. The support and installation shall be designed to allow for piping and cabling to be removed without the cutting of structural members.
Where filter type units with removable heads and/or internal elements form part of the package equipment, permanent handling facilities shall be provided on the package for removal of head/elements. This requirement applies when the weight of any single component exceeds 25kg or where easy access is not available.
4.2.7 Vessels
Vessel internals shall be designed in accordance with the particular service of the vessel and shall be readily removable through a convenient man way. The internals shall be designed so that the performance of the vessel will meet the minimum requirements specified in the data sheet and shall be suitably fixed in position by the provision of bolts or clamps. Loose internal equipment is not permitted. Provision of manual vessel entry need to be taken care (diameters greater than or equal to 16 inches should be considered).
Any internals, which require periodic maintenance or are liable to heavy wear shall be designed for ease of removal from the unit and shall be provided with permanent access facilities.
All liquid outlet nozzles shall be fitted with vortex breakers unless otherwise approved by the Engineer.
4.2.8 Piping, Valves and Fittings
Where appropriate all piping on the skid that is common, i.e. drains or flares should be piped together and terminate with a single flange at the skid edge.
All piping shall be routed to provide a neat and economical layout, to have the shortest run consistent with Good Engineering Practice and to ensure easy access to all in-line
Valves and instrumentation. No piping shall be routed across walkways or access-ways unless they are elevated a minimum of 2.13 m above the top of grating level.
Sufficient space shall be allowed between lines to permit ready access for removal/repair but in no instance shall there be a distance of less than 25mm between a pipe and the outside of the largest flange or fitting in the adjoining pipe. Insulation thicknesses and thermal movement of piping shall be taken into account when determining these spacing.
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The minimum vertical clearance for all piping systems from top of flooring shall be 200mm.
Piping at all equipment shall be supported so that equipment, control valves etc. can be readily removed without provision of temporary piping supports and arranged so as to minimize pipe work dismantling.
Pipe supports shall be provided adjacent to skid edge for all external piping connections. Plate type supports with rigid fixing through pipe work flange bolting are not acceptable.
All access platforms and walkways shall have a minimum clear width of 760mm. No piping, instrumentation or cable runs shall impinge on this minimum requirement.
Equipment and piping shall be installed with supports so as to prevent vibration.
Piping systems shall be routed and supported so as to have sufficient flexibility to allow for thermal expansion and contraction, and for platform movement. The Contractor shall demonstrate to the Engineer/Client that suitable flexibility analyses have been carried out.
The Contractor shall minimize forces and movements imposed on pipe work and shall provide a complete set of forces and moments at each termination point in order that the Engineer may complete analysis of adjacent piping systems.
All piping termination points, including inlets, outlets, utilities and drains shall terminate in ANSI B.16.5 flanges of the appropriate rating having a minimum size of 2 in unless otherwise approved by the Engineer. The pipe work shall be constructed to allow complete draining of equipment and shall have plugged vents at high points to facilitate venting and hydro testing.
All piping connections shall terminate at the edge of the skid. The Contractor shall provide a suitable termination flange schedule with the general arrangement drawing(s). Final orientation of termination points shall be subject to the Engineer approval.
4.2.9 Materials of Construction
The Contractor shall ensure that the design and selection of materials of construction for equipment are chosen to avoid the possibility of galvanic corrosion where necessary by the use of suitable insulation gaskets or spools.
4.2.10 Instrumentation
For instrument air requirement on the package, a galvanized carbon steel air header shall be provided. Air header shall be 1" NB minimum and shall be mounted adjacent to all instrument air users. Each user shall be provided with a block valve adjacent to header. All take-offs shall be from the top of header, which shall be terminated at skid edge with a single flanged connection.
All non in-line instruments shall be provided with suitable stands. Instruments may be supported on Package Steelwork where location and access is suitable. Instruments shall not be supported off Process Pipe work.
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All cables within the skid shall be installed on cable trays or conduits. Cable Glands shall be used for connection of cables at enclosures.
Instrument tubing fittings and cables for all instruments shall be supplied pre-installed on skid. All loose supplied equipment shall be clearly specified and complete installation procedures shall be provided prior to shipment. The Unit Control Panel (UCP) shall have knife disconnect terminals for connection of each instrument cable pair.
Where called for in the main package specification, the Vendor shall be required to supply a Unit Control Panel (UCP), containing the specified controls for the package. The package control system shall be PLC based. Unless it is of a proprietary nature the UCP shall be custom built for the project and shall meet the requirements for panel fabrication set out in this and the main package specification. The form of interface to the Purchaser's control systems is detailed in the main package specification where applicable. The Vendor shall be responsible for the complete design of the package and UCP, including the connections between the equipment skid and the UCP. If a local HMI screen is included with the UCP a weather protection cover shall be provided for the HMI. Skid Mounted UCP shall have appropriate hazardous area classification and IP rating.
PLC based control systems compliant with IEC 61131-3 shall be used as the package controls systems. The PLC shall be modular type and shall have high reliability and availability.
The Contractor shall supply Instrument location drawing separate from Package General Arrangement, highlighting true positions of all instruments in both Plan and Elevation.
4.2.11 Electrical
All electrical equipment shall be as per the requirement of hazardous area classification. All field mounted electrical equipment shall be minimum IP55.
The Contractor shall provide the electrical consumer list, datasheets, specification, wiring/ schematic drawings, installation details etc. for the package electrical equipment.
Power supplies available to the package shall be as specified in the equipment requisition or attachments. If any voltages outside this supply are required these must be generated by the Package Equipment from these supplies.
Electrical equipment, which requires external support shall be provided with purpose built stands or may be supported from Package Steelwork where suitable. Electrical equipment shall not be supported off Process Pipework.
Where junction box/control panel cable glands are bottom entry (preferred arrangement) equipment shall be so located as to allow adequate space for routing and glanding of cables.
Electrical cable shall be routed to minimize the likelihood of mechanical damage. Cable trays shall be of heavy duty type with deep flange to further protect cable runs
4.2.12 Bolting
All internal bolts shall be provided with double locking nuts or other suitable securing device.
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All external bolting shall be brand new and cadmium plated for protection.
4.2.13 Insulation
Unless otherwise agreed the Contractor shall be responsible for the provision of all necessary insulation for heat conservation or the safety and protection of personnel in accordance with the applicable statutory requirements. This shall include the provision of suitable lagging and cladding on hot & cold surfaces within easy reach of operatives. The insulation shall comply with the requirements of the Project Specification for Insulation. In no circumstances shall insulation materials contain asbestos.
4.2.14 Noise
The noise levels from each skid shall comply with the requirements of API 615 but shall not exceed 85 dBA at 1 m unless stated or otherwise approved by the Engineer.
4.2.14.1 Nameplates
All major equipment installed on the package shall be provided with a stainless steel nameplate suitably located so as to be visible from off the skid.
Data to be provided is to be in accordance with the specification for the particular equipment but shall include the following as a minimum:
• Equipment Title • Manufacture Name • Country of Origin • Manufacture Serial Number • Year of Manufacture • Manufacturing Code • U-Stamping • Operating/Test Pressure • Design Pressure • Item Description • Equipment Tag Number • Capacity or Design Conditions • Equipment weight (Empty/Operating)
Letters and Figures shall be 5mm high and clearly stamped.
4.3 FABRICATION AND ASSEMBLY
4.3.1 General
Approval of all the Contractor's drawings, weld procedures, calculations, etc. is required by the Engineer and the certifying authority, where applicable, prior to the commencement of fabrication.
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4.3.2 Welding
All welding shall be in accordance with the requirements of the appropriate code i.e.:
• Structural ANSI/AWS-D1.1 Project Specification for Structural Steel and the Welding and Inspection of off-shore structures. • Piping ANSI B31.3 • Vessels/Exchangers ASME VIII DIV 1, ASME IX
Welders shall be suitably qualified for the work undertaken.
4.3.3 Assembly
The Contractor shall be required to submit an assembly procedure for the skid mounted assembly detailing the order of erection.
4.3.4 Materials
Materials of construction of the skid shall comply with the requirements of the Project Specification for Structural Steel, where applicable.
4.3.5 Inspection, Testing and Certification
4.3.5.1 General
Inspection, testing and certification shall generally comply with the requirements as detailed in the requisition documentation and in the other referenced specifications.
4.3.5.2 Inspection
The Contractor shall provide free access to his works and that of Sub-Contractor for the authorized representative of the Engineer and the certifying authority (if required). All necessary certification on materials, shop test data, etc. shall be made available to verify that the requirements of the purchase order are being met.
No equipment surface shall be painted until all inspection is completed.
4.3.5.3 Hydrostatic Tests
All pressure vessels and piping shall be hydro tested in accordance with the appropriate Project specification and code requirements.
Process piping or tubing shall be tested with water after shop fabrication into sub-assemblies.
The normal test pressure for piping shall be 1.5 times the adjusted cold pressure rating of the valves, fitting, expansion joints or other limiting elements in the line.
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Pressure testing shall be maintained long enough to permit complete inspection but shall not be less than 60 minutes.
4.3.5.4 Equipment Performance Tests
All equipment shall be subjected to an individual performance test where appropriate in accordance with the requirements of the relevant Project Specification. Performance test curves and certificates shall be provided.
When required by the Engineer's Inspector, all equipment, after performance testing shall be dismantled for a visual inspection of the internals.
4.3.5.5 Assembled Skid Testing
The completed pipe work assembled on the package shall be subject to a low pressure (1.0 barg) leak test in the Contractors works to verify integrity of all joints.
The completed assembly shall be given a full functional test including instrumentation and electrical equipment at the Contractor's works. During the test all alarms, shutdown and remote signals shall be simulated.
The Contractor shall be required to submit a full testing procedure, including a check list in accordance with API 700, at least 4 weeks prior to the commencement of testing and covering the full extent of testing on the completed assembly. The testing procedure shall be approved by the Engineer prior to the commencement of testing and shall be complete with all equipment procedures and check lists. The Contractor shall be responsible for providing all necessary utility services to conduct the tests.
4.4 WATER SUPPLY PIPES, PIPE LAYING AND APPURTENANCES
4.4.1 Scope
The work covered by this Section of the specification consists of furnishing all plant, labor, equipment, appliances and materials and of performing all operations in connection with water supply lines and appurtenances in strict accordance with this section of the specifications and the applicable Drawings.
4.4.2 Materials
Material shall conform to the respective specifications and other requirements specified hereinafter and shall be new and unused
4.4.3 Galvanized Iron Pipes and Fittings
The galvanized iron pipes shall strictly conform to BS 1387-1967 “heavy quality” Specifications for “Steel Tubes and Tubulars suitable for screwing to BS 21 pipe threads”. All screwed pipes and
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sockets shall be of wrought iron have BS 1740. A complete and uniform adherent coating of zinc white will be provided for galvanized iron pipes and fittings.
4.4.4 Un-plasticised Polyvinyl Chloride Pipe and Fittings
Un-plasticised Polyvinyl Chloride (uPVC) and fittings if approved by the Engineer shall confirm to BS 3505 pipes shall be class B: Pipe and fittings shall not be stored directly exposed to sunlight handled or laid in conditions where ambient temperatures may cause distortion or damage. In extreme conditions, pipe and fittings may have to be stored under water.
4.4.5 Joints for Un-plasticised Polyvinyl Chloride Pipe
Joints for unplasticised polyvinyl chloride pipe shall be the Z type consisting of a socket with rubber gasket, or approved equal, and assembled in accordance with the pipe manufacture’s recommendations
4.4.6 Mild Steel Pipes
The mild steel pipes shall conform to BS 1387-1967 “medium quality” Specifications for “Steel Tubes and Tubulars”. All pipes shall have thickness suitable to withstand the working pressure as specified in the Bill of Quantities.
4.4.7 Polyethylene (P.E) Pipes and Fittings
High-density polyethylene pipes (HDPE) and fittings shall conform to ISO 4427/DIN 8075 standards. Material, diameters, wall thickness shall be as indicated in 4427/DIN 8074. Tests to be performed for pipes shall be Heat revision, Short term hydrostatic pressure test and Tensile strength and for P.E. compounds shall be Elongation at break, Melt flow rate and Density test.
Warning tape shall be provided for lying over P.E. pipes. It should be single fold, 0.02-inch-thick and 2-inch-wide, with warning for digging continuously printed in Urdu language. The tape shall be placed one foot above the P.E. pipe.
Bricks on edge shall be placed on the P.E. pipes along its edge after it is laid in order to avoid any damage to the pipe.
4.4.8 Sluice/Gate Valve
Valves shall be wedge gate valves conforming to BS EN: 10747. Ends of valves shall be suitable for the type of pipe to which the valves will be connected. The direction of flow should be marked by arrow on the body of the valve.
4.4.9 Check Valve
Check valve shall comply with the requirements of BS EN: 12334 or equivalent. The valve shall be of swing type and shall be of quick acting single door type.
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4.4.10 Approval of Materials and Equipment
Soon as practicable but within 30 days after receipt of notice to proceed and before any materials or equipment are purchased, the Contractor shall submit for approval of the Engineer a complete schedule, in triplicate, of materials and equipment to be incorporated in the work, together with the names and addresses of the manufacturers and their catalogue cuts, diagrams, drawings, and such other descriptive data as may be required by the Engineer. No consideration will be given to partial lists submitted from time to time. Approval of materials and equipment with deviations from the specifications shall not be construed as approval of the deviations unless they are specifically brought to the notice of the Engineer. Laboratory results and certifications, specified or otherwise required, shall be submitted prior to delivery of the material and equipment to site.
4.5 INSTALLATION
4.5.1 Handling
Pipe and accessories shall be handled in such a manner as to ensure their delivery to the trench in sound, un-damaged condition. If any pipe or fitting is damaged, the repair or replacement shall be made by the Contractor at his expenses in a satisfactory manner. No other pipe or material of any kind shall be placed inside of a pipe or fittings. Pipe shall be carried into position and not dragged. The interior of pipe and accessories shall be thoroughly cleaned of foreign matter before being lowered into the trench and shall be kept clean during laying operations by plugging or other approved method. Before installation, the pipe shall be inspected for defects. Material found to be defective before or after laying shall be replaced with sound material without additional expense to the Employer. Rubber gaskets that are not to be installed immediately shall be stored in a cool dark place and protected against the direct rays of the sun.
4.5.2 Cutting of Pipe
This shall be done in a neat and workman-like manner without damage to the pipe. Unless otherwise authorized by the Engineer or recommended by the manufacturer, cutting shall be done with a mechanical cutter of approved type. Wheel cutters shall be used wherever practicable.
4.5.3 Deflection
Maximum allowable deflections from a straight line or grade, as required by vertical curves, horizontal curves, or offsets will be as recommended by the manufacturer and as approved by the Engineer. If the alignment requires deflections in excess of the specified limitations, special bends or a sufficient number of shorter lengths of pipe shall be furnished to provide angular deflections within the limit set forth, as approved.
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4.5.4 Placing and Laying
Pipe and accessories shall be carefully lowered into the trench by means of derrick ropes, belt slings, or other suitable equipment. Under no circumstances shall any of the water line materials be dropped or dumped into the trench. Care shall be taken to avoid abrasion of the pipe coating. Poles used as levers shall be of wood and shall have broad flat faces to prevent damage to the pipe. Except where necessary in making connections with other lines or authorized by the Engineer, pipe shall be laid with the bells facing in the direction of laying. The full length of each section of pipe shall rest solidly upon the pipe bed, with recesses excavated to accommodate bell coupling and joints. Pipe that has the grade or the joint disturbed after laying shall be taken out and re-laid. Pipe shall not be laid in water shall be kept out of the trench until the materials in the joints have hardened or until chalking or jaunting is completed. When work is not in progress, open ends of pipe, fittings, and valves shall be securely closed so that no trench water, earth, or other substances will enter the pipes or fittings. Where any part of a coating or lining is damaged, the repair shall be made by the Contractor at his own expense in a satisfactory manner. D.I pipes shall be installed in accordance with recommendations of the pipe manufacturer. Pipe ends left for future connections shall be provided with valve, plugged or capped, and anchored, as shown or as directed, where connections shall be made by using specials and fittings to suit the actual conditions.
4.5.5 Jointing
• The joints shall be in accordance with the recommendations of the manufacturer or as approved by the Engineer. • Connections between different types of pipes and accessories shall be made with transition fittings where recommended by the pipe manufacturer. • Service connections shall be made as indicated and in accordance with the recommendations of the pipe manufacturer.
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5 CONSTRUCTION OF TUBEWELLS
5.1 SCOPE
The work covered by this Section of the Specification shall consist of all plant, labour, equipment, appliances, materials etc. as necessary for the well drilling, installation of materials, well completion, development, testing and miscellaneous work required for the satisfactory completion of all work involved with the construction of tubewells for water supply system.
5.2 GROUND WATER INVESTIGATION
5.2.1 Electrical Resistivity Survey
The electric resistivity survey shall be conducted using vertical electric soundings by Schlumberger four electrode configurations or any other method/equipment approved by the engineer to determine the lithology and the ground water quality of the aquifer up to a depth of 800ft and as instructed by the engineer. The total numbers of probes proposed to be conducted within the Specified Area are 10 up to depth of 1000 feet or as per instructions of the engineer at the locations marked on the drawing or indicated by the engineer. The number of probes and their depths may be increased or decreased by the engineer as per details of the subsoil strata revealed during investigations. Based on the electric resistivity survey and study of specified surrounding area, the contractor is required to prepare and submit a detailed report incorporating the following:
True resistivity of different sub-surface layers calculated and interpreted in terms of lithology on the basis of field geology and ERS.
The VES curves of the sounding stations obtained by plotting the apparent resistivity against electrode spacing.
Lithology/strata layers, water quality in each strata (fresh and saline), fractures and other geological information.
Colored strata charts of sub-soil formations indicating sand, clay, gravel, sand stone, lime stone, shales and water quality as interpreted from the results of resistivity survey.
Review of results of the resistivity survey work and give recommendations for drilling for tube well at the probe sites of resistivity survey including assessment of permeability, porosity, transmissibility and sustainable yield from different strata and different probe locations including continuation of different subsoil strata and their depths within the specified area.
Providing ground water monitoring equipment for checking depth of ground water table, TDS, TSS, temperature and pH. All the equipments shall be suitable for field use/operation for tube well construction and maintenance and product of reputable manufacturer. The depth measuring equipment shall include calibrated and mounted tape for quick lowering and rewinding with
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suitable insulated wiring and water level indicating devices. All the equipments shall be provided with manufacturers catalogues and provided in suitable original manufacturer’s packing for use in field.
5.2.2 DRILLING
5.2.2.1 General
The Contractor shall drill each bore hole for water supply wells at the location established in the field by the Engineer. The Contractor shall prepare the site for the construction of the tubewell and shall provide for the disposal of water, cuttings and refuse from his operations away from the tubewell.
5.2.2.2 Drilling Procedure
The bore hole shall be drilled by the reverse circulation rotary method with a minimum drill bit diameter of 20 - 26 inches (500 mm - 650 mm) as per project requirement mentioned in Bill of Quantities. The contractor at his own risk and with the permission of the engineer may adopt other method of drilling at locations where sub-surface conditions are such that the reverse circulation rotary method is not feasible or suitable in which case the contractor shall not be entitled to any extra claim. Each bore hole shall be drilled to the depth specified by the Engineer. It is anticipated that the depth of tubewells will vary; however, no minimum depth for any individual tubewell or average depth for all tubewells is guaranteed. The bore holes shall be drilled sufficiently straight and plumb so that the pump and tubewell casing may be installed concentric with the hole and within the tolerance specified for plumpness of the casing. Waste materials from the drilling operation shall be disposed of in a manner approved by the Engineer.
The Contractor shall be responsible for protecting the tubewells from contamination by foreign material until the completion of the tubewell. The Contractor shall bear any expense that may result from damage to any tubewell, tools, or equipment that may be caused by caving, washing, or other disturbances within the tubewell.
Where necessary to prevent sloughing and caving of surface material, the Contractor shall furnish and install a conductor casing with a minimum diameter
2 inches (50 mm) greater than the bit diameter not less than 6 inches (150 mm) above the ground surface upto a sufficient depth to encounter firm material. The conductor casing shall be new or used pipe of adequate strength for the purpose. After the drilling is completed, the conductor casing shall be removed by the Contractor and shall remain his property.
If unstable material is encountered during drilling, the Contractor shall stabilize the material in a manner approved by the Engineer. The use of drilling fluid additives or other suitable materials specially approved by the Engineer may be employed in stabilizing the bore hole. All temporary casing shall be removed by the contractor in 5 to 10 feet (1.50 to 3 meter) stages as ground
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shrouding is placed. If in the opinion of the Engineer, it is necessary to discontinue work on any bore hole because it is out of line more than the amount specified or on account of jammed tools, caving ground, or because of negligence on the part of the Contractor, the Contractor shall drill another bore hole at an alternative location designated by the Engineer. The Contractor will not be entitled to payment for any work done or materials furnished for bore holes abandoned as a result of his operation or negligence.
5.2.2.3 Data and Records
The Contractor shall keep an accurate drilling log of each bore hole including a description of all materials encountered and their location in the bore hole. The fact that the Engineer or his representative may be present and keeping a separate record shall not release the Contractor from this responsibility.
In the case of defective or incomplete records the Contractor shall complete the records at his own expense. All records and data shall be kept by the Contractor on forms approved by the Engineer. The Contractor shall deliver to the Engineer the original of all records.
5.2.2.4 Sampling
Representative ditch samples or cuttings of the material penetrated shall be taken at every 5 feet (1.50 m) interval or at each change in lithology encountered whichever is less of the bore hole. Special care shall be exercised to determine the thickness and location of each change in material encountered and to obtain satisfactory samples. Immediately upon taking each sample, the sample shall be placed in a plastic or cloth bag, partitioned wooden box or other approved container, properly marked for identification, and plainly labeled with the depth of the top and bottom of the section of the bore hole represented. The containers shall be furnished by the Contractor. The method of obtaining, processing, and storing the samples will be subject to approval by the Engineer. The Contractor shall deliver all samples to the Engineer at the site of the tubewells, except that when requested to do so by the Engineer, the Contractor shall deliver specified samples to the Engineer's field headquarters.
5.3 INSTALLATION OF WELL CASING
5.3.1 General
Installation of casing shall consist of all work required in connection with the installation of casing pipe, comprising mild steel housing pipe, blind pipe, reducer, sand trap and brass screen required for each tubewell as specified herein or on the Drawings or as directed by the Engineer and shall include, but not be limited to storing, fabricating and installing all pump housing and tubewell casing including concentric reducers.
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5.3.2 Materials
5.3.3 Casing Pipe
Casing pipe shall be of M.S material of designated diameters and wall thickness indicated in the drawings or BOQ.
5.3.4 Pump Housing Pipe
Pump Housing Pipe shall be of mild steel of designated diameters and wall thickness indicated in the drawings or BOQ. The pipes shall be made from steel plates conforming to ASTM Specifications A-53/79.
The pipes shall have beveled ends. The pipe shall be furnished in standard lengths of 16 ft. (5 m) and shall be painted outside with antirust chemical. All pipes shall be free from dents, injuries, scars and ovalties.
The housing pipe shall be installed to extend a minimum 3 feet (1.0 m) above ground level in addition to the housing as specified by the final design below ground level.
5.3.5 Blind Pipe
Blind Pipe shall be of Mild Steel of designated diameters and wall thickness 6mm or as indicated in the drawings or BOQ. The pipes shall be made from steel plates conforming to ASTM Specifications A-53/79.
5.3.6 Reducer
For connecting M.S. housing pipe and well blind pipe at depths below ground level a transitional reducer shall be provided and made of the same material and of the same thickness as used for well casing specified above. The ends of the reducer shall be suitable for welding to the pump housing and well blind pipe.
5.3.7 Bail Plug
Bail Plug shall be of the Fiber Glass material and thickness as followed for well casing. Bail Plug shall be provided with a base plate, welded at one end of the pipe. A steel hook bent in the form of 'U' shall be bolted to the base plate to sustain a maximum suspended length of 560 ft. (170 m) of well casing. Bail Plug shall be of 10 inches (250 mm) dia and 10 feet (3000 mm) long in sizes or as indicated in the drawing.
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5.3.8 Well Screen / Strainer
Well screen / strainer shall be of Fiber Glass or as mentioned in drawings suitable for gravel pack tubewell. The strainer shall have minimum open area of 10 percent, minimum wall thickness of 0.25 inch (6 mm) and slot size of 0.04 inch (1mm). The slots shall be of a shape that produces an opening of a 'V' form, narrow on the outside and wide on the inside. The openings shall be free from jagged edges, irregularities or anything that will accelerate or contribute to clogging or corrosion of the screen.
5.3.9 Fabrication
The depth of pump housing casing will be established by the Engineer for each tubewell depending on the future water levels and draw down anticipated. Lengths of the specified diameter of steel casing shall be provided to extend the pump housing casing from the elevation of the top of the pump housing casing to the depth established by the Engineer.
Adjoining sections of pump housing casing shall be assembled by field welding. The ends of the casing sections shall be lathe turned or otherwise prepared for jointing. All field welding shall be performed by the electric arc method, using heavily coated welding rods suitable for all-position welding. After being welded, the welds shall be cleaned of slag and shall show uniform smooth sections, feather edges without overlap, and from porosity and clinkers. The pump housing casing shall be connected to the tubewell casing by means of a concentric tapered reducer having a minimum length of 24 inches (600 mm).
The length and sizes of tubewell casing to be installed shall be specified for each tubewell by the Engineer and shall be sufficient to extend from the bottom of the housing casing to the bottom of the tubewell. The bottom of the tubewell casing shall be provided with bail plug as shown on the drawings.
The tubewell casing shall consist of slotted sections for installation opposite water yielding formations and plain pipe sections or bail plug opposite non-water yielding formations as directed by the Engineer
5.3.10 Installation
The Contractor shall install the entire pump housing and tubewell casing assembly straight, plumb, and concentric in the drilled hole to permit the installation of the pump in such a manner that it will operate satisfactorily and without damage. The methods employed by the Contractor in the installation of the casing and in obtaining or correcting the verticality and straightness of the pump housing casing shall be subjected to the approval of the Engineer.
Centralizers, spacers or other suitable devices shall be attached to the tubewell casing so that it will be centered in the drill hole throughout its entire length and held in such position while gravel shrouding is being placed. Centralizers shall be attached to the pipe in a manner that ensures that
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the pipe is accurately centered in the drill hole. The detail design of centralizers and the method of attachment to the pipe shall be subject to the approval of the Engineer. Unless otherwise directed centralizers shall be spaced at 9000 mm along the overall length of screen and casing assembly.
The Contractor shall install the pump casing so that the deviation of its axis from the vertical shall not exceed 4 inches (100 mm) at the bottom of the pump housing casing. Measurements for determination of verticality and straightness of the pump housing casing shall be made by the Contractor in the presence of the Engineer upon completion of the gravel shrouding.
Measurements for determining the deviation of the pump housing casing from the vertical shall be made by the use of a circular plumb having a minimum outside diameter of 1 inch (25 mm) less than the inside diameter of the pump housing casing. The plumb shall have vertically and shall be suspended in the center of the pump housing casing from a point 10 ft. (3.0 m) above the top of the casing. When the plumb is lowered to the bottom of the pump housing casing, the line from which the plumb is suspended shall not deviate from the center of the pump housing casing at the top by more than corresponding to a deviation of the plumb 4 inches (100 mm) at the bottom of the pump housing casing. All deviations shall refer to a vertical line passing through the center of the pump housing casing to the top of the pump housing casing.
Straightness shall be determined by lowering a section of pipe 40 ft. (12 m) long or a dummy of the same length to the bottom of the pump housing casing. The minimum diameter of the pipe or dummy shall be 1 inch (25 mm) less than the inside diameter of the pump housing casing. If a dummy is used, it shall consist of a rigid spindle with three cylindrical rings, each ring having a height of at least 12 inches (300 mm). The rings shall be true cylinders and shall be located at each end and in the center of the dummy. The central shaft of the dummy shall be rigid so that it will maintain the alignment of the axis of the cylindrical rings. The pump housing casing shall be sufficiently straight so the pipe or dummy can be passed freely throughout the entire length of the pump housing casing. Plumbs, pipes and dummies used in these tests shall be approved by the Engineer.
Any tubewell failing to meet the specified requirements for straightness, verticality and concentricity shall be abandoned, and the Contractor shall construct a new well at his own expense at an alternative site designated by the Engineer.
After completion of installation of the pump housing casing and approval of the installation by the Engineer, the Contractor shall paint the letter and number designation of the tubewell on that portion of the pump housing casing which projects above the ground surface. All paint, brushes, stencils and other materials required shall be furnished by the Contractor. The characters shall not be less than 6 inches (150 mm) shall be painted with lines 1 inch (25 mm) wide, and shall be positioned on the casing in accordance with the Engineer's instructions.
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5.3.11 Gravel Makeup Pipe
3 inch (75 mm) diameter galvanized iron (G.I) gravel makeup tremie pipe with capped upper end shall be attached to the upper pump house casing to extend from 3 feet (1.0 m) above ground level to penetrate the full length of the upper grout seal. The tremie pipe shall be attached to the pump house casing by means of welded straps spaced no less than to provide four support straps spaced over the length of the pipe. Support shall be sufficient to hold the pipe in place until placement of the upper grouted seal has been completed. The configuration shall be in accordance with the drawings and the pipe shall be located so as to be at 90 degrees to the direction of the pump outlet.
5.4 GRAVEL SHROUDING
5.4.1 General
Gravel shrouding shall consist of all work required in connection with supply and placing of gravel shrouding in annular space between the walls of the drilled hole and the outside of the pump casing. The work shall include, but not limited to development of source, excavation, stock piling, grading, washing, storing, transporting and placing of gravel shrouding as specified herein or as directed by the Engineer.
5.4.2 Gravel Source
The Contractor may obtain gravel from any source or location subject to the approval of the Engineer provided that the gravel meets the requirements of the specifications. The Employer will not be responsible for the amount of work involved or the amount of materials wastage in order to obtain the required amount of gravel of proper gradation.
5.4.3 Specifications
The gravel shrouding shall be clean, washed, water worn, hard, well rounded of siliceous material and without platy particles free from gypsum shale under no circumstances shall contain > 5% calcareous material. The gravel supplied shall be subject to inspection and screening in the field to ensure proper gradation suitable to the formation. The gravel shall be reasonably graded and shall conform to the following requirements: TYPICAL GRADING ------U.S. Standard Percentage Screen Number Passing ------
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3/8 inch 100 No.4 75 100 No.8 35 65 No.14 05 30 No.16 00 15 No.35 00 0
5.4.4 Placing of Gravel
Gravel shall be placed at constant rate using tremie pipe, hoppers or other similar devices to provide a continuous and uniform gravel flow so as to minimise segregation of particle sizes. When tremie pipe or hoppers are used, gravel shall be introduced in the annular space between the pump-housing and the edge of the hole at two points located 180 apart. The tremie pipe, when used, shall be of suitable size and lowered to the bottom of the well on two opposite sides of the bore hole and calculated quantity of gravel shall be poured in the pipe through a funnel and the pipe shall be raised by 6 ft. (1.85 m) interval. In all cases water shall be circulated steadily during gravel placement by inserting the drilling rod into pump housing and operating the circulation pump on the drilling rig. The water level in the annular space outside the pump housing shall be maintained at or above natural ground surface level by return flow from the cutting bit.
Temporary casing, if used, shall be carefully withdrawn in 6 to 10 ft. (1.82 to 3.0 m) interval during placement of gravel shrouding and the gravel shall be introduced so that each stage of the hole above bottom of the casing is completely filled before the casing is withdrawn to the next stage. The process of withdrawing the temporary casing shall be continued until the bottom of temporary casing is at least 10 ft. (3 m) above the top of the top most screen. Above this point the temporary casing shall be removed.
5.5 GROUTING OF PUMP HOUSING CASING
5.5.1 General
Grouting of pump housing casing shall cover providing all equipment, labour and doing all work required to seal the annular space between the pump housing casing and the bore hole face by the introduction of grout as specified herein and on the Drawings according to procedures approved by the Engineer.
5.5.2 Material
The grouting operation shall be done with 1:1 cement sand mortar. Cement and sand shall conform to the requirements of Section "CONCRETE".
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5.5.3 Placement of Grouting
The grout may be placed by either the trimmie method or by being pumped into place provided that both the method and the type of grout is approved by the Engineer prior to the start of the operation.
If the trimmie method is selected and approved the grout material shall be placed by trimmie pouring, (after water or other drilling fluid has been circulated in the annular space sufficient to clear obstructions). The trimmie method shall be used where there is a minimum annular space of 3 inches (75 mm) only between the upside surface of the inside casing and the inside surface of either the external casing or the borehole. The minimum size trimmie pipe utilized shall be 2 inches (50 mm) inside diameter. Where concrete grout is used the minimum size trimmie pipe used shall be 3 inches (75 mm) inside diameter. When making a trimmie pour, the trimmie pipe shall be lowered to the bottom of the zone being grouted and raised slowly as the grout material is introduced. The trimmie pipe shall be kept full continuously from start to finish of the grouting procedure, with the discharge end of the trimmie pipe being continuously submerged in the grout until the zone to be grouted is completely filled. The minimum curing time before construction may be resumed is 72 hours. If the method of grout placement selected and approved is to be by pumping, the grout shall be injected (after water or other drilling fluid has been circulated in the annular space sufficient to clear obstructions) in the annular space between the inner casing and either the outer casing or the borehole. The annular space must be a minimum of 1½ inches (38 mm) for sand and cement of neat cement grout, and not less than three times the size of the largest coarse aggregate used. The grout pipe shall extend from the surface to the bottom of the zone to be grouted. The grout pipe shall have a minimum inside diameter of 1 inch (25 mm) for sand cement of neat cement grout. It shall have a minimum diameter of 1½ inches (38 mm) for concrete grout.
Grout shall be placed, from bottom to top, in one continuous operation. The grout pipe may be slowly raised as the grout is placed but the discharge end of the grout pipe must be submerged in the emplaced grout at all times until grouting is completed. The grout pipe shall be maintained full, to the surface, at all times until the completion of the grouting of the entire specified zone. In the event of interruption in the grouting operation, the bottom of the pipe should be raised above the grout level and should not be re-submerged until all air and water have been displaced from the grout pipe and the pipe flushed clear water. Curing time before construction may be resumed is minimum of 72 hours.
5.6 DEVELOPMENT AND TESTING
5.6.1 General
Development and testing shall consist of all work required in connection with the development of tube well to produce the maximum safe and dependable capacity of sand-free water with a minimum draw down, and the testing of the tube well to determine the effectiveness of' the
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development operations as specified herein or as directed by the Engineer. Development, by airlift, water jetting or by over pumping, and testing, shall include, but not be limited to, surging, back- washing, jetting and pumping the tube well at higher than the rated capacity, testing the tube well for specific capacity and sand content, and capping of the tubewell, Development and tests shall be completed within one month of drilling.
Well depth shall be sounded and recorded before commencement of development works and on completion of the testing and at other times specified herein or as directed by the Engineer.
5.6.2 Development
The development procedures and methods used for the Tube Well shall include the air lift and water jetting methods and pumping and back washing or similar procedures as directed and approved by the Engineer. These operations will be witnessed by the Engineer's Representative from their initiation to their completion. The Contractor shall maintain a complete record of the development operation with the help of a qualified person and shall make regular periodic measurements of discharge rates, sand content, water level and TDS. The development is required up to stage that the acceptable yield of water is free from sand and silt.
Initial development of Tube Well shall be performed in three stages, water jetting, air lift and pumping, or as otherwise ordered by the Engineer.
The details for the various stages are given below:
Development by water jetting method
i). The jetting Equipment to be provided and techniques adopted by the Contractor shall be adequate to undertake high velocity washing of Tube Well.
ii). The Equipment shall include all necessary jetting tool together with a high pressure pump and necessary hose and piping which in combination shall be capable of sustaining 200 psi pressure at jetting nozzles. The diameter of the drop pipe shall be such to minimize friction loss in the jetting operation and ensure adequate delivery. A metal tank shall be provided for surface storage of the fresh, clear water required for use in jelling.
iii). The jetting operation shall be conducted in two phases both of which shall involve jetting of the entire screened length in small increments starting with the uppermost screened section and continuing to the lowermost screened section.
Prior to the first phase the tube well shall be washed with clean water to thin out any remaining mud.
In the first phase, jetting operations will be directed to high velocity washing of the screened sections.
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During the second phase, the jetting water shall be mixed with an appropriate mud dispersant such as calcium hexametaphosphate or other similar approved chemical. Dispersants shall be mixed to concentrations recommended by the manufacturer and approved by the Engineer.
During all jetting operations, the jelling tool shall be constantly rotated while it is being raised and lowered within an individual screened section to ensure that all portions of the zone to be washed are exposed to the jets.
Pumping or air lifting shall be undertaken as a simultaneous operation with jetting'. The pump or air lift discharge from the well shall be at a rate greater than the flow being jetted into the gravel pack and formation so as to create a small net movement of water through the screen into the well.
iv). Any debris that accumulates in the well during jetting shall be removed by bailing. At the end of the jetting phase the tube well shall be allowed to stand with a column of jetting water and dispersant for a period of 12 to 24 hours prior to clearance pumping by airlift as described below.
Developments by air lift method
i). The air lift development tool shall be as per site requirements and shall be subjected to the approval of the engineer.
ii). The pipe line shall be of I inch diameter;
iii). The compressor shall be capable of delivering not less than 200 cu ft per minute of' air at a maximum pressure of' 125 psi, unless otherwise allowed by tile Engineer;
iv). The air lift tool shall be assembled and lowered towards the bottom of the well, the water being gently discharged (during lowering in order to settle gravel in the annulus). An accurate pipe position shall be kept in order to confirm the tool's position opposite the screen. On reaching the lowest screened portion, the tools shall be operated in the prescribed manner or other method approved by the Engineer until the desired results are achieved prior to lifting the tool by a length equal to the distance between isolators, or into the next tipper screen section, where the operation shall be repeated;
v). Air lift tool operation shall consist of adjusting the airline position and airflow to maximize discharge from any section. After maintaining discharge for a few minutes the discharge valve shall be rapidly closed and opened in sequence to achieve several flow reversals in the treated length without venting excess air to the gravel shrouding. Following such a sequence, the maximum continuous discharge shall be maintained until the discharge is effectively sand-free. The whole operation of flow reversal, followed by maximized discharge, shall be repeated until the discharge is sand-free to the Engineer's satisfaction. Throttling of the compressor airflow may be required for these operations. The contractor shall make assessment of discharge capacity of the tube well through measurement of flow of water at short intervals.
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vi). After the development of the entire screen length, the well shall be sounded. If any material has accumulated at the bottom, it shall be removed with an approved device. Development by pumping method
i). The development by airlift shall be followed by pumping and back-washing of the tube well for four hours (minimum) with a vertical turbine pump subject to approval by the Engineer. The pumping shall be done in steps at rates of 35, 70,105 & 140 percent of the assessed discharge capacity. The flow shall be measured at short interval of time along with draw down. At each step the pumping shall be interrupted at 10 minutes intervals to produce a surging effect and shall continue until the sand content specifications are met. The Contractor may notify the Engineer at any time following the completion of the initial development that the tube well is ready for testing.
ii). The Contractor may choose to cease initial development after four hours provided he recognizes his responsibility for meeting the sand tests except that initial development shall be continued so long as sand contents of 30 ppm can be measured within five minutes of restarting discharge. If these criteria cannot be met within 12 hours of pump development the airlift development process shall be repeated.
5.6.3 Testing
i). The Contractor shall test the tube well for well yield, draw down and specific capacity, under the Engineer's direction as described herein. Upon completion of the initial development operations, the tube well shall be permitted to recover for a minimum period of one hour. The rate of recovery shall be recorded. During this recovery period, the tube well shall be sounded. If the comparison of the depth by sounding and the length of the casing string indicate that there is foreign material in the tube well, it shall be cleaned to the Engineer's satisfaction.
ii). Following the recovery period the tube well shall be pumped at 150 percent of assessed capacity for a period of one hour after which the initial specific capacity of the well shall be determined from the measurement of water level and flow at the end of the period along with draw down. The water pumped shall, at all times, be free of turbidity. Within the first 30 seconds of the pumping and again after 2 minutes, the sand content of the water shall be determined by using a 1000 milliliter Imhof cone or by a centrifugal sand sampler (to be approved by the Engineer). Determination shall also be made 5 minutes after the start of pumping and sand content at this time shall be traces/clear. A further determination shall be made 10 minutes after the start of pumping and the water shall be free of sand at this time and at all subsequent intervals. If these sand content tolerances are exceeded at any time up to final acceptance of the installation, while pumping at the rate of 150 percent the initial development of the tube well shall be considered incomplete and the Contractor shall resume initial development by pumping at his own expense until such time as the sand content tolerances are met. If the sand content tolerance cannot be met within the first 24 hours of pump development the airlift development process shall be repeated. Sand content determination, water level, electrical conductivity and discharge measurements during the whole one hour sand test period shall be made at intervals of 15
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minutes or as directed by the Engineer. The contractor shall continue to measure the draw down and check TDS at all intervals of development and testing and maintain record for incorporating in the report.
5.6.4 Final Development
When the sand test has been satisfactorily completed, the tube well shall be finally developed for 3 hours at 150 percent of the rated capacity by surging and back-washing with the test pump at five to ten minute intervals. Following the development period, the tube well shall again be pumped for a period of one hour at 150 percent of design capacity, during which time the sand test shall be repeated. A second specific capacity value shall be determined from the measurement of water level and flow at the end of the pumping period. If the specific capacity obtained from either this second pump test or any subsequent constant discharge test is found to be more than 10 percent greater or less than that obtained in the first pump test, the development shall be considered to be incomplete and the Contractor shall resume development, at his own expense, until the tube well is developed sufficiently to meet this requirement. In the case of specific capacity reduction, re- development with air lift shall be adopted. Measurement for TDS, draw down and silt contents shall be done during all stages and record maintained.
5.6.5 Step Test
Upon satisfactory completion of the repeat sand test, the tube well shall be permitted to recover for a minimum period of two hours. During this recovery period, the tube well shall be sounded. If the comparison of the depth by sounding and the length of the casing string indicate that there is foreign material in the tube well, it shall be cleaned to the Engineer's satisfaction.
Upon the completion of this recovery period, a four hour multiple step tests shall be performed by pumping the tube well for one hour at each of four equal time increments. The first and last step shall be respectively at 35 percent and 110 percent of rated capacity. Following this last increment of the step test, the tube well shall be pumped at the same rate for a further period of four hours. At the end of this test, a final specific capacity value shall be determined from the measurement of water level and flow including measurement and recording of TDS, draw down and silt contents.
On completion of the test program the tube well shall again be sounded. If the comparison of the depth by sounding and the length of the casing string indicate that there is foreign material in the tube well, it shall be cleaned to the Engineer's satisfaction.
5.6.6 Development & Testing Summary
The following is a summary of the standard development and testing procedure:
i). Development by water jetting followed by airlift development tool as directed by the Engineer. Sounding of well depth and removal of any accumulated material
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ii). Development by pumping : 4 hours (minimum)
iii). Testing: Recovery 1 hour (minimum)
Sounding of well depth and removal of any accumulated material.
Pumping at I50% of rated capacity
(sand test) 1 hour
Measurement of initial specific capacity.
Pumping at 150% of rated
Capacity (re-development). 3 hours
Pumping at 150% of rated
Capacity (repeat sand test). 1 hour
Measurement of, second specific
Capacity.
Recovery 2 hours (minimum)
Sounding of well depth and removal of any accumulated material.
Pumping (step -test). 4 hours (one hour each at 35%, 70%, 105%, and 140% of' rated capacity)
Pumping al 140% of rated capacity
(Constant discharge test). 4 hours
Measurement of final specific capacity.
Recovery test 2 hours (Minimum)
Sounding of well depth and removal of any accumulated material.
Measurements shall be done at all stages for TDS, draw down and silt contents and record maintained and incorporated in the report of tube well.
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5.6.7 Equipment’s
The Contractor shall furnish all necessary Equipment, machinery, tools, material labor and staff required for testing the tube well, including a water lubricated pump set, diesel electric generator with all required machinery, equipment’s, accessories. Tools, fuel oil lubricants and materials for developing and testing capable of delivering at 150 percent of the tube well rated capacity at all stages of the tests, a valve for the adjustment of the discharges, an electric water level measuring device, a discharge measuring device, conductivity meters for determining water quality and Imhof cones or centrifugal sand tester to measure sand content. The actual depth of setting of the test pump will be the maximum possible in each case. Piping, gauges, orifice plates, meters, weir boxes or other measuring devices shall remain the Contractor's property. All measuring devices and testing Equipment will be subject to approval by the Engineer.
5.6.8 Development & Testing Records
The Contractor shall record on suitable forms approved by the Engineer, sand content, conductivity, draw down, discharge measurements, sounding depths and other pertinent data during each test at intervals specified by the Engineer. This record shall be prepared and maintained for tube well and incorporated in the contractors report on construction of tube well. The original of such forms shall be delivered to the Engineer at the completion of the development and testing operation and within the time period stated in the Contract Data.
Well Disinfections & Water Quality Testing
Within 3 days of satisfactory completion of testing the Contractor shall disinfect the well. Before commencement of disinfections, the Contractor shall ensure that all Equipment to be used for disinfections are free of all oil, grease, soil and other materials, which could harbor and protect bacteria.
Chlorine compounds in either dry (calcium hypo chlorite) or liquid (sodium hypo chlorite) form may be used as the disinfectant. The disinfectant shall be delivered to the site in original closed containers which shall bear an original label indicating the percentage of available chlorine. Chlorine compounds in dry form shall not be stored for more than one year and storage of liquid compounds shall not exceed 60 clays. Disinfectants must not be stored in direct sunlight.
Disinfections shall be carried out by placing a chlorine solution in the well so that a concentration of available chlorine of at least 100 mg/1 exists in all parts of the well under static conditions.
The Contractor shall apply the disinfectant uniformly throughout the well without relying on mechanical means for dispersion of the disinfectant and shall then agitate the solution by use of a bailer or surge block for one hour. All surfaces of the well above the static \valor level shall be saturated with disinfectant solution for a period of not less than 24 hours.
The Contractor shall with the prior approval of the Engineer make all necessary arrangements with a competent public health laboratory for sampling and analysis of tube-wells water under a range
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of chemical and bacteriological parameters. The results of' the sampling and analyses shall be compiled for each tube well and incorporated in the report on drilling bore hole and construction of tube well by the contractor.
5.6.9 PIEZOMETER
After completion of tube well construction at site of borehole, two piezometers of 10” diameter shall be installed for constructed tube well at a distance of 100 & 200 feet from the tube well- constructed. The method of boring and installation of pipe and shrouding shall be same as for the tube well except that sampling of strata and testing of yield will not be required except otherwise required by the engineer. Cleaning of piezometers will also be required to carry out by the contractor through air compressor of adequate capacity. The bore hole shall be 10” diameter while a 4” size of casing and strainer will be installed with gravel shrouding. The depth of piezometers shall be up to 200 ft depth and as per approval of the Engineer
5.6.10 Sealing of the Well
Upon completion of the tubewell the Contractor shall seal the tubewell with a ¼ inch (6 mm) thick steel plate cap welded to the pump housing at few points using Arc welding, or by some other method approved by the Engineer. Compliance with this requirement will not relieve the Contractor of his responsibility for the safeguarding of any part of the tubewell completed until the Certificate of Acceptance is issued for the entire tubewell installation.
5.6.11 Hypo chlorinator Pump
Hypo chlorinator (Chemical Material Pump) Capacity: 0.30 gallons/day = 113.5 Litre/day of sodium hypochlorite or calcium hypochlorite solution, Max. Viscosity 300 Cp, at 100 Psi max injection pressure fitted with 1/60 HP Air cooled heavy duty electrical motor 220V, 50Hz, single phase AC thru life time lubricated sealed, Self-maintaining gear train with following accessories,
01- Bleed Valve Assembly
04-Suction Tubing
08-Discharge tubing
01-Foot valve strainer assembly with weight
01-Back check valve assembly
01-0perational
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5.7 MEASUREMENT AND PAYMENT
Measurement and payment of all items described in this chapter will be paid in accordance with BOQ items.
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6 TUBEWELL PUMPING FACILITIES
6.1 SCOPE
The work shall consist of furnishing, installing and commissioning deep well turbine pumps involving all mechanical and electrical works and construction of pump houses in accordance with these specifications and in reasonably close conformity with the lines, grades, and dimensions shown on the plans or established by the Engineer.
6.2 MATERIALS AND CONSTRUCTION REQUIREMENTS
Materials and construction requirements shall confirm all Civil, Mechanical and Electrical Works.
Depending upon the strata, it is likely that the design of tubewell will require certain changes in the deep well turbine pumps. Under such a deviation from the provisional design shown on the Drawings, capacity of motor (below or excess of the specified) shall form the basis for measurement and payment of such a deviation.
The installation, testing and commissioning of turbine pumps shall be strictly in accordance with the instructions of the manufacturer of such machinery.
6.3 CIVIL WORKS
Building for the pump house, fences and gates shall be constructed in accordance with the relevant specifications and Drawings or as directed by the Engineer.
6.4 MECHANICAL WORKS
6.4.1 General
The work shall consist of providing, installing & commissioning pumps, motors and accessories, furnishing all plant, labour, equipment, appliances and materials, and of performing all operations in connection with mechanical works in strict accordance with this section of the specifications and the applicable drawings and subject to the terms and conditions of the contract. Equipment damaged by the Contractor during the course of installation shall be repaired or replaced by the Contractor at his own expense.
6.4.2 Approval of Materials and Equipment
As soon as practicable and within 30 days after receipt of notice to proceed and before any material or equipment is purchased, the Contractor shall submit for approval by the Engineer a complete schedule, in triplicate, with the names and addresses of the manufacturers and their catalogue cuts, diagrams, drawings and such other descriptive data as may be required by the
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Engineer. No consideration will be given to partial lists submitted from time to time. Approval of materials and equipment’s under this provision shall not be considered as authorized, any deviation from the specifications unless the attention of the Engineer has been directed to the specific deviations.
6.4.3 Material and Equipment
Materials and equipment shall conform to the respective specifications and other requirements specified hereinafter and shall be new and unused.
6.4.3.1 Water Pumps
Pumps shall be of the open line shaft water lubricated vertical turbine type for installation and operation in tubewells and shall be suitable for use with vertical, hollow-shaft, squirrel cage, induction type motors. All pumps shall consist of pump bowl assembly, column pipe, line shaft and surface discharge head assembly, including water pre-lubrication system as required and all other parts and appurtenances to provide a complete operating pump in accordance with these specifications.
6.4.3.2 Design
The material, design, fabrication and assembly of equipment shall be in strict accordance with American Water Works Association Standard A 101-61 Entitled "American Standard for Vertical Turbine Pump", or latest revision and the following requirements:
i) General
Water Pumps shall be vertical shaft centrifugal pumps with rotating impellers and discharge from the pumping elements coaxial with the shaft. The pumping element shall be suspended by the conductor system which encloses a system of vertical shafting used to transmit power to the impellers, the prime mover being external to the flow stream. The basic pump shall consist of the following three elements: - Pump Bowl Assembly
The pump bowl assembly shall be either a single or multistage, centrifugal vertical pump with discharge coaxial with the shaft.
- Column and Shaft Assembly
The column and shaft assembly shall consist of the column pipe which suspends the pumps bowl assembly from the head assembly and serves as conductor for the fluid from the pump bowl assembly to the discharge head. Contained within the column pipe shall be the line shaft which shall transmit the power from the driver to the pump shaft. The line shaft shall be
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supported throughout its length by means of bearings which are lubricated with water.
- Head Assembly
The head assembly shall consist of the base (from which the column-and shaft-assembly and the bowl assembly shall be suspended) the discharge head which directs the fluid into the desired piping system and the driver.
ii) The Driver Coupling
The driver coupling is the mechanism, which transmits the power to the top shaft. It shall contain means for impeller adjustment and provide a bearing to carry the thrust load.
iii) Discharge Head
A cast iron flange shall be integrally cast on the discharge head. The discharge flange shall have a companion flange suitable for connection to the discharge pipe.
iv) Motor Mounting Flange
The motor mounting flanges of pumps shall match the NEMA flanged base plates of motors and base plates of right angle gears.
6.4.3.3 Manufacture
The pumps shall be as manufactured by M/s KSB or equivalent of the types as specified in this section. The pumps shall be manufactured to meet the characteristics specified in drawing:
i) Pump Elements
The impellers shall be the enclosed skirt seal type constructed of bronze meeting the requirements of ASTM Standard B 145-61 entitled "Leaded Red Brass and Leaded Semi-Red Brass Sand Casting". Impellers shall be accurately fitted, smoothly finished, and dynamically balanced at the normal pump speeds. The bowls shall be constructed of close-grained cast iron. The inside of each bowl shall be hand finished to mirror-like smoothness. Three or four stage pumps as approved by the Engineer shall be supplied by the Contractor. Each suction bowl shall be fitted with a grease-packed bronze bearing and suction case plug. A suction case and collar shall be provided to protect the bearings. Each pump bowl shall have fluted rubber bearings above each impeller and shall be designed for the future installation of bronze or cast iron wear rings. Each discharge bowl shall be equipped with a bronze bearing. The pump and line shaft shall be of stainless steel, conforming to ASTM Standard A 276-60 entitled Hot-Rolled and Cold-Finished Corrosion Resisting Steel Bars", type 416, and shall be of suitable size to transmit the loads and to maintain correct alignment without
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distortion or vibration. The pump shaft shall be turned, ground and polished and shall be threaded for connection to the line shaft.
ii) Column Pipe and Line Shaft
The column pipe shall be furnished in interchangeable sections having a normal length of 10 feet (3 m). Wall thickness shall be minimum 0.234 inches (6.0 mm). The ends of each column pipe section shall be faced parallel and perpendicular to the axis of the pipe. The threads shall be machined so that adjoining sections of column pipe will butt together to ensure proper alignment on assembly. The line shaft shall be ground carbon steel shafting in accordance with ASTM Standard A 108-61T entitled "Cold- Finished Carbon Steel Bars and Shafting" Grade 1020 or 1045 and shall be furnished in interchangeable sections having a nominal length of 10 feet (3 m). The ends of the shaft sections shall be faced parallel and perpendicular to the axis of the shaft. Adjoining sections of the line shaft shall be connected by means of threaded, sleeve-type couplings of the same material as shall be supported by fluted, oil resistant, rubber bearings designed to be lubricated by water. The bearings shall be mounted in bronze bearing retainers which shall be threaded into the column couplings and butted against the adjoining section of column pipe. The rubber bearing shall be replaceable within the bronze bearing retainers and shall be spaced at intervals of not more than 10 feet (3 m) along the line shaft.
iii) Surface Discharge Head
Each surface discharge head shall be of the above ground type and shall be a suitable base for supporting the specified electric motor and the pump column. The discharge head shall be of cast iron conforming to ASTM Standard A 48-62 entitled "Standard Specification for Grey Iron Casting" Class 30 A or an approved equal quality of casting. Each surface discharge head shall be furnished with an integral ASA 125-pound flange conforming to ASA B16-1-1948 "Cast Iron Pipe Flanges and Flanged Fittings, Class 125". The discharge heads shall include half couplings connecting to discharge pressure and suction pressure to accommodate gear cooling water lines as required by the gear drive unit.
iv) Pre-lubrication System
The contractor shall furnish a manually operated, water pre-lubrication system complete with all valves, piping and storage tank for each turbine pump. The piping for pre-lubrication system shall be complete with necessary valves, lines and fittings to permit filling of the pre-lubrication tank from the pump discharge and to permit the water to be manually released prior to starting pump. The pre-lubrication tank shall be an enclosed tank of sufficient size to adequately lubricate the line shaft bearing before pump start-up and shall be equipped with an opening in the top through which it may be filled from the pump discharge or from an outside source.
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6.4.3.4 Quality Control Tests
The manufacturer shall perform all the quality control tests as specified hereafter and all test results and anticipated field performance curves shall be submitted, in triplicate, to the Engineer.
i. Standard Running Test
The pump bowl assembly shall be operated from zero capacity to the maximum capacity shown on the performance curve submitted with the manufacturer's bid. Readings shall be taken at a minimum of 5 capacity points, including one point within + 2% of design capacity specified. The pump shall be operated at a speed within + 5% of the design speed.
ii. Capacity Measurement Test
The capacity of the pump shall be measured by means of a standard venturi tube, nozzle orifice plate or pilot tube traverse.
iii. Head Measurement Test
For head measurement in excess of 36 ft. (10.9 m) calibrated bourdon or other gauges with equivalent accuracy and reliability shall be used. All gauges shall be calibrated before and after each series of tests.
iv. Test for Velocity
The average velocity in the pump column used to determine the velocity head shall be calculated from dimensions obtained by actual measurement of the pipe and shaft or enclosing tube diameter and the velocity head shall be obtained from actual measurement of the inside diameter of the discharge pipe at the point where the pressure tap is located.
v. Horsepower Input Test
The power input to the pump shall be determined with vertical dynamometer or a calibrated electric motor. Calibrated laboratory type electric motors and transformers shall be used to measure the power input to all motors.
vi. Measurement of Speed
The rotating speed of the pump shall be obtained by a hand counter, electronic computer or a counting slip.
vii. Hydrostatic Test
A standard hydrostatic test on the pump bowl assembly shall be made at 1.5 times the shutoff head developed by the pump bowl assembly or at twice the rated head, whichever is greater.
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6.4.3.5 Motors
The pump motors shall be vertical, hollow shaft fan cooled totally enclosed weather protected squirrel cage, induction type and shall have 4 poles with approximately speed of 1460 rpm on 400 volts, 3-phase, 50 cycle. The motor horse power for each site shall be indicated in the Bill of Quantities. When operating continuously at full rated load, the temperature rise shall not exceed 40 degree centigrade above an ambient temperature of 50 degree centigrade. The motor shall have a service factor of 1.15 times the rated horsepower, and horsepower loadings shall not exceed the name plate at any point on the pump performance curve. The motors shall conform to NEMA Standard MG 1, entitled "Motors and Generators" for a class B design and shall have low starting current and normal starting torque. The locked rotor input shall not exceed 5.6 KVA per horsepower. The winding shall have Class B insulation and shall be suitable for operation under conditions of high humidity and at an ambient temperature of 55 degree centigrade. Each motor shall be equipped with three thermal devices embedded and symmetrically spaced in the stator winding. These devices shall operate on temperature rise to de-energize the control circuit of the motor thus disconnecting it from the power source. The thermal devices shall be so located in the winding and so constructed that they will prevent motor damage due to overheating resulting from overload, lack of ventilation, single phasing, stalling, high ambient temperature or voltage imbalance. The pump motors shall be designed for mounting on the surface discharge head and for direct connection to the line shaft. A thrust bearing of adequate capacity to carry the weight of all rotating parts, plus the hydraulic thrust, shall be provided on each motor. The motors shall be provided with a completed oil or grease- lubrication for each bearing. Each motor shall be provided with a non-reverse ratchet to prevent reverse rotation of the pump.
6.4.3.6 Motor - Control
The motor controls for each motor shall consist of motor starter and control switches with all necessary components for a complete installation. Each motor control shall be suitable for controlling and protecting 400 volts, 3-phase, 50 cycle electric motor. Motor controls shall be furnished in complete accordance with the applicable provisions of NEMA Standard I CI, entitled "Industrial Controls", shall have a minimum insulation level for 600-volt class equipment, and shall be designed to provide short circuit protection in all phases and overload protection in all three phases. The thermal overload relay reset device shall be mounted to be operatable without the necessity of opening the casing. Each motor control shall be furnished complete as a unit with all component parts and accessories completely wired to conform to NEMA Class II construction, Class B wiring. The conductor shall be 600 volt, heat-resistant, thermoplastic insulated wire suitable for 75oC operating temperature. A weather proof enclosure NEMA Type III with a lockable outer door shall be provided.
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6.4.3.7 Piping
Piping for mechanical equipment shall be accomplished as indicated and shall conform to the relevant specification section "PIPES, PIPE LAYING AND APPURTENANCES".
Installation
Installation shall include all bolts, nuts, washers, shims, fittings, grout and other materials required for proper installation of the equipment which are not supplied as part of the equipment. Equipment damage during the course of installation shall be repaired or replaced by the Contractor at his own expense.
6.4.3.8 Pumps and Motors
The Contractor shall carefully clean, assemble, align and install the pumps in accordance with the manufacturer's recommendations. Care shall be taken that all connections are clean and free from burrs and foreign material so as to ensure tight fit and proper alignment. Connections between adjoining sections of column pipe and line shaft shall be correctly assembled and tightened to maintain accurate alignment. A suitable thread lubricant shall be used on all threaded connection to facilitate disassembly for maintenance. The pumps and motors shall be installed in tubewell in accordance with the manufacturer's instructions. The surface discharge heads shall be accurately set on the concrete pump platforms shown on the drawings and shall be aligned with pump housing casing. The surface discharge heads shall be rigidly connected to the reflux (check) valve and the dresser-type couplings. All the fittings shall be properly installed as shown on the drawings. In order to ensure the accurate and proper alignment of the pump, anchor bolts shall set only after the pump has been set and aligned. Anchor bolt holes may be formed in the concrete platform as the concrete is placed or may be drilled in the concrete after the concrete has set thoroughly. The anchor bolts shall be minimum 5/8 inch (16 mm) diameter and minimum 12 inches (300 mm) long with nut and lock washer, and shall be set in the anchor bolts holes with sufficient extension to permit the full threads of the nuts to be engaged by the anchor bolt. The anchor bolts shall then be set in cement grout. Where holes are drilled after the concrete has set thoroughly, expansion bolts or lead expansion anchors may be installed at the option of the contractor in lieu of grouting anchor bolts. Non-shrink grout shall be placed under the entire surface of the discharge head to provide proper support for the pump. Non-shrink grout shall conform to the applicable requirements set forth in the Specifications for concrete.
6.5 LIFTING GEAR (CHAIN PULLY)
The contractor shall supply an overhead mono rail chain pully block suitable for lifting and transportation of such parts of plant as are necessary for the maintenance and replacement of whole plant.
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6.6 CHLORINATION EQUIPMENT
6.6.1 Chlorinator
Chlorinator shall be of vacuum solution feed, manually set, wall mounted type. Chlorinator shall be capable of meeting requirements of water flows of 4 cusecs (0.68 cumecs) and delivering upto 1 lb/hr (0.453 Kg/hr) of chlorine gas in solution to give a maximum dosing rate of 2 ppm. The chlorinator shall be supplied complete with all standard accessories and complete in all respects to ensure satisfactory operation.
6.6.2 Chlorinator Accessories
The chlorinator should include among its accessories an injector, a water booster pump with electric controls, a chlorine gas inlet connected via pressure regulating valve, a linear feed rate indicator, a feed rate adjuster, a pressure relief valve, a drain relief valve, and chlorine pressure gauge.'
6.6.3 Booster Pump
The Contractor shall supply alongwith each chlorinator a water pump for booster water pressure to meet requirement of the chlorinator. The pumps shall have adequate pumping capacity and to ensure proper mixing of chlorine and water in the injection assembly of chlorinator. The pumps shall be electrically driven by single phase motor capable of operation on 220 V, 50 hz. with + 10 percent fluctuation in voltage. The pumps shall be supplied complete with suction and delivery isolating valves, check valves, pressure gauge and appropriate starters.
6.6.4 Empty Gas Cylinders
The Contractor shall supply with each chlorinator two 150 lb. (68.03 Kg) empty chlorine cylinder designed and fabricated in accordance with AWWA or A.S.T.M. Specifications or equivalent. The welded seams shall be fully stress relieved after fabrication. A corrosion allowance of 1/16 inch (1.58 mm) shall be provided for the design thickness of the cylinders. Material of construction shall be according to ASTM A-515 Grade 60 or ASTM A-285 Grade C or equivalent.
Cylinder shall be provided with matching outlets corresponding to chlorinator offered under this Contract. Each cylinder shall also have a protection cap provided along with the cylinder.
6.7 GUARANTEE
Equipment furnished under this section shall be guaranteed for a period of one year from date of acceptance hereof against defective materials, design, and workmanship. Upon receipt of notice from the Engineer of failure of any part of the guaranteed equipment during the guarantee period,
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new replacement of part or parts shall be furnished promptly by the Contractor at no additional cost to the Employer.
6.8 OPERATION AND MAINTENANCE MANUAL
The Contractor shall furnish 6 copies of an illustrated operation and maintenance manual with each piece of equipment furnished under this section.
6.9 SPARES AND TOOLS
The Contractor shall furnish common spares such as O- rings, bushing, bearing, other similar items and special tools for each piece of equipment furnished under this section for its efficient service for over 1 years period.
6.10 MEASUREMENT AND PAYMENT
Measurement and payment of all items described in this chapter will be paid in accordance with BOQ items.
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7 SUPPLY & INSTALLATION OF HIGH DENSITY POLYETHYENE PIPES
7.1 WORK INCLUDED
The work included in this Section consists of manufacture, factory testing and witnessing by the Employer and or the Engineer and supply and delivery of High Density Polyethylene pipes, fittings, valves, specials and other pipeline materials and installation as specified here-in.
All pipeline materials shall be supplied by the Contractor, unless otherwise indicated in these documents or instructed by the Engineer.
All materials and equipment supplied shall be suitable for use under conditions prevailing at the sites of the Works
7.2 SHOP DRAWINGS
A. General
In addition to re-submitting all data required in the Tender the Contractor shall submit for approval detailed shop Drawings together with other required information specified in accordance with the requirements specified in this Section.
The Contractor shall submit for the Engineer's approval a detailed program for submission of drawings, manufacture, testing, witnessing and delivery of pipes, couplings, fittings, valves and other pipe line materials to achieve the completion of the Works within the Contract period. Any deviations from the program shall be notified to the Engineer, but will not relieve the Contractor of his obligations under the Contract.
B. Shop Drawing
Shop Drawings, complete with material, grade and class for all pipes, fittings, couplings, joints and coatings shall be submitted. Detailed catalogue and engineering data sheets shall be submitted for all components such as flexible couplings, rubber gaskets, and insulating joints.
Shop Drawings for valves and miscellaneous components shall be complete with bill-of-materials showing kind and class of materials and catalogue and engineering data showing compliance with the specified requirements. In addition shall submit: a) Instructions and Certificates for each type and model of valve:
- Assembly instructions and spare parts list
- Preventative / corrective maintenance instructions
- Certificate of seat compatibility with entailed fluid exposure
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b) Erection Drawings including the procedures to be used in setting, supporting, and/ or anchoring the valves, the fitting of line pipe to the valves for proper coupling and for adjusting and testing all valve assemblies.
C. Protective Coatings
Protective coatings schedules shall be submitted, showing shop and field surface preparations, materials, methods of application, dry film thickness and tests for defects, all in conformance with this Section.
All exposed pipe work shall be provided with a topcoat of blue color paint compatible with the protective coating unless otherwise directed by the Engineer.
7.3 MARKING
Each length of pipe and fitting shall be marked with the following:
Manufacturing standard Manufacturer’s name Manufacturing date Nominal diameter in mm Inside and outside diameters in mm Pressure rating in bars Inspection mark Coupling "homeline" position on spigot ends Serial Number
7.3.1 Not More than One Manufacturer
Pipes, couplings, fittings and valves for each component classification shall not be supplied by more than one manufacturer, except with the Employer's approval.
7.3.2 Test Certificates
All pipes, fittings and valves delivered to the site shall have been tested (referred to hereinafter as "works test") in accordance with ISO standards or other approved equivalent or better standard. The Contactor shall furnish the Engineer with the manufacturer's test certificates for each consignment before each delivery begins.
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The Engineer and or the Employer reserves the right to inspect the pipes, couplings, fittings and valves to be supplied for the works at the place of manufacture and to witness works tests. The Contractor shall provide the equipment and labour necessary for carrying out the inspection.
7.3.3 Basis of Acceptance
The acceptability of the pipes and fittings will be based on the results of tests carried out at the manufacturer's plant and or at the Contractor's expense and the result of any independent testing carried out by the Employer or his agent.
7.4 INSTALLATION REQUIREMENTS
A. Requirements
Pipes shall be extruded to control the outside diameter, and the sizes of pipes shall be to the metric convention. The allowed tolerances are in accordance with ISO 11920-1. The tighter specification on pipe tolerance will reduce any wall mis-match in butt fusion jointing and will allow easier assembly of socket elector fusion joints on site. The ovality of the outside diameters of the pipes shall be within the values given in ISO 11920-1.
B. Tensile Properties of Pipe
Tensile samples taken from the wall of PE 100 pipes shall exhibit a minimum failure strain of at least 500%. At a crosshead speed of 50 mm/min., the tensile strength at yield shall be greater than 201 MPa for PE 100 pipes. Tests shall be undertaken at 200C using a sample shape defined in ASTMD 638. Test shall be made with each production run of pipe.
C. Offset Butt Joint Performance
For all pipes with a minimum wall thickness of 10mm and above, one butt fusion joint is to be prepared with the two pipe axes parallel but offset by 20% of the pipe wall thickness. Jointing is to be undertaken using the recommended butt fusion jointing parameters. The welded pipe is to be tested at a pipe hoop stress of 4 MPa at 800C and the lifetime shall be equal to or greater than 500 hours for black pipe. This test is a type test.
D. Jointing of PE Pipes
The Contractor shall employ only manufacturer's certified staff to perform all of the following jointing techniques to create PE pressure pipe systems. An approved sub-contractor may be used only with the Engineers approval. i. To join lengths of straight pipe and incorporate fittings such as bends, equal toes and reduced, automatic butt fusion jointing procedures shall be used. ii. To install off-takes from an already installed or a new line and on locations indicated and approved
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by the Engineer, electro fusion fittings shall be used or suitable mechanical fittings as approved by the Engineer shall be used. E. Pipe to Pipe Butt Fusion Jointing
The Contractor shall adhere to the following guidelines in respect of butt fusion jointing PE pressure pipe iii. Automatic butt fusion jointing shall not be undertaken on PE pipes with a wall thickness below 10mm. iv. Pipes of the same outside diameter but either different wall thickness or different classes of resins (i.e PE 80 and PE 100) shall not be butt fusion joined. v. By using PE 100 pipes made from PE 100 resins, it is feasible to join PE 100 pipes of the same dimensions but made by different pipe manufacturers using the common welding conditions. vi. PE pipes made from the very high molecular weight resins (i.e Philips Driscopipe M 8000 Series) shall not be used. vii. The Contractor shall use automatic butt fusion machines. The equipment shall employ data storage and data retrieval to record the conditions used for butt fusion jointing. viii. The Contractor shall follow automatic butt fusion jointing conditions together with good site procedures as given in WIS 4-32-08 or as in manufacturer's guidelines to the Engineer's approval.
For all pipes with a minimum wall thickness of 10 mm and above, one butt fusion joint is to be prepared with the two pipe axes parallel but offset by 20% of the pipe wall thickness. Jointing is to be undertaken using the recommended butt fusion jointing parameters. The welded pipe is to be tested at a pipe hoop stress of 4 MPa at 800C and the lifetime shall be equal to or greater than 500 hours for black pipe.
G. Fittings
Fittings shall be manufactured by injection moulding or other approved method.
Fittings in other materials will only be permitted when the materials and method of manufacturer have received the Engineer's approval.
Lying of polyethylene pipes shall be to the manufacturer’s recommendation and by staff who have
manufacturers certificate for carrying out PE pipe laying and jointing works.
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7.5 PIPE LAYING AND PROTECTION
The routes of pumping mains as shown in the drawings are indicative only, and are provided for guidance of the Contractor. The Contractor shall carry out detailed survey of pumping mains and prepare his layout/design accordingly.
The laying of the pumping mains shall essentially be in excavated trenches backfilled after installation, avoiding sharp bends and providing soil cover a minimum of 1 m from top of the pipe, however, in plant area, certain reaches of pumping mains will have to be installed above ground to avoid interference with existing underground structures.
7.6 PRODUCT HANDLING, DELIVERY AND STORAGE
A. General
Pipe shall at all times be handled with equipment designed to prevent damage to the interior or exterior coating of the pipeline. Pipe with cement mortar lining or having any other special coating or lining shall only be handled with wide canvas or rubber covered slings. Bare cables, chain hooks, or metal bars shall not be allowed to come in contact with the coating.
All pipe ends shall be suitably protected against damage during delivery and handling. All flanges shall have wooden disc bolted on. Plain and sleeve ends shall be wrapped or cushioned to protect from damage to external protection.
All pipes, valves and fittings shall be ensured adequate protection against corrosion, mechanical damage, deterioration and exposure until they are incorporated in the Works. The Contractor shall submit his proposals for protecting the pipes and fittings for approval by the Engineer.
B. Shipping
When making shipments, all chain, and hold-down equipment shall be carefully padded where in contact with the pipe.
C Unloading
Unloading from the trucks shall be done with care using appropriate slings and cables for ductile iron pipe. No pipe shall be allowed to fall from trucks. Pipe shall only be unloaded using a crane or fork lift. Pipe shall not be permitted to strike other pipes or other objects, and shall not be rolled freely or dragged along the ground.
D. Storage
The Contractor shall take into temporary protective storage all pipe and appurtenant materials not required for immediate installation in the Works or, in the case of pipes, for stringing out along
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pipelines. The Contractor shall not string out along pipelines more pipe than can be installed in one day. Jointing materials shall be stored under cover until they are required for installation.
Pipes in storage shall be laid on wedged timber bearers so as to be at least 100mm clear of the ground; pipes may be stacked up to three pipes high if suitable protective packing is placed between layers and additional bearers are provided where necessary to prevent damage to sheathed and coated pipes. Pipes strung out along pipelines shall be raised 100mm above the ground on timber bearers.
E. Gaskets
Gaskets shall be stored in containers or wrappers which will protect the gaskets from ozone and other atmospheric deterioration.
F. Polyethylene Sleeving
Polyethylene sleeving shall be stored with protective packaging and out of direct sunlight.
G. Gaskets and Jointing Materials
Gaskets, gasket lubricants, bolts, and jointing materials shall be delivered in separate, clearly marked boxes.
H. Spare Jointing Materials
As part of the quantity delivered, the Contractor shall include in his bid 10% additional gaskets and loose bolts nuts and washers than may be theoretically required for the amount of pipe furnished to cover field losses.
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8 ELECTRICAL WORKS
8.1 GENERAL
The work shall consist of furnishing all equipment, materials and of performing all operations in connection with the electrical works in strict accordance with DISCO (WAPDA) this section of the specifications and the design drawings, and subject to the terms and conditions of the contract.
8.2 SCOPE
The scope of the document includes general requirements and specifications for internal electrification of filtration rooms.
8.3 BUILDING ELECTRICAL WORKS
8.3.1 Scope
The work shall include furnishing of all labor, materials, equipment’s tools and plants as required and providing the internal electrification and other works as specified consisting of but not limited to conduits and pipes, wires and cables, wiring accessories light fixtures, lighting system, power distribution, fans, fittings. The Contractor shall execute the works as shown in the design drawings specified herein, prepare shop drawings and obtain the Engineer’s approval before Execution of work, as directed by the Engineer, the Contactor shall be responsible for proper functioning, testing, commissioning and satisfactory operation and performance during the defect liability/maintenance period and afterwards.
8.3.2 Codes and Standards
The work shall conform to the requirements of the following Codes and Standards, unless otherwise specified:
Standard Description
BS 89-77 Specification for direct acting indicating electrical measuring instruments and their accessories. BS 4553-70 PVC insulted split concentric cables with copper conductors for electric supply. EN1452-2/ uPVC conduits and Conduit fittings. ISO 4422-2 BS 142-82 (P-2) General requirements for measuring relays used for protection BS 159-57 Bus bars and bus bar connections. BS 161-76 Specifications for tungsten filament lamps for general service. BS 1853-79 Tubular fluorescent lamps for general lighting service. BS 3871-65 Miniature air-break circuit breakers for A.C. Part I-(84) circuits. BS 4752-77 Circuit breakers.
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BS 5419-77 Specification for air-break switches, air-break disconnectors etc. BS 6004-84 Specification for PVC insulated cables for power and lighting. BS 6346-77 PVC – insulted cables for electricity supply. BS 6360-81 Specification for conductors in insulated cables and cords. BS 6500-84 Specification for insulated flexible cords and cables BS 6746-84 PVC insulation and sheath of electric cables. CP 1013-65 Earthing.
8.3.3 Ambient Conditions
All material and equipment supplied and installed shall be designed, manufactured and tested to meet the following ambient conditions unless specifically stated otherwise for any material/equipment.
• Maximum ambient temperature:(+) 50 °C • Minimum ambient temperature:(-) 2 °C • Maximum relative humidity:100%
8.3.4 Qualifications
The Electrical works shall be carried out by the Licensed Contractor authorized under the provisions of Electricity Act, 1910 and the Electricity Rules 1937, as adopted and modified by the Government of Pakistan from time to time.
The installation in general shall be carried out in conformity with the Electricity Rules 1937 and the latest edition of Pakistan standards or any equivalent International standards approved by WAPDA. However, in case of conflict between these specifications and the standards, the prevailing ruling will be the one which requires higher quality of workmanship & materials and safety to personnel or as interpreted by the Engineer.
The Contractor shall set out the work himself and if any discrepancy is found, he shall report the matter to the Engineer and shall act as directed. Any defective electrification work carried out by the Contractor shall be rectified or made good by the Contractor at his cost.
The electrical works shall keep pace with the civil works and the works of any other discipline. The Engineer shall be kept informed about the programme and the progress of work so that there is no hindrance in the progress of work at Site.
8.3.5 Inspection and Tests
a) Factory Tests
All type and routine tests on all equipment shall be performed at the manufacturer's facility in the presence of the Engineer or his Representative. Type tests may be waived off in case test certificates are submitted by an Engineer's approved standard laboratory of international repute; but merely producing the test type certificates will not relieve the manufacturer to carry out the required standard/routine tests. The Contractor shall inform the Engineer about the
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date and time of test of each equipment at least two weeks in advance. The witnessing of test by the Engineer or his representative shall not absolve the Contractor from his responsibility for the proper functioning of the equipment, and for furnishing the guarantees.
b) Site Tests
Upon completion of the installation, the Contractor shall perform field tests on all equipment, materials and systems. All tests shall be conducted in the presence of the Engineer for the purpose of demonstrating equipment or system compliance with the Specifications. The Contractor shall furnish all tools, instruments, test equipment, materials, etc., and all qualified personnel required for the testing, setting and adjustment of all electrical equipment and material including putting the same into operation. All tests shall be made with proper regard for the protection of the personnel and equipment.
c) Insulation Resistance Test
Insulation resistance test shall be made on all electrical equipment by using a meggar of 500 Volts for circuits up to 250 Volts and 1000 Volt for circuits between 250 and 500 Volts. The insulation resistance values of cables shall conform to the requirements of BS2004, BS6004, BS 6346 and Pakistan Electricity Rules. Before making connections at the ends of each cable run or joint between cables, the insulation resistance test of each cable section shall be made.
d) Earth Resistance Test
Earth resistance tests shall be made by the Contractor on the grounding system, separating and reconnecting each earth connection. If it is indicated that soil treatment or other corrective measures are required to lower the ground resistance values, the Engineer will determine the extent of such corrective measures. The electrical resistance of the E.C.C. together with the, resistance of the earthing leads measured from the connection with earth electrode to any other position in the complete installation shall not exceed one ohm.
e) Switchgear
Each circuit breaker shall be operated electrically and mechanically. All interlocks and control circuits shall be checked for proper connections in accordance with the wiring diagrams given by the manufacturer. Trip circuits shall be checked for correct operation and rating of equipment served. The correct size and function of fuses, disconnect switches, number of interlocks, indicating lights, alarms and remote-control devices shall be in accordance with approved manufacturer drawings. Name plates shall be checked for proper designation of equipment served.
f) Inspection Tests
The Contractor shall be responsible for submitting the test certificates and getting the installation passed by the Electrical Inspector appointed by the Employer. Any special requirements of the local building and or municipal authority shall also be complied with.
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8.3.6 Guarantee
The Contractor shall furnish written guarantee against performance of each equipment. Such guarantee shall be for replacement and repair of a part or whole equipment which may be found defective in material or workmanship free of cost. The guarantee shall cover a minimum period of 12 months after commissioning of the equipment
8.3.7 Submittals
All drawings of equipment, appliances, fixtures and accessories that are to be furnished under the Contract. These shall include detailed electrical design drawings, wiring diagram, foundation details, etc. for all electrical switchgear, fuse gear and all other systems. Drawings and data for each equipment to be furnished before commencement of fabrication and manufacture, for approval of the Engineer. The drawings to be submitted by the Contractor shall be as follows:
i. Layout Drawings showing: • Arrangements • Dimensional plans, elevations and front view foundation plans, anchor bolt locations • Bus bar locations and configurations • Incoming and outgoing cable terminating positions terminal blocks location • Grounding arrangement
ii. Electrical Drawings showing • Single-line diagram • Detailed wiring diagram • All interconnections • Other electrical devices including metres, instruments, motors and their wiring diagram • Manufacturer's installation, operation and maintenance manuals wherever applicable.
Specimens of all wiring accessories, fittings, fixtures, conduits, pipes, wires, cables and all the materials to be incorporated into the Works along with specifications of each.
A list of spare parts required for one year's operation of each equipment where deemed necessary together with unit price of each part.
8.4 ELECTRIC POWER SUPPLY FOR THE FILTRATION ROOM
Successful bidder is required to take electric supply from the DISCO connection at site and supply power to the filtration plants at site. Electrical distribution shall be through a properly designed DB as per national and international standards.
Electric supply will be tapped of and recorder in a KWH meter to the distribution board.
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8.5 LOW VOLTAGE (LV) DISTRIBUTION BOARDS
Main Distribution Board (MDB) comprising of cubicles, frame made of sheet steel 14 SWG and doors of 16 SWG, with flexible earthing straps, degreased and derusted, finished with electro-static powder coating of 50 micron thickness in approved color, panel housing to comply with protection class IP-54, indoor concealed type, with hinged door, lockable handle, all auxiliaries, internal wiring, designation labels on MCCB, DOL containing Magnetic Contactors, Over load Relay as per motor rating control wiring for ON-OFF Push Buttons, Indication lights, Terminal Blocks for Remote control of Motor or for interlocking purpose, earthing bar, numbering beads on the control wires, panel suitable for system Voltage 230 V, 50 Hz, 1 Phase and neutral, bus bars of 99.8% purity electrolytic copper, including cost of cable termination lugs, brass cable glands for incoming & outgoing cables, wiring from breakers, indication lamps, instruments and control including.
All incoming and outgoing breakers shall be accessible by opening the front door having additional M.S. sheet cover. Gaskets shall also be provided where necessary. MCCB shall be suitable to operate without any de-rating at 50°C ambient temperature and shall be of one make only and not a mixture of more than one make. The front and back sides of MDB shall also have louvers at bottom and sides of panel for hot air exhaust, complete in all respects as approved by Engineer In- charge.
Typical component specifications are given below:
a) Miniature Circuit Breakers (MCBs)
The MCB shall be single pole 250 Volt and double pole 500 Volts of current ratings as mentioned in the bill of quantity. These shall have fixed magnetic short circuit and fixed thermal overload protections. The single pole and double pole miniature circuit breakers shall have a 6 kA and 10 kA short circuit breaking capacity as per International standards IEC 60898.
The Miniature Circuit Breakers shall be installed such that their switching levers are accessible through the front plate inside the distribution boards for operations. Circuit Numbers and Designation on all circuits shall be clearly marked to facilitate connection and maintenance. These Circuit Breakers shall be suitable for working on lighting and power circuits.
b) Bus Bars
The bus bars shall be made of high conductivity electrolytic copper and shall be completely isolated and mechanically braced for the specified fault level. The phase identification of bus bars shall be by colours applied on bus bars and these shall be red, yellow and blue for phase and black for neutral. The earth bus bar shall be green.
The bus bars shall be triple pole and neutral and shall be of appropriate size to meet the electrical and mechanical requirements of the system. The temperature rise shall not exceed 45 °C at rated current.
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c) Push Buttons
Push buttons shall be momentary make break contact type (normally open/normally close). These shall be suitable for flush mounting. Distribution board, plastic face plate etc. Push buttons shall have round/square head.
d) AC Voltmeters
AC Voltmeters shall be Digital type and shall be suitable for flush mounting on front door of the Distribution Boards or DIN mounting within DB. The front dimensions for door mounted meter shall be 96 mm Wide and 48 mm high.
e) Indicating Lamps
Indicating lamps shall be suitable for flush mounting, complete with base, either 230 Volt neon or 12 Volt incandescent lamp through auxiliary transformer and shall have rosettes of suitable colour or as per BOQ.
8.6 LT CABLES
The cable manufacturer shall be certification holder of ISO-9002 and shall be approved by the Engineer. The main cables shall be PVC insulated, and overall PVC sheathed, 250/440 Volt grade, designed, manufactured and certified in accordance with IEC-60502 or other equivalent international standards.
For internal electrification system, LT cables shall be single or multicore as required with stranded copper conductors and polyvinyl chloride heat and moisture-resistant insulation as per latest applicable international standards.
The route of the cables shall be as shown on the drawing. Any change in route required due to site conditions shall be made in relation with other service layout and with the approval of the Engineer.
Standards and Parameters
The cable shall be suitable for operation at conductor temperature up to 70o C under normal conditions.
Conductors shall be of high purity copper wires and shall conform to the requirement of the following BS or equivalent standard.
• BS 6346 PVC insulated cables for electricity supply • BS 6746 PVC insulation and sheath of electric cables • BS 6360 Conductors for insulated cables • IEC 228 Conductors for insulated cables • BS 6500 Insulated flexible cords
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Construction Requirements
Slack shall be left in cables for which purpose the cut lengths of cables shall allow about 3% more in the measured length between terminations (The Engineer will verify the lengths of cables). At junction boxes, ample slack shall be left to prevent straining of cable joints.
Cables, whether installed in bare ground or in pipes shall not be bent to a radius less than that recommended by the cable manufacturers.
Upon completion of cable installation, the Contractor will be required to undertake testing as approved by the Engineer or the concerned department and shall comply with IEE wiring regulations. The copies of test results shall be supplied to the Engineer.
Cable Sizes
The sizes of LT copper conductor cables shall be as approved by the Engineer. Care shall be taken so that voltage drop at the far end of the cable does not exceed 3% of the nominal voltage. Cables manufactured by the reputed firms shall be used, provided they fulfil all the requirements of the specifications.
Cable Accessories
All accessories shall be provided without additional cost for the complete cabling and wiring system. These shall include but not be limited to items such as clamps, fixing channels, connectors, cable joints (where necessary and as approved by the Engineer), clips, lugs, tapes, solders, identification tags, bushes & glands etc.
8.7 LIGHTING SYSTEM, WIRING & MATERIAL
Description
All single core PVC insulated cables for the following shall be of 240/440-Volt grade copper conductor cables:
• Wiring of light circuits • Switch to point wiring • Light point to light point wiring • Wiring of circuits for 5 amps, 250 Volts, 2 pin switch socket unit • Wiring of push buttons & between push buttons • Wiring of light circuits controlled by push buttons • Wiring between light circuits controlled by push buttons • All single core PVC insulated power cables for the following shall be copper conductor and of 600/1000-Volt grade: • All multicore un-armored control cables shall be copper conductor and of 300/500-Volt grade. • All multicore unarmored power cables shall be copper conductor and of 600/1000-Volt grade.
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The light control switches, switch socket units, fan controllers, industrial socket units, etc. shall be of following ratings;
• Light Switches rated for 5A, 250 Volt. • Fan dimmers rated for 100W, 250 Volt. • 2 pin rated for 5A, 250 Volt.
The locations of the switch fittings & accessories such as sockets, switches etc. are tentatively shown on the drawings. The Contractor shall ensure the exact positions and locations of wiring accessories in coordination with other services drawings, as per site requirements and as directed by the Engineer.
Applicable Standards
The latest editions of the following standards and codes shall be applicable for the materials specified within the scope of this Section:
• BS EN 60228 Conductors for insulated cables • BS EN 50525 PVC insulated cables (non-armored) for electric power & lighting • BS 6746 PVC insulation and sheath of electric cables • BS 6360 Conductors for insulated cables • BS 6500 Insulated flexible cords • BS 67 Two and three terminal ceiling roses • BS 4934 Safety Requirements for electric fans and regulators.
Material
a) Fluorescent light Fixtures
All the light fixtures shall have lamps and ballasts of the wattage specified in the BOQ. The fluorescent lamp shall be 1200 mm - 36 and 40 Watts and the colour shall generally be day light, cool day light and/ or warm white with an average output pf 2600 lumen + (5%) for 36 Watts. The fluorescent lamps shall be from an approved manufacturer conforming to BS 1853 and having a minimum useful life of 5000 hours. The ballast shall be totally enclosed type suitable for operation on 220 V, 50 Hz, single phase supply. A wiring diagram, wattage, voltage and current ratings shall be printed on the body of the ballast. The power loss shall not be more than 10 Watts for 40 Watts ballast. The ballast shall be noiseless in operation without any whistling sound, supported with a guarantee of trouble free life of 1 year, effective from the date of Completion Certificate.
The description of light fixtures and all relevant materials are given in these specifications and stated in the bill of quantities. The determination of quality of the light fixture is based on construction material, the specific shapes of the enclosure & louver, color, finish, etc. The determination of quality of the light output of the light fixture is based on the certified photo- metric data covering the coefficient of utilization, light distribution curves, luminous flux output in lumens of the lamps, color temperature of the lamps, etc.
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All light fixtures shall be finished in standard color schemes as mentioned in the manufacturer's catalogue for respective fixtures, unless specifically stated in the specifications, drawings or bill of quantities or directed by the Engineer.
The Contractor shall submit samples of each and every type and model number of light fixtures specified for approval of the Engineer.
b) Outlet Box
The outlet boxes for installation of switches, Dimmers and socket outlets shall be of PVC having appropriate dimensions. The box shall have suitable arrangement for receiving the conduit.
c) One Way Switches - Indoor type
Switches for controlling light points shall be single pole, rated for 5 Amps, 250 Volt AC. The body of the switches shall be suitable for flush mounting on PVC back box/outlet box. The switches shall have screw contacts and shall operate with snap action.
d) Ceiling Fan
Ceiling fan shall be capacitor type, suitable for 250 Volts’ single phase 50 Hz. The air displacement shall be 330 cubic metre per minute for 1422 mm (56") sweep at maximum speed. The fan motor shall be capacitor type and bearing shall be groove type to give noiseless operation. The fan dimmers rated for 100 W, 250 Volts
The fan hook shall be made of 10 mm diameter mild steel rod. It should be in the form of a loop about 75 mm long and about 50 mm wide. The rod should be bent to have at least 200 mm extension on both sides for tying to reinforcement steel of slab. The fan and regulator shall be the first quality product from an approved manufacturer.
e) Fan Regulator
Fan Controller for fan speed regulating shall be suitable for Ceiling fans, rated for 10 Amps, 250 Volt AC. The body of the fan Controller shall be suitable for flush mounting on PVC back box/ outlet box. The fan Controller shall have ON/OFF switch that shall operate with click action.
f) Ceiling Rose
The ceiling rose shall be suitable for 5 amps 250 Volts’ single phase A.C. It shall have white plastic moulded base plate, copper or brass terminals for wiring with 2.5 sq.mm cable. The ceiling rose shall have a cover with cable inlet hole. The ceiling rose shall not embody any fuse terminal as an integral part of it
g) Exhaust Fan
Exhaust fans shall be 12” dia. size direct driven type complete with motor, angle iron frame, back draft dampers and mounting accessories. Blades shall be of steel and factory adjusted for pitch. Blades of back draft damper shall have a link rod and the design shall be such that damper remains in full open position without rattling when the fan is operating.
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8.8 CONDUITS & PIPES
Description
The route of conduit and pipes should be as per site requirements, specifications and as directed by the Engineer.
Applicable Standards
Latest editions of the following standards/codes shall be applicable for the materials in scope of this Section:
• BS 6099 PVC conduits and accessories. • BS 3595 PVC pipes & accessories. • BS 4346 Cement Solvent for jointing
PVC Conduits and Accessories
The heavy gauge PVC conduits and accessories containing switch boxes shall conform to BS6099 shall be generally used.
The PVC switch boxes bends, sockets, elbows, couplings, etc. shall conform to the same specifications as for the conduits. The PVC bends shall have enlarged ends to receive conduit without any reduction in the internal diameter at joint. Manufactured smooth bends shall be used where conduit changes direction. Bending of conduits by heating or otherwise will not be allowed in any situation. The use of sharp 90-degree bends and tees will not be allowed for concealed wiring.
The round PVC junction boxes for ceiling light or fan points shall have minimum dimensions of 63- mm diameter and depth. The junction boxes for wall light points shall have minimum dimensions of 63-mm diameter and 38 mm deep. Round junction boxes shall be provided with one piece PVC cover plate fixed to the box by means of brass screws.
8.9 EARTHING PROTECTION
Description
The earthing system consists of earth electrodes, earthing leads, earth connecting points, earth continuity conductors and all accessories necessary for the satisfactory operation of the associated electrical system.
Applicable Standards
The latest editions of following standards/codes shall be applicable for the materials in scope of this section: -
• BS 951 Earthing Clamps • CP 1013 Earthing • BS 2874 Nuts, bolts, washers, screws & rivets fixing for use on Copper
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• BS 1433 Hard drawn bare copper conductor for earthing • BS 6346 PVC insulated cables
Material and Execution
The grounding system shall consist of earth electrodes, earth connecting points, earthing leads, earth continuity conductors and all accessories necessary for the satisfactory operation of the associated electrical system. The earthing system shall also comply with the requirements of BS 7430:2011.
A bore is drilled up to slush level 2” Dia GI pipe with GI Tee is hanged inside the bore. Stranded bare copper conductor of 16 mm2 is tied to ¾ inch Dia 6 ft. long Cu rod and placed in the bore. A mixture of half kg each of charcoal and ammonium chloride and one kg of sodium chloride is poured inside the pipe along with water so that the mixture settles down in the depression around the Cu rod. Conductor is drawn from the outlet of the tee and 2’’ GI cap is placed on the tee. An earth pit is excavated around the bore and covering it with a concrete slab at the finished floor level.
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9 FILTRATION PLANTS
9.1 TREATMENT PLANTS
The specifications for water filtration plant equipment and process contained in these specifications are so far considered to be necessary to achieve the required quality of treated water. These are to be regarded as the minimum requirements and the Contractor shall include for such other treatment as he considers necessary.
9.2 WORKS TO BE INCLUDED
The works to be included in this section shall include the design, manufacture, works testing, supply, installation, connecting up, painting, site testing, and commissioning of all equipment and ancillary works including control & monitoring system and one (01) year operation and maintenance of the water filtration / treatment plants and related works. The works also includes the construction of plant houses including ancillary components, including their Operation and Maintenance.
The brief description about the plants, regarding water source, plant capacity and quality of water etc. is given in the following paragraphs.
9.3 BRIEF DESCRIPTION OF WORKS
9.3.1 Water Source
Each Filtration Plant for water distribution will require that a source water be identified and developed and the appropriate process be supplied to produce water to WHO Drinking Water Guidelines.
9.3.2 Water Connection
The Contractor shall provide all water connections to the Filtration plant.
9.3.3 Plants Category & Capacity
Design according to parameters given by the Client, supply, install, test, and commission and operate and maintain for a minimum period of one (01) year water filtration plants of different configurations, depending upon pollutants in the water. Two sizes shall be made available: filtration plants shall be capable to produce 2000 litre/hour of product or filtered water.
The feed water quality test results carried out so far indicate the possible presence of the following pollutants and contaminations.
a. Aesthetics Contamination:
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Turbidity Taste and Odour
b. Biological Contamination: Bacteria Viruses
c. Chemical Contaminations: Arsenic Fluoride Iron Manganese Nitrate Hardness
d. Dissolved Solids: Total Dissolve Solids
Considering the above pollutants, the treatment plants, as discussed In Table have been classified into three categories. Table: Drinking water treatment plant configurations No Plant Type Prime Energy Secondary Product Source Energy Source Water Capacity 1 Ultrafiltration Plant with Chemical Grid Grid 2000 Litre / Reduction Filter (Arsenic / Iron / hour Manganese / Fluoride / Nitrate / Hardness / Iron Manganese) 2 Reverse Osmosis Plant Grid Grid 2000 Litre / hour 3 Direct Supply Plant Grid Grid 2000 Litre / hour
9.3.4 Brine Disposal / Backwash water
RO Brine The Contractor shall dispose of RO brine stream via drainage system. It is preferred that the well be within the Markaz E Aab Centre compound if possible as approved by the Engineer. Typically the brine would be injected beneath the lowermost underground source of drinking water or below the aquifer from which the source water for RO treatment is drawn. USEPA 40 CFR 146.12 gives guidelines for the construction of what would be termed a Class I injection well that can be used for 133 PUNJAB AAB-E-PROJECT (PAPA) SUPPLY CONSTRUCTION, INSTALLATION OF WATER CONTRACT DOCUMENTS FILTRATION PLANTS & DIRECT SUPPLY IN LAHORE DIVISION TECHNICAL SPECIFICATIONS
RO brine. Prior to drilling any injection well, a careful assessment of geological conditions must be conducted in order to determine the depth and location of suitable porous aquifer reservoirs
9.3.5 Electricity Connection
Power supply at 240 Volt, 50 Hz load shall be arranged by the Contractor on behalf of the Client for the plants where secondary energy source is Grid, according to site conditions. Contractor’s scope of work shall start from the power supply point towards the load.
The Contractor shall submit detailed load calculations for the approval by the Engineer.
9.3.6 Operation and Maintenance
The Contractor shall operate and maintain the plants including plant houses and ancillary works for one (01) year, which may be extended by mutual consent. The Client may have a random check of water quality and, in case of non-compliance with the prescribed standards, 20% of the operating and maintenance cost for that quarter shall be deduced for that filtration plant. In case of repetition of non-compliance with standards, the penalty cost shall double. The Contractor shall bear all types of expenses during the operation and maintenance period such as water quality testing (on a quarterly basis), salary of the operator(s), utilities, consumables, etc. Specific responsibilities of the contractor regarding O&M of plants are:
I. Provide detail maintenance schedule specifically for each plant indicating all the replaceable and consumables for the period of one (01) years after completion at the time of issuance of completion certificate, get it approved by the Client/Engineer and fix a hard copy in the office and provide copies to the Client/Engineer. II. Deploy at least one operator (compulsorily local) at each filtration plant and train the operator regarding operation and maintenance of the RO plant as well as staff for other duties associated with the Markaz E Aab Centre. III. Disinfect the whole equipment of the filtration plants on a regular schedule, including the water tanks before their first filling and keep the mechanical, electrical equipment/ system in good working condition. IV. Provide a log book at each plant, filled in daily by the operator. Training must be provided to the operator to allow the recording of all necessary operational data. All the maintenance activities/ replaceable/ consumables must be recorded in the log book with signature of representative of the Contractor. Number of users must also be recorded in the log book if not recorded automatically through the RFID system. Proper entries should be made for maintenance and consumables. V. Ensure change of all cartridges/ consumables and the replaceables as per a pre-approved schedule. VI. All the replaceables must be branded or the firm must guarantee quality of all replaceables/ consumables. VII. Keep all the premises and the dispensing areas of the plants clean and hygienic. VIII. Ensure eight (08) hours of clean and safe drinking water supply daily from the operational plants as per the prescribed standards. IX. Maintain record on daily basis for the water supplied (in m3/ day).
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X. Maintain record for the quality of water supplied. Quarterly water quality tests shall be performed and the official analyses copied to the Engineer and filed to be available whenever needed. XI. Maintain record for all breakdowns (if any), of the plant. XII. Maintain a log of customer complaints made by consumers. XIII. Maintain monitoring system log. XIV. At the end of the Operations and Maintenance period, the filtration plants shall be handed XV. Over to the Client in a good working condition.
Note: The Contractor will operate and maintain the Filtration Plant in close coordination and consultation with AAB E Pak Committee, entrusted with management of the Plant by the Client.
9.4 FILTRATION
The feed water quality test results carried out so far indicate the presence of the following impurities.
- Aesthetic Contamination, - Biological Contamination, - Chemical Contamination (Arsenic, Fluoride, Hardness etc.) if any - Turbidity removal - High Total Dissolved Solids The water supply from distributary canal having TDS < 1000 mg/liter have considered with specific (surface water treatment plant along with RO plant) solutions. The specifications of these plants is given in the following paragraphs.
9.5 FILTRATION PLANTS
Pretreatment shall be provided for removal of suspended chemical impurities. Pretreatment shall also reduce those contaminants that would adversely affect [i.e. reduce] the life of downstream. Following types and capacities of the filtration plants shall be considered.
a. Pre-filtration Plant 2,000 liters/hr
Pre-Filtration plants will be installed at non-brackish sites where Total Dissolved Solids are below 1000 mg/L and feed water is contaminated with chemical and biological impurities. These plants shall comprise of those processes that shall produce product water as per the WHO standards. These processes can include but not be limited to pre-filtration, Arsenic/ Fluoride/ Nitrate/ hardness/ Iron/ Manganese removal, Carbon filtration. An activated carbon filter shall be installed for the removal of taste and odor compounds as well as other organic impurities. More details on these processes are given below.
9.6 DESIGN CRITERIA
These plants shall be powered grid energy as primary source.
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The design methodology for all UF Filtration Plants shall be rendered to the Engineer for approval.
9.6.1 Pre-filtration/ Sand /Anthracite
Pre filtration shall be provided for the removal of the suspended solids / colloids which are present in the water. Pre-filtration will also reduce the load on Ultra-filtration and protect the membrane from being damaged, thus increasing the membrane life. The silica sand shall conform to AWWA B100, including acid solubility requirement, except as modified or supplemented herein. The specification shall include the following:
- Filter media : Silica Sand - Vessel material : FRP - Suspended solid removal : > 20 micron - Acid solubility : Less than 5 percent - Specific gravity : 2.60 ≥ 2.65 - Effective size for sand : 0.6 to 0,8 mm - Anthracite : 0,8 to 1,6 mm - Uniformity Coefficient : 1.7 to 2.2 - Backwash : Automatic, Time based/ Controller
9.6.2 Activated Carbon Filtration
The media used in this filter, shall meet the following minimum requirements.
- Raw material : coconut shells - Bulk density : 440-540 kg/cm³ - Hardness No. : 80 - Iodine No. : 850-1000 - Ash content : 5 % - Surface area : 900 m²/g - Certification : NSF
9.6.3 Cartridge Filters:
Cartridge filter of 05 µm shall be added before the RO unit.
9.6.4 FRP Vessels for Sand, Activated Carbon and Chemical Reduction Filtration:
FRP vessel shall meet the following minimum requirements:
- Material : polyester or vinyl ester - Maximum Operating Pressure : up to 06 Brag - Maximum Operating Temperature: 45 °C - Certification : NSF - For filtration speed : 5-15 m/h
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9.6.5 Stainless Steel Skid
The Stainless Steel Skid shall meet but not limited to the following specification:
- Stainless Steel Grade : SS 304 - Minimum Size : As per proposed design
9.6.6 Chemical Reduction Filters
These filter(s) shall be installed to treat the specified chemical contamination as according the design parameters found in the feed water. It is observed that feed water may be contaminated with any of the following chemical pollutants:
• Arsenic • Fluoride • Nitrate • Hardness • Iron & Manganese
9.6.7 Arsenic removal filter shall be installed with the main plant conforming to the following requirement.
- Filter Vessel : FRP - For filtration speed : 8-10 m/h - Filter media : Granular Ferric Hydroxide (compliant with BS EN 15029:2012 standard / equivalent OR Activated Alumina compliant with BS EN 13753:2009 standard / equivalent - Certification : NSF - Time-clock control programmer : by Controller Time Based system
9.6.8 Fluoride Removal Filter
The fluoride shall be removed from the water by Activated Alumina or other to meet the product water quality. This shall be used as adsorbent for the removal and shall meet the following minimum requirements.
- Time-clock control programmer : by Controller Time Based system - For filtration speed : 8-10 m/h - Certification : NSF
9.6.9 Nitrate Removal Filter
If the feed water contains nitrate and the total dissolved solids are less than 1000 mg/liter, nitrate shall be removed through ion-exchange process. For this purpose, strong base anionic resins shall be used, with the following minimum design parameters.
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- Feed water loading rate : < 300 L/ minute. m³ - Depth of resin bed : > 0.6 m - Time-clock control programmer : by Controller Time Based system - Certification : NSF
9.6.10 Hardness Reduction Filter
The hardness from the water shall be removed through ion-exchange process. For this purpose, strong acid cationic resin, which shall meet the following minimum requirement.
The process comprises of the following:
- Ion exchange media : Sulphonated polystyrene beads / Equivalent, approved from the Client - Recharging of saturated : through Chemical/Salt (NaCl) - Time-clock control programme : by Controller Time Based system - Certification : NSF
9.6.11 Iron and Manganese
Excess iron and manganese shall be removed by the most appropriate and efficient methods (such as oxidation process etc.).
- Certification : NSF
9.6.12 Flow Meter
A variable area flow meter/ Rota meters shall be installed to measure the flow of feed/ permeate water. Flow meter shall be of transparent acrylic material with Stainless Steel float with graduations on them to show proper flow. Flow meter shall be capable of covering the full range of flow. Glass should be acrylic and capable to deal Maximum flow rate 06 m3/hr. Calibration on the scale should be enable for 0.5 m3/hr minimum
9.6.13 Water Meter
Water meter shall be of multi jet/turbine type with a pulse generator with a maximum frequency of 1pulse/ 10Liters. Body of water meter shall be of Cast iron with threaded connections and a minimum pressure rating of PN10. Water meter shall have a totalizer installed on permeate line.
9.6.14 Pressure Gauge
All installed pressure gauges shall be bourdon spring type with Stainless Steel (SS), 304 casing and a minimum diameter of 2.5". All gauges shall be damping fluid filled having back connection and border for easy fitting on the panel.
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9.6.15 For addition of various chemicals like acid, anti-scalant, etc.
- Dosing Pumps Qty : As required - Flow Rate : as required - Resistance Pressure : as system requirement - Diaphragm : PTFE-EPDM/ PVDF Composite - Enclosure : IP65 (NEMA 4X) - Insulation Class : B - Electric Connections : 240V/50Hz - Material : Suction, Injection Valves, Foot Valve etc.
9.6.16 Product Water Tank
The Polyethylene water storage tank shall meet but not limited to the following specification:
- Material : Food Grade, Polyethylene - Ambient Temperature : 45 C - Wall Thickness : Approx. 4 to 5.0 mm Minimum
9.7 FILTRATION PLANTS
The specification of these plants and their possible components are given in the paragraphs described here-over.
A. Filtration Units using Sand Filter and Active Carbon Filter, Capacity 2000 L/h
Sand Filter Mounting FRP Vessel Skid Filtration Rate 15 m/h Backwash rate 25-35 m / h Empty Bed Contact Time (EBCT) 03 Minutes Minimum Backwashing Time Adjustable by Local Timer Sand Effective Size 0.6 - 0.8 mm UC 1.4 - 1.7 Height 800 mm minimum SG ≥ 2.63 Vessel FRP Feed pump Centrifugal type, eff > 60% Piping for units PE or PVC/PPRC/UPVC/HDPE Activated Carbon Filtration Filtration Rate 10 m/h Minimum
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Empty Bed Contact Time (EBCT) 04 Minutes Minimum Backwash Rate 25 m/h Base Material Coconut shell Effective Size 1.2 -1.6 mm Uniformity Coefficient ≤ 1.9 Surface Area 900 m²/g Vessel Material FRP Clean water storage tank 08 hours of a day Max
9.8 GRANULAR FERRIC HYDROXIDE FOR ARSENIC REMOVAL
Waterborne arsenic is a major cause of disease and has been found in abundant quantity in many part of the Punjab as identified by water quality analysis and testing. It is the only contaminant that has been shown to be the cause of human cancers following exposure through drinking water. Besides cancer of the skin, lung and bladder and probably liver, arsenic is responsible for a range of adverse effects, including hyperkeratosis and peripheral vascular disease. WHO for drinking water has set a provisional guideline value of 0.01 mg/l based on the practical limit of achievability.
Granular ferric hydroxide is used widely for removal of arsenic removal from drinking water. Arsenic removal shall be done in case necessary as pre-treatment, conforming to the following requirement using granular ferric hydroxide as removal media.
Parameters Range of Typical Values Mounting FRP Vessel Pad Media Size 0.5 – 4.0 mm Grain Density 1.19 g/cm³ Bulk Density 1100 g/l Filtration speed 10 m/h Absorption Capacity 15 g/kg (GEH) Backwash speed 20 m/h (50% expansion) pH range 7 – 8 Specific Surface Area 270 – 300 m²/g (Dry Weight) Filter Vessel FRP Oxidation of As III to As V with oxygen (air), Chlorine, ClO₂ or KMnO₄ Filter media Granular Ferric Hydroxide, (compliant with BS EN 15029:2012 for drinking water treatment) or Activated Alumina (compliant with BS EN 13753: 2009 for drinking water treatment)
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Certification NSF Process Control Adjustable by PLC/ Local Timer
9.8.1 Granular Ferric Hydroxide for Arsenic Removal 2000 l/h
Arsenic removal shall be done in case necessary as pre-treatment.
Parameters Range of Typical Values Mounting FRP Vessel Pad Media Size 0.32 – 2.0 mm Grain Density 1.19 g/cm³ Bulk Density 1100 g/l EBCT 05 min Absorption Capacity 15 g/kg (GEH) Backwash speed 20 – 25 m/h (50% expansion) pH range 7 – 8 Specific Surface Area 250 – 300 m²/g (Dry Weight) Filter Vessel FRP Diameter / height Minimum 600 mm / 1600 mm Oxidation of AsIII to AsV with Chlorine, ClO₂ / KMnO₄ Filter media: Granular Ferric Hydroxide, (compliant with BS EN 15029:2012 for drinking water treatment) or Activated Alumina (compliant with BS EN 13753 :2009 for drinking water treatment) Certification NSF
9.9 ACTIVATED ALUMINA (AA) ABSORBENT FOR FLUORIDE REMOVAL
High intakes of fluoride can give rise to dental fluorosis, an unsightly brown mottling of teeth, but higher intakes result in skeletal fluorosis, a condition arising from increasing bone density and which can eventually lead to fractures and crippling skeletal deformity.
This is a major cause of morbidity and can manifest itself at a relatively early age with the result that affected individuals cannot work properly and may be economically as well as physically disadvantaged for life. Many factors appear to influence the risk of such adverse effects, including volume of drinking water, nutritional status and, particularly, fluoride intake from other sources. WHO for drinking water has set a provisional guideline value of 1.5 mg/l based on the practical limit of achievability.
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The fluoride shall be removed from the water by Activated Alumina (AA) or other to meet the product water quality. This shall be used as adsorbent for the removal and shall meet the following minimum requirements.
Parameters Range of Typical Values Mounting FRP Vessel Pad Empty Bed Contact Time (EBCT) 5 Min (Minimum) Fluoride Capacity of AA 8 g /kg Media Size 0.5 - 3 mm Grain Density 3.97 g/cm³ Bulk Density 700 kg/m3 Specific Surface Area 300 -350 m²/g (Dry Weight) Bed Depth 0.9 - 1.85 m Backwashing 20 m/h for 50 % bed expansion Backwashing Time 10 -15 Minutes Vessel Material Fiber Reinforced Plastic (FRP) Filter media: Activated Alumina (compliant with BS EN 13753 :2009 for drinking water treatment) Process Control PLC/ Adjustable by Local Timer Certification NSF
9.10 REVERS OSMOSIS PLANT
Pretreatment shall be provided for removal of suspended solids, turbidity and biological contaminant material. Sand filters followed Flocculation tank of surface water will be used as a pretreatment section of RO plant. Following types and capacities of the filtration plants shall be considered.
a. RO Plant 2,000 liters/hr
9.10.1 Design Criteria
The criteria used for the design of RO plants shall be as follows:
This type of Reverse Osmosis (RO) plants shall be powered grid energy as prime energy source. RO design must be based on feed water with total dissolved solids (TDS) for brackish waters up to 5000ppm An allowance should be made (a 50% safety factor) for an increase in TDS in the source water as it is harvested.
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Remineralization of RO product water will be carried out by blending an appropriate fraction of pretreated raw water and/or chemicals to bring up the TDS, alkalinity and hardness to an acceptable level for human consumption. The product water shall be consistent with the Prescribed Standards and the WHO Safe Drinking Water The RO plant shall be installed with more than 50% recovery of permeate. The vendor must submit the projection/simulation based on complete feed water analysis before installation of Plant.
The Bidder shall take into account the following criteria:
Reduced energy consumption by using Low energy membranes with standard size of 4” x 40” or 08” x 40” Reduced chemical usage Increased life span of critical replacements such as membranes and filter parts Small foot print area.
9.10.2 Equipment
This section covers the reverse osmosis (RO) treatment plant for the Punjab Aab E Pak Project (PAPA). The RO system at designated site shall consist of pretreatment, chemical addition systems (Anti Scalant), cartridge filtration, RO membranes with pressure vessels, complete with High pressure feed pump, Pretreated filters water from Sand and activated Carbon filters for blending / mixing arrangement passing through UV system, interconnecting piping, valves controls and instrumentation.
The CONTRACTOR shall furnish all labor, materials, equipment and incidentals necessary to fabricate, ship to the site, install, startup, performance test, and demonstration test the RO systems as shown on the Drawings and as specified herein.
The equipment furnished under this specification shall be made and fabricated from new materials. The use of used or refurbished materials is unacceptable.
9.10.3 Prefiltration/ Pressure Filter
Pre filtration will be done by using multimedia filters for RO Plant. As per mentioned in the P&ID
9.10.4 FRP Vessels for Sand & Activated Carbon Filter
FRP vessels should be NSF certified and size will be according to the mentioned above
9.10.5 Reverse Osmosis Section
The RO sections of the plant include high pressure pump, cartridge filters membrane housings, Reverse Osmosis membranes and instrumentation. This section shall be manufactured by NSF certified OEM manufacturer as per guidelines of the design projections. Plant assembled and tested in Pakistan with all its components assembled at place of manufacture. The pre-treatment and
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post-treatment arrangements shall be performed by bidder to be tested to ensure compliancy with the main plant.
i. High Pressure Pump
HP multistage pump centrifugal pump and motor shall be of reputed manufacturers among Europe/ USA/ Germany/ Equivalent and efficiency above 60% are acceptable. ii. Reverse Osmosis Membranes
Proven and reliable high rejection thin film membrane elements shall be selected to give optimum performance. They shall have an operating range of 3-11 PH. They shall be high flow fiberglass wrapped for maximum durability.
- Membrane Type : Polyamide Thin Film Composite/Spiral wound - Membrane element Size : 4” x 40” / 08” x 40” - Maximum Applied Pressure : 250 psi - Stable Salt rejection : 99% - pH range, short term cleaning : 1-13 - pH range, continuous operation : 2-11
iii. Membrane Pressure Vessels:
Heavy duty reverse osmosis pressure vessel housings shall be made of fiberglass, tested and certified by the American Society of Mechanical Engineers (ASME) and the boiler association of the USA as per ASME’s Boiler and Pressure Vessel Code (BPVC):2013. Enamel coated white. Easy membrane removal, inspection, and installation should be allowed.
- Housing Material : PVC/ FRP along with all port connections - Housing Size : 4” x 40” / 8” x 40” iv. Reverse Osmosis Control System
The reverse osmosis water filtration plants shall be controlled by a Reverse Osmosis PLC manufactured with US / EU/ Germany/ equivalent microprocessor chip featuring a 2-line X 20- character, alphanumeric backlit LCD or process mimic to display operating conditions, and provides adjustable time delays and set points to accommodate varying field conditions. SCADA system for future.
The controller shall display the permeate TDS/Conductivity, water temperature, and operating hours along with the operating status of the RO unit. Low and high pressure switches, tank levels, and pretreatment equipment shall be monitored through a controller.
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Controller shall be providing relay outputs for the RO high pressure pump, inlet solenoid valve, membrane flush solenoid valve, and optional relays for permeate divert or remote alarm and auxiliary output.
The treatment plant automation system shall be established with Standard functions of the microprocessor controller for monitoring and/or control of:
- RO high pressure pump motor - Inlet solenoid valve - Automatic flush solenoid valve - Low feed pressure switch - High pressure pump switch - RO storage tank level switches - Permeate TDS/Conductivity - Water temperature - Operating hours
The microprocessor-controlled system shall be used to monitor pressure and level Switches, TDS / Conductivity monitor/controller with programmable Set points must be an integral part of the controller. The controller shall display the system status and sensor and switch input status on an easy to read backlit display. User programmable Set points to be provided for fast and easy adjustment of system parameters.
- Power : 240 VAC -15+10%, 50Hz, 25 Watts
- Enclosure : 8" X 6" X 4" (203mm X 152mm X 102mm) NEMA 4X
- Display : 2 line X 20 character, alphanumeric backlit LCD Or Process Mimic Display
- Front Panel : Overlay with LCD window, alarm lamp, 7 key membrane switch - Switch Inputs, Dry Contact : Pressure fault, pretreat lockout Permeate Storage Tank full Feed Storage Tank empty
- Relay Outputs : RO pump relay 240VAC, Inlet valve relay 240VAC, 5A Flush valve relay 240VAC, 5A Relays supply same output voltage as board power (240 VAC)
- Regulatory Standards : Reverse Osmosis Controller system shall be new and shall be designed with microprocessor chip manufactured in countries of origin as Europe, USA, Germany/ equivalent only.
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v. Frame/Skid:
Stainless Steel shall be used for Reverse Osmosis Skid meeting minimum following specification can also be used:
- Stainless Steel Grade : SS304 - Minimum Size : as per adjustment vi. Flow Meter
A variable area flow meter/ Rota meters shall be installed to measure the flow of feed/ permeate water. Flow meter shall be of transparent acrylic material with Stainless Steel float with graduations on them to show proper flow. Flow meter shall be capable of covering the full range of flow. Glass should be acrylic and capable to deal Maximum flow rate 06 m3/hr. Calibration on the scale should be enable for 0.5 m3/hr minimum
vii. Water Meter
Water meter shall be of multi jet/turbine/ Gear type. Body of water meter shall be of Cast iron while wetted part should be bronze/ SS-304 with threaded connections and a minimum pressure rating of PN10.
viii. Pressure Gauge
All installed pressure gauges shall be bourdon spring type with Stainless Steel (SS), 304 casing and a minimum diameter of 2.5"-3". All gauges shall be damping fluid filled having back connection and border for easy fitting on the panel.
ix. Automatic Chemical injection systems with 70-liter tanks:
For addition of various chemicals like acid/ antiscalant, etc.
- Dosing Pumps Qty : One - Flow Rate : as required - Resistance Pressure : as system requirement - Diaphragm : PTFE-EPDM Composite - Enclosure : IP65 (NEMA 4X) - Insulation Class : B - Electric Connections : 230V/50Hz - Material : Suction, Injection Valves, Foot Valve level controller etc.
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x. Product Water Tank
The Polyethylene water storage tank shall meet but not limited to the following specification:
- Material : Polyethylene, - Material Class : Food Grade - Working Temperature : up to 45C - Capacity : 2000 Liter (minimum two tanks at - each plant) as per plant capacity - Wall Thickness : Approx. 4.5 to 5.0 mm - Volume : 1-2m3 as per plant capacity - Working Pressure : atmospheric - Standard : ASTM D1998 - 13 xi. ORIGIN AND MAKE OF IMPORTED COMPONENTS
Origin and make of the major components mainly membrane, Pumps and Reverse Osmosis Plant shall be from any of the following countries:
Europe, USA, German/ equivalent.
Before placing purchase order/manufacturing, the Contractor shall submit manufacturers’ catalogues and specifications for approval from Client in case of import, import documents. The installation of the plants shall not be started, unless the procurement document checked by the Employer/ Consultant and go ahead is provided in writing.
9.11 CERTIFICATION ON THE PLANT COMPONENTS
All certifications as required in the bidding / BOQ / Engineers Cost Estimates documents shall be submitted.
9.12 ACCEPTANCE CRITERIA AFTER INSTALLATION
The performance of the installed plants shall be accepted if quality of filtered water is as per WHO requirement. The quality of water shall be considered acceptable, if the result of water samples shows the pollutants concentration below prescribed limit.
The cost incurred on the water sampling and testing from the consultant/client approved laboratory, shall be borne by the Contractor, without any financial liabilities to the Client.
9.13 ACCEPTANCE CRITERIA FOR OPERATED AND MAINTAINED PLANTS
The plant shall only be accepted for satisfactory Operation and Maintenance if all the requirements of specifications are met. Satisfactory performance of the water quality test results are the main factors, without which the plants operation and maintenance of each month shall not be accepted.
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9.13.1 Standards/ Certifications
The following references shall be read in conjunction with other references / standards given in the documents.
ASTM American Society for Testing and Materials
ASTM A105/A Forgings, Carbon Steel, for Piping Components
ASTM A106 Seamless Carbon Steel Pipe for High Temperature Service
ST NI A193/A Alloy-Steel and stainless Steel Bolting Materials for High Temp. Service
ASTMI A194/A Carbon and Alloy-Steel Nuts and Bolts for High pressure and High Temp. Service
ASTM A570 Steel sheet and Carbon. Hot-rolled structural quality.
ASTM D1785 Specifications for Polyvinyl chloride (uPVC) Plastic pipe, schedule 40, 80, and 120.
ASTM D2564 Specification for solvents cements for Polyvinyl chloride (uPVC) Plastic pipe and fittings.
ASTM D1998-13 Standard Specification for Polyethylene Upright Storage Tanks, 2013
ANSI American National Standard Institute
ANSI B16.5 Steel Pipe Flanges and Flanged Fittings
EN 15029:2012 Ferric Hydroxide Granular Media for Drinking Water
Electrical International Electric Code (IEC), NEMA
Quality System ISO 9001 certified
NSF National Sanitation Foundation
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10 PUMPING EQUIPMENT AND O&M INSTRUCTIONS
10.1 GENERAL
10.1.1 Work Included
This Sub-section covers the general requirements for designing, manufacturing, shop testing, commissioning, furnishing, installing, painting, placing in satisfactory operating conditions in the location, testing and quantities shown on the Drawings with the specified duties and warranty of devices, appurtenances for the satisfactory operation of the pumping equipment. All the pumps shall be selected for the prime operation on Electric Grid utility power.
10.1.2 Reference Standards
ASTM - A 27 Standard Specification for Steel Castings, Carbon, for General Application ASTM - A 240 Heat Resisting Chromium and Chromium - Nickel Stainless Steel Plates ASTM - A 276 Standard Specification for Stainless Steel Bars and Shapes ASTM- A 105 Standard Specification for Carbon Steel Forgings for Piping Applications ASTM - A 743 Castings, Iron-Chromium, Iron-Chromium-Nickel, Corrosion Resistant, for General Application ASTM- A 193 Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service ASTM- A 194 Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure OR High Temperature Service ASTM- A 570 Standard Specification for Steel, Sheet and Strip, Carbon, Hot-Rolled ASTM-D 1785 Specification for polyvinyl chloride (PVC) Plastic pipe, Schedule 40, 80 and 120 ASTM-D 2564 Specification for solvent cements for polyvinyl chloride (PVC) Plastic piping systems HI - E 35.01 Hydraulic Institutes - Standard for Centrifugal Pumps
10.1.3 Design Criteria
A. The pumps shall be designed in accordance with applicable requirements of Hydraulic Institute Standards. B. The Contractor shall check the design duties of each equipment, analyze system pressure loss, hydraulic transients for normal and emergency conditions. C. Each equipment shall be suitable for rendering intended duties individually as well as part of the system under the Project's climatic and environmental conditions. D. Pumps shall be suitable for operating un-attended and remotely controlled.
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10.1.4 Submittals
Shop drawings: Indicate general assembly, components, dimensions, weights, clearances and methods of assembly.
Product Data: Provide manufacturer's literature including general assembly, certified pump curves showing performance characteristics with pump and system, operating point indicated, NPSH curve, controls, wiring diagrams and service connections System design and pressure loss calculations.
Manufacturer's Installation Instructions: Including handling, storage and start-up instructions for pumping system. Manufacturers recommended spare parts and tools list.
Manufacturer's Certificate: Certifying that pumps meet or exceed specified requirements at specified operating conditions.
Field Reports: Submit as directed by the Engineer.
10.1.5 Materials
General
All the pumps parts, unless otherwise specified shall be of standard materials of the manufacturer, suitable for the specified operating conditions and contents of the feed water/media attached hereof duly approved by the Client and the Engineer.
All materials shall be new and of first-class quality, suitable for the purpose, free from defects and imperfections.
Material for pump and valve parts coming in contact with pumped water shall be selected such as no part renders any harmful effect to the water for human consumption.
Materials of pump and valve parts shall be compatible with the corrosive and / or abrasive properties of the pumped water.
All materials or parts used in the equipment shall be tested, unless otherwise directed in conformity with applicable methods prescribed by the ASTM for mechanical, fracture, corrosion, fatigue, erosion, effect of temperature, metallography and chemical analysis, or such other organization as may be specifically required, and generally in accordance with the best commercial methods. When requested, tests shall be made in the presence of the Engineer, stocked material may be used, provided evidence is furnished to show that such material meets the requirements as specified herein.
Certified material test reports shall be furnished as soon as possible after the tests are made. The test certificates shall identify the component for which the material is to be used and shall contain all information necessary to verify compliance with the Contract Documents.
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10.1.6 Operation and Maintenance Data
Operation Data: Include manufacturer's instructions, start-up data, and trouble-shooting check lists for pumps, pump motors and controls.
Maintenance Data: Include manufacturer's literature, cleaning procedures, replacement parts lists, and repair data for pumps, pump motors and controls.
10.1.7 Quality Assurance
A. Perform work in accordance with manufacturer’s recommendation. B. Maintain one copy of document on Site.
10.2 TESTS
10.2.1 Shop Tests
The pumps shall be assembled completely in the shop to ensure correct fitting of all parts and shall be match marked before shipment, unless the pump is shipped completely assembled, to ensure correct assembly in the field. The pump casing shall be tested hydrostatically under a pressure equal to 150 percent of either the sum of the pump shut off head plus the maximum suction head or the maximum working pressure whichever is greater.
The hydrostatic test pressure shall be held for not less than 30 minutes after all leaks have been stopped.
The pumps shall be tested by and at the expense of the Contractor to establish that the performance requirements of these Specifications and the Contractor's guarantees have been fulfilled. The pumps shall be tested in the manufacturer's shop and the performance tests shall be made with the entire pumping unit. Readings shall be taken at a minimum of five capacity points, including one point with plus or minus 2 percent of capacity specified.
The tests shall be conducted in accordance with the accepted practices at full speed and unless otherwise specified, the procedure and instruments used shall conform to the latest applicable standards of the Hydraulic Institute Test Code, Centrifugal Pump Section. The test shall be carried out in the presence of the representatives of the Client and the Engineer.
The test shall cover:
A. Determination of the total head. B. Determination of rate of water pumped. C. Measurement of input to the pump or output of the motor. D. Determination of pump efficiency. E. Preparation of characteristic curve showing pump efficiency, flow and head. F. Measurement of reverse runaway speed. G. Determination of NPSH required. H. Minimum submergence required.
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10.2.2 Operational Tests
Operational tests may be performed by the Client on the pump before the pump is placed in service. If so desired by the Client/Engineer, the tests shall be repeated one month before the expiry of the Maintenance Period.
10.2.3 Performance Tests, Capacity and Efficiency
General: Within two weeks after the operation of the pump has been approved by the Client, as provided in the Contract, the pumps shall be tested by and at the expense of the Contractor to determine whether the equipment meets the guarantees as given. If so desired by the Client / Engineer, the tests shall be repeated one month before the expiry of the Maintenance Period.
Provision in Case of Damage or Wear: Prior to the tests, the pumps will be inspected by the Engineer and the Contractor. Should such inspection disclose any damage or wear has taken place the Contractor shall rectify such damages at his own cost.
Capacity and Efficiency Tests: The capacity and efficiency of the pump will be determined for as many different heads within the range of operating heads as possible. The capacities and efficiency at the guaranteed conditions will be determined from smooth curves drawn through the test points.
Conduct of the Tests: The tests will be conducted in accordance with latest applicable standards of the U.S. "Hydraulic Institute Test Code, Centrifugal Pump Section".
Determination of Rate of Flow: The rate of flow of water through the pump will be determined by the properly calibrated rate of flow indicator furnished with the pump.
Determination of Total Head: Total head on the pump (H) will be the difference between the pressure elevation at the pump discharge and the pressure elevation near the entrance to the suction elbow, both corrected for velocity head. All measurements will be determined by the instruments furnished with pump.
Determination of Power: The electrical input to the motor will be measured by using accurate, sensitive and calibrated, test instruments connected to the permanently installed instrument transformers or as directed by the Engineer. The input to the pump will be the measured input to the motor minus the mechanical and electrical losses in the motor. The losses in the motor will be determined by separate tests in accordance with the latest standards and test codes of the Institute of Electrical and Electronic Engineers, Inc; and the American National Standards Institute.
Determination of Efficiency Curve: The efficiency curve of the pump will be determined from smooth curves of the input, head and rate of flow of water, all as determined in accordance with the above sub-paragraphs.
Runaway Tests: The pumps will be subject to runaway tests & witnessed by the Engineer. The tests will be performed under normal operating conditions by interrupting the power supply.
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10.2.4 Delivery, Storage and Handling
• Deliver, store, protect and handle products according to Manufacturer's Instructions. • Accept pumps and components at site in factory packing. Inspect for damage. Comply with manufacturers rigging and installation instructions. • Protect pumps and components from physical damage, including effects of weather, water and construction debris. • Provide temporary inlet and outlet caps, and maintain in place until installation.
10.3 PRODUCTS
10.3.1 Pumps
AWWA E103-15 Horizontal and Vertical Line-Shaft Pumps
This standard provides minimum requirements for the horizontal centrifugal pumps and vertical line-shaft pumps for installation in wells, water treatment plants, water transmission systems, and water distribution systems should conform to AWWA-E103-15.
Pumps described in this standard are intended for pumping freshwater having a pH range between 5.5 and 10.0, a temperature range from up to 45°C, a maximum chloride content of 250 mg/L, and a maximum suspended solids content of 1,000 mg/L, and that is either potable or will be treated to become potable.
Pumps covered by this standard
Driver power range: 10 hp to 1,500 hp (7 kW to 1,100 kW)
Rate of flow (at BEP): 100 gpm to 40,000 gpm (23 m³/hr to 9,100 m³/hr)
Maximum discharge pressure ratings. The maximum steady-state pressure at the pump discharge (which considers the suction pressure, possible operation for short periods at shutoff head, and the elevation of the discharge) is limited to the pressure rating for the ANSI/AWWA C207 class of flange shown for the pump types described below.
1. For horizontal pumps:
Pump should conform to Test Standard ISO-9906-2012, Roto-dynamic Pumps Hydraulic Performance Test.
Motors Operates on 240 Volts, 3 phase, shall have enclosures affording protection IP55 and shall be capable of operating continuously at a rated torque at any voltage between +5 & -10 of the nominal value. The motor frames should be constructed of ferrous metals. Frames made of Aluminum alloy shall be accepted. All motors shall be given corrosion resistant paint finishes and shall have corrosion resistant parts. The flow of the cooling air shall be in the direction of driven equipment. The maximum temperature of motor casing shall be accessible by hand and shall not be more than 80 °C.
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10.3.2 Head, Capacities and Speeds:
A. Feed Pump / Backwash Pump
Type: Horizontal Centrifugal Design Head 50 m (or as Recommended by plant manufacturer)
Design discharge: Required as per the capacity of the plants (1000, 2000 or 4000 liters/per)
Efficiency of Pumps: Not less than 60%
Rated Power of pump motor set (as selected by plant manufacturer)
Material or equivalent
Casing DIN 1.4308 / SS304
Impeller DIN 1.4301 / SS304
Shaft Chrome Steel
B. Efficiency:
The best efficiency of the pumps shall be at the design head and it shall not be less than 60 percent.
10.4 EXECUTION
10.4.1 Installation
• Install in accordance with manufacturer's instructions. • Provide access space around pumps for service. Provide space not less than as recommended by manufacturer. • Decrease from line size with long radius reducing elbows or reducers if required. Support piping adjacent to pump such that no weight is carried on pump casings. Provide supports under elbows on pump suction and discharge. • Provide drains for bases and seals, piped to and discharging into floor drains. • Lubricate pumps before start-up.
10.5 OPERATION AND MAINTENANCE
The Contractor will operate and maintain the pumping machinery, piping and appurtenances for 1 years after completion. The Contractor shall bear all types of expenses during the Operation and Maintenance period for inspection and repair/replacement of equipment (if required). Specific responsibilities of the Contractor regarding O&M of Plants are:
a. Eight 08 hours operation is required per day on utility electricity provided by local electrical distribution company.
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b. Provide detail maintenance schedule specifically for each plant indicating all the replaceable and consumables for the period of one years at the time of issuance of completion certificate, get it approved by the Client/Engineer and fix a hard copy in the office and provide copies to the Client/Engineer. c. Deploy at least one operator (compulsory local) as per agreement with the Client after project execution stage at each treatment plant and train the operator regarding operation and maintenance of the plant. d. Keep the mechanical and electrical equipment/system in good working condition. e. Provide a log book at each plant and operator must be guided to record the operational meetings. All the maintenance activities, replaceable/consumables must be recorded in the log book with signature of representative of the firm. Proper entries should be made for maintenance consumables. f. All the replaceable should be branded or the firm should guaranty quality of all replaceable/consumable. g. Keep all the premises and the dispensing area of the plant clean and hygienic. h. Ensure 08 hours of clean and safe drinking water supply daily. i. Maintain record of the breakdowns (if any), of the plant. j. Prepare and provide monthly reports on operation and maintenance of the plant to the Client. k. The Contractor will conduct quarterly water test for parameters specified and agreed between the Client and the Contractor. These tests shall be performed from recognized ISO certified laboratory as approved by the Client/consultant.
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11 CONTROL AND MONITORING SYSTEM (CMS)
11.1 SCOPE OF WORK
The scope of work includes Installation, Integration, Testing and Commissioning of the Control and Monitoring System (CMS) of treatment plant in accordance with the Functional, Technical and Special provisions lay down herein. In case of conflict in the provisions herein with those present in the balance of the Bidding Documents, the requirement of the BOQ will take precedence. A typical baseline solution is described herein.
a) Specific Requirement The Control and Monitoring System (CMS) shall be installed for the local control and monitoring of to be installed at site referred herein as “Filtration Plant”. The CMS shall be implemented as an integral part of Filtration Plant. All the control and monitoring activities shall be performed by operators manning the stations.
Monitoring of total water flow for Filtration Plant. Plant Data Storage Modem will be provided in the PLC based Grid pump drive panel. Filtration Plant pumps hour meters with display units will be provided. All the instruments with transmitters for control/protections/Monitoring/Displays shall be according to latest applicable ISA or IEC standards. Motor protective units will be provided in the PLC based pump drive panel. i. CMS tube well station shall have following features (Min) CMS & panel at each Filtration Plant shall have following minimum facilities.
Programmable Logic Controller (PLC) / data logger-based Grid pump drive panel with mounting hardware, and interconnection cables, peripherals, contactors, invertors, MPPT, overloads, motor protective units, VFD unit for source pump, memory & battery backup for data logging and storage system. RTUS/GSM/GPRS appropriate telecommunication backbone modem interfacing option. Flow measuring meters for tube well water. Pressure Transducers. Utility Power Supply (WAPDA) system data HMI or text display (min 10 inch). Rugged and industrial grade local control panel housing the PLC / data logger / modem, over current and voltage protection devices, instrument and equipment power supplies and all the required instrumentation (sensors/meters etc.) for the complete monitoring and operation of Filtration Plant. The control supply shall be 220V single phase (Battery Backup Panel) and main power supply shall be as per single line diagram.
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Chlorination equipment & chlorine analyzer. Data storage modem. Pump running hour’s data. b) Functional Description
The CMS Panel shall be fully automated and its intelligent system shall be capable of controlling and monitoring of all the process at Tube well and treatment plant. Filtration Plant information shall be continuously available in the control room at all times. The system shall have built in features and failsafe procedures to prevent against catastrophe situations and provide disaster management in the event such a situation develops. The CMS shall be able to monitor and control the following functions mainly: -
. Presence or absence of usable (safe) AC electric utility power. . Control (on/off) of delivery of water from source pump. . Display of "no water available" alarm from each site at the control room. . Display of total water delivery from a Filtration Plant integrated over a period of time. . Emergency power off switch. . On demand water flow check . Operation schedule . Chlorinator system.
11.2 KEY SYSTEM FEATURES AND ELEMENTS FOR CMS
In order to effectively manage the system, a complete control and monitoring network shall be provided. Functional description of the key elements of CMS is given herein:
11.2.1 Programmable Logic Controllers (PLCs) Pump Drive Panel
Programmable Logic Controllers (PLCs) Pump drive panel shall be installed at of the plant site. PLC shall be equipped with controllers, communication module (Option) and electronic modules for DI, AI and DO, mounting hardware and interconnection cables, peripherals, equipment housing and memory backup. The PLC based panel shall also house contactors for motors, overloads and protective units for motors. Servers running HMI shall be located in the Control Room.
The PLCs shall have adequate intelligence and appropriate number of input/output cards suitable for controlling the process. The PLCs / data logger shall also be able to communicate over the GSM/GPRS/RTO modem (Optional). The PLCs shall have front mounted digital interface i.e. LCD panel with keypad for local data monitoring, control and annunciation unit for operation and alarm status monitoring.
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Additionally, the controllers shall have built in 10% extra capacity for future expansion/additional control and monitoring functions. All equipment supplied shall be new and shall have a proven track record of performance and shall be accompanied with test results certifying capability of satisfactory operation in the environmental conditions of the Filtration Plant sites. PLC shall support 16 I/O points as minimum requirement and shall be expandable to 32 I/O points or higher based on process requirements.
Latest PLC standards prevailing at the time of bidding shall be used. As a minimum requirement PLCs shall be based on IEC/IEEE standards. Complete details for Standards conformed by the PLC shall be submitted by the Bidder.
a) General Technical Specifications of Programmable Logic Controllers
Programmable logic controllers (PLCs) shall be selected from the range of one manufacturer. Each PLC shall be provided complete with a power supply unit, central processing unit (CPU) input/output (I/O) digital and analogue cards and all interfacing equipment necessary in order to connect the control panel and field devices and to function as a complete and operable PLC. All PLCs shall be composed of identical hardware elements to ensure compatibility and interchange ability amongst other PLCs within the MCTS. The PLC shall be modular in construction and field expandable. It shall be tray / DIN mounted in order to ensure ease of interchange ability and replacement of components. Fixed I/O may be acceptable for small applications with the approval of the Engineer. All modules within the system shall be mechanically interlocked to prevent incorrect insertion. The PLC proposed to be deployed shall have downward compatibility whereby all new module designs can be interchanged with all similar modules in an effort to reduce obsolescence.
b) Program Storage
Program storage facilities shall be provided by a solid-state RAM. Battery backup shall be provided capable of retaining a stored program through a continuous power outage of at least 4 months. During the presence of mains power, it shall be possible to change the battery without interrupting system operation. It shall be possible to provide the capability where specified to use EEPROM as a backup for volatile memory up to the full capacity of the CPU. It shall be possible to back up the memory by downloading to a floppy disk or hard disk via a programming terminal. All user memory capacity not used for program storage shall be allocable for the purpose of data storage. The management of data types into memory subsections shall be an automatic function of the CPU operating system. The PLC program shall not take up more than 60% of the available memory capacity.
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c) Input/ Output Modules
i. General
. Input/output (I/O) modules shall be self-contained and housed within an enclosure. . I/O modules shall where possible be tray mounted. Trays shall be sized to accommodate I/O in increments of typically 4, 8, 12 or 16 slots per chassis. . Isolation between internal logic and external power supply circuits shall be not less than 500 V.
. It shall be possible to replace any 16 or 32 point I/O module without disturbing field wiring. ii. I/O Configuration . I/O shall be installed logically in grouped and repeated patterns. Single plant devices shall have their inputs and outputs on adjacent modules in the same tray with this pattern repeated for other plant units. . I/O shall be configured such that failure of a single module (or tray in large multiple tray systems) does not cause total plant shutdown. Duty and standby plant I/O must not be connected to the same module or tray.
a. Digital . Digital inputs shall be up to isolated. . Digital outputs shall be provided with output relays, or solid-state outputs suitable for the application.
b. Analogue . Analogue modules shall be suitable for either voltage or current input/outputs (typically . 0 to 10 V, 0 to 5V, 0 to 20 mA and 4 to20 mA) and shall have a resolution of at least 12 bits. . External or integral signal isolation facilities shall be provided for each analogue input and output.
11.3 FACTORY TESTS:
11.3.1 THIRD PARTY INSPECTORS
All testing shall either be witnessed by a team comprising the Employer and Engineer, or a neutral third-party inspector who shall be well versed with the testing procedure. The Bidder/Contractor shall submit for the Employer’s approval three internationally acclaimed inspectors. Bidders shall quote the rates of such third-party inspection teams/companies in their Bids.
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11.4 TESTS ON INSTALLATION COMPLETION
The following tests as a minimum are required to be performed on the completion of installation of the power plant.
11.4.1 Commissioning Tests
After completion of all visual inspections from the checklist, the service provider must perform commissioning tests to ensure all inter-connections of the components are satisfactory.
The commissioning tests comprise the following:
Cable and wiring AC Distribution Box Cable insulation test String fuse continuity & String Open circuit voltage test Grid connection tests Acceptance test
11.4.2 Trial Run
Upon successful completion of testing and commissioning, the reliability of the system is tested using Performance Ratio (PR) test During the Performance Ratio (PR) test, the following real time parameters must be sampled at one-minute intervals for at least seven consecutive days:
Ambient temperature Module temperature AC voltage from each inverter Following in-factory tests shall be witnessed by the Employer and/or his representative. Applicable standard G 59/2 BS EN 61000-3-3.
Harmonic current emissions Voltage fluctuations and flicker Power factor Under over voltage tests Loss of mains test Following standards as a minimum:
EN 62109-1 2010 (Safety)
EN 61000-6-2:2005 (EMC compatibility)
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11.5 GENERAL TECHNICAL REQUIREMENTS
i. Service Conditions a) Climate Conditions Air temperature and relative humidity conditions are specified as a function of climatic characteristics of the location where the equipment is to be installed. The table below shows the ambient temperatures (see definition (1)) and the relative humidity rates to which the equipment can be submitted according to the category they belong; the latter may be stated by the particular specifications.
Category I II III
Rated operating T1: T2: T1 T2: T1: T2: (2) range + 15°C + 30°C - 5°C + 40°C - 25°C + 55°C
Maximum operating T3: T4: T3: T4: TI: T2: (3) limits + 5°C + 40°C - 10°C + 55°C - 40°C + 70°C
Maximum relative 75% 80% 100% humidity at + 23°C at + 23°C at + 45°C
Storage and transport - 40°C + 70°C - 40°C + 70°C - 40°C + 70°C conditions (4)
Operating location Non air conditioned Air conditioned room Outdoor example room
Definitions:
1) Ambient temperature (IEC 441-02-06): Temperature determined within specified conditions of the air which surrounds the whole equipment. 2) Rated operating range: Range of values at which the equipment performs within specifications. 3) Maximum operating limits:
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Range of values at which equipment can still work without deterioration or degradation of its operating qualities when it works again at its rated operating conditions. 4) Storage and transport conditions: Set of climatic conditions to which the equipment can be submitted, when not operating, without deterioration or degradation of its operating qualities when it works again in its rated operating conditions. The above definitions are extracted from IEC 64319.
Unless otherwise specified in the relevant particular specification (or in the scope of work):
For Site (i.e. for equipment to be installed outside) all equipment will be at least of category II. Indoor equipment if installed in air-conditioned room shall be at least category I. For Telecommunication equipment (if any) to be installed in air-conditioned rooms shall be, at least, of category I; all equipment installed in other environments, shall, be at least of category II.
Temperature and irradiance are specified as a function of climatic characteristics of the location where the equipment is to be installed. The table and graphs below shows the ambient temperatures and the irradiance level to which the equipment can be submitted according to the category they belong; the latter may be stated by the particular specifications. b) Service Experience The bidder shall include a reference list of locations and clients to whom the specific system and equipment type being offered has already been installed and commissioned by the bidder itself successfully. The system and equipment type being offered shall have a minimum of five year proven service record.
ii. Design Manufacturing and Installation Requirements a) Quality Control & Quality Assurance
The products and systems to be supplied and installed under this Contract shall conform to the requirements of the Specification, to the best accepted international practice and to the severe requirements imposed by the service conditions. As a means of ensuring these objectives, the Contractor shall maintain a documented quality control and quality assurance system, which shall be generally in accordance with ISO 9001 or approved equivalent. The Contractor shall ensure that the same requirements are applied to products, systems, and services supplied by sub-contractors and suppliers. The Bidder shall submit with his Bid an outline statement of his quality control and quality assurance policies and procedures.
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b) Regulatory Standards All equipment shall follow regulatory standards of above countries typically
. IEC 61449 . IEC 60947 . IEC 68-2-6 . IEC 68-2-27 . JIS 8370 . GB 14048 . JIS 8201 . NEMA etc.
Except where otherwise stated in the Specification, materials shall be designed, manufactured, tested and installed according to relevant IEC/ISO/ITU Recommendations. Where no such recommendations have been issued to cover a particular subject then a recognized regional or national standard shall be applied. The latest edition and amendments shall apply in all cases. In case of conflict between the Specification and any of the IEC/ISO/ITU Recommendations, regional or national standards, then this Specification shall take precedence.
The Bidder shall state in his bid the standards and codes of practice which he proposes for any items of system or equipment not covered by IEC/ISO/ITU Recommendations. If required by the Engineer, the Contractor shall submit two English language copies of any standard or code of practice. c) System of Units The SI system of units and Imperial system shall be used. Temperature shall be in degrees Celsius, power in watts and irradiance in kWh/m2 etc. d) Interchangeability To limit the required stock of spare parts to be inventoried by the Employer all equipment and parts thereof performing similar duties shall be interchangeable. e) Suitability of Proposed Design The design shall make adequate provision for:
a. Safety of Operation and maintenance personnel. b. Reliability and continuity in service c. Ease of inspection and maintenance d. Ease and clarity of operation e. Ability to withstand the sever service conditions specified. f. Free from undue vibration g. Precautions to minimize fire risk
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f) Degree of Protection provided by Enclosure All probes, terminal boxes, kiosks, cabinets and equipment enclosures shall have degrees of protection provided by enclosure according to IEC 529 as follows:
. Outdoor IP 44 (minimum). For submersible sensors IP 68 shall be provided. . Indoor IP 32 (minimum). . Condensation. Any equipment enclosure such as cabinets, kiosks, mechanism boxes, etc. within which condensation could occur and affect the performance of equipment shall be provided with an anti-condensation space heater. They shall be automatically controlled by a humidistat, the operating range of which shall be adjustable. It shall be possible to switch the heater on and off manually. A space heater test circuit shall be installed in each enclosure with a test push button and associated lamp. A switch for the purpose of isolating the power supply to the heater circuit shall be provided at each enclosure.
All enclosures shall be designed to minimize condensation, with provision for ventilation and drainage as appropriate. g) Support Structures for Equipment All support structures for equipment shall be designed to suit the service conditions specified, the loads imposed on them, and any appropriate electrical clearance requirements.
All outdoor structures shall be hot-dip galvanized. Steel structures for indoor use shall be hot- dip galvanized if specified in the technical sections of the specification. h) Small Wiring All small wiring shall comply with the provisions of the Electricity Regulations in Pakistan. i) Equipment and Materials All equipment and materials shall be new and of the highest quality, and shall be capable of withstanding the stresses imposed on them under the most severe electrical, mechanical and atmospheric conditions which may occur in service. Repair of damaged equipment or materials shall not be allowed without the approval of the Employer. j) Surface Treatment of Metals Due to incidence of dust storms the surface finish proposed for outdoor equipment shall be sufficient to prevent accelerated deterioration due to dust abrasion and dust contaminants.
All exposed metal surfaces shall be either painted, galvanized, anodized, plated or otherwise finished to take account of the metal and the climatic conditions to be encountered in service. k) Protective Treatment for Metal Work i. Galvanizing All galvanizing shall be carried out by the hot-dip process to BS 729. The zinc coating shall be smooth, continuous and uniform. It shall be free from acid spots. There shall be no impurities in
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the zinc or additives to the spelter bath, which could have a deleterious effect on the durability of the zinc coating. Before pickling, all welding, drilling, cutting, grinding etc. shall be completed and all grease, paint, varnish, oil, welding slag etc. completely removed. All protuberances, which would affect the life of galvanizing, shall also be removed. The weight of zinc deposited shall be in accordance with BS 729. ii. Welding Welding of proprietary items shall be carried out in accordance with an approved standard or code of practice. The welding plants and processes used shall be suited to the materials, configurations and purposes of the welded parts. Only qualified welders, certified for the type of welding required, shall be employed. The Contractor shall exercise strict control over the welding conditions and parameters and shall continuously monitor the standard of welding achieved in accordance with the requirements of the Clause on Quality Control and Quality Assurance, to the satisfaction of the Engineer. l) Care of the Works and Equipment Till such time that the plant has not been installed and tested, The Contractor will be held responsible for the care of the works generally until their completion, including all work executed and materials deposited on the site by him or by Sub-contractors and suppliers.
11.6 DOCUMENTATION a) Contractor’s Responsibility All relevant designs and drawings shall be approved by the Employer prior to commencement of installation on site. Approval by the Employer of any design or drawing shall not relieve the Contractor of responsibility for the correctness of designs and drawings or for the safety, adequacy and suitability of any part of the equipment manufactured or constructed in accordance with that design or drawing. b) Design and Information with the Bid The Bidder shall submit with his Bid the necessary drawings and information as specified in the Schedule of technical Data appearing at the end of the document. c) Design Submissions i. General All designs shall be submitted for the Employer's approval. Designs approved by the Employer shall not be altered without his written agreement.
Design submissions shall be made within the times named in the particular sections of the Specification. They shall be made in an orderly and timely manner so that the Employer shall have adequate time for their detailed examination and for checking and approving any necessary revisions. A period of one week shall be allowed for the Employer's checking and
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approval of any design submission from date of receipt of each submission to date of notification of approval or comments.
Each design submission to the Employer shall be serially numbered and dated and shall refer to one subject matter only. Each submission shall be accompanied by a summary sheet, which lists the documents comprising the submission. Where a submission includes revisions of documents previously submitted the summary sheet shall include a reference to the original submission number.
Two copies of each design submission shall be furnished to the Engineer.
Submissions made to the Employer relating to matters normally handled at site level shall be similarly numbered serially but in a distinctive series.
Documentation includes but not limited to:
. Description of system and components including nameplate data and lists of equipment. . Operating procedures including step-by-step instructions for normal and emergency operation. . Maintenance procedures, including routine maintenance procedures, guides to trouble- shooting, procedures for dismantling, cable jointing instructions, repair and reassembly procedures for alignment, adjusting and checking. . General arrangements and detail drawings for interfacing between the components and integration with the existing system, cabinets, cables and all other items of system or equipment. . Schematic circuit diagrams. . Detailed wiring diagrams and cable lists. . Detailed records of all type tests, routine tests and site tests. . Spare parts lists. Each design submission to the Engineer shall be serially numbered and dated and shall refer to one subject matter only. Each submission shall be accompanied by a summary sheet, which lists the documents comprising the submission. Where a submission includes revisions of documents previously submitted the summary sheet shall include a reference to the original submission number. ii. Drawings Drawings shall be complete in all respects, accurate numerically and geometrically correct and shall be sufficiently detailed to enable system and equipment erection to proceed without the need for further supporting drawings, details or interpretation. All drawings and calculation sheets shall have title blocks, which shall be correlated one with the other.
The Contractor shall maintain drawing reproduction facilities, to the approval of the Engineer in his office for the duration of the Contract.
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iii. Deviations Where the Contractor proposes a deviation from the detailed requirements of the Specification he shall make a written application for approval of such deviation to the Engineer and he shall highlight the proposed deviation on the relevant drawings and design sheets of the submission. Except in the case of a deviation specifically approved by the Engineer the Contractor shall be responsible for ensuring the conformity of the Works with the Specification, notwithstanding any general approval or lack of approval of design submissions by the Engineer.
11.7 OPERATION & MAINTENANCE INSTRUCTIONS
Operation and Maintenance instructions shall be prepared in the form of a manual for use by the Employer's personnel.
Draft copies for the Employer's approval shall be submitted two weeks before erection of equipment commences.
The preparation of the manual shall be carried out by personnel who are trained and experienced in the operation and maintenance of the system and equipment described, who are skilled as technical writers to the extent required to communicate essential data and who are skilled as draughts-persons competent to prepare the required drawings.
11.8 PROGRAM AND PROJECT MANAGEMENT
a. Outline Works Program The Bidder shall submit with his Bid an Outline Works Program showing in bar chart form the key dates, commencement dates, duration and completion dates of the main activities for each site. Where the work in a site is to be completed in more than one phase the work sequences associated with each phase shall be shown separately. The following items shall be shown:
System and equipment design and approval. Supply of drawings and information necessary for civil design. Manufacture of system and equipment. System and equipment erection. Tests on Completion. Guaranteed Dates for Completion. The Contractor shall perform the Works in accordance with the Outline Works Program submitted with the Bid until the Engineer approves a detailed Works Program.
b. Detailed Works Program Within 30 days from the date of Award of Contract the Contractor shall submit to the Employer for approval a detailed Works Program showing the activities and sequence needed for the orderly and coordinated performance and completion of each separate part of the Works in
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order to meet the major contract events set out in the approved Outline Works Program, except as otherwise approved in writing by the Engineer. c. Training The Contractor shall submit a Training Plan, which shall describe in detail how the Contractor proposes to train the Employer's staff pursuant to the provisions of the Contract. d. Putting into Service The Contractor's responsibility shall include the commissioning and putting into service of all system and equipment. No system or equipment shall be put into service without the written approval of the Employer. e. Tests on Completion Prior to taking over of the system or any section of the Works or to putting any portion of the Works into service the Contractor shall carry out Tests on Completion in accordance with the provisions of the specifications. The tests shall be carried out in the presence of the Employer and/or Engineer and to their satisfaction. Such tests shall be carried out at the Contractor's risk.
The Contractor shall submit for the Employer's approval a detailed schedule of all tests and inspections to be carried out together with complete sets of the proposed measurement, recording and reporting forms for each part of the Works. Following their approval by the Employer/Engineer these submissions shall become part of the Test and Inspection Plan.
The Contractor shall be responsible for the measurement, recording and reporting of Tests on Completion. As each item is completed its completion shall be certified by the Contractor and countersigned by the Employer and Engineer.
The Tests on Completion shall verify the correct functioning of individual parts of the Works and of systems involving more than one item of equipment. The tests shall include tests for dielectric withstand, insulation resistance, earth resistance, correct wiring and connections, correct functions and operating characteristics, calibration of measuring devices and other tests as may be directed by the Engineer.
If in the opinion of the Engineer the Tests on Completion are being unduly delayed he may by notice in writing call upon the Contractor to make such tests within 10 days from the receipt of such notice and the Contractor shall commence such tests on such day or days within the said 10 days as the Contractor may determine and of which he shall give notice to the Engineer. If the Contractor fails to carry out such tests within the time aforesaid the Engineer may proceed to carry out such tests himself. All costs and losses incurred by the Employer by reason of such failure and/or by the carrying out such tests by himself shall be borne by the Contractor.
If any portion of the Works shall fail to pass the Tests on Completion then tests on the said portion shall, if required by the Employer, be repeated within a reasonable time upon the same
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terms and conditions, save that all costs and losses incurred by the Employer in consequence of such failure and/or by such repetition shall be borne by the Contractor.
Proximate notification of each particular test or inspection shall be given to the Employer on an approved form not later than 24 hours prior to the scheduled commencement of the particular test.
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12 TESTING, COMMISSIONING AND HAND-OVER
12.1 GENERAL
The Test and start-up operation shall be executed in accordance with the requirements specified in the GCC and PCC of Contract.
During the testing and commissioning the Contractor shall validate the actual inflow water characteristics and parameters. He shall also verify and demonstrate that the constructed facilities can be operated to meet the desired treated water parameter parameters which provide safe and clean quality drinking water.
Furthermore, the Contractor shall verify and demonstrate the automatic/manual control operation of water treatment facilities
The Contractor shall bear all the cost for completion of a satisfactory Operational and Performance Test including all power and water supply.
12.2 PREREQUISITES
The following activities, as applicable to the Works, shall be completed prior to start of onsite commissioning activities:
Commissioning Planning Meeting(s) between Contractor, Employer and the Engineer. The Contractor shall submit a Commissioning Schedule for approval by the Employer and the Engineer prior to any works taking place. The commissioning plan shall also include measures to be undertaken in case of unexpected events like flooding to properties, no water during tests, no power supply during the test and develop alternatives, etc. The Contractor shall submit test sheets and test procedures for all equipment and plant components. The Contractor shall prepare properly calibrated test instruments according to the requirements in Pakistan. Test instruments shall have been calibrated within 1 year prior the test date. The Contractor has to submit proof of proper test calibration. Verification that equipment is installed and ready for operation, including receipt of Manufacturer’s Certificates of Proper Installation for equipment where required in the individual equipment Specifications. Coordination with public utilities, if necessary Coordination with permits issuers and inspectors to obtain required permission to operate
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system for testing, if necessary Programming and initial set point adjustment of PLC instruments, etc. Calibration of flow meters, pressure transmitter, chemical dosing equipment, etc.
Conduct and complete leak testing.
12.3 TEST AND COMMISSIONING
No test shall be conducted without the approved test procedure including test sheets and if the Contractors fails to submit the document according to the GCC.
On the completion of construction, installation and erection works of any equipment, water treatment units and whole plant, the contractor shall carry out the following performance tests:
Appropriate inspections, No load test (dry) functional tests, Functional tests under load conditions.
The Contractor shall submit the performance test reports to obtain Engineer’s approval.
12.4 START-UP OPERATION
When all performance tests are completed and the test reports are approved by the Engineer, the contractor shall operate selected units or whole water treatment units. Unless otherwise specified the Contractor shall conduct the operational tests and start-up the operation of the facilities by the following activities and procedures: i. Running: The Contractor shall maintain continuous running of testing units. During test running, following main indicators shall be analyzed and recorded every 4 hours:
Water flows through running units, expressed as m3/h; Production capacity, Power consumptions, expressed as Kwh;
Chemical dose in mg/l and chemical use in L/m3 treated water; Water quality of inlets and outlets, Period of filter backwashing, real time backwashing cycle; ii. Adjustment and calibration: The Contractor shall adjust the flow, capacity, chemical dosing etc. if the recorded water analyses do not meet the requirements
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iii. Commissioning: The operational test will be completed and commissioned only when all operational indicators become stable within the limit for continuous operation of 72 hours, and shall be subject to the Engineer’s approval iv. Operational test fails: In the case the operational test does not meet the requirement due to the Contractors faults in supply or construction works; the test will be immediately suspended. The contractor shall remedy all defects and seek prior approval of the Engineer for a full re- test which will be conducted under the same conditions until successful completion.
12.5 HAND OVER OF THE SITE
In compliance with the contractual requirements and with approval of the Engineer, the Contractor shall hand-over the commissioned units or plants to the Employer for operation after completion of O&M period of 01 Years.
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13 OPERATION AND MAINTENANCE PROCEDURES
13.1 GENERAL
The main objection of the Client, Punjab Aab-e-Pak Authority, is the stable supply of safe drinking water in accordance with valid standards to the rural population. Therefore, proper operation and maintenance of the water supply system on a routine basis is the most important element which has to be considered by the Contractor.
At a date to be agreed with the Engineer, the plants shall be commissioned, and the Contractor shall be responsible for operation and maintenance of the plant for a period of five years.
The commencement of the 12 month (01 years) operation and maintenance period will be when the last Treatment Plant and Site has been successfully tested and commissioned within the time period of the contract. The 1-year O&M period will also include the 12 months’ defect liability period.
The Operating Contractor will at the end of each 12 month’ period prepare and agree jointly with the employer an asset condition register of all major Plant and Equipment items by mutual agreement and this ‘Condition Register must be signed off by both parties. The registers will be an accumulated chronology for a full 01 years (12 months) culminating in an agreed forensic asset condition survey after 12 months. All attendances to the Site & Treatment Plants will be logged in a GIS data base for asset identification and record any and all attendances for the geo-tagged location.
If the asset condition assessed on a simple evaluation schedule is found wanting the Contractor will be instructed to improve the asset to a mutually acceptable condition.
The Contractor will be encouraged to conduct Operation and maintenance on the successfully tested and commissioned treatment plants and sites prior to Contract completion by pricing for this activity separately in the Bill of Quantities.
13.2 SCOPE
The scope of works covered by this section is to improve the efficiency, effectiveness and sustainability of the water supply and the equipment. Operation and Maintenance activities described here are the minimum requirements of the Employer (PSPC) and shall be directed towards the elimination or reduction of the major constraints which prevent the achievement of sustainability.
This document presents the general concepts and practices that must be adopted for effective Operation and Maintenance (O&M). The O&M specifics are considered for the proposed infrastructures to be installed by the Contractor and include, but not limited to, the following elements:
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Water source and tube well pump Power source Processes (Filtration, etc.) Chemical Dosing and Handling Reservoirs Markaz E Aab (safe water distribution point) Pipelines, valves and other appurtenances Security and ancillary structures.
The Operation and Maintenance Period shall include a period during which the Contractor shall:
Employee operators (minimum one operator for each plant, unless otherwise agreed by the Employer) for the operation and maintenance of the plant, and Shall carry out the routine maintenance and water quality test results. During this period the operating hours of the plants shall be 8 hours daily except
When attending to maintenance or in emergencies when his services shall be placed unreservedly at the disposal of the Engineer, in these cases the operational hours will be extended to 16 hours.
13.3 AIM OF OPERATION AND MAINTENANCE
Unless where otherwise specified, the Contractor shall be responsible for the establishment and implementation of the following programs, standards and procedures, which require Employer approval and which are included in the “Services” to be provided by the Contractor.
i. The program for establishing specific operating goals for each functional Project area, for managing resources to minimize personnel turnover, and for qualifying personnel, to operate and maintain the Project (including the basis for qualification of personnel). ii. The program for communicating and cooperating with Employer and governmental agencies.
iii. The Project management standards for conduct of operations, Project safety and security, conduct of maintenance, housekeeping, material condition, and records management. iv. The program for preparing supporting documentation, meter readings and information necessary to accurately prepare, justify and support monthly invoices in accordance with the terms and conditions of the Project Agreements.
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v. Developing the procedures used to operate the Project as well as monitoring, evaluating, and proposing revisions to such procedures. vi. The Project operations and monitoring program which provides the requirements for: Monitoring of Project Performance Monthly Project Performance Calculations and Report Monthly Fuel Consumption (if any) Calculations and Report Project Permitting and Environmental Reporting Operating Practices Control of Equipment Project Chemistry Control and Water Treatment Training Programs Contractor’s Qualifications Operating Procedures Status of Major Equipment vii. The maintenance program which provides the requirements for: Maintenance Planning Maintenance Procedures Preventive Maintenance Predictive Maintenance Maintenance Training viii. The assets and materials management program which provides the requirements for: Procuring Materials and Tools
Inventory Levels and Control
Renewal of Inventories
Asset management system: PSPC will develop its own GIS based asset management system. During execution and O & M period, Contractor shall fill in the asset details in Web module and update accordingly (where required). ix. The diagnostic testing program for maintaining the Project and Project equipment, including both system and component level testing.
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x. The housekeeping / cleanliness program which provides the requirements for: Hazardous Material Control
General Project Cleanliness
Equipment Condition Inspections
Hazardous Waste Program
Staff Uniforms
Android Phones for Project Monitoring: Android Phones incl. monthly bills, internet charges and SIM cards will be provided by the Contractor to his staff for real time reporting from Project Sites on Client’s Dashboard. The progress report of each site will be uploaded on weekly basis on client\s monitoring Dashboard. Water bottles to each household as approved by the client xi. The diagnostic assessment program which provides the procedure for determining the cause(s) of operational or equipment failures and preventing future failures through intended improvements, including justification for such actions. xii. The records management program for maintaining the traceability and documentation of Project performance. xiii. The Project safety program which provides the requirements for establishing: Safety Monitoring Accident Prevention Program Accident Reporting xiv. Monthly and yearly reporting systems of Project performance to EMPLOYER. This should include any complaints from the community regarding the quality of water or other communal grievances. The report should also contain the remedial actions taken to redress the complaints so received. xv. Irrespective of the proposed treatment / solution the security, watch and guard of each site will be contractor’s responsibility during execution and operation and maintenance.
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13.4 REPAIR TIME AND COSTS FOR O&M
Apart from the operation times, incurring repair times shall be considered as part of the O&M contract. All costs of repairs shall be part of the Contractors annual remuneration. For the avoidance of doubt that includes any repairs due to lightening, theft and vandalism.
All repair works and compensations shall have to be documented and to be submitted to the Employer within two weeks. Workforce should be trained (with evidence of same) to repair any equipment using skills that will enhance LMTRV (Low Mean Time Repair), except where specialist repairs are called for.
The contractor will prepare a complete and comprehensive SOP for repair of any defect which may include but not limited to:
i. The contractor shall keep inventory of spares in a sufficient number to reduce downtime. ii. In case of breakdown the complaint will be attended in a minimum possible time but not later than as given below: Tube well 24 hours Treatment Plant 24 hours Electrical equipment 24 hours Piping 24 hours
iii. Membranes & filters and other parts will be replaced by the Contractor as per given schedule.
13.5 PERFORMANCE TARGETS DURING THE OPERATION PERIOD
The Contractor shall bear all types of expenses during the Operation and Maintenance period for inspection and repair/replacement of equipment (as required). Specific responsibilities of the Contractor regarding O&M of Plants is to ensure eight (8) hours of operation per day. Provide detail maintenance and costed asset replacement schedule specifically for each plant indicating all the replaceable and consumables for the period of five years at the time of issuance of completion certificate, get it approved by the Employer and fix a hard copy in the office and/or plant and provide copies to the Employer.
Deploy at least one operator for each plant
Provide and ensure continuous supply of clean and safe drinking water during Eight (8) hrs daily operation according to designed capacity of respective plant meeting the WHO water quality
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standards.
Keep the mechanical and electrical equipment/system in good and safe working condition.
Provide a log book at each plant and operator must be guided to record the operational meetings. All the maintenance activities, replaceable/consumables must be recorded in the log book with signature of representative of the firm. Proper entries should be made for maintenance consumables. All the replaceable and consumable components shall be in compliance with the contractual requirements
Maintain record of the breakdowns and attendance on the plant.
Prepare and provide monthly reports on operation and maintenance of the plant to the Employer. Continuous Pressured Water Supply must be provided to every Markaz E Aab Centre in the project area. Emergency stoppages shall not exceed twelve hours and no more than an average of four emergency stoppages [of less than 12 hours each] shall occur in any continuous period of twelve months.
Metering and computerized (soft copy) records of the water consumption must be maintained for each Markaz E Aab Centre Leaks appearing at the surface or any component of the plant must be repaired within 24 hours of notification/observance. Maintain the Facilities to an improved standard of maintenance and develop a comprehensive maintenance management program Keep all the premises and the dispensing area of the plant clean and hygienic.
Improve the management, operations, maintenance, rehabilitation and repair of the Facilities as specified in the Contract
13.6 PENALTIES
If the Contractor fails to comply with the criteria of the Operation Service within his responsibility, then the Contractor shall pay to the Employer the relevant sum penalty as stated below:
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Water Quality on Demand
The Employer will randomly inspect 20% of the plants on a quarterly basis and also take samples for water quality testing of these plants. If compliance to the prescribed water quality and plant maintenance standards falls below the prescribed standards (WHO) for those plants during that quarter, 10% of the O&M costs of all plants for subject quarter will be deducted as penalty, and the Employer may subsequently carry out water quality testing for all the plants at the Contractor's expense. If compliance to the prescribed water quality standards is less than the prescribed standards, 100% of the O&M payment will be withheld until the Contractor ensures 100% compliance to the satisfaction of the Employer.”
Submission of Documents, Reports and Data etc.
If the Contractor fails to be compliant in producing and delivering accurate reports and documentation etc. to the requirements given notice in the Contract Documents then he shall incur a deduction in payment of a further 1% of his interim monthly account compounded monthly for every deliverable that he fails to supply. For the avoidance of doubt the deliverables identified within the Contract Documents will be identified and scheduled by the Contractor for both the Construction and Operation periods and agreed with the Engineer within 30 days of being awarded the Contract.
13.7 OPERATION AND MAINTENANCE MANUAL
Operation and Maintenance manuals shall be provided by the Contractor for the Employer three (3) months prior to mechanical completion of the plant. The Contractor shall also submit the training manuals. They shall include Instruction Manuals that are complete and specific, and whose contents conform to the index. Documents shall be used which are specific to the work, including literature of the suppliers or manufacturers that would be useful to the Employer in the care, operation and maintenance of the equipment. Nomenclature used to reference each item shall be consistent throughout the manuals.
Information furnished shall be complete for equipment and systems furnished by the Contractor and its suppliers. Material that does not contribute to the understanding of the design, care, operation and maintenance of the equipment shall be excluded from the Instruction Manuals where practical. If it is necessary to use existing material containing extraneous items, the item referred to shall be clearly and plainly marked, the irrelevant data shall be deleted in an orderly and systematic manner and the date of publication shall be clearly shown.
The Instruction Manual shall be organized as follows:
SECTION I: OPERATION
Shall include the following:
General description of equipment, including overall design, specific and special features of
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design and descriptive drawings. Performance specifications for equipment stating the basis for calculations and allowable variations.
Information to allow the EMPLOYER to operate the facility, which shall include but not be limited to detailed operating instructions for start-up, shut-down, normal operation and emergency shut-down as further detailed below. Starting instructions complete, detailed and specific for equipment furnished, noting the step- by-step procedure to be followed. Precautions and critical points to be observed shall be noted and emphasized as required. These instructions shall be divided into Initial Starting, Normal Starting and Starting after extended shutdown. Operating instructions complete, detailed and specific for equipment furnished. It shall include precautions and critical points to be observed, including suggested form to be used in taking periodic readings to maintain an operations record. There shall be a tabulation of possible operating difficulties with the probable cause listed and remedial action to be taken Shutdown instructions complete, detailed and specific for equipment furnished, noting the step- by-step procedure to be followed for shutting down the equipment. Precautions and critical points to be observed shall be divided into "Normal Shutdown" and "Emergency Shutdown." Design data for equipment and systems specifying horsepower, kilowatts, voltage, amperage, pressure, temperature, revolutions per minute, flow, etc. Characteristic curves for equipment where called for in the Technical Section(s) of the equipment specifications or when normally furnished for the particular equipment, such as fuel consumption, head, capacity, horsepower, efficiency etc. Test reports and material specifications where the requirement for these items has been specified in the Technical Section(s). Operator alarm responses for enunciator alarms.
Piping and instrument diagrams which provide proper valve alignment for equipment for normal operation. Normal process operating ranges and set points for all plant equipment.
SECTION II: MAINTENANCE
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Shall include the following:
Disassembling instructions complete, detailed and specific for assemblies of equipment furnished, noting the step-by-step procedure to be followed. Unusual care and precautions to be taken shall be noted and emphasized. Reassembly instruction shall also be included. Maintenance instructions complete, detailed and specific for equipment furnished normal preventive maintenance instructions and lubrication information, including periodic inspection, testing and maintenance requirements in accordance with applicable codes and manufacturers 'instructions. Schedule covering tests and inspections to be performed after various periods of operation and overtime shall be included. A summary description and identification of special tools required and/or furnished for maintenance shall also be included. Settings, clearance and adjustment data tabulated for equipment, covering instrument settings for operation, alarm and shutdown and operating clearance sand adjustments required for proper operation. Also, a tabulation of recommended and actual operating conditions, such as temperature, pressure, flow, etc., for equipment and systems. The actual shall be entered after installation or field test. Included also shall be calibration procedures and instrument datasheets.
13.8 SPECIFIC REQUIREMENTS
Contractor's scope of Services is based on the Project design as described in the Project Agreements, the Project Operating Manuals and Vendor’s manuals and design/as built drawings. The Contractor shall prepare Annual Project Operating Plans, which, in part, will define the operations procedural requirements for the Project to meet the requirements of the Project Agreements. The Contractor, as part of the Services, is responsible for:
i. Providing such trained personnel as is reasonably necessary to operate and maintain the Project and provide the Services set forth in this Agreement. ii. Operating and maintaining the Project in accordance with the approved Annual Project Operating Plan. iii. Planning and managing on-site operations and maintenance activities, including: Assuring that operational goals and operating plans are consistent with the Annual Project Operating Plan. Assuring that the Project is operated in accordance with this Agreement and in a safe, reliable, efficient, and prudent manner.
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Assuring that operations and maintenance personnel are trained and qualified for their assigned responsibilities and tasks, and that such qualification is maintained. A GIS based android reporting application should be enforced and each site supervisor should be provided with a phone compatible to run the application developed by the Employer. Assuring that the Project meets contract, regulatory, and environmental requirements set forth in the Project Agreements or otherwise identified by Employer or Contractor. Managing and controlling costs consistent with agreed O&M costs.
Planning, scheduling and managing work and maintenance activities.
Defining and documenting operational technical requirements
Defining and delineating responsibilities between Contractor and Employer and identifying reporting requirements.
Establishing labor relations and personnel programs that will meet state federal and provincial requirements and encourage employee retention.
Maintaining a current inventory of materials and procuring all services, spare parts, operational materials, consumables, office equipment, tools and shop equipment, or any other items or materials required to operate or maintain the Project.
Controlling outages, both planned and unplanned, by using detailed and integrated plans and schedules, and resource management.
Maintaining Project performance levels by using routine system and component performance testing.
Maintaining a file of preplanned outage-related work to allow for efficient use of any forced outage downtime.
Establishing open purchase order or contract agreements with Project equipment vendors, industrial suppliers, jobbers, and maintenance contractors in accordance with Project Agreements to ensure timely response to Project maintenance needs
Promptly notifying Employer in writing of any teardowns and overhauls of major equipment or capital improvements that Contractor believes are necessary together with a proposed schedule for completing such repairs or improvements.
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Performing such other tasks which Contractor deems appropriate, from time to time, in connection with operation of the project.
Performing such other tasks and services which Employer may reasonably request from time to time in connection with operation of the Project.
13.9 OPERATING RECORDS AND REPORTS
General
The Contractor shall maintain, at a location acceptable to Employer, the Project operating logs, records, and reports that document the operation and maintenance of the Project, all in form and substance sufficient to meet Employer’s reporting requirements under the Project Agreements.
The Contractor shall maintain current revisions of drawings, specifications, lists, clarifications and other materials related to operation and maintenance of the Project provided to Contractor by vendors. The Contractor shall provide to the Employer reasonably necessary assistance in connection with Employer’s compliance with reporting requirements under the Project Agreements, applicable Laws or any other agreement to which Employer is a party relating to the Project. Such assistance shall include providing reports, records, logs and other information that Employer may reasonably request as to the Project or its operation.
To counter check the quality of the water produced as per Contract on a monthly analysis report for the following parameters from PCRW/UET or other laboratories approved by the Employer from time to time shall be submitted:
Biological Testing Arsenic Chromium and other heavy metals Iron Manganese Nitrates Nitrites Any other as specified from time to time
Records
An effective maintenance program can only be sustainable if the correct documents are in place. The documents start with the commissioning period collecting all data collection, proper filing, and safekeeping of the supply scheme’s records. For the O&M function, the following records are particularly important and, as a minimum, should be kept and available:
All manuals on equipment and instruments
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All drawings as per design
Maintenance plan
Water Analysis
Maintenance register including equipment description and identification details, maintenance history (including condition monitoring if applicable), spare parts and supplier details. Logbook for the purposes of recording any significant or unusual events and information which do not logically fit into other records. Maintain records to sufficiently document all aspects involved with the daily operation and maintenance of the Plant, as well as any information required by any regulator. The records to be kept, but not limited to: chemical usage, to be recorded daily;
chemical dose rates including associated information on which the choice of dosage rates has been based; Records of instantaneous disinfection dose rate checks;
All equipment faults and action taken; and Stock levels of treatment chemicals, equipment spare parts and their consumables. Reporting
The Contractor shall develop a communication and reporting program that will keep the Employer fully informed about all aspects of operations and maintenance as well as the performance of the Plant. In this respect, a monthly and annual report on plant performance, incidents, failures, and the general operation should be provided to the Employer. The Contractor shall also develop a protocol for immediate notification to the Employer of any failure to meet water quality or effluent quality standards. The report should contain but not be limited to:
The type and frequency of corrective maintenance carried out in the Plant. A summary of the operations and maintenance activities for the Plant.
Moreover, provide a supplemental operating report which may reasonably be required by the Owner from time to time.
Formal monthly reporting will be submitted to the Client within week after the end of the calendar month and shall include all labor plant and equipment records associated with the monthly and cumulative attendance together with running hours, breakdowns along with compliance by way of evidence with water quality testing reports. The MOM’s of the Monthly Operating Progress will be
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produced by the Engineer and formal signatures of agreement for the final MOM’s must be made within 2 weeks of the set\scheduled meetings.
Complaints and Penalties
Complaints shall be classified into two classes as follows:
General complaints are day to day maintenance issues like minor breakdowns caused by the consumer, having no influence on the quality of water and malfunctioning of the installation. These complaints shall be addressed as per the conditions of the contract. These complaints must be addressed within single working day failing which the conditions of contract and its relevant clauses will be invoked which may lead to doing the work on the risk and cost of the contractor adding consequential damages and overheads expenditures by the client the amount spent by the client will either be adjusted from the monthly invoice submitted or retention money held or/performance guarantee forfeiture.
Serious complaints shall be the ones having impact on the quality of water delivered and non- provision of water to consumer for more than one day. For all such complaints a penalty at the rate of PKR 10,000/- per day each complaint unresolved shall be imposed to be deducted from the payable invoice for the month. However, the penalty imposed shall not be more than the invoice of that month.
13.10 CAPACITY BUILDING PLANS FOR O&M PERSONNEL
The Contractor shall organize a training program through National or by State Resource Centers authorized by the Government of Pakistan. The personnel who are already available during construction or chosen to later carry out the works contained in the program may have to be trained through special courses or by “on the job training “to ensure that these personnel are thoroughly trained to carry out the action listed in the plan of Preventative maintenance. The supervisors can be trained initially who in turn may train the operators. Regular inspections by Supervisors could also eliminate plant shutdowns.
The Contractor shall propose an organogram for the O&M personnel with one main responsible and suitable person in charge of the O&M of all the water supply scheme (s), the “O&M Manager”. This person shall have to fulfil all local requirements and standards, shall have sufficient experience and shall be approved by the Employer. Any replacement or substitute of this person shall be subject to approval by the Employer.
13.11 PLAN FOR PROVIDING SPARES AND TOOLS
It is essential to ensure the availability of spare parts like stand by pump-sets, minimum numbers of different sizes of jointing materials assessed on the basis of lengths of pipe lines, all sizes of nuts and bolts, bearings, pipe pieces of different sizes & materials, electric spares like MCBs, Relay etc. A
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critical spares list and along with a schedule of spare plant and equipment must be kept in hard and soft form and submitted and updated monthly to maintain the same spares.
Elimination of wastes should be avoided when having spares inventory. Stores should have “minimum” spare parts but “maximum” to fulfil the need of the Maintenance Schedules. This will lead to unnecessary parts lying for years and be thrown away.
The contractor should provide an inventory planning schedule and it should indicate the method of collaboration between stores and staff.
13.12 APPROVAL
Extensive repairs requiring an amendment to the designed water supply schemes or an exchange of original equipment against different types, as for example by the installation of non-original spare parts have to be approved by the Employer. For any such major repairs or replacement, a report must be submitted with a copy of all the maintenance that has been done on the equipment that needs to be replaced.
13.13 SECURITY AND SAFETY
The Contractor shall ensure the security of the Plant and access only to the respective Operators and implement a site-specific safety program to include training, record keeping, safety meetings and an emergency response program.
The Contractor has the responsibility to provide labor and safety equipment necessary for conducting any inspections to identify any deficiencies related to the safety of the Facilities or any inspection which the Operator considers necessary.
The Operator shall regularly inspect the Facilities for safety deficiencies. The Operator shall carry out these inspections at least once every 90 days.
The Contractor shall prepare a comprehensive report to the Employer outlining any safety deficiencies at the Facilities and setting out a plan to correct the safety deficiencies
13.14 VEHICLES
For the purpose of this item, vehicles and equipment shall include but not be limited to:
All cars, trucks and four-wheel drive vehicles whether provided to the Operator by the Contractor or purchased by the Operator on the Contractor´s behalf.
The Operator shall repair and maintain all vehicles and equipment in accordance with the Preventive Maintenance Program.
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14 SAFETY
14.1 LABOR AND SAFETY
14.1.1 Labor
All steps pertaining to painting works shall only be performed by skilled personnel duly qualified to do so. The Contractor shall have its own supervision personnel working in relation with the Engineer’s quality personnel.
14.1.2 Protection of Works
Works under Progress
All necessary protection steps shall be taken to protect works under progress from dust and a sufficient supply of clean drop clothes shall be maintained. The Contractor shall lay such drop clothes in all areas where the painting works under progress are to be protected.
Other Works
The Contractors shall lay drop clothes in all areas where painting is being done, to protect floors, machinery and equipment as well as other work, from damage during the prosecution of painting works.
As a general rule, spilled paint should be cleaned up immediately.
14.1.3 Safety at Work
Personnel Safety
The Contractor shall take all necessary safety measures for the personnel, equipment and material.
o For personnel safety special personal safety equipment shall be provided to the workers during the works. This will include but not limited to: o Splash-proof goggles to be worn during chipping, wire brushing, sandblasting, spraying etc. o Rubber gloves to be worn when using paint removers, acid treatment, cleaning compounds, etc. o Safety belts when working inside tanks, on high equipment such as bridges, structural steel works, water towers, etc. o Airline mask when sandblasting, spraying toxic products, etc. o The Contractor shall provide required safety gears to the Engineer’s personnel during the inspection of work.
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14.2 SAFETY EQUIPMENT
Ladders
All extension and straight ladders should be equipped with safety shoes.
All ladders shall be inspected once a month and the defected units shall be removed from the Site.
No metal ladders are allowed to be used where electric cables or sources are installed.
It is to be reminded that neither piping nor equipment is to be used to support painters, ladders or scaffolding.
Swinging Stages and Scaffoldings
Swinging stages and scaffoldings shall always have a back-rail. They shall be tested with twice the load they will be expected to bear in service.
Provision shall be included in the back of the back-rail for providing suitable support for all hand tools that may be used. All tools shall be kept in this support when not in use.
General Precautions
Other requirements:
o Overhead danger signs should be used when working near walkways, over doorways, platforms or roadways. o Do not use paints containing a volatile solvent in enclosed areas where welders are at work. o Use chemical type respirators when doing any spray painting except when in front of proper spray booth. o Face shields should be worn when using power cleaning tools and chipping hammers. o Manila or hemp ropes are not being used for scaffolds more than 7 meters away from the center of road tracks. o Wear rubber gloves when using spark tester for locating breaks or pores in coatings. o Do not seal paint cans of ready-to-mix paints after they have been mixed. The materials are not stable when mixed. For temporary storage punch a hole in the lid. o No lead base paint or primer should be used.
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