SPECIFICATIONS

MECHANICAL WORKS

Table of Contents

2. SPECIFICATION FOR MECHANICAL WORKS-GENERAL

REQUIREMENTS ............................................................................................. 4

2.1 GENERAL REQUIREMENTS .......................................................................... 4

2.1.1 Introduction ....................................................................................................... 4
2.1.2 Standard Specification...................................................................................... 4
2.1.3 Workmanship .................................................................................................... 4
2.1.4 Substances and Products ................................................................................ 4
2.1.5 Welding ............................................................................................................. 5
2.1.6 Castings ............................................................................................................ 5
2.1.7 Forgings ............................................................................................................ 5
2.1.8 Non-metallic Materials ...................................................................................... 5
2.1.9 Engineering Hardware ...................................................................................... 6
2.1.10 Threads............................................................................................................. 6
2.1.11 Guards for Moving Parts................................................................................... 6
2.1.12 Safeguarding Plant ........................................................................................... 6
2.1.13 Rating Plates, Name Plates and Labels........................................................... 7
2.1.14 Lubrication General .......................................................................................... 7
2.1.14.1 Oil Lubrication ................................................................................................... 7
2.1.14.2 Grease Lubrication ........................................................................................... 8
2.1.15 Gaskets and Joint Rings................................................................................... 8
2.1.16 Electroplating, Galvanising and Sherardising .................................................. 8
2.1.17 Noise ................................................................................................................. 9
2.1.18 Vibration............................................................................................................ 9
2.1.19 Corrosion and Erosion ...................................................................................... 9
2.1.20 Precautions against Damp ............................................................................. 10
2.1.21 Machinery, Lifting and Dismantling ................................................................ 10
2.1.22 Seals General ................................................................................................. 10
2.1.23 Soft Packed Glands ........................................................................................ 10
2.1.24 Mechanical Seals ........................................................................................... 10
2.1.25 Bearings below Water .................................................................................... 11
2.1.26 Bearings above Water .................................................................................... 11
2.1.27 Gearboxes ...................................................................................................... 11
2.1.28 Safety Signs.................................................................................................... 11
2.2 PUMPS, VALVES, PIPEWORK AND ANCILLARY PLANT .......................... 12
2.2.1 Pumps ............................................................................................................. 12
2.2.1.1 General ........................................................................................................... 12
2.2.1.2 Pump Performance......................................................................................... 13
2.2.1.3 Double Entry Split Casing Pumps .................................................................. 14
2.2.1.4 End Suction Pumps ........................................................................................ 14
2.2.1.5 Sump Dewatering Pumps ............................................................................... 15
2.2.1.6 Submersible Pumps ....................................................................................... 16
2.2.1.7 Submersible Sludge Pumps ........................................................................... 17
2.2.1.8 Positive Displacement Pumps ........................................................................ 17
2.2.1.9 Progressive Cavity (rotating positive displacement) Pumps .......................... 17
2.2.2 Valves ............................................................................................................. 18
2.2.2.1 General ........................................................................................................... 18
2.2.2.2 Gate Valves .................................................................................................... 18
2.2.2.3 Butterfly Valves ............................................................................................... 19
2.2.2.4 Air Valves........................................................................................................ 19

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2.2.2.5 Check Valves (no-return valves) .................................................................... 20

2.2.2.6 Control Valves - General ................................................................................ 21
2.2.2.7 Pressure Reducing Valves ............................................................................. 21
2.2.2.8 Pressure Relief Valves ................................................................................... 21
2.2.2.9 Ball Float Valves ............................................................................................. 21
2.2.2.10 Solenoid Operated Valves .............................................................................. 21
2.2.2.11 Spindles and Caps ......................................................................................... 22
2.2.2.12 Manual Operating Mechanisms...................................................................... 22
2.2.2.13 Electric Actuators............................................................................................ 22
2.2.2.14 Marking and Packing ...................................................................................... 23
2.2.2.15 Handling.......................................................................................................... 24
2.2.2.16 Installation....................................................................................................... 24
2.2.3 Pipework ......................................................................................................... 24
2.2.3.1 External Pipework ........................................................................................... 24
2.2.3.2 Pipework within Structures - General ............................................................. 24
2.2.3.3 Steel Pipework ................................................................................................ 26
2.2.3.4 uPVC Pipework (for in-door installations) ...................................................... 26
2.2.4 Electric Overhead Travelling Cranes ............................................................. 26
2.2.5 Compressed Air Plant..................................................................................... 27
2.2.5.1 General ........................................................................................................... 27
2.2.5.2 Air Intake......................................................................................................... 27
2.2.5.3 Reciprocating Compressors ........................................................................... 28
2.2.5.4 After-Coolers................................................................................................... 28
2.2.5.5 Air Receivers .................................................................................................. 29
2.2.5.6 Air Pipework.................................................................................................... 29
2.2.5.7 Air Isolating Valves ......................................................................................... 29
2.3 TESTING OF PUMPS, VALVES, PIPEWORK, CRANES AND GENERAL
PURPOSE MACHINERY ............................................................................... 30
2.3.1 Tests at Manufacturers' Works ....................................................................... 30
2.3.2 Tests at Site .................................................................................................... 31
2.4 DETAILED MECHANICAL REQUIREMENTS ............................................... 32
2.4.1 Scope of Works .............................................................................................. 32
2.4.2 Plant Design ................................................................................................... 32
2.4.2.1 Intake Structure and Raw Water Pumping Station ........................................ 32
2.4.2.2 Fine Screens................................................................................................... 32
2.4.2.3 Belt Conveyor ................................................................................................. 32
2.4.2.4 Sluice Gates before and behind the Screens and the By-pass ..................... 32
2.4.2.5 By-pass Chamber ........................................................................................... 33
2.4.2.6 Raw Water Pumps .......................................................................................... 33
2.4.2.7 Piping and Fitting ............................................................................................ 33
2.4.2.8 Surge Protection (if necessary) ...................................................................... 34
2.4.2.9 Crane .............................................................................................................. 34
2.4.2.10 Ventilation System .......................................................................................... 34
2.4.2.11 Inductive Measuring Device ........................................................................... 35
2.4.3 “Water Treatment Units” ................................................................................. 35
2.4.3.1 Coagulation Chamber..................................................................................... 35
2.4.3.2 Flocculation Chamber..................................................................................... 35
2.4.3.3 Clarifiers.......................................................................................................... 35
2.4.3.4 Filtration Plant ................................................................................................. 36
2.4.3.5 Filter Backwashing System ............................................................................ 39
2.4.3.6 Chlorine Contact and Treated Water Tank .................................................... 42
2.4.3.7 Chemical Preparation ..................................................................................... 42
2.4.3.8 Coagulant Dosing (Poly-Aluminium-Chloride) ............................................... 43
2.4.3.9 Tanks for PAC ................................................................................................ 44
2.4.3.10 Polymer (flocculent) Dosing ........................................................................... 46
2.4.3.11 Tanks for Polymer .......................................................................................... 47
2.4.3.12 pH Correction (Lime Dosing) .......................................................................... 49

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2.4.3.13 LIME Tanks..................................................................................................... 50

2.4.3.14 LIME Process Piping and Valves ................................................................... 52
2.4.3.15 Chlorination..................................................................................................... 53
2.4.3.16 Pre - Chlorination Booster Pump.................................................................... 61
2.4.3.17 Chlorine House ............................................................................................... 63
2.4.3.18 Treated Water Pumping Station ..................................................................... 66
2.4.3.19 Sludge Pumping Station ................................................................................. 74
2.5 PIPEWORK .................................................................................................... 74
2.6 SPARE PARTS .............................................................................................. 75
2.7 TOOLS............................................................................................................ 76

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2. SPECIFICATION FOR MECHANICAL WORKS-GENERAL REQUIREMENTS

2.1 GENERAL REQUIREMENTS

2.1.1 Introduction
This Part of the Specifications sets out the minimum standards of materials,
workmanship and design to be used by the Contractor for the mechanical equipment.
Reference to any specific material or equipment does not necessarily imply that such
material or equipment is included in the Works.
All component parts of the Works shall, unless otherwise specified, comply with the
provisions of this Chapter or be subject to the approval of the Engineer.
2.1.2 Standard Specification
All material described in these Specifications, shall comply with the relevant EN
Reference Standards (https://en.wikipedia.org/wiki/List_of_EN_standards ), like ANSI,
ASME, ISO, DIN, or equivalent.
Equivalent Standards may substitute the Standards referred to in the Specifications,
provided that the Contractor has justified such substitution to the Engineer. These
Standards shall only be applied after written approval has been obtained from the
Engineer.
In addition, all materials and workmanship shall comply with the current national
standards of the country of manufacture, provided that these standards are not less
stringent than the equivalent specified EN Standards, or provided that they comply with
the requirements of the International Organisation for Standardisation (ISO) or the
International Electrotechnical Commission (ICE) as appropriate.
The Contractor may be asked to make copies of standards available to the Engineer
together with their English translations. He shall provide these as requested for prior
assessment and for use during inspection and testing.
2.1.3 Workmanship
Workmanship and the general finish of plant installations shall be of first-class
commercial quality and in accordance with the best workshop practice, and shall be
performed by persons skilled in their respective trades.
Pipework, fittings etc., shall be fitted in a neat, straight and symmetrical manner so as
to present a pleasing appearance.
Indicating gauges fitted to machine assemblies or to control panels shall generally be
of similar style and grouped in a neat manner. External welds and flame cuts shall
have a smooth finish by means of careful grinding. Chequer plate coverings shall be
fixed squarely in their frames and with their patterns properly lined-up. Handrailings
shall be free from burrs.
2.1.4 Substances and Products
Substances and products used in the Works which may be applied to or introduced into
water which is to be supplied for drinking, washing or cooking shall not contain any
matter which could impart taste, odour, colour or toxicity to the water or otherwise be
objectionable on health grounds.

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2.1.5 Welding
In all cases where welds are liable to be highly stressed the Contractor shall supply to
the Engineer before fabrication commences detailed drawings of all weld preparations
and procedures proposed. No such welding shall be carried out before the Engineer
has approved procedures. No alteration shall be made to any previously approved
procedures without prior approval of the Engineer.
2.1.6 Castings
The structure of the castings shall be homogeneous and free from non-metallic
inclusions and other defects. All surfaces of castings which are not machined shall be
fettled to remove all foundry irregularities.
Minor defects not exceeding 10 mm in depth or 10% of total metal thickness whichever
is less or which will not ultimately affect the strength and serviceability of the casting
may be repaired by welding. The Engineer shall be notified of larger defects and no
repair welding of such defects shall be carried out without his prior approval.
If the removal of metal for repair should reduce the stress-resisting cross-section of the
casting by more than 25%, or to such an extent that the computed stress in the
remaining metal exceeds the allowable stress by more than 25%, then that casting shall
be rejected.
Castings repaired by welding for major defects shall be stress-relieved after such
welding, or as otherwise instructed in writing by the Engineer.
Non-destructive tests may be required for any casting containing defects whose effect
cannot otherwise be established, or to determine that repair welds have been properly
made.
Unless otherwise specified castings shall be produced to the relevant standard:
2.1.7 Forgings
Major stress-bearing forgings shall be made to a standard specification which shall be
submitted to the Engineer for approval before work begins. They shall be subject to
internal examination and non-destructive tests for the detection of flaws and shall be
heat-treated for the relief of residual stress. The name of the maker and particulars of
the heat treatment proposed for each major forging shall be submitted to the Engineer.
2.1.8 Non-metallic Materials
Fabrics, cork, paper and similar materials which are not subsequently to be protected
by impregnation, shall be treated with a fungicide. Sleeving and fabrics treated with
linseed oil varnish will not be permitted.
The use of organic materials shall be avoided as far as possible, but where these have
to be used they shall be treated to make them fire resistant and non-flame propagating.
The use of wood shall be avoided as far as possible. If used, woodwork shall be
thoroughly seasoned teak or similar hardwood which is resistant to fungal decay and
other blemishes. All woodwork shall be treated to protect it against damage by fire,
moisture, fungus, vermin, insect, bacteria or chemical attack, unless it is naturally
resistant to all these. All joints in woodwork shall be dovetailed or tongued and pinned.
Metal fittings on wood shall be of non-ferrous material. Adhesives shall be impervious
to moisture and fungus growth. Synthetic resin cement only shall be used for joining
wood. Casein cement shall not be used.

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2.1.9 Engineering Hardware

Nuts and bolts for pressure fittings shall be of high quality steel machined on the shank
and under the head and nut. Bolts shall be of such a length that only one to three
threads shall show through the nut when in the fully tightened condition.
Fitted bolts shall be a light driving fit in the reamed holes they occupy, shall have the
screwed portion of such a diameter that it will not be damaged in driving and shall be
marked in a conspicuous position to ensure correct assembly at site.
Washers, locking devices and anti-vibration fittings shall be provided where necessary
to ensure that no bending stress is caused in the bolt.
When there is a risk of corrosion, bolts and studs shall be designed so that the
maximum stress in the bolt does not exceed half the yield stress of the material under
all conditions.
All bolts, nuts and screws which are subject to frequent adjustment or removal in the
course of maintenance and repair shall be made of nickel-bearing stainless steel or
brass.
All bolts, nuts and screws used on submerged equipment shall be made of stainless
steel.
The Contractor shall supply all holding down, alignment and levelling bolts complete
with anchorages, nuts, washers and packings required to attach the Plant to its
foundation, and all bedplates, frames and other structural parts necessary to spread
the loads transmitted by the Plant to concrete foundations without exceeding the design
stresses.
2.1.10 Threads
All threads shall be of preferred metric sizes with the standard coarse form of medium
fit to the relevant standard except for special applications for which the metric fine
thread may be utilised, or other thread forms subject to the approval of the Engineer.
2.1.11 Guards for Moving Parts
All moving parts shall be protected by safety guards.
Guards shall be rigid, securely fixed and designed to allow normal operation, running
maintenance and routine inspection to be carried out on equipment, without the need
to remove the guard. Where this is impractical, guards shall be designed for easy
fixing, dismantling and re-assembly.
2.1.12 Safeguarding Plant
The Contractor shall ensure that all designs and equipment for which he is responsible
are safe. Nothing in this Specification shall remove the Contractor’s obligation of
drawing the attention of the Engineer to any feature of the Works which is not consistent
with safety, or to prevent him making proposals for incorporating equipment or designs
which would increase the safety of the Plant.
The installation layout and plant design shall not allow any item of plant to be so
positioned that danger to operating personnel could arise during normal operation and
maintenance. Particular attention shall be paid to the position of hot pipes, valve hand-
wheel s, air vents and rotating machinery.

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2.1.13 Rating Plates, Name Plates and Labels

The Contractor shall ensure that each main and auxiliary item of Plant and equipment
shall have permanently attached to it in a conspicuous position a nameplate and rating
plate. Upon these shall be engraved the manufacturer’s name, direction of rotation,
type and serial number of plant, details of the loading and duty at which the item of
Plant has been designed to operate, and such diagrams as are deemed necessary. All
indicating and operating devices shall have securely attached to them or marked upon
them designations as to their function and proper manner of use. Provision shall be
made to incorporate descriptive numbering codes.
All valves shall have an identification plate bearing the valve number and a short
description of valve function.
On major items of plant and valves, details of proposed plates, labels and inscriptions
shall be provided by the Contractor for approval by the Engineer.
Such nameplates, rating plates and labels shall be of a non-flame propagating material,
either non-hygroscopic or transparent plastic, with engraved lettering of a contrasting
colour. Fixing shall be by means of screws. No drive rivets or adhesives shall be used.
2.1.14 Lubrication General
Provision shall be made for suitable lubrication to ensure smooth operation, heat
removal and freedom from undue wear. Plant selected shall require minimum
lubrication attendance and down time for lubricant change.
The Contractor shall supply the first fill of oil and grease from approved lubricants
suppliers.
All grease nipples, oil cups and dip sticks shall be readily accessible, being piped to a
point as near as practicable to the lubrication point.
2.1.14.1 Oil Lubrication
Gear boxes and oil baths shall be provided with adequately sized filling and draining
plugs and suitable means of oil level indication.
Roller chain drives shall have oil bath reservoir lubrication.
Drain points shall be located or piped to a position such that an adequately sized
container can be placed beneath them. Where a large quantity of oil is involved or
drainage to a container difficult, a drain valve and plug shall be provided at the point of
discharge.
Bearings equipped with forced fed oil lubrication shall be automatically charged prior to
machinery starting up and pressure monitored during operation with automatic
shutdown of machinery and alarm on low oil pressure.
All points where oil leakage may occur shall be suitably trapped to prevent oil
contamination of water. Oil filling and drain points shall be arranged so as to avoid the
risk of contamination of water by accidental spillage.
Access, without the use of portable ladders, to lubrication systems shall be such as to
permit maintenance, draining and refilling, without contamination of the charged
lubricant.
The design of breathers shall take into account the humidity and atmospheric
contamination at the vent point and measures be incorporated to prevent contamination
of the lubricant.

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Oil reservoirs shall be fitted with oil-level indicators of the sight glass type, or where this
is not practicable, with dipsticks. The normal, maximum and minimum levels shall be
clearly visible to an operator standing on the normal access floor to the particular item
of plant. The sight glasses shall be made from toughened glass, easily dismantled for
cleaning and, in exposed situations, fitted with guards.
Drain points shall be located or piped to such a position that an adequately sized
container can be placed beneath them.
For forced oil lubrication systems, the pressure shall be monitored during operation
with automatic shut-down of the machine and alarm on low oil pressure.
All oil lubricated machinery shall utilise a common grade of oil which is readily available.
High temperature high performance lubricants shall be avoided as far as possible.
2.1.14.2 Grease Lubrication
Anti-friction bearings requiring infrequent charging shall be fitted with hydraulic type
nipples.
Plain bearings requiring frequent charging shall be fitted with button head pattern
nipples.
A separate nipple shall be provided to serve each lubrication point. Where a number
of nipples supply remote lubricating points they shall be grouped together on a
conveniently placed battery plate, with spacing.

2.1.15 Gaskets and Joint Rings

Joint rings suitable for hot or cold water or specified hydrocarbon fluids or for drainage
or sewerage applications and shall be of chloroprene rubber or other approved
synthetic material suitable for temperatures up to 80 deg. C, or greater to suit the
application.
Joints shall be made in accordance with manufacturer’s instructions or as specified
herein.
Until immediately required for incorporation in a joint, each rubber ring or gasket shall
be stored in the dark free from the deleterious effects of heat or cold, and kept flat so
as to prevent any part of the rubber being in tension.
Only lubricants recommended by the manufacturer shall be used in connection with
rubber rings and these lubricants shall not contain any constituent soluble in water of
the quality stated in the Specification, shall be suitable for the climatic conditions at the
Site and shall contain an approved bactericide. Graphite grease or similar shall be
applied to the threads of bolts before joints are made.
2.1.16 Electroplating, Galvanising and Sherardising
Hot dip galvanising shall be carried out with a deposition rate of at least 460 g/square
metre. After galvanising all parts shall be passivated to minimise discoloration.
Electroplating or galvanising will be acceptable as an alternative to painting for small
ferrous components.
All fixing bolts, washers, nuts and other fixings required for erection shall be spun
galvanised, or sherardised unless otherwise specified.

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2.1.17 Noise
No item of Plant intended for installation in a building shall produce a sound pressure
level exceeding 80/85 dB(A) when measured at a distance of 1 m from the reference
surface of that item in a horizontal direction and under environmental conditions
appropriate to the test requirements . ”.
Sound pressure levels shall be measured in dB(A) using a calibrated sound meter. The
background noise level shall be at least 10 dB(A) below the operating noise level of the
machine or other item of Plant.
For major items of Plant the Contractor shall provide certificates from the manufacturer
covering noise level tests carried out on the Plant or type test certificates for a similar
item of Plant.
If an item in its standard build does not comply with the above requirement, the
manufacturer shall be required to reduce the sound pressure level by providing
improved or additional silencers or fitting sound insulating materials to the item until the
above requirement has been complied with. In general acoustic hoods or similar will
not be accepted.
Plant such as compressors, diesel engines, blowers etc. where reduction of noise
emission to below 85 dB at 1 m is impractical will be installed in a separate room
constructed in or containing sound absorbing material. The noise level shall not exceed
75 dB(A) when measured 1m from the outside of the room or structure. In such areas
the Contractor shall fit warning notices to each access door indicating that ear
defenders are required and shall provide two sets of ear defenders in a suitable storage
cabinet.
Noise levels in control rooms and offices shall not exceed 45 dB(A) with equipment
such as printers in operation. Local plant control rooms shall not exceed 70 dB(A).

2.1.18 Vibration
All rotating elements shall be dynamically balanced so that the level of vibration at any
point on a machine when operating at Site, either singly or with other machines, and at
any speed throughout the operating range, shall be within the limits of Class IV, grade
B, “Machine” shall mean a pump including drive shafting, motor and bedplate,
generator, compressor, etc.
Pipework, valves and other equipment connected to the machine, or forming part of the
operating system, shall be provided with adequate supports, brackets and fixtures, as
necessary, to restrict any induced vibration to a minimum, under any operating
condition.
Vibration measurements shall be taken on Site by the Contractor at various points on
each complete machine as defined above. Measurements shall also be taken on
connecting plant. If any item is found to be vibrating beyond the level considered by
the Engineer to be a reasonable minimum for the particular item, the Contractor shall
take further steps to reduce the vibrations to the required level. Equipment with
unacceptable vibration levels may be rejected if the Contractor is unable to achieve
satisfactory operation of the equipment involved.
2.1.19 Corrosion and Erosion

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Unless otherwise specified, the Contractor shall make proper provision for the
prevention of corrosion and erosion in any part of his Plant. Such provision shall include
the use of suitable materials, choice of operating speeds, design of components, and
type of protective coatings and finishes.
2.1.20 Precautions against Damp
Special precautions shall be taken to prevent corrosion due to humidity, rainfall and
moisture.
All wall mounted equipment shall be fitted with spacers to provide a minimum gap of
5 mm. All holes in equipment shall be effectively sealed against the ingress of water.
All items exposed to the weather or water shall be free of water traps; where necessary,
drain holes shall be provided to prevent the accumulation of water.
All fixings, fastenings and spacers which may be submerged in a corrosive liquid shall
be galvanised or sherardised, unless otherwise specified.
All electrical equipment which is not sealed against free movement of air shall be
protected from condensation with anti-condensation heaters. In general these heaters
shall be thermostatically controlled and switched off when heat is generated by
operation of the Plant.
2.1.21 Machinery, Lifting and Dismantling
Machinery bedplate design, packing and fixing shall be such as to minimise distortion
and vibration. Aligned machinery shall be mounted on either bed or sole plates,
permitting removal and reinstatement without a requirement to regroup. Bedplates
shall incorporate fine adjustment of the vertical and horizontal alignment between driver
and driven members.
All machinery shall be fitted with lifting facilities. Large structures shall be provided with
jacking points.
Tapped holes or other provision must be made in all main castings, for the insertion of
jacking screws or the fixing of drawing gear to facilitate dismantling on items of
machinery subject to frequent dismantling. Bolts or studs shall be employed in
preference to set screws.
2.1.22 Seals General
The Contractor shall select a seal, compatible with his Plant and best suited for the
worst conditions likely to be met when the Plant is in operation.
All seal materials shall be compatible with and/or resistant to the fluid or gas being
handled. For potable water, seal materials shall be specifically approved.
2.1.23 Soft Packed Glands
Shafts shall be provided with renewable gland sleeves. Glands, subject to abrasive
liquors or negative pressures, shall embody suitably positioned lantern rings and a
clean water continuous flushing system, operative whenever the Plant is in motion.
Gland adjustment nuts shall be readily accessible for routine maintenance.
2.1.24 Mechanical Seals
Mechanical seals which are subject to abrasive liquor or gas, negative pressures or
corrosive elements, shall be provided with a clean water continuous gland flushing
system, operative when the item of plant is in motion or the corrosive element present.

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A back-to-back sealing arrangement with a flushing/cooling system shall be accepted

as satisfying the requirements of this clause.
2.1.25 Bearings below Water
The Contractor shall select the most appropriate type of bearing for the Plant being
supplied.
Equipment with vertical shafts shall have thrust and guide bearings. All bearings shall
be designed to exclude the ingress of dust and water.
Sealed for life units are acceptable subject to a minimum design life of 50,000 hours
operation at maximum loading.
Plant which may be subject to vibration whilst stationary shall be provided with bearings
designed to withstand damage from such a cause.
Below water bearings shall be of the journal type, of ferrobestos, gunmetal or equivalent
and journals of stainless steel.
2.1.26 Bearings above Water
Single journal plain bearings shall be phosphor bronze or synthetic lubrication
impregnated bushes with carbon or stainless steel journals respectively. Synthetic
bearings shall only be used where bearing condition can be inspected readily.
Plain type bearings shall be self-lubricating by either grease, forced oil or impregnation.
Ball and roller type bearings shall be adequately lubricated by oil or grease and sealed
to prevent leakage of lubricant along the shaft. Attention shall be given to ensure the
dismantling of bearings is simple and free from risk of damage.
Bearings fitted to gear boxes shall a minimum design life of 100,000 hours at maximum
loading.
2.1.27 Gearboxes
Gearboxes shall have a life of 100,000 hours, be selected in accordance with American
Gearbox Manufacturers Association recommendation for horsepower calculation and
service factor application and employ a standard reduction ratio.
Gearboxes which have to be angle-mounted shall have a rating, choice of bearings,
seals and lubrication system which are suitable for such mounting.
Dependence on splash lubrication alone is not acceptable but it may be used in
conjunction with a forced feed method to reach all bearings and gears.
Calibration of the oil dipstick and its position together with that of the sump drain plug
will require special consideration.
2.1.28 Safety Signs
All signs providing health and safety information or instructions shall comply with
relevant standard.
The signs shall be of durable quality and shall comprise a substrate of 22 gauge
aluminium, pre-drilled for fixing and with rounded corners free of burrs or sharp edges.
Symbols and lettering shall be screen printed.

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2.2 PUMPS, VALVES, PIPEWORK AND ANCILLARY PLANT

2.2.1 Pumps
2.2.1.1 General
For the purpose of the specification the following definitions shall apply:

(a) Design duty The total head to be developed and the quantity of
fluid to be discharged when the pump is running at
rated speed.

(b) Static head The difference between free water surface level on
the suction side of the pump and the delivery level.

(c) External friction head The head required to overcome friction external to the
Works and the velocity head at the outlet of the
pumping main.

(d) External plant losses The friction losses in all pipework and valves included
in the Works.

(e) Internal plant losses The friction losses in the pump suspension main and
head bend up to the delivery flange of vertical wet well
pumps.

(f) Total head The sum of (b), (c), (d) and (e)

(g) Net effective lift The sum of (b) and (c).

(h) NPSH Net positive suction head

Pumps, motors and driving arrangements which are mounted on combined baseplates
shall be fitted with dowels after assembly and alignment in the manufacturer’s works,
to facilitate realignment after any subsequent dismantling.
The spindles of pumps with packed glands shall be fitted with replaceable sleeves
where they pass through the gland.
Pumps may be fitted with mechanical seals in place of packed glands only if the seals
have a proven record of satisfactory running over a long period when fitted to the design
of pump in question and with the prior approval of the Engineer. They shall be designed
for easy adjustment and seal removal.
Effective means shall be provided for collecting gland leakage water and piping this to
an approved discharge point.
The raw water could contain solids of undetermined sizes. The pumps should be
protected against the passing of such solids to avoid possible choking by weeds or
other tough sinuous materials.
Lubrication arrangements shall be designed to avoid any contamination of the pumped
fluid.
Unless otherwise specified, all pump bearings shall have a design running life of not
less than 75,000 hours. Bearings shall be designed for loading 20 percent in excess

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of calculated maximum loading and shall be suitable for reverse rotation at 150 percent
of rated speed or the maximum reverse speed that the pump can reach under installed
conditions when driven backwards by reverse flow whichever is greater.
Bearing cooling arrangements if used shall be designed on the closed-circuit principle.
Open discharge of cooling water into the pumping station drainage system shall not be
permitted. The coolant flow shall be easily visible and local indication of bearing metal
temperature shall be provided. Excessive metal temperatures shall result in safe shut
down of the pump.
Where water-lubricated bearings are used, means shall be provided to ensure that such
bearings are supplied with adequate quantities of strained water at adequate pressure
so that bearings are flooded with water before the pump starts and that a failure of the
water supply results in safe shut down of the pump.
The rotating assemblies shall be statically and dynamically balanced in accordance
with the relevant Standard and designed so that the first critical speed of the pump and
its drive is at least 50% higher than the maximum operating speed. Where the rotating
assemblies are small and any out of balance forces are negligible, the Engineer may
waive this requirement. The manufacturer is required to state whether or not balancing
has been completed.
The speed of main pumps shall not exceed 1500 rpm without approval of the Engineer.
The pump head/quantity characteristic shall be stable at all rates of flow between closed
valve and open valve and shall be steep enough to permit satisfactory operation in
parallel under conditions specified.
The pump efficiency shall be maintained over the whole of the specified duty range,
even if this necessitates the use of a larger motor to provide the peak power demand.
For vertical spindle suspended pumps the efficiency shall take into account shaft and
rising main losses up to and including the pump discharge bend, and the pump
coupling.
The NPSH requirements of the pumps, based on the 2% output drop criterion, shall be
at least one metre less than the NPSH available at every working condition.
Water velocities in the suction branch of a pump shall not exceed 2.0 m/s and the
discharge branch 2.0 m/s when the pump is operating within its specified duty range.
Within this range there shall be no discernible noise due to hydraulic turbulence or
cavitation within either the pump or its associated pipework and valves. Where
discharge velocities exceed 2.0 m/s at run out condition in the duty range the use of
profiled taper pipes will be permitted. Taper pipes shall be specifically designed to
progressively reduce velocity with profiled internal contours which contain no steps or
acute angle from which turbulence or cavitation can occur. Taper pipes shall be
considered as part of the pump and be included in all performance calculations and
tests.
Unless otherwise specified, all pumps shall be fitted with delivery pressure gauges,
automatic air-release valves and lifting lugs. Split casing and end suction pumps shall
also be fitted with suction compound vacuum-pressure or pressure gauges and drain
cocks.
2.2.1.2 Pump Performance
The Contractor shall guarantee the flow rate, the total head and the efficiency of the
pump when tested at the manufacturer’s works. Verification of works test results shall
form part of the tests at Site.

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The pump shall operate at its duty point within the acceptance tolerances for flow and
total head laid down in the relevant Standard.
For the purpose of evaluating mean specific power consumption, the sum of weighted
power consumption ratios of the pump when operating at separate points over the duty
range shall be used which shall be calculated as follows:
(Pi/Po)m = A (Pi/Po)a + B(Pi/Po)b + C(Pi/Po)c
Where:
Pi = power input at the motor terminals, kW
Po = power imparted to the water pumped, kW
m = subscript referring to weighted mean.
a = subscript referring to duty point.
b, c = subscripts referring to the upper and lower limits of working range
A, B, C = proportions of total operating time that the pump will operate at
points a, b and c respectively.
Unless otherwise specified, A = 0.50, B = 0.25 and C = 0.25
2.2.1.3 Double Entry Split Casing Pumps
Pumps shall be horizontally or vertically mounted as required.
Each pump casing shall be split along the axis of the shaft to permit the removal of the
impeller/shaft assembly without alignment. Jacking screws shall be provided on the
casing flanges to facilitate dismantling.
The bedplate shall be a substantial fabricated steel construction with floor fixing bolt
holes ready drilled.
Bearings shall be of the ball or roller type, or adequate standards, as appropriate, or
alternatively shall comprise phosphor bronze or white metal bearings, complete with
means of lubrication and seals. Bearings shall be mounted outboard.
Where shafts are susceptible to wear at bearings and glands, renewable sleeves shall
be fitted. Wear rings and bushes shall be fitted to the casing and impeller at the points
of running clearance.
Unless otherwise specified, pump shafts shall be forged steel and the impellers shall
be zinc-free bronze. Pump casings shall be fitted with an air release cock and cleaning
openings on the suction and pressure side. Provision shall be made for periodic
lubrication of bearings without removal of any parts.
Glands may be fitted with suitable mechanical seals or conventional soft packing. The
gland arrangement shall be designed for ease of adjustment or removal of the seal or
packing material.
Flushing facilities shall be provided for packed glands. Where soft packed glands are
used, means shall be provided for collection of the gland leakage water which shall be
piped to an approved discharge point.
2.2.1.4 End Suction Pumps
Pumps shall be horizontally mounted complete with drive motor on a common base
plate. The pump/drive coupling shall be of the spacer type to facilitate removal of the

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pump rotating element and bearing housing without dismantling the pump casing,
adjoining pipework or drive motor.
The dimensions of the pump shall be metric conforming to or its equivalent. Flanges
shall conform to.
The bedplate shall be of substantial fabricated steel construction with floor fixing bolt
holes ready drilled. All holding down bolts, etc. shall be supplied with the units.
The velocity at the entrance to the pump impeller shall not exceed 3.5 m/s.
Impellers shall be provided with means to prevent abrasive matter reaching the glands
and, with fully shrouded impellers, to prevent the trapping of matter between the
impeller vanes and the casing.
The speed of any pump shall not exceed 1,500 rpm.
Glands may be fitted with suitable mechanical seals or conventional soft packing. The
gland arrangement shall be designed for ease of adjustment or removal of the seal or
packing material. Shafts shall be sleeved around the area of the gland when soft pack
glands are used.
Flushing facilities shall be provided for mechanical seals or packed glands where pump
fluid may be contaminated with abrasive material. Where soft packed glands are used,
means shall be provided for collection of the gland leakage water which shall be piped
into the drainage system through adequately sized ports. Lubrication arrangements
shall be so designed that there is no contamination of the pumped fluid.
The pumps and associated pipework shall be, wherever possible, arranged so that air
can be completely expelled during priming. Where this is not possible, facilities shall
be provided for the removal of the trapped air.
Adequate facilities shall be provided for drainage of the pumps for inspection purposes.
Tapings shall be provided at both the suction and discharge flanges for pressure gauge
equipment.
2.2.1.5 Sump Dewatering Pumps
Sump pumps shall be of the vertical open impeller centrifugal or mixed flow type.
Pumps shall be supplied with all necessary discharge pipework, including check and
isolating valves. Pumps shall be complete with suitable lifting gear for lowering and
removing the pump from the sump. Pumps weighing 40 kg or more shall be lowered
into the sump on guide rails and be connected to their respective discharge pipework
with an angle flange and self-locating clamps. Pump impellers shall be designed to
pass solids of sizes which pass through the inlet ports of the pump and shall be capable
of pumping solids of up to 20 mm diameter.
Pump motors shall be of the submersible type. The depth of submergence shall be as
specified or as required for the application.
Pumps shall be suitable for continuous operation under the specified conditions and
shall be capable of handling the pumped medium without undue wear and tear. The
depth of submergence shall be as specified.
Pump motors shall have a built-in cooling system which shall permit continuous
operation at rated output both when submerged and not submerged.
Motor cable terminations shall be provided with a cable sleeve and strain relief.
Motor bearings shall be maintenance free.

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The pump and motor shall be separated by two mechanical face seals. The lower seal
shall rotate in the water medium and the upper seal shall rotate in an oil bath medium.
Means of detecting seal leakage shall be provided and the grade and type of oil shall
be subject to approval.
Pumps shall have a non-overloading performance characteristic and the efficiency shall
be high at the duty point and remain at a reasonably high level over the duty range of
the pumping system.
Pumps shall be statically and dynamically balanced and shall be designed so that the
first critical speed of the pump and its drive is not less than 50 percent greater than the
maximum operating speed.
Pump wear rings shall be easily replaceable.
2.2.1.6 Submersible Pumps
Submersible pumps shall be designed to pump satisfactorily solids of up to 100 mm
diameter and shall be non-clogging.
Unless otherwise specified, the pumps shall be designed to have stable head/discharge
characteristic so as to avoid large changes of discharge with small changes of head.
They shall be capable of operating with the sump surcharged to its maximum level.
Pump motors shall be rated to meet this condition.
Pumps bodies, covers, brackets, bearing housings, wearing plates, eye rings, support
brackets and similar items shall be manufactured from close-grained cast iron or nickel
iron.
Pump casing shall be of substantial construction to give long life under abrasive
conditions and to enable them to withstand shock loads caused by solids in suspension.
Impellers shall be of best quality close-grained cast iron or nickel iron.
Shafting shall be of high tensile steel of adequate size to avoid the possibility of fatigue
failure. The duty speed range shall be well below the first critical speed. At any change
in diameter of the shaft the shoulder shall be generously radiused to reduce stress
concentrations.
The rotating elements of pumps larger than 300 mm diameter inlet shall be dynamically
balanced before final assembly, smaller pumps shall be statically balanced.
Glands shall be fitted with mechanical seals or soft packing. Conventional packed
glands shall be provided with spring-loaded non-return grease feeds or water flushing.
A sufficient number of turns of packing shall be allowed above and below the lantern
ring to avoid wastage of grease or flushing water.
The shafts of pumps fitted with packed glands shall be made wear resistant where they
pass through the stuffing box by the application of “Stellite” or similar and approved.
Alternatively suitable stainless steel wearing sleeves shall be fitted.
The pump motor shall be a maximum of 1500rpm and of squirrel cage induction type,
with protection class IP 68 and be continuously rated, special attention should be paid
to the climatic condition.
The size of the motor shall be selected and de-rated as specified to ensure the pump
operation over the full range of the Q/H curve. The motor shall allow 6 starts per hour
and be protected from overheating by the use of PTC thermistors.
The motor shall be protected with a moisture resistant Class “F” insulation capable of
resisting temperature of up to 155°C. For monitoring moisture intrusion into the motor

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cavity, the pump shall be supplied with an additional and independent moisture sensor
in the motor cavity.
The pump/motor shaft shall rotate on at minimum two (2) grease lubricated and
adequately sized bearings with a B10 bearing life of at minimum 50,000 hours. Pumps
shall have temperature measuring of the thrust bearing by PT 100 sensors.
The pumps power and control cable entry design shall ensure that no entry of moisture
into the pumps terminal board and/or motor is possible even if the cable is damaged.
2.2.1.7 Submersible Sludge Pumps
Submersible motor sludge pumps as vertical, floodable, close-coupled unit for wet pit
installation.
Single-stage, with three-phase motor, protected against overheating with waterproof
electrical cable up to LV distribution panel. Capsulated mechanical seals in tandem
arrangement of hard metal with leakage detector wired to terminal strip. Casing to be
protected with wear rings/plates of stainless steel.
Materials:
Pump casing : cast iron
Impeller : cast iron
Shaft : stainless steel
Studs, screws + bolts : stainless steel
The pump characteristics curve and complete documentation shall to be submitted with
this Tender.
The pump shall be complete with duck-foot bend, coupling device and profile gasket
and guide of galvanized or stainless steel tube and lifting chain, ready for operation.
2.2.1.8 Positive Displacement Pumps
Positive displacement pumps, whether rotary or reciprocating, shall be provided with
relief valves to prevent generation of excessive pressures and, unless otherwise
specified, means to minimize pressure fluctuations.
Pressure relief valves may be an integral parts of the pump or fitted externally.
Positive displacement pumps which are belt driven shall incorporate, means to prevent
overstressing the belt drive by using a torque limiting clutch.
2.2.1.9 Progressive Cavity (rotating positive displacement) Pumps
Progressive cavity pumps shall be self-priming and of the horizontal helical rotor and
fixed stator type. They shall be driven by electric motors and mounted together with
their motors on a combined baseplate. Rotors shall be long enough to provide more
than 360 degrees of helical passage. Stators shall be of synthetic rubber moulded into
a rigid outer barrel. Dry running of the rotor shall be prevented in the event of suction
failure and the pump working on “snore”.
Suction and delivery connections shall be flanged.
Progressive cavity pumps for sludge shall be driven by their motors through vee-belts
or by flange mounted motors through speed reducing gearboxes. The rotor shall be of
the eccentric type and shall be connected to its drive shaft through a coupling rod fitted
with a universal joint at each end.

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The vee-belt drive and driven pulley shall be attached with keyed taper lock type
bushings. Vee-belt drives shall have full guards of the type that allow the belts to be
observed without removal of the guard.
The drive shaft shall be supported by two antifriction bearings, sealed from the pumped
fluid and shall pass through a single/double soft-packed gland.

2.2.2 Valves
2.2.2.1 General
All valves shall be suitable for use with water at the temperatures and pressures
specified or otherwise as required for the application. Generally, the pressure
designation shall not be less than PN 10.
Unless otherwise specified, valves shall have integral flanges . Flanges to other
standards shall be used only if approved by the Engineer and provided that any
differences do not affect mating dimensions. Back faces of flanges shall be machined.
All standard valves shall be suitable for frequent operation and for infrequent operation
after long periods in the open or closed condition.
Rubber used in valves shall be ethylene propylene rubber (EPDM or EPM) or styrene
butadiene rubber (SBR). It shall comply with the requirements of Appendix B of the
relevant standards, be suitable for making a long term flexible seal and be resistant to
mechanical, chemical or bacteriological attack leading to deterioration of the flexible
seal.
Where valve bodies or other parts are specified to be of cast iron, valves incorporating
bodies or other parts, of spheroidal graphite iron (ductile iron) may be supplied if
available, provided that they otherwise comply with the specification.
Unless otherwise specified or expressly approved by the Engineer, valve components
shall be of materials not inferior in strength or resistance to corrosion to those listed
below:
2.2.2.2 Gate Valves
Standard gate valves up to and including 1000 mm nominal diameter shall conform to
the requirements of relevant standard for copper alloy faced or resilient seated valves
with solid or split wedge, save that gate valves up to and including 600 mm nominal
diameter may alternatively conform to relevant standard.
Gate valves larger than 1 000 mm nominal diameter shall comply with the materials
and other relevant provisions. Gate valves up to 300 mm in diameter shall be of the
resilient seal type. Gate valves of 350 mm in diameter and over shall be of the gunmetal
faced seal type.
Valve spindles shall be of the internal non-rising type. The valve seal shall be
replaceable with the valve fully open and the main under pressure.
Resilient seated valves shall have straight-through bores.
Unless otherwise specified, gate valves in chambers and other similar locations shall
be provided with extension spindles with intermediate guides where necessary and
hand-wheel s. Valves which are to be buried in the ground shall be provided with
extension spindles, spindle caps, spindle supports, protection tubes and surface boxes
as required.

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2.2.2.3 Butterfly Valves

Butterfly valves shall comply with relevant standard, except as specified herein. Valves
shall be suitable for mounting in any position.
The Contractor shall provide details of the materials of manufacture and the design of
butterfly valves, including the access route to repair or replace seals. He shall provide
evidence to show that the proposed materials and designs for the sealing and seating
arrangements have given satisfactory performance in similar conditions elsewhere.
Flanges and hubs for shaft bearing housings shall be integrally cast with the valve body
except where otherwise specified. All bearings shall be of a type which is independent
of external lubrication.
Hollow discs, and any other castings with voids, shall be fitted with threaded plugs.
Discs shall be capable of maintaining their fully open and fully closed positions with the
gearbox removed. Limit stops shall be capable of absorbing full operating torque with
a minimum design safety factor of 5.
The shaft shall be fabricated in stainless steel if it is exposed to pipeline fluid. The shaft
and disc fixing shall be capable of absorbing the full operating torque with a minimum
design safety factor of 5. Shaft seals, when used, shall be of the resilient 0-ring type.
Packing shall be either of the resilient 0-ring or self-adjusting chevron type.
Resilient seated valves shall have tight shut-off.
The valve seal shall be resilient, durable, replaceable and formed of approved material.
The valve seal shall be securely clamped either into a machined groove in the valve
body or to the edge of the disc by seal retention members or other equivalent retention
device, in such a manner as to prevent leakage of water under the seal and to hold the
seal securely in position during opening and closing of the valve disc. The seal
retention members shall be of stainless steel and shall be securely fastened to the body
or disc with stainless steel fasteners.
The seal and its retention members shall be adjustable to ensure water tightness and
to minimise the seating and unseating friction forces. When all the seal retention
members are in place, the finished edges of the seal shall fit closely and the surface
shall be smooth with all fastenings set flush in the water passage so as to offer the least
resistance possible to the flow of water through the valve.
Valve seats which extend over the face of the flanges to secure the seat in place, or
which require surface grinding and/or hand fitting of the disc, or designs which require
the adjoining pipe flange to retain the seat in place and resist line pressure, are not
acceptable.
2.2.2.4 Air Valves
Air valves shall be provided for installation at high points or changes in gradient in
pipelines and elsewhere as shown on the Drawings, to fulfil the following functions:
(a) to exhaust air from a pipeline automatically when it is being filled with water, the
air being released at a sufficiently high rate to prevent back pressure restriction
of water inflow rate;
(b) to ventilate a pipeline automatically when it is being emptied of water, the air inflow
rate being sufficiently high to prevent the development of vacuum conditions in
the pipelines;

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(c) to release air accumulating in pipelines automatically during normal working

conditions.
Air valves shall be of one of the following types:
(i.) Double orifice type with a large orifice for automatic ventilation or exhaust of the
pipeline and a smaller orifice for automatic release of air under normal working
pressure.
(ii.) Single large orifice type for automatic ventilation or exhaust of pipeline.
(iii.) Single small orifice type for automatic release of air under normal working
pressure.
Large orifice air valves, including those incorporated in double air valves, shall be
constructed so that the air flow actively holds the valve open during the discharge of air
at all flows up to and including sonic velocities. They shall, when coupled to their
respective isolating valves, be capable of admitting to or exhausting from the pipeline
to which they are connected the required quantities of free air without the pressure
differential across the combined air valve and isolating valve exceeding 0.5 bar.
Small orifice air valves, including those incorporated in double air valves, shall be
capable of opening and discharging up to not less than 0.5 m3/min of free air when the
pressure in the pipeline is at the maximum working pressure for which the valve is
designed.
Balls or floats shall be of ABS plastic, vulcanite, rubber-covered metal or stainless steel,
and shall operate automatically at all pressures up to the test pressure when installed
in their valves. Orifices shall be bronze or stainless steel.
Air valves shall be designed so that each float seats against its orifice or causes the
orifice to be closed without leakage at all pressures between 0.2 bar g. and the specified
test pressure. Balls and seats shall be designed so as to minimise the risk of adhesion
of the ball to the seat. They shall be of a type proven by experience to be suitable for
the specified duties.
Each air valve shall be provided with an isolating valve. Air valves with a connection
not exceeding 25 mm diameter to the main pipeline shall each have an integral lever-
operated isolating ball valve. All other air valves shall have a separate resilient seated,
double flanged, butterfly valve with lever operation.
Each small orifice or double air valve shall be fitted with a test cock in the valve body
to permit easy verification that the small orifice air valve is operating properly and that
its orifice is not blocked.
2.2.2.5 Check Valves (no-return valves)
Check valves shall be designed for rapid closing without slamming no later than the
moment of cessation of forward flow. The valve size and design shall be selected to
give the optimum performance in this respect taking full account of the system within
which the valve is to be installed, especially when the system includes surge vessels
or when the system static head is high. If self-closing without slamming cannot be
achieved, then external mechanisms may be employed to control the rate of closure.
Details of these mechanisms shall be given by the Contractor in his tender and will be
subject to approval by the Engineer.
Unless otherwise specified check valves shall conform to relevant standards and shall
be double flanged, swing type, faced with copper alloy, nickel alloy or stainless steel.
Valves may be single or multi door type for applications free of stringy materials in the

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flow. They shall have high speed closing characteristics with minimum shock on
closing.
2.2.2.6 Control Valves - General
Control valves shall be designed for the operating conditions specified or shown on the
Drawings. The valves shall be of the type specified or detailed on the Drawings for the
particular application.
The valves shall be capable of controlling the required parameter of flow or pressure
within plus and minus 5 percent of the set value. The rate of response of opening and
closing of the main valves shall be controllable at the valve. Means for external
indication of the position of the valve element shall be fitted. Any hydraulic control
system shall include isolating valves to permit maintenance or replacement without
interrupting the supply.
2.2.2.7 Pressure Reducing Valves
Pressure reducing valves shall be designed to reduce a constant or variable inlet
pressure to a predetermined constant outlet pressure, at flows varying from the
maximum capacity of the valve to zero flow. The outlet pressure shall be adjustable.
A pressure gauge shall be provided to indicate downstream pressure over the operating
range of the valve.
2.2.2.8 Pressure Relief Valves
Pressure relief valves shall be designed to prevent the pressure in the pipeline
immediately upstream of the valve rising above present level. The valve shall remain
closed at lower pressure.
The pressure at which the valve opens shall be adjustable. A pressure gauge shall be
provided to indicate upstream pressure over the operating range of the valve, and shall
be equipped with a discharge pipe.
2.2.2.9 Ball Float Valves
Ball float valves shall be designed for installation on the inlet pipe to a storage tank,
and shall automatically shut off when the water reaches a predetermined level. They
shall be of the single beat type with balancing piston, resilient seating and direct float
and lever operation.
Ball float valves shall be suitable for long term operation in a part-open state.
2.2.2.10 Solenoid Operated Valves
Solenoid operated valves shall be of the direct acting type, full bore and balanced. They
shall not depend upon pressure differential for their operation.
Valve bodies shall be of cast iron or stainless steel as specified with screwed or flanged
ends. Sealing shall be effected by means of ‘0’ rings.
The operating solenoid shall have direct current coils and an integral rectifier for use
on a 230 V a.c. supply, unless otherwise specified. The coils shall be encapsulated in
epoxy resin.
Limit switches with voltage-free changeover contacts shall be provided for remote
signalling of the open and closed positions.
The enclosure shall have a minimum degree of protection IPW 67.
A manual mechanical override shall be fitted.

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2.2.2.11 Spindles and Caps

Operating and extension spindles for valves operated by tee key shall be capped.
Extension spindles shall be circular in section. For valves installed in chambers,
extension spindles shall be provided with split bearings rigidly held on brackets spaced
no more than 1500 mm apart. For buried valves the spindle shall be supported inside
a protecting tube held on a purpose-made support fixed to the top of the valve and
provided with a spindle guide.
Bearings and spindles shall be suitably protected against corrosion.
Extension spindle couplings shall be provided with split pins to prevent pull-out.
2.2.2.12 Manual Operating Mechanisms
Manual closing of valves shall be by the clockwise rotation of a tee key or hand-wheel.
Tee key operated valves shall be provided with detachable cast iron spindle caps to
take the key. One key shall be supplied for every five valves installed, with a minimum
requirement of two keys in any one size.
Hand-wheel s shall be shaped to give a safe grip without sharp projections, clearly
marked with the direction of closing and be fitted with integral locking devices. A
padlock and chain will not be an acceptable device.
All manually-operated valves shall be capable of being opened and closed by one
person only, when the specified maximum unbalanced pressure is applied to the valve
in use. Under this condition the total force required at the rim of the hand-wheel or at
the tee key to open the valve from the closed position shall not exceed 30 kg (15 kg
each hand; hand-wheel s diameter not less than 300 mm). Where necessary, gearing
and bearings shall be provided and the hand-wheel sized to fulfil this requirement.
Gearboxes shall be totally enclosed oil bath lubricated. Thrust bearings shall be
provided in such a way that the gear-case may be opened for inspection or be
dismantled without releasing the stem thrust or taking the valve or penstock out of
service. Oil and grease lubricated gearing, bearings and glands shall be protected
against the ingress of dust and moisture.
Operating mechanisms shall be of the weatherproof type and those parts subject to
submergence shall have a degree of protection IP 68 according to the relevant
standard, at a depth of submergence of 5 m. Where practicable, operating mechanisms
shall be fitted with mechanical position indicators clearly visible from the operating
position.
Headstocks of the non-rising spindle type shall each have an index pointer working
over a polished and engraved, graduated, open-to-closed position indicator fixed to the
side of the pillar. The indicator shall have a robust clear plastic protection plate
provided to exclude dust from the mechanism.
2.2.2.13 Electric Actuators
Electrically actuators shall operate valves at opening rates that will not impost
unacceptable surge pressures on the pipework. Electric actuators shall be rated at not
less than 20 percent in excess of the power required to operate the valve under
maximum working conditions.
Actuator enclosures shall have a minimum protection IPW 67
Actuator electric motors shall comply with relevant standards. For non-modulating type
actuators the motor short-time rating (STP) shall permit the successive full travel

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operation of the travel from open to closed and vice versa but shall be not less than 15
minutes. For modulating type actuators the motor shall have a duty-type rating (DTR)
to meet varying cyclic load requirements of the valve.
Electric motors shall be provided with built-in thermal protection complying with the
relevant standards.
Actuators shall be complete with:
(a) An alternative system for manual hand-wheel operation which shall be lockable.
(b) An interlock, to prevent engagement of the hand-wheel whilst the actuator is being
power driven and to positively disengage the manual drive when the power drive
is started.
(c) Reversing type motor starter complete with isolating switch.
(d) Local and remote control selector switch when specified which shall be lockable.
(e) 4-20 mA generator for remote valve position indication when remote control is
specified.
(f) Torque switches for mechanical disengagement of the drive at the extremes of
valve operation in the event of excess torque.
(g) Supply failure and remote control available monitoring relay(s). The supply failure
relay shall operate under single phasing and phase reversal conditions.
(h) Voltage-free changeover type contacts for the remote indicate of:
- Motor tripped on overload.
- Valve fully open.
- Valve fully closed.
- Supply failed.
- Remote control available.
The rating of voltage-free contacts shall be not less than 15 A at 240V a.c. and 2
A at 50V d.c. unless otherwise specified. The contacts shall be suitable for
inductive load switching.
(k) Anti-condensation heater.
Separate or segregated terminal boxes shall be provided for the connection
motor, heater and control cables.
2.2.2.14 Marking and Packing
Each valve shall be indelibly marked with the diameter and pressure rating and shall,
in addition, carry a unique reference number to enable each item to be clearly identified
with works fabrication records, works test certificates, delivery notes and the like.
Wherever possible, the identification marks shall be painted on the outside of the item
but where there is insufficient smooth surface area to accommodate the identification
marks they shall be put on rust-proofed metal tags secured to the item with galvanised
wire or chain (not through flange holes).
Valves shall be packed in the ‘closed’ position except that uncrated resilient seat gate
valves for transport to tropical areas shall be in the ‘open’ position.

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2.2.2.15 Handling
The Contractor shall supply equipment as necessary to handle and install valves and
associated equipment without damage to exterior or interior coatings. The equipment
shall include lifting beans, reinforced canvas slings, protective padding, cradles and the
like. Wire rope or chain slings shall not be used for handling these items.
Temporary packing, coverings or crates provided for protection in transit shall not be
removed (except for inspection purposes after which they shall be replaced) until
immediately before installation.
2.2.2.16 Installation
Valves shall be installed and commissioned in accordance with manufacturer’s
instructions. After installation, valves shall be cleaned, gates, discs, seats and other
moving parts closely inspected, foreign matter removed and the valves checked for
ease of operation. Moving parts shall be lightly greased or otherwise treated in
accordance with the manufacturer’s recommendations.
Except when otherwise specified or directed by the Engineer, butterfly valves shall be
enclosed in chambers and fixed with the disc spindle horizontal and supported as
detailed on the Drawings, and installed so that when the valve is opening the lower
portion of the disc moves in the direction of the main or normal flow. Except where
shown otherwise on the Drawings, gate valves shall be fixed with their spindles vertical.
Gate valves without external gearing, and not otherwise required to be in a chamber,
may be buried. The buried part of the valve shall be protected as specified. Except
where shown otherwise on the Drawings the valve shall be backfilled to just below the
top of the valve or spindle shroud, and a surface box shall be provided.
Jointing, sleeving, external wrapping, anchor and thrust blocks, valve chambers, valve
marker posts and the cleaning and disinfection of valves shall be executed as specified
for the associated pipeline.

2.2.3 Pipework
2.2.3.1 External Pipework
All pipework provided external to buildings shall comply with the requirements of the
Specification Part 4 - Civil Works.
2.2.3.2 Pipework within Structures - General
The term ‘pipework’ shall include pipe of any description and associated flanges,
adaptors, couplings, jointing material, fittings, fixings, supports, drain valves, traps and
the like, which are necessary to complete installation pipework systems associated with
Plant.
Pipework shall conform to the requirements of the relevant British Standards. All
recommended tests shall be carried out and certified in writing.
Adequate provisions shall be made to anchor, support, drain, vent, pressure test,
dismantle and clean all pipework. Valves, meters, strainers and the like shall be
supported independently of the pipes to which they connect.
Pipework systems shall be designed to withstand the maximum internal and external
forces which could occur in service and under hydraulic test pressure. The
configuration and method of support shall minimise bending stresses.

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Systems shall be sized so that the maximum design flow through the pipework will not
produce cavitation, erosion, excessive noise or vibration. Systems shall also be sized
where practicable so that the minimum operating flow of fluid will prevent deposition of
suspended solids. No forces developed within the pipework system shall be transferred
to the civil structure without the approval of the Engineer.
None of the forces and moments transmitted by the pipes to connected machines,
apparatus and other components must exceed the maximum permissible values given
by the manufacturer of these items.
Sockets welds will not be permitted for lines above DN 50, for corrosive media lines, or
for lubricating lines.
Special care shall be taken in the design of pipe hangers and supporting elements.
They shall be arranged, dimensioned and fastened in such manner that no vibration
and undue stresses appear during start-up, operation, or shut down and during field
tests. The reaction forces and moments of the piping system shall be borne by fixed
points. Loads on walls, foundations and other civil structures, are to be reduced to the
utmost minimum. The Contractor shall provide suitable thimbles and flashing where
pipelines pass through floors and walls. Floor thimbles shall be installed to provide 90
mm projection above the finished floor surface.
Plastic pipes, flexible pipes and hoses of less than 50 mm nominal bore shall be
supported throughout their length.
Pipework shall be colour coded after installation in general accordance with the system
presently adopted and to the approval of the Engineer. The normal direction of flow
shall be clearly marked on the pipe near each valve, junction, terminal and other
positions required by the Engineer. Where applicable, colour coding shall be added
after protective coatings, lagging and cladding have been applied.
The pipework shall be laid out and designed so as to facilitate the erection, painting in-
situ and dismantling of any section for maintenance, and to give a constant and uniform
flow of working fluid with a minimum of head loss. Where steel pipework is used, the
number of flanges shall be kept to a minimum and the size of each unit of pipework
determined by the ease of handling, installation and general appearance of the
completed pipe system. Positions of flanges shall take into account any necessary
concrete pipe supports or thrust blocks.
Flexible joints shall be provided where necessary to facilitate removal of Plant and/or
to allow for differential settlement of building structure. Wherever practical, flexible
joints shall be provided with tie bolts or other means to transfer longitudinal thrust along
the pipework as a whole.
All pipes and fittings over 150 mm diameter and within the confines of building
structures shall be in steel. In general, all pipes and fittings under 150 mm shall be
manufactured either in steel or in ABS plastics in accordance with relevant standards.
Where steel and cast flanges are mated together, the steel flange shall be machined
over its full face after welding to its respective pipe is completed. Wherever possible,
standard fittings shall be used in preference to fabricated or special fittings.
Facilities shall be provided for draining pipework systems and releasing air. The
drainage fluid shall be piped into the appropriate drainage system and the period of
time for drainage shall not exceed 30 minutes.
The pipework layout within water treatment work shall have the approval of the
Engineer.

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Valves, strainers and other devices mounted in the pipework shall be supported
independently of the pipes to which they connect.
Flanges shall conform to the relevant standard and shall be drilled in accordance with
the appropriate pressure rating.
Where a pipe passes through a wall, retaining wall or is subject to thrust, it shall
incorporate a puddle flange which shall conform to the dimensions stated in the relevant
standard but remain undrilled.
2.2.3.3 Steel Pipework
Pipes shall be specified by nominal diameters in accordance with relevant standard
Carbon steel pipes shall be in accordance with relevant standard.
Carbon steel fittings shall comply with relevant standard.
Welding shall be carried out in accordance with relevant standard. All welders shall
be tested by an independent inspection authority and shall satisfy the requirements of.
Welder test certificates shall be provided by the Contractor for examination by the
Engineer.
All fabrication and corrosion protection shall be carried out the manufacturer’s works.
Linings and coatings shall comply with this Specification.
2.2.3.4 uPVC Pipework (for in-door installations)
uPVC pipework for water service shall be the ‘hi-impact’ type class E with solvent
welded joints and fittings complying with the relevant parts.
Screwed connections to metal components shall be made with proprietary iron to uPVC
adaptor fittings.
Where flanged joints are required, full face uPVC flanges and galvanised mild steel
backing rings shall be used.
Where uPVC pipework systems connect to steel mains, the off-take points shall be
isolated by means of gate valves. Valves in uPVC pipework systems shall be as
specified under this Section or as specifically approved by the Engineer with regard to
function, location and operating conditions. Pipework shall be supported in accordance
with manufacturer’s recommendations and adequate provisions shall be made for
thermal expansion and contraction.

2.2.4 Electric Overhead Travelling Cranes

Cranes shall be designed in accordance with relevant standard and shall comply with
the requirements for Class 2 medium duty operation.
The term crane shall be deemed to include gantry rails, platform with hand rails for
maintenance purposes, access ladder, down shop conductors, end stops, holding
down bolts and all other items required for complete installation.
Operation shall be from ground floor level by bridge-mounted pendant push-button
controls. Controls shall be mechanically and electrically interlocked to prevent
inadvertent operation of opposing motions. The pendant control voltage shall not
exceed 50 V a.c. The pendant shall be supported independently of the electric cable
and shall be arranged for extending when necessary.

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The crane shall be fitted with limit switches to prevent excess travel, over-hoisting and
over-lowering of the crane hook. Electro-mechanical fail safe brakes shall be
incorporated on all power-operated motions. Crane hooks shall be fitted with safety
catches and the hook block shall incorporate fully guarded rope sheaves.
Down shop conductors shall be of the fully insulated shrouded busbar type. The current
collectors shall have renewable contact pieces. Festoon cables may be used for the
cross travel. A crane power supply isolating switch, padlockable in the off position and
incorporating a supply on indicator light, shall be provided at the bottom of the access
ladder. A second isolating switch shall be provided at the control cubicle located on
the crane platform.
All motors shall be of the quick reversing type. All movements shall be electrically
operated and shall function with the hook loaded. Facilities shall be provided for the
accurate location of the hook by means of “inching” the cross travel and down shop
travel motions.
Sufficient slings, ropes, shackles and lifting beams shall be supplied to handle all items
of plant served by the crane. They shall be labelled or marked with the Safe Working
Load and the purpose for which they are intended.
All necessary contactors, control cubicles and protection equipment necessary to
operate the crane and provide adequate electrical protection against overload, phase
and earth fault and fail safe protection in the event of an interruption in the power
supplies shall be provided.
All electrical equipment shall be fully tropicalised where necessary. Motors and
switchgear shall be provided with anti-condensation heaters which shall be energised
when the crane is at rest and suitable warning labels shall be fitted.
The Contractor shall supply the test load. The test load shall be removed from site by
the Contractor after successful tests have been carried out.

2.2.5 Compressed Air Plant

2.2.5.1 General
Compressed air plant shall include at least one duty and one standby compressor set
which shall be electrically driven by cage induction motors.
Air shall be filtered on the intake side of the compressors to remove dust in order to
protect the compressor from undue wear.
Oil lubricated compressors may be used provided that oil eliminating filters are installed
on the delivery side of the compressors. Where oil mist lubrication is recommended
for certain types of valve actuators then the lubricators shall be installed at each point
of use of the air.
Air shall be cooled by means of after-coolers. Air receivers shall be provided to balance
supply and demand or to provide a reserve to operate a prime mover. Air dryers shall
be provided.
Noise from compressed air plant shall be limited as set out in the Specification.
2.2.5.2 Air Intake
Air intakes shall be positioned in a manner which avoids collection of contaminants
such as engine exhaust fumes and excessive dust and always away from any extractor
fan discharge points.

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Air may be admitted to the room which houses the compressors either through an
external- wall or, where this is not possible, via an intake duct.
A louvered panel or panels shall be installed at the air inlet point together with primary
filters. The filters shall comprise removable panels with convoluted elements mounted
in frames. The elements shall be of the washable type and a spare set shall be provided
to facilitate substitution for this purpose.
Intake ducting shall be in galvanised steel and of adequate proportions to minimise
pressure drop and vibration. Where necessary to suppress low frequency noise, a
silencer of the multiple aerofoil or ‘beam splitter’ type shall be installed within the duct
close to the inlet point.
Where air is drawn by the compressors directly from the room, appropriate provision
shall be made to protect equipment and pipework from low ambient temperatures.
Where air is drawn from outside the building, then heat from the machines must be
dissipated effectively at times of high ambient temperatures. The room shall be
properly ventilated.
2.2.5.3 Reciprocating Compressors
The compressors shall be of the reciprocating oil-lubricated type.
Each compressor shall be rated for continuous operation at twice the maximum air
demand or to recharge the receiver from empty in one hour whichever is greater. They
shall be suitable for intermittent operation and shall maintain the associated air receiver
pressure between pre-set limits irrespective of actual air demand up to the maximum
demand.
Cylinder heads shall be readily removable for inspection.
Each compressor shall be driven via a Vee belt drive arrangement by a cage induction
motor which shall be rated to allow the compressor to operate at the safety valve setting
without overloading. The compressor and motor shall be mounted on a combination
baseplate with slide rails for belt tension adjustment. A sheet steel guard shall be bolted
to the baseplate.
Where necessary, each compressor shall have an automatic solenoid operated
unloading system to facilitate starting. This system shall be initiated by auxiliary
contacts on the compressor motor starter and shall be subject to an adjustable time
delay.
Oil-lubricated machines shall have an automatic oil lubricator fitted with indication of oil
level and feed rate. The delivery side of each machine shall have an oil-eliminating
filter with provision for draining into a portable container.
Each compressor shall have an inlet air filter and silencer, a pressure safety valve,
fusible plug, check valve and isolating valve.
Compressors shall be tested in accordance with relevant standard Part 2.
Safety valves shall comply with all relevant standards. The installation of safety valves,
gauges and fusible plugs shall comply also with relevant standard.
2.2.5.4 After-Coolers
The compressed air plant shall incorporate after-cooling.
Unless otherwise specified, a single after-cooler with isolating and bypass arrangement
shall be provided for applications. After-coolers shall either be of the air-cooled type
with finned-tubes and electrically driven cooling fan or the water-cooled shell and tube

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heat exchanger type. Materials in contact with cooling water shall be resistant to
corrosion. All heat exchange surfaces shall be accessible for cleaning.
Generally, the air outlet temperature shall approach the cooling medium temperature
to within 10 C at maximum air throughput or as otherwise specified.
2.2.5.5 Air Receivers
Air receivers shall be installed wherever it is necessary to balance a variable rate of air
consumption with a fixed rate of supply. The capacity shall be sufficient to limit the
number of compressor starts to no more than 10 per hour.
Air receivers shall be of welded steel construction with a corrosion allowance of 2 mm
and may be either vertically or horizontally mounted according to capacity. The vessels
shall have suitable supporting feet or cradles as appropriate. The fittings shall include
a pressure gauge, pressure safety valve, automatic drain valve with isolating valve and
separate manual drain valve. The drain connections shall discharge to an approved
point.
Pressure switches with voltage-free contacts shall be installed on the receiver to control
the associated compressors and to initiate a low pressure alarm. The control relays
shall normally be mounted in the same panel as the compressor motor starters. Both
the cut-in and cut-out pressure settings of the standby machine(s) shall be set lower
than the corresponding settings of the duty machine(s).
2.2.5.6 Air Pipework
Pipework up to and including 50 mm ND shall be in steel with heavy fittings in malleable
iron . Threaded joints shall be made with a temperature resistant jointing compound.
PTFE tape shall not be used.
Pipework over 50 mm ND shall be in steel to with flanged joints drilled to PN 10 or
higher rating where applicable.
All steel pipework shall be hot dip galvanised. No other internal coating is required.
Instrument air pipework and fittings from the offtake point on the air supply main
onwards shall comply with Part 6 of the Specification.
Pipework shall be arranged to minimise the transmission of vibration and where
necessary, connections shall be made with anti-vibration couplings.
Particular care shall be taken at points where condensation is likely to form or to
accumulate such as following compression or cooling of ambient air or discharge of
reactivation air from dryers. Appropriate traps and automatic drain valves discharging
to approved points shall be installed.
Thermal insulation and cladding where fitted shall be arranged in a manner which
provides access to valves and other components for maintenance purposes.
2.2.5.7 Air Isolating Valves
Air isolating valves shall be generally of the cast iron gate type or butterfly type
Air isolating valves up to 50 mm ND may alternatively be in copper alloy where
compatible with the required temperature and pressure rating.
All isolating valves shall be tested in accordance with relevant standard

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2.3 TESTING OF PUMPS, VALVES, PIPEWORK, CRANES AND GENERAL PURPOSE

MACHINERY
2.3.1 Tests at Manufacturers' Works
Details of the general requirements for inspection and testing are set out elsewhere in
the Specification (ER). Tests to be carried out during manufacture on particular items
of mechanical plant shall include the following:
(a) Pumps
Each pump shall be tested individually. Site conditions shall be simulated as near as
possible, including the minimum, site NPSH condition and suction pipework
configuration.
Each pump shall be tested with its own motor. It shall be tested at the guaranteed duty
point and over its full working range from its closed valve condition to 30% in excess of
the quantity of the minimum head duty point. Head/quantity curves, power/quantity and
overall efficiency/quantity curves shall be plotted to demonstrate that the plant will be
capable of meeting the full range of operating conditions at Site. Efficiency of both pump
and pumpset as a whole shall be established on test.
Pump casings shall be subject to a pressure test at least 1.5 times the maximum
pressure obtained with the delivery valve closed. The positive suction head shall be
taken into account in determining this pressure.
Pumps shall be dismantled after test and a witnessed inspection carried out to confirm
the satisfactory condition of all parts prior to dispatch to Site.
(b) Pumpsets
The results of the above tests on pumps and motors will be used by the Engineer to
determine whether each pumpset has achieved the performance guaranteed by the
Contractor. If a pumpset fails to achieve the guaranteed performance, the Contractor
shall carry out such further work as he considers necessary and shall arranged for the
tests to be repeated. This procedure shall be continued until the Engineer is satisfied
that the pumpset performs as guaranteed, or the plant is rejected.
(c) Valves
All valve bodies shall be hydraulically tested closed ended to 1.5 times the rated
pressure. All isolating valve seats shall be tested to the maximum working pressure,
at which pressure they shall be drop tight. Each valve shall be tested for functional
operation with its own actuator.
(d) Castings
Castings subject to hydraulic pressure shall be pressure tested to at least 1.5 times the
maximum working pressure.
(e) Pipework
The inspections and witness testing of all pipework shall be carried out in accordance
with the appropriate manufacturing standard approved by the Engineer. This shall
include dimensional inspection, welding NDT examinations and corrosion examination.
(f) Cranes
The cranes shall be completely assembled and tested in the manufacturer’s works. A
full functional test of all crane motions shall be demonstrated with the crane carrying
the maximum safe working load. All mechanical and electrical equipment shall be

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shown to operate smoothly within rated capacity. A deflection test in accordance with
the relevant standard shall be carried out.

2.3.2 Tests at Site

Details of the general arrangements for inspection and testing on Site are set out
elsewhere in the Specification. The following pre-commissioning tests shall be carried
out on plant prior to setting to work.
(a) Pumpsets
Each pumpset shall be checked for alignment between pump and motor. The
alignment shall be the best that can be achieved by good working practice and within
the limits required by the coupling design. An alignment certificate shall be issued and
incorporated in the 0&M manuals.
Tests to demonstrate that each pumpset is reliable in operation and is able to cover the
whole working range. Each pump shall be tested at the minimum, guaranteed and
maximum duty points. The values obtained will be compared with the values obtained
during the tests on the manufacturer’s premises and any discrepancies shall be
rectified by the Contractor.
Temporary facilities, including flow measurement, instrumentation and throttling valves
shall be provided at the pumping installation for recycling the test flow from any single
pump back to the suction conduit or manifold. This may be through permanent pumping
station by-pass pipework, if provided.
(b) Valves
All valves on completion of erection shall be fully functionally tested in association with
their actuators and controls. Each installation shall be checked for water tightness and
the valves for leakage. Valves shall be subject to the system test pressure and shall be
demonstrated to function satisfactorily under maximum site differential head conditions.
Where appropriate, valves shall be internally inspected after functional tests to verify
seals remain in a satisfactory condition.
(c) Ancillary equipment
Demonstration of satisfactory operation of the plant and associated control equipment.
(d) Station pipework
At the first opportunity following completion of installation, all station pipework shall be
water tested for leakage at appropriate test pressures. In the case of delivery pipework,
and such other pipework on the suction side as may be vulnerable to full delivery
pressure, the test pressure shall be the same as the Site test pressure for the
associated delivery pipeline(s).
Where bursting disks are installed, one disk shall be tested to demonstrate satisfactory
operation.
(e) Cranes
Cranes shall be tested after erection, the test load being provided by the Contractor.
In addition, a vertical deflection test shall be carried out with the “safe working load”
suspended from the hook with the crab in the centre of the span. Workshop functional
tes

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A further condition assessment and functional check shall be carried out prior to taking
over. Any deterioration resulting from the Contractor’s use of the crane during plant
erection, shall be rectified by the Contractor.

2.4 DETAILED MECHANICAL REQUIREMENTS

2.4.1 Scope of Works
The Contract shall include the design, manufacture, testing at manufacturers’ works,
delivery to site, off-loading, storage, erection, testing and setting to work a complete
mechanical plant installation for the Katosi Water Treatment Plant. The installation shall
include the works, which are described in detail, in the Employer’s Requirements.
2.4.2 Plant Design
The standard of equipment provided shall be at least equivalent to that currently in-
stalled on existing City of Kampala systems, and shall be of a quality and standard
commensurate with international water industry practice.
Detailed requirements for the mechanical equipment required for the conceptual design
are given hereunder.
2.4.2.1 Intake Structure and Raw Water Pumping Station
Supply, installation, testing, commissioning and operation of all mechanical pre-
treatment devices (e.g. screens, strainers, etc.), pumps, pipework, including raw water
off-shore pipeline ND 1500 and the new Katosi intake structure, pump room crane,
fitting into civil and structural elements.
2.4.2.2 Fine Screens
Fine screens for automatic removal of fine pollutants with simultaneous removal of
coarse debris. The fine screens mainly consists of:
Endless filter band made of mesh panels of stainless steel with mesh size of about
4 mm, the mesh panels interchangeable to larger or smaller mesh size by dismantling
the panels. On the descent movement the panels are open to allow free water passage.
The endless filter band is revolving over two upper driving sprockets and two lower
guiding sprockets and driven by two side-bar chains.
The cleaning of the mash panels shall be done by a rotating brush and with spray water.
The revolving speed of the filter band should be variable.
Overload Protection
All equipment made of stainless steel as far as possible and for long service life.
2.4.2.3 Belt Conveyor
Belt conveyor shall be supplied for the transmission of the screening from the screens
to a container.
2.4.2.4 Sluice Gates before and behind the Screens and the By-pass
Frame, gate and guide rails made of cast iron with lamellar graphite GG 20 gate sealing
face of alloy Cu AG 8 stem of stainless steel X20Cr 13. Varnishing coating on coal far
pitch basis. Headstock with hand-wheel.

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2.4.2.5 By-pass Chamber

The by-pass chamber shall be equipped with a manual screen made of stainless steel
tackle complete with lifting gear block and to pull out for cleaning.
2.4.2.6 Raw Water Pumps
Tubular casing pump with axial propeller.
Inlet with suction nozzle.
Discharge branch above floor level.
Shaft bearings made of wear-resistant ceramic material.
Lubrication by the medium handled.
Vertical motor with hollow shaft is saddled to the drive and coupled with a torsion ally
flexible clutch.
Maximum length of each length of column pipe approx. 2 m.
Column pipe connections are flanged shaft connections with rigid disc coupling.
Electric motor with PT 100 protection and anti-condensation heating.
Material of construction:
 Column pipe CrNi steel
 Bellmouth CrNi steel
 Discharge elbow CrNi steel
 Diffuser CrNi steel
 Impeller CrNi steel
 Motor stool Carbon steel
 Intermedia lantern Carbon steel
 Base plate Carbon steel
 Pumpshaft Duplex SS
 Disc coupling Duplex SS
Surface protection by epoxy coated with Amerlock paint or equal permitted for potable
water.
Instrumentation:
Oilfilled pressure gauge
mechanical flow sensor
pressure switch max/min setting
Low voltage motor JP 55 with temperature sensor and standby heater
The pump offered shall be capable of operating between the specified range of heads
without undue cavitations or vibration in single and parallel operation.
Numbers, Capacity, efficiency in accordance with the Employer’s requirements.
2.4.2.7 Piping and Fitting
The discharge starts with the connection to the pump outlet and ends with the header
and shall consist of the following components.

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Rubber compensator to be used as noise and vibration damper for the absorption of
stresses, vibrations and small lateral and angular movements.
Connection of the pump outlet without any tension and stress
Concentric taper enlarge the pump outlet to approx. DN 500
Non-return valve with adjustable weight or similar for cushioned closing
Dismantling piece
Double offset butterfly valve flanged with gear and hand operation
Air valve with single chamber and ball valve
Header DN 800 about 4 m long with connection of the 3 discharge pipes and with flange
ending outside of the building.
Complete with all fixing material and supports.
2.4.2.8 Surge Protection (if necessary)
The contractor has to prove the necessary protection arrangement by calculating all
possible operation situations. The calculation shall be submitted to the Engineer
together with the proposed protection system.
The volume and maximum working pressure shall be proved by the contractor based
on the surge analysis.
2.4.2.9 Crane
A gantry crane with lifting capacity 1.5 times the max load, which will be required to lift
the heaviest part, shall be installed in the pumping station including all necessary
equipment to operate the crane ready for operation.
Side rail with supporting beam
Bridge out of double TEE-profile or welded on wheels manually movable.
Trolley shall be manually movable
Hoisting shall be done by electrically operated chain block.
2.4.2.10 Ventilation System
The Vent System shall assure a sufficient air exchange at all points of the pump floor.
The air exchange shall normally automatically controlled. In case of service and
maintenance the air exchange rate shall be triple.
The air shall be extracted by exhaust fans mounted on the sidewalls with canal down
to the floor of the pumping station.
Number of fan: two.
Drain Pumps (mobile)
Motor:
 Flow Q 10 l/s
 Head total 8 mWS
 Supply 3 x 415 V, 50 Hz
 Speed 2800 RPM
 Protection class IP68

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Drain pumps shall include floater and 15 m cable including 15 m hose with coupling.
2.4.2.11 Inductive Measuring Device
A measuring chamber for the installation of a magnetic inductive measuring device
including flanged butterfly valves and pipework for bypass purposes shall be provided
at the raw water pumping main prior to entering the coagulation chamber.

2.4.3 “Water Treatment Units”

2.4.3.1 Coagulation Chamber
One a single concrete tank shall be built, as starting point of Phase 1a treatment line,
with sufficient effective process water depth (3.30 m in Admin’s Proposal). The
coagulation chamber shall be designed to accept the pumped raw water from the raw
water pumping station. The coagulation chamber shall be provided with frequency
controlled, 3 blade propeller mixers, providing appropriate turbulence
Mixers
Rapid mixers with variable speed
4 stirrers with variable speed. Technical description of the stirrers:
 Shaft length S= 4.70 m;
 Stirrer diameter D= 1.5 m;
 Power P= 10 ÷ 28 kW.
2.4.3.2 Flocculation Chamber
Four (4) new flocculation chambers shall be constructed in front of the new clarifiers.
The water from the coagulation chamber shall be conveyed to the flocculation
chambers via pipes or channels and distributed evenly by adjustable overflow weirs.
Mixers
The flocculation chambers comprise 4 mixers with variable speed. Technical
description of the stirrers:
 Shaft length S= 4.70 m;
 Stirrer diameter D= 1.0 m;
 Power P= 0.9 ÷ 2.0 kW.
2.4.3.3 Clarifiers
Lamella Clarifiers or Tube Settlers
The settling zone shall be sized for a rising velocity not exceeding 5 m/h, calculated on
the net horizontal section of the area provided with lamella packing. The retention time
shall not be less than 30 minutes. The lamella or tube packing and its supports shall be
made of totally corrosion resistant materials. The lamella or tube packing shall be
characterised by a hydraulic diameter not exceeding 50 mm, a channel length not less
than 750 mm and a slope of 60° on the horizontal. The invert shall either be
continuously scraped type, drawing the sludge to suitable desludging pockets or sludge
cones with pumped sludge removal.
The Contractor will allow for the top of the clarifiers to be covered with the awning,
which is dismountable. The awning shall be manufactured in accordance with the size
of covered area and each parts of awning shall be considered separately module part.

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The stainless steel or aluminium fixing elements shall be fixed to tanks in order to fasten
each part of awning. The stainless steel or aluminium fixing elements shall be on the
each part of awning in order to fasten them to the tanks. A solid roof covering material
other than any steel or galvanised iron sheets may be used. Lighting shall be provided
below the roof for access during night.
Internal equipment of clarifiers
All internal equipment of the clarifiers, including pipes, supports, scrapers, etc., shall
be adequately protected against corrosion. All parts of the clarifiers shall be provided
with drain valves allowing complete drainage within 4 hours or less.
2.4.3.4 Filtration Plant
The Contractor shall provide all labour, materials and incidentals to complete the
construction and testing of filters to the requirements specified hereinafter.
The mechanical equipment of the filters shall be designed for:
Isolation of each filter unit for maintenance and repair purpose without disturbance of
any other filter.
Water distribution shall be designed so as to ensure equal distribution of flow to all
filters in operation.
Automatic operation of filtration using constant flow or constant level.
Automatic backwash system.
The filtration plant is explain as follows:
Filter Underdrain System
General
The filter uses a false bottom under drain design. The system for the collection of filtrate
and the distribution of wash water and air score shall be by means of nozzles set in
perforated blocks (pre-cast reinforced concrete panels).
Under drain systems using porous or fabric covered perforated pipe systems shall not
be accepted.
The underdrain systems shall be designed to provide uniform draw-off of filtered water
and uniform distribution of backwash water and air scour over the whole area of the
filter. Back-washing, water/air, flow uniformity shall not exceed ±5 percent at any point
of filter media area.
All components of the under drain system and materials used for installation and
assembly shall be non-corroding, and non-toxic and shall be certified safe for use in
potable water service by an internationally recognized public authority.
The use of asbestos cement in any part of the under drain system is not allowed.
Manufacturer’s Qualifications
The Contractor shall provide all labour, materials and incidentals to complete the
construction and testing of filters to the requirements specified hereinafter.
The products for the under drain system and all required appurtenances shall be
sourced from well-established, reputable firms with previous experience in design,
manufacturing and installation of equipment that is supplied.
Nozzles

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General
The Contractor is required to construct the necessary perforated blocks containing the
nozzles and water/air conveyance systems. The nozzles are set in perforated blocks
with minimum thickness of 100mm. The panels are lowered into place and anchored to
a supporting structure above the water/air plenum. Both sides of the pre-cast panels
are coated with non-toxic hydro epoxy paint.
The completed nozzle assembly shall consist of the following major parts: the slotted
nozzle head, the plunger pipe attached to the nozzle head and the nozzle insert that is
embedded in the pre-cast concrete floor panels. The plunger pipes shall be mounted
to the insert at field from above after the perforated blocks have been installed. The
system for attaching the nozzles must allow for easy removal of the nozzle heads and
plunger pipes for maintenance. When installed, the bottom of the nozzle head shall be
essentially flush with the top of the false bottom slab.
Nozzle Head and Plunger Pipe
The body of the nozzle head shall have cylindrical walls with a solid top cover. The
cylindrical walls shall be slotted. Slot width on the media side shall be compatible for
use with single media sand filters and not greater than 50% of the effective (10%) size
for the filter sand specified. The width of the slots on the media side shall not deviate
by more than plus or minus 0.05mm. The slots shall be designed so that the width gets
progressively larger from the media side towards the interior of the nozzle head. The
length of each slot and the total area of slots per nozzle head shall be determined by
the Contractor in order to achieve the specified under drain opening ratio.
The internal diameter of the nozzle head, measured to the furthest inside protruding
material, shall not be less than the inside diameter of the plunger pipe.
The nozzle head and plunger pipe shall be designed to permit field installation and
removal from the embedded nozzle insert. The plunger pipe assembly shall be such
that flow from the filter side of the false bottom floor to the plenum, or vice versa, shall
only occur through the nozzle slots with no leakage through any other portion of the
assembly.
Nozzle Insert
The embedded nozzle insert shall have a cylindrical body and shall match the thickness
of perforated blocks. The nozzle insert shall nave a centre anchor ring or other suitable
device to ensure firm anchorage in the concrete. The embedded nozzle insert shall be
designed to permit filed mounting and easy removal of the nozzle head and plunger
pipe unit after the perforated blocks have been placed and secured into position at the
bottom of the filter. The plunger pipe shall be screwed to the insert. A locknut system
must be provided to ensure that the plunger pipe is tight against the nozzle insert and
will not work itself loose by repeated backwash cycles.
Each nozzle insert shall be furnished with a plug or cap to prevent concrete from
entering the inside of the sleeve during pre-cast concreting. The nozzle insert shall also
be equipped with a fastening system that will permit accurate alignment and spacing
and will hold the nozzle insert firmly in place while placing the concrete.
Materials and Manufacturing Process of nozzles insert
General
The nozzle insert shall be made from a thermosetting plastic material. Bolts, screw or
any other metal parts that may be required shall be made of type 304 stainless steel.
The assembled parts shall be able to sustain the pressure differential forces across the
filter false bottom floor. All parts in contact with the filter media shall be abrasion proof.

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Nozzle Head and Embedded Nozzle Insert

The nozzle head and embedded nozzle insert shall be made of ABS (acrylonitrile-
butadiene-styrene) or approved equal material. The nozzle head and the nozzle insert
shall be injection molded for precision.
Plunger Pipe (Sleeves for Concrete Floor)
The plunger pipe shall be rigid PVC (polyvinyl chloride), PP (polypropylene) or PE
(polyethylene).
The plunger pipe shall be attached to the nozzle according to the manufacturer’s
instructions.
Gaskets
Gasket ring, for sealing the nozzle against the insert or concrete surface shall be
neoprene or approved equal, suitably insert and satisfactory for use in a potable water
filter.
Vertical Adjustment and Locking Nut
Adjusting the vertical position of the nozzle head with respect to the filter floor slab shall
be by use of threaded connection with locking out to lift and lock the nozzle into place.
The locking nut shall be of the same materials as the nozzle head.
Perforated Blocks
The Contractor shall fabricate the perforated blocks made of reinforced pre-cast
concrete on-site using specially designed steel forms. The Contractor shall submit shop
drawings for the formwork for approval prior to starting work. Concrete and reinforcing
steel will be as specified on the drawings.
Under Drain Filter Installation
The Contractor shall install the filter underdrain systems in strict conformity with the
supplier's installation drawings and recommendations, and as specified herein. The
Contractor shall provide a manufacturer's representative to inspect and supervise the
installation and testing of the underdrain system, and shall obtain from the underdrain
supplier such installation details and recommendations as are necessary to acceptably
interface the filter underdrain system with all surrounding structures.
The Contractor shall take all necessary precautions recommended by the underdrain
supplier and as specified herein to ensure that the underdrain system and piping
connected thereto is completely clean and free of any debris, dirt, or other foreign
materials, which would clog the underdrain system or interfere with flow.
Backwash piping shall be thoroughly flushed clean.
Air piping shall be flushed with air only. All loose debris and dirt within the filter and
flume shall be removed by brooming down and vacuuming. Care shall be taken as
necessary to prevent grout from extruding into any flow passages or ports, and any
such grout shall be removed. As installation progresses, underdrain sections partially
completed shall be protected with heavy building paper, vinyl sheeting or other
acceptable means to maintain cleanliness. Cleanliness shall be maintained until final
placement of filter media.
Field Inspection and Testing
Before placing the filter media within the filter bed, the underdrain installation shall be
inspected by the Engineer's representative to ensure compliance with these
specifications and approved installation procedures.
After inspection, the underdrain system shall be tested for the maximum anticipated
flow rates for each of the three backwashing methods to ensure that the installation

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functions properly.
2.4.3.5 Filter Backwashing System
General
Each filter shall be designed to have separate water and air flow and stop devices such
as valves and gates in order to operate filters individually and to isolate completely each
filter from other filters.
The separate water and air flow and stop devices which will be required to operate in
sequence with link up washing mode shall be equipped with automatic operators or an
automatic operation system.
The automatic operators for valves and gates shall be motorized operators. Any other
type of automatic operators such as oil or water hydraulic power or pneumatic power
cylinder or diaphragm type operators shall not be used.
All valves and gates shall also have manual operators.
Typical arrangement of the separate water and air flow and stop devices for each filter
unit shall be as follows.
a. Filter inlet (sluice gate)
b. Filter water outlet
c. Filter air wash
d. Filter backwash
f. Filter drain (minimum 75 mm in diameter)
g. Main backwash regulation valve
Butterfly valves flanged type shall be used with motorized limit and torque switches,
capable of restraining of working pressure at 10 bars with Actuator mounted direct on
valve shaft, with Integral motor type. The actuated valve opening time (close to open)
will be 60 s at full open- or closed position. The valves will be for water with separate
control unit with remote control.
The filter valves or penstocks will be sized according to the following maximum
velocities, when applicable:
 unfiltered water inlet 0.5 m/sec
 filtered water outlet 1.0 m/sec
 wash water inlet 3.0 m/sec
 washout 2.6 m/sec
 air scour 35.0 m/s
Backwashing System
Backwashing of filters shall be done by water and air. Backwash water shall be supplied
by backwash pumps and compressed air by rotary piston air blowers.
The backwash sequence shall be according to the Contractors design and shall be in
principal as shown at the following table.
The following backwash pump units shell be installed and accessories shall conform to
all provisions specified below
Backwash Water Pumps
No. of units: 2+1 for Phase 1a and 1b and 2+1 for Phase 2

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Type: Horizontal Split Casing Pump

Capacity: 1595 m3/h
Delivery head 11.8 m WC
Efficiency: Above 85%
Power demand at shaft 70 kW
Pump Material:
housing : Casing – cast iron
Motor housing: Cast Iron
Impeller: CrNi steel
Shaft: Duplex SS
type of coupling: Direct
Impeller type: 1.4517
Motor for Backwash Water Pumps
No. of units No. 2+1 for Phase 1a and 1b and 2+1 for Phase 2
Type: Horizontally TEFC for 40° ambient temperature
Voltage 400 Volts
Nominal power 90 kW
motor speed 1500 Rpm
safety class IP: 55
Starting method: D/SD/FI Soft starting and stopping by FI
Back Wash Air Blowers
General
The Scope of works comprises delivery and installation ready for operation, testing and
commissioning of air scouring blowers. Blowers shall be positive displacement, rootes-
type rotary piston blowers producing oil-free air, directly coupled with the motor, except
the following items, and in additional shall conform to the following requirements.
The blower with its driving motor shall be factory mounted on a common rigid structural
steel base.
The technical data sheets an all manufacturer documents have to be submitted to the
engineer for approval prior to purchasing.
Backwash Air Scouring Blowers
Number of units : Two (2) units, One (1) duty and one (1) standby
Rated capacity : 4785 m3/h
Rated discharge pressure: At least 400 mbar (as required)
Blower speed : Not exceeding 1000 rpm
Motor type : Squirrel cage induction motor
Motor output At least 115% of the required shaft power at rated
operation point
Power transmission V-belt drive, self spanning V-belts, hinging motor
Power supply : 400 V, 3-phase, 50 Hz

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Others Motor with PTC Protection, Soft starter, integrated start up release valve for start
up without load
Construction and Materials of Blower
The casing and head plates shall be constructed of cast iron with the inlet flange on the
top or the side and the outlet flange on the side.
The impellers shall be ductile iron or high tensile cast iron of the straight lobe involute
type and shall operate without rubbing, or liquid seals, or lubrication, and shall be
positively timed by a pair of accurate machined, heat treated chromium molybdenum
steel timing gears.
The shafts shall be of heat-treated hardened wear resistant alloyed carbon steel. Each
impeller shaft assembly shall be supported on double row spherical roller bearings. Each
bearing shall be provided with a positive oil seal to prevent oil leakage into the blower
casing. The oil bath lubrication system for the bearings and timing gears shall be the
built-in type..
Each blower and its driving motor shall be capable of operating on a continuous or
intermittent cycle. Each system shall be capable of at least ten (10) starts and ten (10)
shut downs in any 60 minutes period.
Blower design requirements:
 Blower shall be special designed for easy maintenance and space saving design
 Blower shall be “oil free” type, produced air stream shall not contain any oil.
 Blower stage shall have pulsation reduction
 Blower shall have automatic belt tension device, due to hinged motor mounting
plate
 V-belt power transmission to the blower is desired.
 All service tasks and component that require maintenance shall be accessible
from the front of the unit
 The oil level shall be possible viewed and checked from the outside during the
blower is fully in operation.
 The blower unit shall encapsulated by the noise reduction hood, reducing the
operating noise level of each blower to maximum 70dB and for prevention of any
endangerment of operating staff, by rotating or hot parts.
 Mechanical fan mounted on the blower drive shaft, shall be used to ventilate the
acoustic hood, without the need for an electric fan and additional electrical
installation.
The Blowers shall be delivered with a service pack, which includes lifting jack, oil funnel
and an initial filled of oil.
Absorption Material for noise reduction shall be eliminated. Absorption material which
is subject to possible clogging, shall not be used in any part of the blower unit.
Intake Filter Silencers and Discharge Silencers
Each blower shall be provided with a combination filter and chamber type inlet and
discharge air filter silencer designed for indoor installation.. The filter element shall be of
the reusable metallic or other suitable material type that can be cleaned. Oiled filters are
not permitted. The Intake filter silencer shall be part of the package unit “air blower”
Pressure Relief Valves

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A pressure relief valves shall be provided with each blower. The valves shall be the
weight-loaded type, constructed of cast iron with flanged connection. The relief system
shall have a capacity of not less than that of the blower when operating. The valves shall
be the standard product of the same manufacturer of the blower.
Rubber Expansion Joints
Expansion joints shall be provided and installed in the air inlet and discharge pipes to
each blower as shown on the Drawings. The joints shall be fanged molded rubber,
designed for installation between pipe flanges. The joints shall be suitable for discharge
air temperatures of up to 110 degrees C and gauge pressures up to 1 kg/cm2. Each joint
shall be equipped with steel retaining rings. Joints on the discharge line from each blower
shall be equipped with control unit to limit expansion of the joint due to pressure. Each
joint shall have two control units. Each control unit shall consist of two steel plates, one
bolt and nut and two rubber and two steel washers. Each plate shall have two holes to fit
over two holes in the steel flanges on the pipe at each end of the expansion joint. The
plates shall extend beyond the outside diameter of the flanges and be provided with a
hole for the tension bolt to be installed through the two plates.
Blower Motor
Motor shall be the squirrel cage induction type with totally enclosed fan-cooled enclosure.
Blowers shall have power saving drive motors class EFF1 made.
Blower Installation
The Contractor shall install all blowers specified herein. All handling and placing of the
blowers including levelling and alignment shall be done by the Contractor. A supervisor,
from the blower manufacturer, shall do final checking of levelling and alignment of each
blower.
2.4.3.6 Chlorine Contact and Treated Water Tank
After filtration and dosing with chlorine the treated water will enter the chlorine contact
tank. For final disinfection chlorination shall be possible after filtration and with a contact
time of not less than 30 minutes at the maximum flow. Therefore the volume shall be
approximately 3,850 m³ (Phase 1a and 1b flow).
The free available chlorine concentration after the contact tank shall be not less than
0.5 mg Cl2/l.
2.4.3.7 Chemical Preparation
General
Scope of Work
The Contractor shall furnish and install equipment and materials for the PAC, Lime and
Polymer (flocculent) Dosing feed system with all necessary piping and appurtenances
as specified herein.
The work specified herein includes, but is not limited to furnishing, installing, testing,
placing in satisfactory operation, start-up services and maintenance services for the
PAC, Lime and Polymer (flocculent) Dosing feed system complete.
The PAC, Lime and Polymer (flocculent) Dosing systems including tanks, pipes valves
pumps, control unit and all ancillaries’ equipment shall be delivered as package unit
only from one single supplier.
Manufacturer’s Service
The supplier of the equipment and accessories, furnished under this Section shall
execute the following services which shall be done by a fully qualified manufacturer's
service engineer(s).

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Workshop drawings
Prior to manufacturing and delivery, contractors detailed workshop drawings for all
equipment, operating stage and stairs, data sheets and all documents have to be
submitted to the engineer for approval prior to purchase of equipment.
Supervision
Checking the installation of all components before power and water supplies are applied.
Checkout
Taking the equipment into operation and implement necessary adjustments.
Instruction
The supplier shall execute at least fourteen (14) days training during start-up phase and
under normal operation conditions to instruct the Employer's personnel in the use,
operation, safety regulation and maintenance of all the equipment. Comprehensive
documentation and operation manuals have to be submitted.
References
The aforementioned standards shall be referred to and the Manufacturer shall be
certified according ISO 9001.
Chemical dosing pipes
For chemical dosing as such as lime and Alumn or PAC the complete piping shall be
made of reinforced tube suitable size with minimum diameter of 25mm. The tube shall
be placed inside a protection pipe, for easy replacement of tube, in case the tube is
blocked by clogging. The protection pipe shall ensure that the tube can be pulled and
be replaced by a new one. Suitable flushing point’s sufficient in number and size shall
be provided as well, at least at all major points. The location and number of flushing
points shall be coordinated and approved by the engineer
2.4.3.8 Coagulant Dosing (Poly-Aluminium-Chloride)
The preparation of the chemical dosing solutions shall take place in the chemical house.
The building shall be equipped with appropriate gates and ventilation, sufficiently sized
and easy accessible storage area. Access for easy delivery of chemicals must be
ensured
The plant shall be suitable for preparing solution from powdered or granulate Poly-
Aluminium-Chloride, delivered in bags
PAC Dosing Pumps
Three chemical dosing pumps for PAC, shall be installed (2 + 1).
Type : Simplex diaphragm type metering pump
Number of units: Three (3)
Rated capacity : Max.500 L/h with a minimum discharge pressure of 0.5
MPa
Rated head : 50 m
Measuring range: Adjustable range of at least 10:1
Accuracy : Within ±1% of full stroke
Motor power : Approx.: 0.55 kW, motor protection by PTC
Motor drive: FC (Frequency Converter)

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Power supply : 400 V, 3-Phase, 50 Hz

Construction and Material of PAC Dosing pump
The PAC Dosing Pumps, shall be simplex, diaphragm type metering pumps. Pumps
shall be suitable to adjust the dosed amount of PAC to the real actual demand by
manual stroke adjustment.
The liquid end shall be designed to have pump head, plunger, check valves, diaphragm
and others. Pump head shall be made of type 316 stainless steel casting. Plunger shall
be made of type 420 stainless steel. Check valves shall be ball type or other suitable
type, and shall be made of type 316 stainless steel. Check valves shall be designed to
permit filling metering chamber on return stroke and discharging the measured quantity
on the forward stroke. Diaphragm shall be designed and manufactured to ensure high
durability, and shall be of Teflon. Other parts, which may contact with chemicals, shall
be made of type 316 stainless steel. The liquid end shall be provided with additional
provisions such as gas venting, pressure relief valve and sniffing valve, which ensure
long term trouble-free performance and protect the pump against damage from fault
operation.
Pumps shall have integrated sensor for diaphragm leakage indication. Parts in contact
with chemicals shall be fully resistant, dosing diaphragm shall be PTFE coated, dosing
head.
Motors for PAC Dosing pump
Motors shall be squirrel cage induction type protected against overload by PTC.
Appurtenances for PAC Dosing pump
Appurtenances specified herein shall be furnished and installed as shown on the
drawings. They shall be manufactured by the same manufacturer of the PAC feed
pumps as specified above.
Pressure Relief Valves for PAC Dosing pump
The pressure relief valves shall be spring loaded, relieve pressure adjustable type and
shall be designed to relieve pressure in excess of a preset pressure and the blow down
pressure shall be adjustable. Relief valve and stop valve which may contact with
chemicals shall be of type 316 stainless steel or PVC.
Pulsation Dampers (Air Chamber) for PAC Dosing pump
The pulsation dampers shall be designed to have sufficient capacity for damping
pulsation and have connections, for inlet, drain and vent. Connections of drain and
vent shall have stop valves. The pulsation damper and stop valves shall be made of
type 316 stainless steel or PVC. Diaphragm type pulsation dampers will not be
permitted.
Parts in contact with chemicals shall be fully resistant, dosing diaphragm shall be PTFE
coated, dosing head.
2.4.3.9 Tanks for PAC
General
Two (2) identical PAC solution tanks shall be furnished and installed as shown on the
drawings.
Each tank shall have all required connections and appurtenances. The design live load
shall be the weight of the liquid when the tank is filled to overflowing. The unit weight
of the PAC liquid and horizontal seismic factor shall be considered as 1,200 kg/m3 and
0.075 respectively.

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The PAC solving basket shall be equipped with close meshed screen, basket shall be
of sufficient capacity to receive at least one bag of PAC.
Schedule of tanks is summarized in the following table.
Type : Open square with rounded corners
Purpose: To prepare PAC solution
Number of units Two (2)
Location: Chemical Building
Material: reinforced concrete with a bituminous epoxy resin coating
Pipe Connections of Tanks for PAC
The following pipe connections shall be provided as shown on the drawings. Each
connection shall be either flanged or socket end.
- Plant water supply, 40 mm in diameter
- Solution recirculation line 32 mm in diameter
- Solution relief line 32 mm in diameter
- Drain, 50 mm in diameter
- Overflow, 50 mm in diameter
- Outlet, 50 mm in diameter
Operating stage
Access stair, operating stage including supports, handrails, support frames and
gratings and all other necessary appurtenance shall be delivered and installed.
Operating stage shall fit to the tanks and shall provide adequate working space.
Access stair and supporting structure, grating and hand rails shall be made of hot dip
galvanized steel. Operating stage shall facilitate easy operation of the lime dosing tank
and shall ensure easy access for filling of the lime solving basket without any
endangerment for staff.
Mixers for PAC
Mixers shall be installed on top of PAC Solution Tanks and shall maintain PAC solution
in dissolved conditions as far as solution is filled in the tank. The mixer rotation speed
has to be adjusted accordingly to ensure proper mixing and dilution but not to create
too much turbulences in the tank.
Scope of mixers includes all necessary ancillary device, like local control and operating
switch, cabling, including mixer support beams and all fixing materials made of the
same material as the tank made from, ready for operation.
Schedule of the mixers for the PAC unit shall be as follows:
Type of mixer Vertical, mechanical mixer directly coupled with drive unit
Number required Two (2) units
Location PAC Solution Tank
Purpose Solution PAC stone, 5% by weight solution
Type of drive Gear speed reducer with motor
Speed Variable speed 10 -100 rpm
Minimum motor output 1,8 kW

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Power supply 400 V, 3-Phase, 50 Hz

Remarks Motors shall have PTC protection device
Valves for PAC
Valves to be provided for the PAC Feed Unit shall be as follows:
 Plunger valve (tank connection to the pumps)
 Globe valve on suction and pressure of the pumps
 check valve on pressure side of the pumps
 Pressure relief valve
 Pulsation damper
All valves to be used for the PAC feed system shall be made of type 316 stainless steel
and/or PVC
Diffuser for PAC
PAC solution shall be fed before Flash Mixing Tank on line on pipe DN900 at the Water
Treatment Plant through the diffusers. Every dosing point must have his own ball valve.
Type Diffuser pipe, Dosing Points
Length Acc Drawing
Materials PVC pipe, DN 25
2.4.3.10 Polymer (flocculent) Dosing
The preparation of the polymer solution shall take place in the chemical house. The
building shall be equipped with appropriate gates and ventilation, sufficiently sized and
easy accessible storage area. Access for easy delivery of chemicals must be ensured.
Polymer Dosing Pumps
Three chemical dosing pumps for Polymer shall be installed (1 + 1).
Type : Simplex diaphragm type metering pump
Number of units: Two (2)
Rated capacity : Max.120 L/h with a minimum discharge pressure of 0.5
MPa
Rated head : 50 m
Measuring range: Adjustable range of at least 10:1
Accuracy : Within ±1% of full stroke
Motor power : Approx.: 0.37 kW, motor protection by PTC
Motor drive: FC (Frequency Converter)
Power supply : 400 V, 3-Phase, 50 Hz
Construction and Material for Polymer Dosing pump
The Polymer Dosing Pumps, shall be simplex, diaphragm type metering pumps. Pumps
shall be suitable to adjust the dosed amount of Polymer to the real actual demand by
manual stroke adjustment.
The liquid end shall be designed to have pump head, plunger, check valves, diaphragm
and others. Pump head shall be made of type 316 stainless steel casting. Plunger shall
be made of type 420 stainless steel. Check valves shall be ball type or other suitable

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type, and shall be made of type 316 stainless steel. Check valves shall be designed to
permit filling metering chamber on return stroke and discharging the measured quantity
on the forward stroke. Diaphragm shall be designed and manufactured to ensure high
durability, and shall be of Teflon. Other parts, which may contact with chemicals, shall
be made of type 316 stainless steel. The liquid end shall be provided with additional
provisions such as gas venting, pressure relief valve and sniffing valve, which ensure
long term trouble-free performance and protect the pump against damage from fault
operation.
Pumps shall have integrated sensor for diaphragm leakage indication. Parts in contact
with chemicals shall be fully resistant, dosing diaphragm shall be PTFE coated, dosing
head.
Motors for Polymer Dosing pump
Motors shall be squirrel cage induction type protected against overload by PTC.
Appurtenances for Polymer Dosing pump
Appurtenances specified herein shall be furnished and installed as shown on the
drawings. They shall be manufactured by the same manufacturer of the Polymer feed
pumps as specified above.
Pressure Relief Valves for Polymer Dosing pump
The pressure relief valves shall be spring loaded, relieve pressure adjustable type and
shall be designed to relieve pressure in excess of a preset pressure and the blow down
pressure shall be adjustable. Relief valve and stop valve which may contact with
chemicals shall be of type 316 stainless steel or PVC.
2.4.3.11 Tanks for Polymer
General
Two (2) identical polymer solution tanks shall be furnished and installed as shown on
the drawings.
Each tank shall have all required connections and appurtenances. The design live load
shall be the weight of the liquid when the tank is filled to overflowing. The unit weight
of the PAC liquid and horizontal seismic factor shall be considered as 1,200 kg/m3 and
0.075 respectively.
Schedule of tanks is summarized in the following table.
Type : Open square with rounded corners
Purpose: To prepare Polymer solution
Number of units Two (2)
Location: Chemical Building
Material: reinforced concrete with a bituminous epoxy resin coating
Pipe Connections of Tanks for polymer
The following pipe connections shall be provided as shown on the drawings. Each
connection shall be either flanged or socket end.
- Plant water supply, 40 mm in diameter
- Solution recirculation line 32 mm in diameter
- Solution relief line 32 mm in diameter
- Drain, 50 mm in diameter

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- Overflow, 50 mm in diameter
- Outlet, 50 mm in diameter
Operating stage
Access stair, operating stage including supports, handrails, support frames and
gratings and all other necessary appurtenance shall be delivered and installed.
Operating stage shall fit to the tanks and shall provide adequate working space.
Access stair and supporting structure, grating and hand rails shall be made of hot dip
galvanized steel. Operating stage shall facilitate easy operation of the lime dosing tank
and shall ensure easy access for filling of the lime solving basket without any
endangerment for staff.
Mixers for Polymer
Mixers shall be installed on top of Polymer Solution Tanks and shall maintain Polymer
solution in dissolved conditions as far as solution is filled in the tank. The mixer rotation
speed has to be adjusted accordingly to ensure proper mixing and dilution but not to
create too much turbulences in the tank.
Scope of mixers includes all necessary ancillary device, like local control and operating
switch, cabling, including mixer support beams and all fixing materials made of the
same material as the tank made from, ready for operation.
Schedule of the mixers for the Polymer unit shall be as follows:
Type of mixer Vertical, mechanical mixer directly coupled with drive unit
Number required Four (4) units
Location Polymer Solution Tank
Purpose Polymer dosage, 35-135 l/h
Type of drive Gear speed reducer with motor
Speed Variable speed 10 -100 rpm
Minimum motor output 1,0 kW
Power supply 400 V, 3-Phase, 50 Hz
Remarks Motors shall have PTC protection device
Valves for Polymer
Valves to be provided for the PAC Feed Unit shall be as follows:
 Plunger valve (tank connection to the pumps)
 Globe valve on suction and pressure of the pumps
 check valve on pressure side of the pumps
 Pressure relief valve
 Pulsation damper
All valves to be used for the PAC feed system shall be made of type 316 stainless steel
and/or PVC
Diffuser for Polymer
Polymer solution shall be fed after flocculation chambers into distribution channels for
clarifiers at the Water Treatment Plant through the diffusers. Every dosing point must
have his own ball valve.

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Type Diffuser pipe, Dosing Points

Length Acc Drawing
Materials PVC pipe, DN 25
2.4.3.12 pH Correction (Lime Dosing)
The preparation of the lime solution shall take place in the chemical house. The building
shall be equipped with appropriate gates and ventilation, sufficiently sized and easy
accessible storage area. Access for easy delivery of chemicals must be ensured.
The LIME feed system shall consist of
a. LIME Solution Tanks for preparing LIME solution from powder LIME
(delivered in bags), with solution level instrument
b. Mixer with local control panel
c. LIME Dosing Pumps for accurate measuring and feeding of LIME solution,
pressure holding valve (back pressure valve) and control panel.
d. Flow Meter (for dosing solution demand measuring)
e. Supply header pipe for gravity transfer of LIME solution from LIME Solution
Tank to LIME Dosing Pumps.
f. Diffusers for LIME solution at dosing points
g. Complete Piping from dosing system to the injection point
h. Pressure relief valves for each pump
The LIME feed system shall be able to feed LIME solution at variable rates as needed
by the raw water quantity and quality. The control and adjustments of feed rates shall
be set manually, by the operator changing the stroke length of each dosing pump.

LIME Dosing Pumps

Pump Schedule
Schedule of LIME Dosing Pumps are as follows:
Type : Simplex stroke diaphragm type metering pump
Number of units : Three (3)
Rated capacity : Max. 760 L/h with a minimum discharge pressure of 0.5
MPa
Rated head : 50 m
Pump stroke : Approx. 80 mm
Pump speed : Approx. 46 rpm
Measuring range: Adjustable range of at least 10:1
Accuracy : Within ±1% of full stroke
Min Motor power: 1.55 kW, motor protection by PTC
Motor drive: FC
Power supply : 400 V, 3-Phase, 50 Hz

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Construction and Material for LIME Dosing Pumps

The LIME Dosing Pumps, shall be simplex, stroke diaphragm type metering pumps.
Pumps shall be suitable for manual stroke length adjustment to adjust the dosed
amount of LIME to the real actual demand.
The liquid end shall be designed to have pump head, plunger, check valves, diaphragm
and others. Pump head shall be made corrosion resistant material such as of type 316
stainless steel casting or suitable Plastic. Plunger shall be made of type 420 stainless
steel or suitable plastic. Check valves shall be ball type or other suitable type, and shall
made of type 316 stainless steel or suitable plastic.. Check valves shall be designed
to permit filling metering chamber on return stroke and discharging the measured
quantity on the forward stroke. Diaphragm shall be designed and manufactured to
ensure high durability, and shall be of Teflon. Other parts, which may contact with
chemicals, shall be made of type 316 stainless steel. The liquid end shall be provided
with additional provisions such as gas venting, pressure relief valve and sniffing valve,
which ensure long term trouble-free performance and protect the pump against damage
from fault operation.
Pumps shall have integrated sensor for diaphragm leakage indication. Parts in contact
with chemicals shall be fully resistant, dosing diaphragm shall be PTFE coated, dosing
head.
Motors for LIME Dosing Pumps
Motors shall be squirrel cage induction type protected against overload by PTC. Motor
shall be suitable for frequency inverter drive.
Appurtenances
Appurtenances specified herein shall be furnished and installed as shown on the
drawings. They shall be manufactured by the same manufacturer of the LIME feed
pumps as specified above.
Pressure Relief Valves
The pressure relief valves shall be spring loaded, relieve pressure adjustable type and
shall be designed to relieve pressure in excess of a pre-set pressure and the blow down
pressure shall be adjustable. Relief valve and stop valve which may contact with
chemicals shall be of type 316 stainless steel.
Pressure Holding Valves (Back Pressure Valve)
The pressure holding valves shall be spring loaded, Teflon diaphragm, pressure
adjustable type and shall be designed to keep a pressure difference in the pump
discharge pipeline. Pressure holding valves and stop valves, which may contact with
chemicals shall be of type 316 stainless steel.
2.4.3.13 LIME Tanks
General
Four (4) identical LIME solution tanks shall be furnished and installed
Each tank shall have all required connections and appurtenances. The design live load
shall be the weight of the liquid when the tank is filled to overflowing. The unit weight
of the LIME liquid and horizontal seismic factor shall be considered as 1,200 kg/m3 and
0.075 respectively.
The lime solving basket shall be equipped with closed meshed screen, basket shall be
of sufficient capacity to receive at least one bag of lime.
Schedule of tanks is summarized in the following table.

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Type : Vertical, open, cylindrical tank

Purpose : To prepare LIME solution
Number of units Two (2)
Location : Chemical Building
Material : Stainless steel, Type 316 with protective inliner or made
of HDPE
Tanks, and all related appurtenance shall be fabricated from minimum type 316
stainless steel sheets or plates and coated inside and outside fully by corrosion
resistant material or inliner (made of rubber, epoxy or other eligible material), and shall
be welded, shop fabricated, tested and cleaned. As alternative, tanks could be fully
made of suitable plastic material such as PEHD. Reinforcing ribs or plates where
required shall be provided on the exterior of the tank. Minimum sheet or plate thickness
shall be 5.0 mm.
Field cutting, welding and fabrication of the tanks also will not be permitted.
Pipe Connections
The following pipe connections shall be provided. Each connection shall be
flanged end.
- Plant water supply, 32 mm in diameter
- Solution recirculation line 40 mm in diameter
- Solution relief line 50 mm in diameter
- Drain, 50 mm in diameter
- Overflow, 50 mm in diameter
- Outlet, 40 mm in diameter
Tank Top
Top of the tanks shall be open. Tank top shall be provided with type 316 stainless steel
handrails, which are 800 mm high for safety. The handrails shall be removable type.
Support Legs
Support legs with maintenance step as shown on the drawings shall be provided and
fabricated from type 304 stainless steel plate or sheet.
Operating stage
Access stair, operating stage including supports, handrails, support frames and
gratings and all other necessary appurtenance shall be delivered and installed.
Operating stage shall fit to the tanks and shall provide adequate working space.
Access stair and supporting structure, grating and hand rails shall be made of hot dip
galvanized steel. Operating stage shall facilitate easy operation of the lime dosing tank
and shall ensure easy access for filling of the lime solving basket without any
endangerment for staff.
LIME Mixers
Mixers shall be installed on top of LIME Solution Tanks and shall maintain LIME solution
in dissolved conditions as far as solution is filled in the tank. Mixers shall be operated
manually by monitoring the water level in the tank.
Scope of mixers includes all necessary ancillary device, like local control and operating
switch, cabling, including mixer support beams and all fixing materials made of the
same material as the tank made from, ready for operation.

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Schedule of the mixers for the LIME unit shall be as follows:

Type of mixer Vertical, mechanical mixer directly coupled with drive unit
Number required Two (2) units
Location LIME Solution Tank
Purpose Solution LIME stone 5% by weight solution
Mixing volume of each mixer 2,3 m3
Shaft overhung length 2.5 m
Type of drive Gear speed reducer with motor
Speed Adjustable speed 70- 200 rpm
Minimum motor output 2.5 kW
Power supply 400 V, 3-Phase, 50 Hz
Remarks Motors shall have PTC protection device
2.4.3.14 LIME Process Piping and Valves
Process Piping
All necessary LIME process piping shall be furnished and installed as to complete the
LIME feed system as shown on the drawings.
PVC pipe and reinforced hose made of suitable resistant material to be used for the
LIME feed system.
Design of piping and valves shall ensure that each pump can be feed from each tank
and each pump can be used as duty and stand by pump.
Complete connecting piping between pumps installation and dosing points shall be
made of reinforced hoses, sufficient sized over the full length, at least diameter 40mm.
Sufficient number of flushing points located at all critical points shall be provided. The
hose must be laid over the full length in a protection pipe made of PVC other suitable
material. The protection pipe must ensure that in case of blockage, the hose could be
easily replaced. This means the design and layout of dosing pipe laying must avoid 90°
bends and other trammelling form pieces. The protection pipe must have minimum
diameter DN 100. The dosing hose must be subdivided in eligible sections and the
layout must ensure that a sufficient number of places where the hose can be pulled out
and replaced as well as flushed will be provided.
Prior to installation detailed workshop drawings must be submitted to the engineer for
approval.
LIME Valves
Valves to be provided for the LIME Feed Unit shall be as follows:
 Electrical plunger valve (tank connection to the pumps)
 Globe valve on suction and pressure of the pumps
 check valve on pressure side of the pumps
 Pressure relief valve
 Pulsation damper
All valves to be used for the LIME feed system shall be made of type 316 stainless
steel and/or PVC.
Stand Pipe

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Stand pipe shall be installed at suction header of LIME Dosing Pumps in order to save
suction line head loss for the pumps.
Type : Cylindrical vertical pipe
Number of standpipe : One
Diameter : Minimum 160 mm
Height : Minimum 5.5 m*
Material : Stainless steel
Note: Top level of stand pipe shall be sufficiently above the top of LIME Solution
Tank, to avoid LIME solution overflowing through the stand pipe.
Stand Pipe shall be self-stand vertically and cylindrical pipe made of stainless steel.
The top of Stand Pipe shall be open.
Protection Against Corrosion
The dosing pumps shall be shop painted with the epoxy resin plus urethane paint
conforming to Paint System C.
All interior LIME feed piping and pressure pipe in the inside and outside chemical
building except PVC pipes, shall be of reinforced hose type, laid in protection pipe.
2.4.3.15 Chlorination
The preparation of the Cl-solution shall take place in the Chlorination house. The
building shall be equipped with appropriate gates and forced ventilation above roof,
sufficiently sized and easy accessible storage area for chlorine tanks. Access for easy
delivery of the chlorine tanks must be ensured
Chlorine Pipework
Flexible connections to chlorine bottles shall be of cadmium (or silver) plated copper.
All rigid pipework conveying chlorine gas under pressure shall be constructed from solid
drawn steel tube with heavy fittings in malleable iron.
Threaded joints shall be sealed using a jointing compound compatible with chlorine.
Polytetrafluoroethylene (PTFE) tape shall not be used.
All piping for chlorine solution shall be rigid ‘hi-impact’ Unplasticised polyvinyl chloride
(uPVC) with solvent weld joints and fittings.
Piping and flexible tubes carrying chlorine gas under vacuum shall be of a type
approved by the Consultant.
Chlorine solution hoses shall be of suitable grade flexible reinforced rubber.
All vent pipes from chlorinators shall be rigid PVC.
Valves on piping carrying chlorine gas under pressure shall be specifically designed for
chlorine service with forged steel bodies, monel metal spindles and seats, and shall
have gland packing or special diaphragms in chlorine resistant material.
Valves on piping carrying chlorine solution or gaseous chlorine under vacuum and the
water shut-off valve just upstream of the chlorine injectors shall be cast iron bodies,
flanged, rubber lined valves of the diaphragm type or approved equivalent.
General Requirements Pre-chlorination and disinfection
General requirements of the Pre-Chlorine and disinfection feed system, offered system
shall fit calculated design figures are as follows:

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Pre-Chlorination
Liquefied Cl2-gas

Design flow (raw water) m³/h 7290

m3/d 175.000

Average Chlorine dosage mg/l 4

Maximum Chlorine dosage mg/l 10

Average Cl2gas-dosing rate kg/h 38,5

No. of dosing pumps (2 + 1) 3

Maximum capacity of each dosing pump

m3/h 6

Post Chlorination-Disinfection
Liquefied Cl2-gas

Design flow (clear water) m³/h 3850

m3/d 92.400

Average Chlorine dosage mg/l 2

Maximum Chlorine dosage mg/l 3

Average -dosing rate kg/h 7,83

Maximum -dosing rate kg/h 11.6

Average Cl2 gas- dosing rate l/h 2.31

No. of dosing pumps (1 + 1) 2

Maximum capacity of each dosing pump m3/h 4

Vacuum type Gas chlorinators shall be supplied with one duty and one standby unit for
post chlorination. The capacity of the chlorinator unit shall not be less than 38.5 Kg/hr.
Chlorinators shall be free-standing, floor-mounted, and shall have a turn down ratio of
10: 1 over the full range of works operation.
Each chlorinator shall be equipped with a motorised plug positioned to be actuated by
a Filtered water flow at the works outlet.
Provision for manual setting of the dosing rate shall be built in the system in addition to
automatic dosing adjustment and each chlorinator shall be equipped with a 0 to 5 mg/l
scale and a manual dose setter over the range above this.

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Mal-operation of the duty chlorination system shall be indicated in the chlorination room
and the central MMI. The change to the standby system shall be carried out
automatically in the event of a duty chlorinator failure.
Chlorine solution diffusers shall be supplied and installed at the dosing point
Chlorine Drum Connector Tubes
The plastic sheathed copper tubes connecting the liquid chlorine drums and the liquid
chlorine header system shall be equipped with adaptors to accept drums supplied by
the Employer.
Flanges and Joints for Liquid Chlorine Pipe Work

Flanges for liquid chlorine pipe work and valves shall be raised face flanged double
fillet welded, stress relieved and radiographed, drilled according to the relevant
standards
Joint rings shall be 2 mm compressed Asbestos Fibre (CAF) tabbed to the relevant
standard Grade B fitting within the bolt circle. Prior to installation the joint rings shall be
impregnated / smeared with graphite compound or similar jointing compound
compatible with liquid chlorine.
Liquid Chlorine Pipe Work

Pipe work conveying liquid chlorine shall be carbon steel hot finished seamless, cold
drawn seamless to the relevant standard. Pipe work shall be adequately supported
throughout its length and sufficient number of flanges shall be incorporated to enable
maintenance or repairs to be carried out without having to work from one end of the
pipe work.
The pipe work shall include rupture disc and expansion chamber as per
recommendations of Chlorine Institute, USA. An alarm switch shall be provided set to
function if rupture occurs.
Following any welding work on the pipe work the entire section of the affected pipe
work shall be stress relieved and radiographed.
Valves for Liquid Chlorine
Valves for liquid chlorine duty shall be Polytetrafluorethylene sleeved plug type 2-way
valves with carbon steel body and Monel plug.
Where the valves are manually operated, they shall be wrench situated with padlock
type locking feature.
Power actuated valves shall have electric actuators with built-in position feedback limit
switches, torque overload protector, IP 56 enclosures and manual override facilities.
Chlorine Pressure Gauges

Pressure gauges for use with chlorine shall be of the Bourdon tube type with a special
diaphragm isolating the tube from the liquid or gaseous chlorine. Pressure gauges shall
have dials not less than 150 mm diameter except where they form an integral part of
equipment, such as a chlorinator. No aluminium shall be used in the construction of the
gauges; the dials and bezels shall be of bronze and internal components shall be of a
stainless steel or other alloy or material resistant to corrosion by chlorine.
All pressure gauge piping shall include isolating valves at each point of connection to
the main piping.

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Where necessary, pressure gauges shall be fitted with adjustable electrical contacts for
initiation of alarm conditions with either rising or falling pressure, to suit the system
design.
Automatic Drum Changeover Panel

The automatic drum changeover panel shall be a specially designed unit capable of
selecting liquid chlorine containers for duty on an alternate basis. The unit shall be
capable of working in conjunction with two liquid chlorine drums (one duty, one
standby).
The panel shall satisfy the following duty functions in chronological order:
(i) Check pressure in the line initiate automatic changeover and alarm
if pressure is low;

(ii) Shut the delivery valve of the drum that has just become empty and
open the valve of the standby drum on-line;

(iii) Re-check pressure as in (1) above and initiate alarm if pressure is

still low;

(iv) Proceed until next changeover is initiated, then repeat the

sequence;

(v) At each step, the operation of valves shall be monitored using

position feedback limit switches and valves failing to operate in a set
time shall immediately initiate an alarm.

Chlorine Gas Pipe Work

Pipe work conveying chlorine gas shall be solid draw steel with taper threads to. All
fittings shall be of malleable iron. Chlorine gas pipe work shall be adequately supported.
Threaded joints shall be sealed using jointing compound compatible with chlorine. Poly
tetrafluoroethylene tapes shall not be acceptable.
Where installation involves injectors to be located near the dosing points or remote
injectors, the vacuum chlorine gas delivery lines downstream of chlorinators shall be of
uPVC or approved equivalent and the lines to be run in RCC ducts with proper Pre-
cast covers.
Chlorine Gas Valves
Valves for gaseous chlorine duty shall be specifically designed for chlorine with forged
steel bodies, Monel valve packing or special diaphragm in chlorine resistant materials.
Chlorine Gas PRV and Shut-Off Valves

Chlorine Gas Pressure Reducing and shut-off valve shall be a spring loaded,
diaphragm operated valve with super-imposed electric actuator designed to reduce
varying gas pressure upstream to a desired regulated pressure downstream and
maintain this pressure within close limits.
The diaphragm shall be made of Polytetrafluorethylene (PTFE).
The electric actuator shall ensure quick shut-off of the gas flow in the event of a
breakdown or similar event.
Injector Motive Water Supply System

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Injector water supply system shall be compatible with the flow and pressure
requirements at the maximum rated output of the chlorinators offered and to limit the
chlorine solution concentration to an acceptable limit at operational fluid temperature
up to 330 C.
Chlorinators
The chlorinators shall be vacuum operated aqueous solution feed type units working in
conjunction with wall-mounted injectors.
The units shall be discrete floor standing cabinets of plastic/composite construction.
The chlorinators shall be suitable for manual feed rate control and incorporate a flow
metering device for precise regulating of chlorine gas over a 20:1 flow range, with a
metering accuracy of plus or minus 4% of the indicated gas flow rate.
Each chlorinator shall be fitted with the following principal components;
a. Gas inlet pressure regulating valve

b. Pressure/vacuum relief valve with safety vent

c. Vacuum regulating valve

d. Gas feed rate regulator preferably of the 'V' notch cylindrical plug and variable
area orifice type

e. Variable area type flow meter with linear feed rate indicator calibrated in kg/hr

f. Thermostatically controlled gas inlet heater

g. Wall mounted injector, preferably of adjustable throat type

h. Rigid PVC pipe work to wall mounted remote injectors.

i. Chlorinators shall be provided with panel mounted indicators for the chlorine
gas inlet pressure, injector vacuum, motive water pressure, chlorine solution
pressure immediately downstream of injector and a feed rate adjustment knob.

j. Chlorine gas feed piping shall be provided with valves to allow isolation of each
chlorinator without disturbing the operation of the other chlorinators.

k. Rigid PVC chlorine vent piping shall also be provided and arranged to
discharge at a high level outside the room housing the chlorinators to ensure
safe atmospheric dilution.

l. The chlorine supply to the injector shall shut down automatically if:

- The water supply to the injectors shall fail

- The injector vacuum line breaks

- The chlorine solution line is accidentally shut down by the closing of a chlorine
solution dosing valve.

m. A check valve shall be provided between chlorinator and injector to prevent

accidental backflow into the chlorinator. This shall be consistent with the
injector design with respect to gas flow and water pressure. While effectively
preventing backflow, this valve shall allow requisite gas flow.

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n. Additional safety devices shall be incorporated in the equipment to prevent

hazards to the operators or damage to the components under normal
operating and shutdown conditions.

o. All electrical services and control signal lines (where applicable) shall be wired
to a single termination board within the chlorinator cabinet. The termination
board shall preferably be totally enclosed in a gas-tight junction box with
glanded cable entries and fitted with a clearly labelled warning sign stating the
supply voltage. Electrical supply isolating switches interlocked with the panel
doors shall also be provided in each chlorinator cabinet.

Chlorine Draw-Off System

Chlorine shall be drawn off as gas; to minimize drum handling there shall be adequate
connections and drum isolating valves provided to enable one drum from each row to
be connected to the automatic drum changeover device to be provided under this
Contract.
The local supply of liquid chlorine may contain 0.1% to 0.2% ferric chloride and about
50 mg/l moisture. Tenderers shall provide for suitable devices such as filters so that the
pipe work and equipment are protected against deposits or corrosion.
The duty/standby drums shall be located on plinth-mounted casters with four rollers per
set or drums. The casters with rollers for these drums shall be supplied and installed
under this Contract.
The installation shall include all necessary chlorine headers including supports, power
actuated valves and manual isolating valves, for connection of drums to the drum
changeover device.
The liquid chlorine pipe work interconnecting the drums, changeover panel and the
liquid chlorine evaporator shall be safeguarded by a pressure relief system.
The pressure relief system shall comprise locked open isolating valves, bursting disc
assembly, pressure gauge with adjustable alarm contacts and relief vessel.
The bursting disc shall preferably be made of nickel sheathed in PTFE, or approved
equivalent.
Chlorine Solution Delivery Pipe Work and Valves

The Contractor shall provide all necessary rigid pipe work, valves and fittings for the
delivery of the chlorine solution from chlorinator injectors/manifold to the points of
application.
The chlorine solution delivery lines shall be of Mild steel ebonite lined or approved
equivalent. The pipe work shall be adequately protected externally against corrosion
and installed complete with necessary supports, thrust restraints, etc., and incorporate
sufficient flexibility to allow for any thermal expansion effects.
When selecting material for pipe work, consideration shall be given to the deteriorating
effect on some synthetic materials due to the action of ultra-violet rays. Where such
materials are employed, particularly in the case of uPVC, pipe work shall be shielded
from direct sunlight.
The valves in the chlorine solution pipe work shall be of forged steel body, monel
spindles, stainless steel seats and PTFE gland packing or carbon steel, monel plug,

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PTFE sleeved plug, flanged, or approved equivalent. Locking devices and position
indicators shall be provided. The diaphragm of the valves shall be PTFE faced with a
backing of viton synthetic rubber (co-polymer of vinylidene fluoride and hexa
fluoropropylene).
Test pressure for the solution delivery pipe work, valves and specials shall be twice the
working pressure or 1 1/2 times the shut-off head of the injector motive water pumps,
whichever is higher.
Chlorine Solution Distributors & Injection Fittings
Where chlorine solution is to be dosed into flow in an open channel, chamber or
downstream of a hydraulic jump it shall be applied using a chlorine solution distributor.
The distributor shall be either tube drilled ceramic tubular diffuser, designed to ensure
uniform distribution of the specified flow rate of chlorine solution at the point of
application.
The materials of construction of the distribution and sealing shall be compatible with
3500 mg/l chlorine solution at operational fluid temperature up to 33°C. Porous ceramic
material where used shall be inert, and non-toxic, uPVC tube where used shall conform
to the relevant standards.
The distributor shall be adequately supported and designed to withstand the stream
velocity at the point of application and any flow or turbulence induced vibrations.
Where chlorine solution is to be dosed into flow in pipe lines it shall be applied using
an injection fitting/device designed for specified duty flow rate.
The injection tube shall extend across the pipe bore and be supported with ends located
in diametrically opposite flanged branches.
The injection fitting shall be installed in diametrically opposite flanged branches with
their axis making an angle of 45° with the horizontal in a plane normal to the direction
of flow within the pipe line.
The injection fittings shall be adequately supported and designed to withstand the flow
or turbulence induced vibrations. Provisions shall include necessary support brackets
also.
Chlorine solution distributors or injection fittings shall be supplied complete with
necessary non-return and isolation valves.
Tonner Roller Supports

These supports shall be used to hold the Tonner containers securely in place and also
to facilitate the positioning of the Tonners, so that inbuilt valves (Gas side and Liquid
side) lie one over the other vertically.
The Roller support body shall be made of Cast Iron, rollers shall be Cast Iron/Mild steel
and Bushes shall be of Brass.
Lifting Beam with Hooks

To facilitate safe lifting of standard Tonner container, the lifting Beam with hooks shall
be provided. The Beam shall hold the Tonner securely while hoist and Trolley are used
to lift, place and position the containers. The Beam material shall be Cast Iron/Mild
steel.
Chlorine Plant Ventilation

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The Container Store area and the Chlorinator Room shall be made reasonably gas tight
and provided with separate forced ventilation facilities. A ducted system shall be
provided with a number of fan units such that even though any one unit fails reasonable
ventilation would still be effected.
Inlets to the exhaust duct system shall be placed at the floor level. The exhaust system
shall directly discharge air to atmosphere outside the building.
Each exhaust system shall include two sets of fans, one for continuous running giving
4 air changes per hour and the other designed for intermittent running giving 20 air
changes per hour.
Movable louvers shall be provided on the inlet and outlet ports of the forced air
circulation system. The louvers shall open automatically when the ventilation is started
and close by gravity when stopped. Contactor starters for operating ventilation
equipment shall be provided in the motor control center in the Office and Control Room
as well as local to the units, and be subject to shut-down control from leak detection
units.
All necessary ducting, self-closing louvered outlets, exhaust fans with external mounted
control gear indicator lights shall be provided under the Contract. Special attention shall
be given to materials of construction and particularly to motor protection.
Chlorine Container Weighing Equipment:
Equipment provided for weighing chlorine containers shall be spring type loaded with
circular scale indicator and shall conform to IS: 1438.
The scale shall be designed suitable for suspension from the load hook of Lifting Beam
to be properly secured to the crane or hoist.
The scale shall be suitable for operation with a working load of not more than 2000 kg.
The indicator scale shall be calibrated in 5kg divisions, with the zero at the top of the
scale and the pointer vertical with no load. The pointer shall incorporate means of tare
adjustments up to 20% of the indicator scale. The indicator dial shall be slanted from
the vertical plane so as to minimize parallax errors when the indicator is read from the
floor with the unit hoisted to a high level.
The scale shall have an overall accuracy of better than 10% of the full scale deflection
and the unit shall be unaffected by the temperature variations in the range 4 to 50°C.
Bidders are encouraged to propose Digital type weighing Equipment and shall be
subject to approval by the Engineer.
Safety Equipment
Materials and equipment necessary to ensure the safety of personnel operating the
chlorination plant and others shall be provided.
The equipment shall include inter alia:
i. Two sets of approved self-contained breathing apparatus, each comprising an
air set, carrying harness, face mask and valves and ancillary equipment. Each
set shall be provided with three 1 200 litre capacity, 140 mm diameter, air
cylinders;

ii. Two sets of approved positive airline breathing apparatus, each comprising
body harness, face masks and valves and 30 m of airline. One air trolley,
comprising wheeled frame with two air cylinders, control manifold, airline hose

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and hose winding drum. Two spare cylinders suitable for changeover shall be
provided;

iii. one portable electric motor driven air compressor for recharging air cylinders,
complete with quick-release air hose couplings;

iv. Two `instant action' resuscitators.

v. Four sets of safety clothing in various sizes, each comprising PVC overalls,
wellington boots with steel toe caps, goggles, gloves and safety helmets.

Each set of safety equipment shall be mounted in a glass-fronted, non-locking PVC

coated steel cabinet in approved locations on the outside of the Chlorine building.
Two emergency showers shall be provided and shall be installed outside on either side
of the Chlorine drum room.
Each shower shall be operated automatically by a quick acting hand or foot valve.
Four eyebaths shall be supplied. Two eyebaths shall be adjacent to each of the
showers. The eye bath unit shall be fitted with fine mesh filters with built-in pressure
regulating device to ensure a safe rate of flow to prevent foreign matter being further
embedded into the eye and instead flush away contamination
Water for the showers, etc., shall be drawn from the service water supply.
2.4.3.16 Pre - Chlorination Booster Pump
Type : Multistage Vertical centrifugal pump
Number of units : Three (3)
Rated capacity : Max. 6 m3/h with a minimum discharge pressure of 0.5
MPa
Rated head : 60 m
Material: Body in stainless steel 1.4408, impeller in stainless steel 1.4401
Min Motor power: 2.2 kW, motor protection by PTC
Motor drive: FC
Power supply : 400 V, 3-Phase, 50 Hz
Accessories for Pre-chlorination booster pumps:
Manometer with max. (or min.) contact, range 0-10bar strainer
 with strainer, 0.50 mm
 nominal width: DN50
 nipple diameter: 63.00 mm
 PVC
 transparent
 gasket: Viton
 10.00 bar
Angle seat check valve
 nominal width: DN50

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 connection: nipple
 material: PVC
 gasket: Viton
 pressure: 10.00 bar
Ball valve
 nominal width: DN50
 diameter: 63.00 mm
 material: PVC
 gasket: EPDM
 pressure: 16.00 bar
 version: industrial ball valves
Post-Chlorination (Disinfection) Booster Pump
Type : Multistage Vertical centrifugal pump
Number of units : Three (2)
Rated capacity : Max. 4 m3/h with a minimum discharge pressure of 0.5
MPa
Rated head : 60 m
Material: Body in stainless steel 1.4408, impeller in stainless steel 1.4401
Min Motor power: 2.0 kW, motor protection by PTC
Motor drive: FC
Power supply : 400 V, 3-Phase, 50 Hz
Accessories for Post-Chlorination booster pumps:
Manometer with max. (or min) contact, range 0-10bar strainer
 with strainer, 0.50 mm
 nominal width: DN50
 nipple diameter: 63.00 mm
 PVC
 transparent
 gasket: Viton
 10.00 bar
Angle seat check valve
 nominal width: DN50
 connection: nipple
 material: PVC
 gasket: Viton
 pressure: 10.00 bar
Ball valve

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 nominal width: DN50

 diameter: 63.00 mm
 material: PVC
 gasket: EPDM
 pressure: 16.00 bar
 version: industrial ball valves
2.4.3.17 Chlorine House
A vacuum chlorine system shall be housed in the existing chlorine storage and dosage
house. The chlorination system shall be comprising of chlorinator/control room with
booster pump, electrical switchboard, instruments and injector and a chlorine drum
store shall be gas tight with full and empty drums scale, gas manifold and automatic
cylinder changeover.
Equipment for Chlorine Storage
Two drum batteries each with eight drums.
Floor mounted rollers for the support of drums and for rotating the drums.
Automatic changeover device with servomotor and the necessary pressure gauges.
Local panel for manual and automatic changeover, indicator lamps which drums are on
duty. Alarm shall be initiated locally on automatic operation of the changeover device
with repeat alarms in the main control room.
Chlorine drum balance for each first drum in the row.
Chlorine evaporator. Pressure reducing valve and filter, vacuum regulator, liquid trap.
The complete installation including all necessary gas headers, pipes isolating valves,
safety equipment, etc.
The layout, location and design of the chlorine storage and handling equipment shall
conform to the relevant technical service notes and literature published by chemical
and equipment manufacturers.
Chlorine Drums
The design and construction of the drums shall be in accordance with the latest version
of the appropriate EN standard or other approved standard for gas drums and
containers and to the requirements of the local suppliers of chlorine. They shall be of
fusion-welded construction made from mild steel suitable to meet the mechanical
stresses and chemical corrosion conditions in the handling of chlorine and the climatic
conditions of the site.
Each drum shall be stress-relieved by heat treatment after manufacture, all welded
seams first having been X-ray tested. After being stress-relieved and hydraulically
tested, the inside of each drum shall be shot-blasted and protected against moisture by
a suitable desiccant. External surfaces shall be shot-blasted and painted in colour and
form approved by the Employer before delivery to site.
Each drum shall be complete with all necessary internal dip pipes, drum valves and
removable domed valve protection cover. The Contractor shall provide 10 % spare
parts for spiral connectors and valves of chlorine cylinder.
The Contractor shall provide an emergency tool kit for liquid chlorine cylinder to enable
personnel to deal with slight leakage from chlorine drums, such as could occur as a

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result of a handling mishap, valve damage or leakage. The Contractor shall give the
details of the kit.
Chlorinators
The chlorinator room shall be designed to ensure that all number of equipment in it is
laid out functionally and aesthetically.
The types and numbers of chlorinators shall be selected according to the table shown
below and the maximum rated flow of the Works:

Chlorination Chlorinator Number of

point kg/h Chlorinators

Duty Standby

Raw water 0,5 – 10 4 2

Treated water 0,5 – 10 2 1

Chlorinators shall be of the vacuum operated type with aqueous solution output and
shall be supplied by a manufacturer who has an authorized representative in Uganda.
Satisfactory arrangements shall exist for this representative to supply spare parts and
technical assistance and service when necessary. The Tender shall state the name of
the manufacturer and his representative in Uganda.
The whole installation shall be designed to fail safe and the closing down of any duty
chlorinator whether by failure of gas or operating water flow shall initiate an alarm
indicating the cause of failure. Alarms indicating low chlorine gas pressure and low
operating water pressure shall also be provided on the local control panel. The initiation
of any of these alarms shall also initiate a common alarm on the main control room
panel.
The chlorinators for manual and automatic operation with servomotor, gas flow meter,
differential pressure regulator, vacuum meter.
The dosing rate shall be according to a pre-set dosing rate and additional flow
proportional for pre-chlorination and according to the residual chlorine content with the
flow rate as disturbance value for post chlorination.
The chlorinator with all necessary equipment for a safety operation.
The chlorinators shall be located in a separate room.
Motive Water Pump
The motive water pumps shall be located in the control room in the chlorine building.
They shall be supplied with filtered water drawn from the contact tanks or some other
suitable place. The quantity and pressure required for this supply shall be stated in the
Tender.
 Number of pumps: Nine (6 duty + 3 standby)
 Type of pump: Vertical in-line centrifugal
 Power supply: 3 ph / 415 V / 50 Hz
 Speed: 2900 rpm

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The operating pressure and the capacity of motive water pumps shall be as
recommended by the chlorinator manufacturer.
Dosing Point
The disinfection point shall be applied into the inlet of the contact tank and the
coagulation tank, complete with all piping and injection units.
The Contractor shall determine chlorine dosing points with sufficient hydraulic mixing
intensity to ensure rapid contact of chlorine with the water.
Safety Equipment
Materials and equipment shall be provided to ensure protection of operators of chlorine
equipment in the event of gaseous or liquid chlorine leakage or shutdown and
dismantling of chlorination equipment. Ready means of escape from within the building
shall be provided.
Kits shall be provided to seal up small leaks or damaged valves on drums.
Two sets of self-sustaining (air cylinder type) breathing apparatus with full face masks
approved by the Employer shall be obtained from an approved supplier together with
two sets of PVC overalls, gloves, goggles and two pairs of rubber boots. Each set shall
be stored and displayed in a glass-fronted non-locking anti-corrosion cabinet so that
any deficiency in the equipment shall be apparent.
There shall be an emergency shower and a large earthenware sink with eyewash spray
provided outside the chlorine building close by the door to the control room. Both of
these shall be connected to the domestic water supply. The area around the shower
and sink shall be covered and shall have a concrete floor with concrete kerbs and
adequate drainage. Pipe work and fittings shall be suitably insulated against freezing.
There shall be two emergency buttons. One will be close to but outside the door of the
cylinder store and the other in the control room. They shall operate an audible alarm
and repeater alarms at the central control room and the central panel in the chemical
house, as detailed in the ICA Specification.
Sprinkler System
A ceiling mounted sprinkler system shall be provided in the chlorine cylinder store and
the chlorinator room. The system shall be manually operated with separate control for
each room. The controls shall be mounted in a location, which is remote from chlorine
cylinder and chlorination equipment. The water supply shall be taken from the site water
supply system. An automatic booster set shall be incorporated if the pressure in the
site water supply is not sufficient to meet the maximum demand of the sprinkler system.
Ventilation
The chlorinator room, the control room and the drum store shall be air-tight to each
other. The chlorinator room and the drum store shall be equipped with emergency
ventilators of sufficient capacity to change the air in these 6 times and 12 times per
hour respectively.
Emergency ventilation shall be started automatically by:
 a signal from a chlorine leak detector, and
 remote control from the chlorine building control room.
If the concentration of chlorine in air exceeds 2 mg/l, the emergency ventilation system
shall work automatically and continuously until the chlorine gas concentration in the air

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becomes less than the sensing limit of the detector, from when it started upon receiving
a signal form that detector. Ventilation shall continue for approximately 5 minutes in the
drum store and for approximately 2 minutes in the chlorinator room from the time the
system was started by remote control.
Inlets to exhaust ports shall be placed at floor level, located as far as possible from
doors, air inlets and other inlets. The outlets of these exhaust ports shall be sufficiently
high above the roof level so as to ensure effective atmospheric dilution of the expelled
air. The exhaust ducting shall be adequate in size and made of material resistant to the
chlorine, preferably PVC material.
The outlets of the exhaust ports shall be fitted with movable louvers. The louvers shall
open the system is started and shall close by gravity when stopped. The components
of the system shall be covered with chlorine-protective paints or shall be rubber lined
and shall be made of material suitable for the ambient conditions.
In case of major chlorine gas leakage in excess of 15 mg/l, the ventilation system shall
automatically shut down to contain the leakage and an audible alarm and a lamp in the
control room shall operate. The sprinkler system would then be manually activated. Full
details of other measures to be taken shall be given by the Contractor in the operating
manuals.
Crane
An overhead traveling crane with trolleys and double beams shall be provided and
installed in the drum storage room. The electric operated hoisting unit shall be mounted
in a trolley assembly which travels on the upper flanges of the girders
 capacity 2000 kg
 lifting beam for chlorine drums
 spring balance for cranes
 capacity 2000 kg accuracy ± 1 % of full scale value with extra-large easy to read
scale
2.4.3.18 Treated Water Pumping Station
The new treated water pumping station shall provide sufficient space to accommodate
the required pump-sets, which draw water from the reservoir and pump it to the three
different reservoirs. In the pump room there are also equipment for backwash
operations (air blower, backwash pumps and flow control equipment). Also technical
water equipment with pumps, priming equipment and drainage pumps are located in
this space, which is equipped with manual overhead crane.
The three treated water pump units will have the following main characteristics:
Pump Unit for Nsumba Reservoir
No. of units: 2+1 for Phase 1a and 1b and 2+1 for Phase 2
Type: Horizontal Split Casing Pump
Capacity: 1818 m3/h
Delivery head 136.7 to155.5 m WC
Efficiency: Above 80%
Power demand at shaft 1130 kW
Pump Material:

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housing: Casing – cast iron

Motor housing: Cast Iron
Impeller: CrNi steel
Shaft: Duplex SS
type of coupling: Direct
Impeller type: 1.4517
Motor Particular Spec for Pump Unit for Nsumba reservoir
No. of units. 2+1 for Phase 1a and 1b and 2+1 for Phase 2
Type: Horizontally TEFC for 40° ambient temperature
Voltage 3300 Volts
Nominal power 1250 kW
motor speed 1500 Rpm
safety class IP: 55
Starting method: FC Soft starting and stopping by FC
Axially split volute casing pumps
Axially split single/multistage volute casing pump for horizontal installation with double
entry radial impeller.
Shaft seal type Soft-packed stuffing box
Casing material Cast iron
Type of coupling Direct
Type of bearing Rolling element and plain bearings for long life
Type of lubrication Grease/oil lubrication
Impeller material 1.4517
Shaft material 1.4462
Casing wear rings 1.4462
Impeller wear ring 1.4462
Shaft protection sleeve 1.4138
Pump and motor on common base plate, complete set of pressure gauges (suction and
pressure side) temperature sensor for anti-friction bearings, mechanical flow sensor.
The pumps offered shall be capable of operating between the specified range of heads
without undue cavitations or vibration in single and parallel operation.
The delivery pipeline losses for all pump stations and suction pipeline losses have been
calculated with a K factor of 0.1, full details of the pumping mains are included for the
Contractor to make their own assessment, which shall be included in the tender with
supporting calculations.
The Contractor shall also determine station losses between the limits of the pipework
of the contract supply. The Contractor shall guarantee the performance of each pump
at the duty flow and the guaranteed duty point, with supporting calculations, shall be
stated in the tender.

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The pumping plant characteristics shall also permit satisfactory operation of a single
pump into the delivery main without cavitation or unacceptably low efficiency.
The Contractor shall calculate the NPSH available based on the lowest possible draw
down level and the selected setting depth of the pumps. The NPSH required by the
pumps shall under all operating conditions be at least 1.5 m less than is available.
Pumps shall be founded at or about ground level. However, alternative arrangements
may be proposed if these can be shown to be advantageous.
Pumping Equipment Requirements
The pumping installation shall be designed and constructed generally in accordance
with the Outline Drawings. Pumping plant, pumps and motors, shall be horizontally
mounted on a single fabricated steel baseplate and positioned to permit satisfactory
operational and maintenance access to the equipment.
The Contractor shall base his design on identical duty pumps, which shall have stable
operating characteristics, permitting single or parallel operation of pumping plant.
Pumps shall be selected with flat efficiency curves permitting economic operation at
the duty flows. Pumpset speed shall not exceed 1500 rpm without the approval of the
Engineer.
The maximum rated impeller diameter for the pump units selected shall be at least 10%
above the diameter required for the maximum duty condition.
The Contractor may propose the use of gearboxes between pump and motor only if it
can be shown that this is advantageous in matching pump and system characteristics,
is economically beneficial, and maintains an acceptable level of plant reliability.
Pump construction shall be suitable for an operational life of 20 years and shall be de-
signed for minimum maintenance. Pumps shall be fitted with impeller and casing wear
rings, shaft sleeving and soft packed type shaft seals. The pumps shall be provided
with an automatic venting system to prevent build-up of gas in the pump casings.
The Contractor shall assess the properties of the water pumped and provide pumping
equipment with appropriate materials of construction and ancillary services, such as
seal flushing and cooling water systems to suit the requirements of the pumping plant
selected. Pump materials of construction shall as a minimum utilise cast iron fit to the
relevant standard, for casings and impellers of bronze fit to the relevant standard. All
wetted internal components shall as a minimum be stainless steel or an equivalent
compatible corrosion resistant material. All materials in contact with the clear water
shall be suitable for potable water standards.
The design of the pumping plant shall be such as to ensure that noise levels inside this
area of the building do not exceed the specified limits. The Contractor shall provide
acoustic protection to the pumping equipment to achieve this requirement, if necessary.
Pump Motors Additional Spec
The motors shall comply with the following:
 Type : Wound rotor slip ring induction or squirrel cage
rotor with suitable device to reduce the starting current
 Number of phases : 3
 Number of poles : 4
 Rated voltage : 3.3 kV / 10 KV
 Voltage variation : plus and minus 5%

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 Frequency : 50Hz
 Rated output : To suit maximum pump requirement
 Duty : Continuous
 Protection class : IP 55
 Insulation class : F
 Anticondensation heating
 PTC protection
 PT 100 for temperature measuring for bearings, windings and cooling
 Cooling : Water cooled with separate motor mounted stator
and slip ring enclosure heat exchangers with water circulation by separate pump
or from water system pressure.
 Method of starting : Rotor resistance or similar
 Starting current : To limited the transient volt-drop at the 3.3 kV
busbar to not greater than 10% of rated voltage under minimum fault level
conditions
 High voltage cable box : Phase segregated
For pump and motor it is important to provide a sufficient and safe cooling system
designed for the max temperature and 24 h operation.
Monitoring and Pump set Protection Equipment
Pump and motor controls and monitoring equipment shall be designed to facilitate
automatic and manual operation. Pump sets shall be provided with adequate protection
devices and controls for safe operation under all operating conditions and during failure
of electricity supply, pipe burst situations or other system fault conditions.
Pumps not available for service shall have suction and discharge isolating valves
closed and ancillary systems shut down. Pumps in the available mode shall have
suction valve open, delivery valve closed, and ancillary circuits such as cooling water
systems shall be in operation. Under the start sequence the delivery valve shall open
automatically when the pump starts. A normal stop signal shall close the delivery valve
before stopping the pump. If a protection device should trip a pump, the delivery valve
shall remain open but shall close automatically before the pump can be re-started. The
pump shall not restart before the delivery valve is fully closed.
Facilities shall be provided on the pump sets for mounting pump/motor monitoring and
protection systems. The following features are required as a minimum:
 Delivery pressure;
 Suction pressure;
 Pump/motor bearing temperatures;
 Pump/motor vibration;
 Cooling system flow and temperature;
 Lubricant levels;
 Mechanical flow sensor.

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Facilities for the installation of the required control and monitoring equipment shall be
provided on each pumpset and associated pipework as described elsewhere in this
Specification. Local indication shall be provided at each pumpset showing pump
delivery pressure and suction pressure. The open/travel/closed position of delivery and
suction valves shall also be indicated locally.
Piping and Fitting
Complete piping, starting with the suction strainer in the reservoir and ending with
flange connection 1 m outside of the building including all fittings like:
Puddle flange
Rubber compensator to be used as noise and vibration damper for the absorption of
stresses, vibrations and small lateral and angular movements.
Connection of the pump outlet without any tension and stress
Eccentric taper enlarge the pump outlet to suction and pressure pipe
Non-return valve with adjustable weight or similar for cushioned closing
Dismantling piece
Double offset butterfly valve flanged with gear and motor operation for suction and
pressure side
Air valve with single chamber and ball valve
Header with connection of the 3 discharge pipes and with flange ending outside of the
building
Drainpipes to the pump sump
Complete with all fixing material and supports.
Surge Protection
The contractor has to prove the necessary protection arrangement by calculating all
possible operation situations. The calculation shall be submitted to the Engineer
together with the proposed protection system.
The volume and maximum working pressure shall be proved by the contractor based
on the surge analysis.
Surge Vessel Type
Surge vessel shall be of the gas pressured vertical, bladder type suitable for open-air
installation.
Quality Assurance
The surge vessel manufacturer shall have a test certificate for total quality assurance
of the manufacturing process from the relevant authority (BSL, ISO, etc.) for the
manufacturing facility of the surge vessel. The certificates valid for current production
(years 2017) shall be produced with the offer. Surge vessel to be supplied under this
contract shall only be from the approved factory location.
Design Requirements
The vessel shall be designed to maintain the pipeline pressure between – 0.6 bar to
16 bar in the treated water pumping main.

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The surge vessel shall be designed for anchor bolting to a concrete foundation. The
supports shall be designed to withstand all natural loading, any hydraulic and
pneumatic thrusts resulting from surges.
For basic data required for surge analysis please refer data given under pump
specifications.
Hydraulic Test
The surge vessel shall be hydrostatically tested at 1.5 times the maximum working
pressure for not less than 60 minutes.
The contractor shall furnish the Engineer with certified results of the tests.
Performance Test
The surge vessel shall be factory tested for its performance. The supplier shall submit
the test results before shipment of the vessel. Test results should show how the
pressure transients very with the time. The vessel shall be provided with all pipe works
and connections, tapping points for instrumentation, vents and drains.
The vessel shall be protected with a safety valve.
Bladder
The bladder shall be made out of thermoplastic polyurethane or butelene each
approved for use with foodstuff and shall be easily replaceable. The bladder shall be
perfectly watertight and airtight after the installation inside the vessel.
Gas is housed in the chambers between the bladder and the tank. In the hut connecting
with the pipe, there shall be an anti-extrusion grid for the protection of the bladder.
Fittings and Instruments
The surge vessel shall be equipped with the following:
 Flange outlets
 Inspection hole
 Drainage plug
 Pressure gauge with isolating valve
 Safety valve
 Air inflation plug
 Supporting legs
 Lifting lugs
The vessel is connected to the header with a butterfly valve. The connection flange size
shall be the same size as the header.
The protection equipment shall be maintenance free, easy to monitor and reliable.
The pressure test of the surge vessel shall be 1.5 x of the maximum pressure.
Crane
A gantry crane with lifting capacity 1.5 times the max load which will be required to lift
shall be installed in the pumping station including all necessary equipment to operate
the crane ready for operation.
Side rail with supporting beam

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Bridge out of double TEE-profile or welded on wheels manually movable.

Trolley shall be manually movable
Hoisting shall be done by electrically operated chain block.
Ventilation System
The Vent System shall assure a sufficient air exchange at all points of the pump floor.
The air exchange shall normally automatically controlled. In case of service and
maintenance the air exchange rate shall be triple.
The air shall be extracted by exhaust fans mounted on the sidewalls with canal down
to the floor of the pumping station.
Number of fans: min two and according to air volume
Air Blower
Two air blowers shall be housed in the Drinking water pumping station.
The rate of free air delivered to each filter unit shall be chosen according to the
experience and the standard filter design of the Contractor and shall be distributed
uniformly over the filter media, as may be seen when viewed from above a filter. The
Contractor shall state his air scour rate as m3 free air per hour per m2 of filtering area.
The Employer will require the air scour rate to be proved if he is not satisfied that the
rate will be sufficient and the Contractor shall bear all costs of such proving. The
Contractor shall take any necessary correcting measures should they be needed.
The air scour rate recommended by the Employer is 60 m3/h free air per hour per
m2 filter area.
Two identical capacity air blowers shall be supplied (one duty – one standby).
Automatic changeover of these blowers after each cycle shall be provided in order to
provide each blower with equal operation time and selector switches shall be installed
to ensure manual operation of this automatic system.
Blowers shall be of the positive displacement rotary type giving a constant discharge
rate. They shall incorporate profile rotors in casing, gear trains and electric motor drives.
Air blowers will be coupled to the electric motor drives through belt drive mechanisms.
Valves and pipe work shall be designed for air velocities not exceeding 30 m/s. Care
shall be taken in the design of the filter inlet to handle high air velocities.
Each blower unit shall be provided with an air filter and silencer on the suction side and
a pressure relief valve, non-return valve and pressure gauge on the delivery side.
A pressure gauge shall be installed on each common air main.
Each unit shall be provided with anti-vibration mountings and flexible connections.
The Contractor shall state the noise level of the proposed blowers.
The noise level shall not exceed 85 dBA.
Speed control shall be done by changing fan belt drive.
Air release only with silencer.
Material:
 Blower casing GGG 40
 Cylinder GG 25

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 Bearings: Oil lubricated for at least 60,000 hours

 Control gears: Harden and polished, oil submersed
 Seal rings: Labyrinth out of GGG
 Shaft seal: Mechanical radial seal with bushing out of 1.3505
 Closed cooling system
Protection:
 Pressure safety valve
 Pressure switch
 Temperature switch
 Speed control and monitor
 Clutch with overload limit
Accessories:
 Air filter out of polypropylene fibre
 Suction silencer
 Common foundation frame
 Pipeline connection with rubber suspensor
 Load release valve
 Non-return valve
 Sound cover
Installed with all pipe connection fittings fixtures ready for operation.
Air Blower:
 Number of blowers: Two (one on duty, one on standby)
 Rotary piston Type
 Atmosphere Pressure 1 bar
 Ambience Temperature max 40 °C

Blower Motor IP55

Blower capacity Q m3/h 4800 Volt 3 x 415

Air Flow Q m3/min 80

Pressure mbar 45

Revolution min-1 2500 Frequency Hz 50

Each Air Blower is connected to the header by discharge pipe with butterfly valve,
hand/motor operated and soft sealing non-return valve for air. Installed with all pipe and
fitting work ready for operation.

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Adequate ventilation of the blower station shall be foreseen.

2.4.3.19 Sludge Pumping Station
To pump the backwash water collected in the settling tanks back to the head of the
water treatment plant, a sludge pumping station shall be constructed as follows:
 Backwash Water Pumps
- 2 centrifugal pumps dry installed, horizontal installation position with non-
clogging impeller and direct coupled E-motor
- Speed of rotation 1500 1/min
- Shaft seal gland packing
- Casing material: cast iron
- Impeller and wear plate made of nickel cast iron (wear resistant)
- Pump and motor on common base plate
- One pump designed for
- Q = 225 m3/h
- Hman ≈ approximately 10 m
- The second pump is for standby
- Each pump with pressure gauge, dismantling pieces, complete piping and
fittings, non-return valves and gate valves on suction and pressure side.
- The pipes laid up to 1 m outside of the building
- Drainage system to the drainage pump sump
 Drainage Pump
- 1 submersible drainage pump
- Q ≈ approximately 10 l/s
- Hman ≈ approximately 13 m
- with non-clogging impeller
- complete with float switch and fixed piping system with non-return valve
and gate valve to pump to the drainage system

Crane
 Overhead traveling crane as monorail
 The rated capacity shall be 1.5 times the maximum load which will be required to
lift.
 Traveling crab and lifting gear manually operated

2.5 PIPEWORK
All pipework shall be provided to complete the treatment plant works from the point of
connection on the raw water supply main to the point of connection for the treated water
main.
External pipework shall be fabricated steel, utilising welded joints and minimising the
use of buried flanges and flexible connections except where items of plant are

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connected. The external pipework systems shall as a minimum be of an equivalent

specification to the adjacent water transmission pipelines.
External equipment connected to buried pipework, such as valves, flowmeters, tapping
points, etc. shall be easily accessible for operational and maintenance purposes and
will be located in chambers of reinforced concrete construction and equipped with a
forced ventilation system and drainage sump. Chambers shall be fitted with small
power and lighting services.
The Contractor shall ensure sufficient thrust blocks and pipe supports are provided to
accommodate the forces generated by the transfer of water and other liquids through
the pipework systems under all operational conditions. Requirements for support of
pipework shall be incorporated on the drawings submitted by the Contractor.
Insulation joints will be provided between pipeline and treatment works as part of the
corrosion protection system adopted by the pipeline Contractor.
All pipework shall be accessible, pipework shall not be covered by building structures
or access roads as far as possible.
Buried pipework shall be internally and externally coated with an epoxy coating system.
Pipework, joints and fittings shall be externally wrapped with a proprietary heavy duty
self-adhesive rubber bitumen wrapping system.
Pipework within the plant buildings shall be of fabricated steel using flanged sections
for ease of assembly and subsequent maintenance. Pipework shall be internally and
externally coated with an epoxy coating system.
Pump branch pipework shall be designed to give velocity of flow not greater than
2.5 m/s under maximum throughput. Velocities in pipework shall not exceed 1.5 m/s for
suction manifolds and 2.5 m/s for delivery manifolds.
Isolating valves shall be solidly bolted to all suction and delivery pipework. Tied flexible
couplings shall be installed between items of plant to facilitate erection and removal of
equipment for maintenance. Air release and drain valves shall be provided at high and
low points in each pipework system.
Instrumentation tapping points shall be provided as necessary and shall be positioned
on pipe horizontal centre lines. Tapping points shall incorporate stainless steel isolating
cocks.
Pipework connecting pump tundishes to the station sump shall be provided for drainage
of gland leakage.
Delivery pipework pressure ratings shall not be less than whichever is the greater of
pump closed valve delivery pressure or any possible operating condition. Suction
pipework shall be rated not less than PN10, or the pipeline rating to which it is attached,
whichever is the greater.

2.6 SPARE PARTS

Spare parts shall be accurately manufactured from the same materials and to the same
dimensions and tolerances as the originals. They shall be new, unused and strictly
interchangeable with the parts for which they are intended to be replacements. They
shall be treated and packed for long storage under the climatic conditions prevailing at
the site. Special care shall be paid for storing electrical and electronic equipment in the
prevailing conditions. Each spare part shall be clearly marked or labelled on the outside

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of its packing with its description and purpose, and when more than one spare is packed
in a single case or other container, a general description of its contents shall be shown
on the outside of such case or container and a detailed list enclosed. Cases, containers
and other packages shall be marked and numbered in an approved manner for
purposes of identification. Cases, containers or other packages shall be marked and
numbered in an approved manner for purposes of identification. Cases, containers or
other packages shall be designed to facilitate opening and thereafter repacking.

2.7 TOOLS
To facilitate the on-site maintenance and repair activities required at the water
treatment works, equipment suitable for routine maintenance of mechanical, electrical
and instrumentation plant, shall be provided. Equipment shall also be provided for
removal, transport and replacement of items of plant located outside of main service
buildings.
Tools shall be equipped to enable routine maintenance functions to be carried out,
dismantling, site repair, removal and replacement of plant. The workshops shall be
equipped to enable mechanical, electrical and instrumentation maintenance work to be
undertaken. The workshops shall be self-contained having all the facilities, tools,
equipment and services needed for the work to be undertaken on the water treatment
work’s plant.
The workshop facilities shall incorporate equipment for supporting, lifting and
dismantling mechanical equipment, pipework and valves, facilities for cleaning plant,
minor workshop facilities sufficient to enable simple repairs to be carried out, and
measurement and test equipment to ensure repaired plant is functional. It shall also
have equipment for dismantling, cleaning, inspection, repair, calibration and testing of
electrical plant, including motors, switchgear, cables, instruments, control systems,
electronic devices, PLC instruments, transducers and other equipment installed.
The workshop structure shall provide a dust-free environment for the maintenance
equipment and adequate ventilation and lighting for the activities to be carried out within
the enclosure.

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