ANNEXURE A2 PART II– Gate Pumps

FOR POISAR RIVER REJUVENATION PROJECT

For8/6/2020 reference purpose only. Submersible Pump With Gate

POISAR RIVER REJUVENATION PROJECT ANNEXURE Sr.no Particulars

1 TYPICAL DRAWINGS AND MASTEPLANS

2 GATEPUMP LOCATIONS

3 GLOBAL MANUFACTUERS AND TECHNOLOGY APRTNERS

4 GATE PUMP TENDER DETAILS

5 CONCEPT OF GATE PUMPS SELECTION

6 GATE PUMP VENDERS 1. TYPICAL DRAWINGS AND MASTEPLANS 1A. Typical layout of wetwell with Gate Pumping Arrangements 1B. POISAR RIVER MASTER PLAN

1C.POISAR RIVER PHASE –GATE PUMP LOCATIONS 2.GATEPUMP LOCATIONS TABLE 1. POISAR GATEPUMP DETAILS 1.1 POISAR RIVER: GATEPUMP1 APPA PADA

MCGM SCHOOL LAND IN DISPUTE

SGNP LAND

SGNP LAND 1.2 POISAR RIVER: GATEPUMP2 M&M GREENGATE 1.3 POISAR RIVER: GATEPUMP3 THAKUR COMPLEX SAMTANAGAR NALA 1.4 POISAR RIVER: GATEPUMP4 THAKUR COMPLEX ASHANAGAR NALA

PRIVATE LAND PRIVATE LAND 1.5 POISAR RIVER: GATEPUMP5 GAODEVI NALA

W-RAILWAY LAND RIVER W-RAILWAY LAND 1.6 POISAR RIVER: GATEPUMP6 TULASKARWADI NALA

PRIVATE LAND

RIVER 3. GLOBAL MANUFACTUERS AND TECHNOLOGY APRTNERS

• GROUNDFOS WATER UTILITY • HUSH INDUSTRIES CORPORATIONS – KORIA • ISHAIGAKI (IGAH-S)- JAPAN • KJI CO. LTD –KORIA • YEIMANS CHICAGI CORPORATION (YCC)- ITALI 4. TENDER SPECIFICATION

Specifications for Gate Pumping: PART 1 GENERAL 3.1 DESCRIPTION A. Pumps shall be submersible & dry Non clog type installed wastewater pump(s) with watertight and totally encapsulated electrical 3-phase motor prepared for operation at a supply voltage of 415 volts in 50 Hz complete with adequate length of submersible rubber cable. B. The cable shall be sized to match the electrical consumption of the motor running at full load and dimensioned according the latest IEC 60335-1 standard or equivalent grade as per IS. C. Pumps and drives shall be rated for continuous duty and shall be capable of pumping the flow range specified. D. The pumps shall not overload the motors at any point of the performance curves. The pumps shall sized according to IEC 60034 and IEC 60335 / NEMA MG1 and UL 674 or equivalent grade as per IS with a service factor of 1.10 (+10%) in 50Hz. 4.1 SCOPE AND REFERENCE STANDARDS

SCOPE A. The pump(s) shall be designed, manufactured, selected and equipped with accessories suitable for above the purpose, the duty and the operation of the entire system. B. The pumps shall be tested and commissioned for the purpose of which the product is intended.

REFERENCE STANDARDS The following standards are referred to in this Clause: For 50 Hz pumps 1. Machinery Directive (2006/42/EC). Standard used: EN 809: 1998 + A1: 2009. 2. Low Voltage Directive (2014/35/EU). Standard used: EN 60204-1: 2006 + A1: 2009. 3. EMC Directive (2014/30/EU) or equivalent grade as per IS 4. Standard of enclosure class (IP) (IEC 60529) or equivalent grade as per IS 5. Referenced vibration standards: ISO5199:2002 and ISO10816 or equivalent grade as per IS 6. DIN flange standard (EN-1092-2): Pressure stage PN 10 or equivalent grade as per IS. 4.2 DESIGN & PERFORMANCE CONDITION 3.4 DESIGN & PERFORMANCE CONDITION A. The pumps shall be designed and constructed to operate in a media temperature of maximum 50°C and in the operating conditions they are designed for. B. The pumps shall be designed for a life of 100,000 operating hours given the recommended service intervals stated by the pump manufacturer. C. Pumps vibration levels shall refer to the principals stated in the equivalent grade as per IS. D. The submersible pump when establish on a discharge connection and operated in the system shall be free of leakage in the discharge connection. The pump’s shall be installed according to pump supplier recommendations for respective distances between intake and ground floor, sidewalls and minimum water levels to ensure cavitation caused by either surface or submerged vortices is eliminated over the full area of operation. E. The construction should be designed so dismantling, service and re- installation can be accomplished easily. DESIGN & PERFORMANCE CONDITION F. The controls and starting/drive equipment to be suitable for use with the pump/s motor’s, taking into account all requirements including starting torque and starting currents and number of starts per hour. G. For the performance curve of the selected pump, the head shall continuously rise as flow decreases throughout the entire curve from run out to maximum allowable shutoff head. H. Pumps shall be with an uncompromised free spherical passage through the pump hydraulics. The minimum free spherical passage through the pump shall be 65 mm to 85 mm. I. The pump’s shall be tested in test facilities standardized according grade as per IS or equivalents, with regularly calibrated instruments. Based upon selected test grades according to above standards, the manufacturer shall guarantee the following parameters: • Flow rate • Total head • Power input • Efficiency. 4.3 Pumps Specifications PUMP A. Castings, fabrications, machined parts and drives shall conform to the industry standards for strength and durability and shall be rated for continuous duty over the entire operating range. B. Pumps shall be manufactured of the following materials and standards as a minimum: 1. Volute castings shall be executed in either cast iron grade no less than EN-GJL- 250 / ASTM A48 Class 40B or equivalent grade as per IS . 2. Impellers shall be executed in either cast iron grade no less than EN-GJL-250. Or equivalent grade as per IS 3. Pumpset should be IP 68 type with or without cooling jacket suitable for dry installation. 4. The wetted part of the rotor shaft shall be executed in stainless steel grade no less than EN 1.4401. or equivalent grade as per IS 5. Fasteners shall be executed in stainless steel grade no less than EN 1.4436 or equivalent grade as per IS 6. O-rings shall be executed in NBR rubber 7. Shaft seal shall be a single unit double mechanical seal of the cartridge type. The seal faces of the primary shaft seal shall be silicon carbide/silicon carbide (SiC/SiC) and the seal faces of the secondary shaft seal shall be either carbon/ceramics or SiC/carbon. 8. The cartridge shaft seals shall be tested from factory before fitted in the pumps.

PUMPS SPECIFICATIONS C. The pumps shall be fitted with flanges according to IS or Equivalent D. The lifting system shall be manufactured of the following materials: 1. The guide rail system shall be stainless steel grade . 2. Lifting chains shall be certified and executed in electro stainless steel . E. For pumps that are to be installed partly submerged or dry on Gate installation: The pumps shall be equipped with cooling system with or without the need of motor liquid. F. For pumps that are to be installed fully submerged: The pumps shall be equipped without a cooling system. G. Bearings shall be greased for life and designed for an L10 life time with a minimum of 35,000 service hours at the best efficiency point (BEP). H. Painting and surface preparation: All cast iron parts shall be treated with cataphoresis and powder coating with a layer thickness of minimum 80 microns. I. All pumps shall be capable of starting minimum 20 times per hour no matter installation method. 5. CONCEPT OF GATE PUMPS SELECTION

1 . The decision for using the gate pumps as sewage interceptor was taken considering the various alternatives and space constraints at the site . Vendors of such pumps were called for meeting at MCGM office and they demonstrated the solution apt for the site situation . Also these kind of pumps are currently been used by MCGM for storm water pumping stations .

2. The design and type of pumps suitable for the project has been finalized after much deliberation with industry experts , MCGM engineers and experts from consultants . Further this solution was vetted with Experts from IIT & NEERI .

3. One of the criteria of selection of this solution is minimum three reputed pump manufacturers are offering such kind of pumps in and has been used by MCGM itself.

4. Further the tender specifies only minimum specifications of any component which has to be designed by the bidders and installed and maintained by them for the useful life of the product.

So the bidders can choose the venders of their choice who satisfy such condition. Also the arrangement is critical to the project and if it fails due to any reason then sewage shall either enter into river or spill over the roads and both the conditions has implications to public health so it is desired that the vendors of the project should be reputed and have proven technology , and should be in use in India . CONCEPT OF GATE PUMPS SELECTION

. For the gate pumps following venders are available in India and who have offered to provide the solution of sewage interceptors as gate pumps to MCGM . 1. Grundfos- India . 2. Ishigaki – Japan . 3. Hasuh - South Korea . . These companies have their representation and presence in India and have been providing solutions world wide. . Also many Indian pump manufacturers have the capabilities to develop such pumps if the market is there . . As this type solution is viable only where land is not available for conventional arrangement of construction of wet-wells and then pumping with conventional pump. . This conventional technology is used in where the space was available . However for Poiser and rivers due to heavy encroachment the space is not available hence this technology was proposed CONCEPT OF GATE PUMPS SELECTION • Gate Pumping is nothing but the dry pit type installation which have openable provisions in monsoon season to avoid flow restrictions during the peak flow in nallha. • The modification of flood control gate pumps ( which usually installed axial pump with high flow and low head) was replaced with conventional submersible sewage pumps with cooling jackets for the site specific installation as the dry weather flowing is low and pumps head may be in the range of 20-30 meters to feed to STP / nearby sewage pumping wells. • So the application wise these techniques of dry pit installation are specified in the CPHEEO manual and the new technology of flood control.

FIG 5.1 GATE PUMPS JUSTIFICATION

FIG 5.2 GATE OPEN POSSITION

FIG 5.3 6. Gate pump Venders

• For the gate pumps following venders are available in India and who have offered to provide the solution of sewage interceptors as gate pumps to MCGM – 1. Grundfos- India – 2.Ishigaki – Japan – 3.Hasuh - South Korea . • These companies have their representation and presence in India and have been providing solutions world wide. Also many Indian pump manufacturers have the capabilities to develop such pumps if the market is there . • As this type solution is viable only where land is not available for conventional arrangement of construction of wet-wells and then pumping with conventional pumps GATE CLOSE POSSITION

FIG 6.1 Successful Installations

FIG 6.2 Successful Installations

FIG 6.3