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STANDARD

SPECIFICATIONS FOR
CONSTRUCTION WORKS
2008

Module – 18 – Sewerage M&E Works


Introduction

The Standard Specification is published in a series of 21 stand-alone modules each addressing

single distinct areas of the construction process. This stand-alone module 18 addresses the main

aspects of sewerage Mechanical and Electrical (M&E) works in general.

The purpose of the MoW STANDARD SPECIFICATIONS FOR CONSTRUCTION is to provide the

design professional with a guide for accepted construction practices for Ministry of Works projects.

As an aid to the designer, these Standard Specifications are provided for the inclusion in proposed

development projects for ease, efficiency and cost savings.

The Standard Specifications are not intended to limit the design responsibility of the design

professional. However, they establish a minimum acceptable criterion and/or quality for use within

Ministry of Works projects.

The design professional may increase the requirements of an item contained in the Standard

Specifications to meet job requirements, but when this is done, there should be no reference for

that item on the drawings to the Ministry of Works Standard Specifications and a new specification

should be included with the drawings or project contract documents.

The design professional must review all Standard Specifications to be sure that they are adequate

for the proposed project based on the job site conditions; the design professional is solely

responsible for the designs submitted under his seal.

In order to keep design standards current with changing regulations and improved construction

materials and practices this section will be updated and maintained by the concerned authorities of

the Ministry of Works. Prior to starting a new project, the design professional should contact the

concerned Directorate of the Ministry of Works to verify that he/she has the latest document

revisions.

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Module List
Module
No Module Title
1 Guidance and General Specifications

2 Concrete

3 Earthworks

4 Glass and Glazing

5 Joinery and Carpentry

6 Ironmongery

7 Internal Finishes including Thermal Insulation

8 Painting and Decorating (Internal & External)

9 Metalwork

10 Roofing

11 Structural Steel (and Coatings)

12 Structural Timber

13 Masonry

14 Plumbing and Sanitary

15 Mechanical Installation in Buildings

16 Electrical Installation

17 Sewerage Pipelines and Pipe work

18 Sewerage M&E Works

19 Roadworks

20 Landscaping

21 Dredging, Reclamation and Shoreline Protection

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Table of Contents

CLAUSE DESCRIPTION PAGE

Introduction 1

Module List 2

Table of Contents 3

Foreword 5

1. PART 1 GENERAL 6

1.1 Scope………………………………………………………………………………... 6
1.2 Extent of Contract………………………………………………………………….. 6
1.3 Standard Specifications…………………………………………………………… 6
1.4 The International System of Units (SI)…………………………………………… 6
1.5 Materials…………………………………………………………………………….. 6
1.6 Castings and Forgings…………………………………………………………….. 7
1.7 Lubrication………………………………………………………………………….. 8
1.8 Bolts, Screws, Nuts, Studs and Washers……………………………………….. 8
1.9 Noise and Vibration………………………………………………………………… 9
1.10 Notices and Labels………………………………………………………………… 9
1.11 Sub-Contractors and Suppliers………………………………………………….. 10
1.12 Delivery and Storage……………………………………………………………... 10
1.13 Documentation to be supplied by the Contractor……………………………… 12
1.14 Approval Procedures……………………………………………………………... 14
1.15 Shipping Documents……………………………………………………………… 14
1.16 Information Prior to Approval…………………………………………………….. 15
1.17 Installation…………………………………………………………………………. 15
1.18 Site Works…………………………………………………………………………. 16
1.19 Training…………………………………………………………………………….. 17
1.20 Nameplates and Data Labels……………………………………………………. 18
1.21 Spares……………………………………………………………………………… 18
1.22 Special Tools………………………………………………………………………. 18
2. PART 2 MECHANICAL EQUIPMENTS 19

2.1 Pumps……………………………………………………………………………… 19
2.2 Surge Vessels……………………………………………………………………...30
2.3 Actuators…………………………………………………………………………… 31
2.4 Blowers…………………………………………………………………………….. 31
2.5 Air Conditioning and Ventilation Installations………………………………….. 32
2.6 Refrigeration Plant………………………………………………………………… 42
2.7 Ductwork, Grilles and Diffusers…………………………………………………. 56
2.8 Odour Treatment Technologies…………………………………………………. 61
2.9 Pipe Work Systems for Sewerage Works……………………………………… 66
2.10 Cast Iron Covers and Frames…………………………………………………… 73
2.11 Electric Overhead Travelling Crane…………………………………………….. 73
3. PART 3 ELECTRICAL EQUIPMENTS 79

3.1 Electric Motors and Ancillaries…………………………………………………... 79


3.2 Standby Generators………………………………………………………………. 80
3.3 Cabling……………………………………………………………………………... 84
3.4 Plant Earthing……………………………………………………………………… 87
3.5 Outdoor Equipment……………………………………………………………….. 89

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3.6 MCCs and Control Panels……………………………………………………….. 90
4. PART 4 CONTROL AND INSTRUMENTATION 112

4.1 Control Circuits and Equipment………………………………………………... 112


4.2 Instruments General…………………………………………………………….. 114
4.3 Level Instruments………………………………………………………………... 114
4.4 Flow Instruments………………………………………………………………… 117
4.5 Pressure Instruments…………………………………………………………… 121
4.6 Temperature Instruments………………………………………………………. 122
4.7 Analytical/Quality Instruments………………………………………………….. 122
5. PART 5 METHODOLOGY AND WORKMANSHIP 125

5.1 Workmanship…………………………………………………………………….. 125


5.2 Equipment Access and Maintainability………………………………………... 125
5.3 Fixing of Machinery……………………………………………………………… 126
5.4 Electrical………………………………………………………………………….. 127
6. PART 6 TESTING AND APPROVAL 128

6.1 Testing……………………………………………………………………………. 128


6.2 Submittals………………………………………………………………………… 129
6.3 Mechanical……………………………………………………………………….. 130
6.4 Electrical………………………………………………………………………….. 131
6.5 Commissioning…………………………………………………………………... 131
7. PART 7 REFERENCE STANDARDS 132

7.1 Mechanical……………………………………………………………………….. 132


7.2 Instrumentation,Control and Automation……………………………………… 134
7.3 Electrical………………………………………………………………………….. 136

Abbreviations 140

Page 4
Foreword
This specification provides the basis for Sewerage Mechanical and Electrical Works. It covers the

main requirements for all plant, labour, materials, transport, testing etc involved with the installation

of Mechanical and Electrical plant and equipments.

This specification must be read in its entirety, as it is structured in order of work-flow, which means

that items or activities appear in several places in the specification corresponding to the

progression of the construction process.

For larger or more complex or specialist projects, a project-specific Particular Specification for

Sewerage M&E Works may also be provided.

Absence of clauses for materials and methods does not necessarily signify that they can not be

used. Proposals for use of innovative methods and materials are encouraged and are subject to

review and approval by the Client.

Where the word ‘approved’ is used in this specification, this means that the Client or Engineer has

been consulted and has confirmed that the item or procedure is acceptable in the specific context

for which approval has been requested.

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1. PART 1 GENERAL

1.1 Scope

This module for Sewerage M&E works covers the general requirements for sewage
Mechanical and Electrical Installations at works. Requirements that are particular to the
installation are given in the Particular Specifications. In the event that the Particular
Specification requirements conflict with these general requirements, then the Particular
Specification requirements shall take precedence.

1.2 Extent of Contract

The Contractor shall provide everything necessary for the proper execution of the Works
according to the Contract, including any work, matter or requisite not particularly
described in these specifications that is required to meet the provision of the performance
specified.

The Contractor shall provide for the design, manufacture, delivery to Site, storage,
erection, testing and take over procedures of the Mechanical and Electrical Plant and
Equipment and documentation supplied through this Contract. The Contractor shall also
carry out any specified ancillary civil works required.

1.3 Standard Specifications

The British Standard Specifications and International Electromechanical Commission


Standard quoted generally in this Specification are for guidance as to the quality of
materials, equipment and workmanship required. The Contractor may offer materials,
equipment and workmanship to alternative National Standards Specifications and shall
satisfy the Engineer that the quality demanded by such specification is equal to or better
than the appropriate British Standard Specification.

In all cases the quoted or appropriate British Standard or International Electromechanical


Commission Specification shall be the latest edition with amendments made immediately
prior to the date of submission of Tenders.

Where materials and equipment are specified to comply with British or other National
Standards the Contractor shall, if required, obtain from the manufacturers and supply to
the Engineer's Representative the appropriate certificate of compliance with such
standards.

1.4 The International System of Units (SI)

The International System of Units (System International d'


Unites) of Weights and
Measures shall be used for all material and equipment.

1.5 Materials

Only materials and equipment that has a proven track record in the region will be
accepted by the Engineer for inclusion in the Works. Major items incorporated in the
installation shall be manufactured according to the most well known standards and
specifications and of a type that has a proven usage history in different regions.

Equipment and materials to be provided by the Contractor and incorporated in the Works
shall be new, unused, and of the most recent, or current design and specification, and
shall incorporate all recent improvements in design and materials unless detailed
otherwise in this Specification. Materials shall be free from any flaws, defects or
imperfections.

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Equipment catalogues, manufacturer’s specifications and detailed designs shall be
submitted for the examination and approval of the Engineer before any equipment is to
be ordered.

Equipment catalogues; manufacturer’s specification and detailed designs related to the


proposed equipment shall be specific and shall include all information necessary for the
Engineer to ascertain that the equipment complies with this Specification and the detailed
electrical & mechanical Specification and drawings. Data and sales catalogues of a
general nature will not be accepted.

Items selected for the Works shall require low maintenance and provide a high level of
reliability.

Manufacturer' s standard equipment shall be provided and as a minimum requirement,


shall incorporate those features normally associated with the equipment as detailed in
manufacturer' s specifications and literature, unless specifically excluded. Where this is
not possible, it shall be made clear at the Bid stage how and why the equipment
proposed differs from the manufacturer’s standard.

Unless otherwise specified, all items of Plant shall be rated for continuous service at the
specified duties under the prevailing atmospheric and operating conditions at site.

Equipment carrying out the same or similar functions shall be of the same size, type and
manufacture.

All component parts of the Plant shall be manufactured to a strict system of limits and
complete interchange ability of similar parts is required.

Unless specified otherwise, heavy-duty long life materials and related components shall
be fitted to rotating equipment.

Submerged parts of the Works, shall be of non-corrodible material. Where this is


impractical appropriate treatment shall be applied to prevent corrosion. Equipment in
contact with chemicals shall be resistant to corrosion or abrasion by those chemicals and
maintain their properties without deterioration by the passage of time, exposure to light or
other cause.

Materials and components shall be stored in such a manner as to preserve their quality
and condition to the standards required by the Contract.

Materials and components shall be handled so as to avoid any damage or contamination


and in accordance with manufacturers'recommendations where applicable.

The use, installation, application or fixing of materials and components shall be in


accordance with applicable manufacturers'recommendations.

Where dissimilar metals would otherwise be in contact, insulation strips and/or sleeves
shall be fitted as appropriate to prevent electro-chemical corrosion. Where stainless steel
has been referred to in this document it shall be provided to BS EN 10250: Part 4 Grade
316L or equivalent grade.

1.6 Castings and Forgings

Only sound castings and forgings shall be incorporated in the Works. Welding, building
up, filling or any other processes to recover castings will not be permitted in respect of
any casting associated with pumps, compressors, gear boxes or other such plant subject
to pressure or vibration.

Machined surfaces shall be free from blemishes and other surfaces shall be carefully
fettled to remove any foundry irregularities including fused-on sand.

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1.7 Lubrication

1.7.1. Bearings

Bearings shall be selected for adequate load bearing capacity and reliability.. They shall
be sealed for life or be fitted with automatic grease or oil lubricators. Lubrication points
shall be grouped with a separate nipple and pipe feeding individual bearings. Lubrication
points shall be easily accessible. Bearings shall have a minimum design life of
100,000 hours operation at maximum loading.

1.7.2. Gearboxes

Reduction gearboxes shall be robust and continuously rated and selected for reliability
and efficiency over the required range of loadings.

Non-submersible gearbox drive casings shall be fitted with filling, level and drain points.
Taps shall be fitted to the drain, and the gearbox shall be positioned such that the oil may
be collected in a suitable container.

1.7.3. Seals

Gearboxes shall have a life of 100,000 hours, be selected in accordance with A.G.M.A.
recommendations for horsepower calculation and service factor application, and employ
a standard reduction ratio.

Except where particularly specified 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.

Seal materials shall be compatible with and/or resistant to the fluid or gas being handled.

1.7.4. Glands

Glands 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.

Gland drain pipe work shall be installed, incorporating roding facilities and adequate
inclines of 25 mm minimum diameter on water reclamation plant and 12.5 mm on water
supply plant, discharging to the nearest sump or drainage channel.

1.7.5. Lubricants

The Contractor shall tabulate all lubrication points, the recommended grease or oil, its
grade and the recommended service interval in the form of a chart. The Contractor shall
include the supply all necessary oils and lubricants for the initial fill and the first years
operation so that testing and commissioning may be carried out without undue delay.

1.8 Bolts, Screws, Nuts, Studs and Washers

Fixings to be used in conjunction with the works shall have thread forms which comply
with BS 3643: Part 1 and Part 2 Isometric screw threads, and also BS 4190.

Exposed bolt heads and nuts shall be hexagonal and the length of bolts shall be such
that, when fitted with a nut and washer and tightened down, the threaded portion shall at
least fill the nut and not protrude from the face thereof by less than two threads or more
than four threads.

Fasteners and fixings shall generally be manufactured from nickel-bearing stainless steel.

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Pipe work flange fixings shall be stainless steel.

Wood screws and fixings shall be of brass with round heads.

1.9 Noise and Vibration

With the envisaged maximum number of items of Plant running ' on-load'the sound
pressure outside an envelope of 1 m radius from any item of Plant shall not exceed
80 dB(A). Where the noise cannot be reduced to a level complying with this requirement,
acoustic enclosures shall be provided. Where the Plant is installed in a separate
room/enclosure, the noise level shall not exceed 80 dB(A) outside the room/enclosure.
Control room noise levels shall not exceed 55 dB(A).

Hazardous warning notices indicating that ear defenders are to be worn shall be installed
at entrances to rooms/enclosures where the sound pressure level exceeds 80 dB(A).

Noise level measurement shall be made with a sound level meter which complies with BS
EN 61672-2:2003 and which is fitted with an '
A'weighting network. The sound pressure
level shall be measured in dB(A).

Machinery vibration shall not exceed the limits defined in BS 7854-1:1996, ISO 10816-
1:1995.

Revolving parts shall be properly balanced both statically and dynamically so that in
running up to, and at full normal speeds, and at any loads up to the maximum in each
case, there shall be no undue vibration anywhere in the machine or in the Works or
surrounding neighbourhood.

The criteria adopted for vibration severity shall be the RMS value of the vibration velocity
in millimetres per second.

Instruments for measuring vibration severity shall be in accordance with BS 4675: Part 2,
ISO 2954 Mechanical vibration in rotating machinery. Requirements for instruments for
measuring vibration severity.

Limits of vibration severity for rotating electrical machines shall be in accordance with BS
EN 60034: Part 14. This level shall not be exceeded when connected to the driven plant
in the service position.

1.10 Notices and Labels

1.10.1. General

Wherever notices or labels are required the Contractor shall provide two labels. The first
shall be engraved with the text in English and fitted at prior to inspection at the
manufacturer’s works. The second label shall be left blank for the Arabic text to be added
after the equipment has been installed. The Engineer will provide the Contractor with the
Arabic translations and the Contractor shall engrave the labels and fix them to the
equipment in addition to the English labels

1.10.2. Notices

The Contractor shall provide and fix necessary instruction notices and schematic
diagrams adjacent to the various items of plant/plant system.

Equipment that may start automatically or may be started from a location remote from the
equipment shall have a notice affixed. The notice shall bear the following legend in
"WARNING THIS PLANT MAY START AUTOMATICALLY".

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Exits from the site, buildings and structures shall be indicated by notices, where these are
within buildings they shall be illuminated.

1.10.3. Labels

Labelling shall include compulsory signs covered by British Standards BS 5499: Part 5
and BS 5378: Part 2.

Each item of equipment shall be tagged with a unique tag number, the tag numbers will
be allocated by the Engineer following the submission by the Contractor of the equipment
list for the Works.

Each item of equipment shall have a name and rating plate, engraved or stamped with
the Manufacturer's name, type and serial number of the equipment, details of the loading
and duty at which the item has been designed to operate and sufficient detail to allow the
assembly to be readily identified in correspondence and when ordering spare parts.

Labels shall be robust, weatherproof and resistant to cracking and fracture. Colourfast
numbering and lettering, in block capitals and/or symbols shall not be less than 5 mm
high. A label schedule shall be provided for equipment supplied. Labels shall include a
maintenance reference number for the item of equipment to which they are fixed.

The Contractor shall furnish the Engineer with a schedule of labels as part of the detailed
design information.

Labels shall, where practicable, be mechanically fixed to the equipment; the use of other
fixings shall be subject to specific written approval of the Engineer.

Outdoor labels are to receive 2 coats of lacquer.

1.10.4. Pipeline Identification

Pipes shall be colour banded in accordance with BS 1710 to identify their contents. Band
widths may be reduced in agreement with the Engineer where space is at a premium.
Bands may be applied using paint or approved plastic bands. Additionally, each pipe shall
have words describing its contents over each colour band.

1.11 Sub-Contractors and Suppliers

Any work carried out or equipment supplied by specialist firms, shall be approved by the
Engineer. Installation Contractors shall be approved by the Engineer for the category of
work to be undertaken.

The Contractor shall use manufacturers and suppliers as indicated on the drawing or
where not indicated submit details of his proposed manufacturers, suppliers and/or
agents for the approval of the Engineer.

1.12 Delivery and Storage

Plant agreed by the Engineer for delivery prior to erection shall be delivered to a position
agreed with the Engineer. Equipment not being immediately installed shall be stored on
Site in a secure weatherproof temporary storage facility. The storage facility shall be to
the approval of the Engineer.

If for any reason the Employer delays the installation, the Contractor shall make provision
for storage of his Plant and Equipment and shall not deliver to Site until the Engineer has
certified that the Site is ready to receive the equipment. In this case payment for
extended storage beyond the programmed date for delivery shall be borne by the
Employer, and paid in accordance with the rates in the Schedule of Prices. These rates
shall include for refurbishment of goods in store to prevent deterioration and maintain a

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defects liability guarantee of 12 months from the issue of the Certificate of Completion of
the Works.

Plant shall not be delivered to Site until all tests and inspections have been carried out to
the satisfaction of the Engineer. On approval of the test/inspections the Contractor shall
apply to the Engineer for approval to ship. The request shall be in writing specifically
relating to the plant to be shipped, and shall be submitted at least 14 days prior to the
shipping date.

1.12.1. Packing and Protection of Equipment

The Contractor shall be responsible for ensuring that items of equipment, special tools,
spares, special lubricants, test equipment and documents are packed for transport and, if
necessary, for storage in such a manner that protection against environmental conditions,
mechanical damage and deterioration is effected.

All Plant shall be packed in accordance with BS 1133 in bundles or seaworthy containers
or packing. No second hand timber shall be used.

All packing shall be suitable for the type of equipment involved and for transport from
factories to the port of embarkation, sea/air freight, rough handling at the port of
destination and movement to and on the Site.

Special provisions shall be made regarding the prevailing severe local climatic conditions.

All boxes, cases and/or bundles containing Plant shall be clearly marked on all sides.

The markings on the box, case and/or bundle shall be of block letters not less than
50 mm in height, stencilled with black indelible paint. The following information shall be
shown on each box, case and/or bundle:

CLIENT’S NAME AND ADDRESS


CONTRACTOR' S NAME
PORT OF DESTINATION
CONSIGNMENT SERIAL NO.
GROSS WEIGHT
NET WEIGHT
SIZE OF BOX OR BUNDLE (LENGTH x WIDTH x HEIGHT)
BRIEF INDICATION OF CONTENTS
EQUIPMENT TAG NO.

The Contractor shall be entirely responsible for ensuring that the packing is suitable for
transit and shall be liable for any loss or damage due to faulty packing, having due regard
for the nature of the voyage.

1.12.2. Lifting Equipment

The Contractor shall be responsible for any lifting equipment necessary for off-loading,
handling between storage and erection if necessary, and for the erection of his plant. The
Contractor shall be responsible for satisfying himself as to the adequacy of Site roads
and hard standing necessary for lifting equipment requirements, and shall advise the
Engineer at least 7 days in advance of the type, space and gross weight of any lifting
gear or cranes.

The Contractor will be allowed use of the Employers permanent existing lifting equipment
if deemed suitable by the Contractor. The Contractor shall submit a lifting schedule and
method statement to the Engineer for approval before using the permanent lifting
equipment. On approval of the method statement, the Employer shall provide a Permit to
Work for the lifting equipment.

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1.12.3. Receiving Damage Reports

The Contractor shall submit receiving reports to the Engineer to cover each individual
shipment received and checked at the Site. Each shipment on arrival at the Site shall be
unloaded, opened and carefully checked for any damage in transit and the Contractor
shall immediately submit a damage report, countersigned by the Engineer, to the
Insurance Company with copies to the Employer and to the Engineer. Where damage
has occurred in Marine Transportation a copy of the damage report shall also be sent to
the registered/appointed surveyor.

In all cases of irreparable damages, the Contractor shall immediately notify the relevant
manufacturer(s). He shall also immediately notify the Engineer of the actions he will be
initiating and undertaking in order to repair or replace the damaged part(s) and of the
consequences this damage will have on the completion date of the Works. Any repairs
proposed by the Contractor will be subject to the approval of the Engineer.

1.13 Documentation to be supplied by the Contractor

1.13.1. General Requirements

Documentation shall be submitted in English.

Documentation shall be supplied in both paper and electronic versions in the quantities
detailed below. The format of the electronic copies shall be agreed with the Engineer.

Documents submitted for approval shall be signed as approved by the Contractor. In the
case of sub-contractor documents, these shall also be checked by the Contractor prior to
issue for approval. The Contractor shall date stamp, and sign each of the sub-contractor'
s
documents. Any documents submitted to the Engineer for approval that have not been
signed as checked and approved by the Contractor will be returned for re-submission.

Submissions by the Contractor shall be accompanied by detail of any proposed


deviations from the requirements of the Contract, or failing which it shall be deemed that
the Contractor’s proposal are fully compliant vide the requirements of the Contract.

1.13.2. Drawings

Four copies of the following drawings shall be submitted for approval within the period
stated from the date of the Order to Commence or other date thereafter as directed by
the Engineer:

Details of electrical circuits and components.

Schematic diagrams complete with a legend of symbols used. The diagrams shall
incorporate a grid system for relay contact identification.

For PLC systems a fully annotated version of the PLC programme software shall be
supplied in both paper and electronic format.

Instrumentation schedules and loop diagrams.

Cable schedules and cable route drawings; including cable sizing calculations in
accordance with BS 7671 Requirements for electrical installations, IEE Wiring
Regulations - Seventeenth edition

Draft Plant and valve schedules including Employers plant numbers. This schedule shall
be updated monthly until all Plant has been approved. A final version shall be included in
the Operation and Maintenance manuals.

Additional drawings of particular items: if called for by the Engineer.

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Dimensions of cubicle support plinth including loading.

1.13.3. Testing and Commissioning Documentation

The Contractor shall produce documents which fully describe and detail tests to be
undertaken on the Works and shall include but not be limited to the following:

• Manufacturing and type test certificates.


• Factory Inspection programmes.
• Inspection procedures.
• Test reports.
• Commissioning Programme.
• Commissioning procedures and records.
• Dry (and clean water) test procedures and method statements, identifying approval
required, i.e. permits to impinge.
• Taking Over test procedures and method statements identifying approvals required,
that is, permits to impinge.
• Records of plant maintenance and plant failures prior to take-over.

Documents detailing test programmes or procedures shall be submitted to the Engineer


for approval 2 weeks prior to the testing or commissioning taking place. A complete
record of the testing and commissioning procedures and results shall be included in the
O & M manuals.

1.13.4. O&M Manuals

No later than 2 weeks before plant is offered up for Tests before Completion 3 copies of
the draft instructions for the Operation, Maintenance and Overhaul of the plant shall be
submitted for approval by the Engineer.

The Contractor shall provide the Employer with three copies of approved instructions for
operation, maintenance and overhaul of the equipment, including drawings of the internal
details referenced to enable any spare parts to be readily ordered. Instructions shall be
bound together in durable, hard backed, plastic covered binders or folders.

The instructions shall comply with BS 4884: Parts 1-3.

Equipment not supplied under the Contract shall not be referred to in the instructions
except where the operation control and instrumentation of equipment requires existing
equipment to be incorporated.

The instructions shall include but not be limited to the following:

• Recommendation for consumable supplies, for example, pump spare parts for two
year operation.
• A brief outline of the operation of the Plant including the sequence of events required
for the operation of each item of Plant. The information shall be in sufficient detail to
allow uninstructed personnel to be instructed in the operation of the Works.
• Instructions on how to stop and start the Plant, noting any safety and operating
sequence requirements.
• Details of required preventive maintenance with recommended frequencies of action
including the testing, adjustment, and calibration of equipment following
maintenance and during normal operation.
• Details of each item of equipment including the name and address of the
manufacturer and the local agent, type and model, serial number, duty and rating,
clearances and tolerances where applicable.
• Spare parts lists containing all necessary information for ordering parts.
• Lists of packing seals and gasket materials.
• List of special tools required for maintenance.

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1.14 Approval Procedures

Approval will be given by the Engineer within twenty-one days of receipt of the drawings
or documents. The Engineer will inform the Contractor by returning a copy of the
document, or alternatively the status may be confirmed by letter without returning a copy
of the document, marked with one of the following remarks:

• "Approved"
• "Approved Subject to Comments"
• "Returned with Comments"
• "Examination Not Required"

The remark "Approved Subject to Comments" authorises the Contractor to proceed with
the fabrication subject to the corrections or comments noted on the document and/or
accompanying letter or approval sheet.

After correction, the document shall be resubmitted to the Engineer for approval with all
corrections made on the drawing.

The remark "Returned with Comments" indicates that the document must be revised and
resubmitted for approval before proceeding with the manufacture.

The remark "Examination Not Required" indicates that the details on the document are
not considered to require approval by the Engineer due to such details being standard,
typical etc., or not relevant to the acceptability of the equipment/design.

The approval shall not be taken as constituting an expression of opinion on the part of the
Engineer as to the strength or efficiency of the plant and equipment or to its correctness
or in any way relieving the Contractor from his responsibilities or obligations under the
Contract.

1.15 Shipping Documents

The Contractor shall submit complete shipping documents as soon as possible after
shipping, in order to reach the Engineer before the arrival of the ship. Responsibility for
delays, loss or damage to shipping documents shall rest with the Contractor. The
shipping documents shall be distributed as shown in Table 1:

Table 1 – Document Distribution

Documents Employer Engineer’s Site Office


Shipping Invoice for Original 1 -
the Consignments Copy 1 1
Packing List 1 1
Original 1 -
Bill of Lading
Copy 1 1
Original 1 -
Certification of Origin
Copy 1 1
Manufacturer’s Original 1 -
Certificate Copy 1 1
Confirmation of Declaration of Insurance 1 1
Certificate of Inspection Authority 1 1

Should the Work or any part thereof, the manufacture and/or supply of any material,
equipment or plant component as well as any equipment or tool required for the Work be
delayed with respect to the relevant time schedules, the Contractor shall transport the
part or component delayed by air at no extra cost to the Employer.

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1.16 Information Prior to Approval

The Certificate of Completion shall be processed upon the completion of the following.

• Dry test
• Wet Test
• Submission of O&M Manuals
• Submission of As Built or As Installed Drawings

Certificates of Completion of the Works will only be issued by the Engineer upon his
receipt and approval of the following:

Three copies of approved Instructions for the Operation, Maintenance and Overhaul of
the plant installed, specifically written for this particular installation.

Four copies of recommendations for consumable supplies, fro example, packing and
lubricants for the plant installed. This shall include a summary routine maintenance chart
covering all plant supplied.

The information contained in the manuals shall be correct for the installation at the time of
issue. The Contractor shall supply up-dated information for incorporation in these
manuals.

Information during Period of Maintenance:

After installation of the plant has been completed the Contractor shall supply three copies
of the following associated `AS INSTALLED'drawings and documentation for approval
within 6 weeks of the issue of any Certificate of Completion of the Works.

General arrangement drawing showing all equipments, switch gears, motor control
centres, control panels, cabling and pipe work.

Detailed arrangements of any conduit work buried in floors, walls or ceilings, in any
structure.

Schematic electrical circuit diagrams.

Any modification or corrections undertaken during the commissioning affecting the


operating and maintenance instructions.

Within 12 weeks of the issue of any Certificate of Completion of the Works the Contractor
shall provide and forward to the Engineer two complete sets of associated reproducible
drawing negatives of final 'As Installed'drawings of the Works. Lines and lettering on
drawings shall be of a consistent black colour suitable for reduction to 35 mm negative
microfilm.

1.17 Installation

1.17.1. Setting Out and Fixing

The Contractor shall be responsible for accurately aligning, setting and fixing in position
equipment supplied by him, including drilling holes required for expanding bolts and the
provision and placement of bolts, holding down bolts, grout and so on.

1.17.2. Plinths and Grouting

The Contractor shall provide all supports (excluding reinforced concrete piers/plinths),
anchors, grouting and fixings necessary for the installation of his plant unless indicated
otherwise on the drawings.

Page 15
The Contractor shall apply a concrete protective coating to all grouting works, which
generally is to be as per the surrounding concrete works.

1.17.3. Position of Equipment

The exact position of equipment supplied under this Contract shall be agreed on Site by
the Engineer.

1.17.4. Contract Drawings Details

The position of structures shown on the Drawings shall be deemed to be correct for the
purpose of costing the Contract. The Contractor shall check dimensions prior to
submitting his drawings for approval. Any conflict between the Drawings and measured
dimensions shall be brought to the attention of the Engineer.

1.18 Site Works

1.18.1. Erection

The Contractor shall be responsible for all aspects of erection to provide a complete
working installation.

1.18.2. Take Over Procedure

Take over Procedures shall be carried out in three stages; visual inspection; tests before
completion of the Works; setting to work and trial operation.

1.18.2.1 Visual Inspection

Visual inspection of the Works shall be carried out, after the Contractor has notified the
Engineer of substantial completion of installation of the Works, by the Engineer and the
Contractor who shall produce a list of outstanding Works to be completed prior to the
issue of the Certificate of Completion of the Works. The Engineer may permit certain
minor items to be effected during the Period of Maintenance providing they do not affect
the safe and satisfactory operation of the Works.

1.18.2.2 Tests before Completion

The Contractor shall agree a programme for carrying out tests before completion at an
agreed time and date. A detailed schedule of tests before completion shall be produced
and agreed with the Engineer, highlighting each test to be carried out. Space shall be
allowed in the schedule of tests for the Engineer and the Contractor to sign and date
each item of the schedule. The schedule of tests shall include a breakdown of systems,
equipment, instrument and device installed in the Works with each light, alarm lamp,
control function and circuit being included to enable them to be 'signed off'when they
have been demonstrated as operating in compliance with the Specification.

The Contractor shall carry out tests before completion prior setting the Plant to work.

Tests before completion shall include all equipments, instruments and devices installed.

Pumps: The Contractor shall demonstrate the operation of pumps, over the entire range
of operating levels in the sump, to show that pump run out, cavitations, a closed valve
condition, motor overload or other failure does not occur. The Contractor shall undertake
flow tests using the Contract flow meters and calibrated pressure gauges to determine
the ability of the system to deliver the required flow.

Pipe work: The Contractor shall carry out pressure tests on individual lengths of pipe
work to at least 1.5 times the maximum working pressure, including surge. Air pipe work

Page 16
shall be tested hydraulically, before a repeat test on air is carried out at normal operating
pressures and pipe joints tested for leaks.

Motor Control Centres: The Contractor shall carry out complete function tests of
sequence and automatic control circuits including fault conditions, safety interlocks and
telemetry signals. Function testing shall be as far as is practicable carried out by the
simulation of remote instrumentation and controls at their mounting position.

Instrumentation: The Contractor shall carry out calibration and proving tests. Where
instrumentation drives recorders or controls process Plant, simulation of operating
conditions shall be carried out to demonstrate the correct functioning of the recorders or
process Plant.

Electrical and Earthing Systems: The Contractor shall carry out tests in compliance with
the Wiring Regulations of the Institution of Electrical Engineers

Other M & E Items: The Contractor shall carry out a mechanical and electrical inspection,
and full operational tests on each item.

Lifting equipment: The Contractor shall ensure that all items of lifting equipment are
tested on site by an independent inspector and a Test Certificate issued.

The Contractor shall provide three copies of test certificates for each item of Plant, and
include the same within the Operation and Maintenance manuals.

1.18.2.3 Setting to Work

On satisfactory conclusion of the tests before completion the Contractor shall set the
Plant to work and test it to demonstrate its ability to comply with the Contract.

For plants which use chemicals, the optimisation of the use of chemicals means setting
the Plant to Work at minimum chemical cost to achieve the Specified Performance.

Full functional testing of the Plant under working conditions shall be undertaken.
Following completion of the demonstration the Contractor shall submit certificates for the
Engineer's signature to confirm satisfactory performance.

1.18.3. Electricity Supply Company Tests

Where a connection is required by the “Electricity Distribution Directorate of the


Electricity and Water Authority” at the Site, the Contractor shall be responsible for serving
a completion of installation advice, together with an inspection certificate, kWh meter
calibration, to the Electricity and Water Authority for the whole of the installation.

A copy of the inspection certificate shall be displayed at the installation, and a copy
included in the Operation and Maintenance Manual.

1.19 Training

During the setting to work period, the Supplier shall, using the approved instructions for
operation, maintenance and overhaul, train the Client staff in the safe and efficient
operation of the Works. A Certificate of Completion will not be issued without the training
being completed to the satisfaction of the Client.

Instruction of the SEOMD staff shall be divided into two categories: Operation and
Maintenance. The syllabus of the instruction for each category of staff shall be suited to
their particular needs and agreed in advance with the Engineer.

The programme of instruction shall be agreed with the Engineer at least two weeks
before the commencement of the instruction.

Page 17
Training shall be carried out by suitably qualified personnel approved in advance by the
Engineer. The Contractor’s training instructors shall provide the training periods as
detailed in the Scope of Works.

Instruction of the different categories of staff may proceed concurrently, providing that
separate instruction is provided for each category.

One man-day shall be defined as an eight hour working day at the Works. Travelling time
shall not form part of this period. Allowance shall be made for varying instruction times
from day to day to take into account shift working by the operations staff.

The purpose of the instructions shall be to familiarise the operations staff with all aspects
of the Works and provide detailed instruction of the operation and maintenance of the
particular mechanical and electrical equipment supplied under the contract, as relevant to
the category of personnel. The operations staff can be assumed to be experienced in
their respective trades in general, but not necessarily on any particular equipment
provided as part of the Works.

1.20 Nameplates and Data Labels

Pumps, motors, gearboxes, control panels and similar items of equipment shall be fitted
with cast bronze or stainless steel engraved nameplates, giving relevant information, e.g
Model, Type, Rating, Speed, Electrical Information, and Bearing Details. Nameplates with
data embossed on by punching or etching are not acceptable

Items supplied with rating plates in an inaccessible position (for example, submersible
pumps) shall have an additional identical rating plate provided as a loose item with a non-
conducting cord or string suitable for hanging within the control panel.

All items of equipment shall be provided with a unique identification number to a system
to be advised by the Engineer. The Contractor shall provide a schedule of plant including
identification numbers.

1.21 Spares

Wherever possible there should be a local dealer or Agent within the Kingdom of Bahrain
for imported equipment.

Within three months of the issue of the Order to Commence the Works, the Contractor
shall issue the Engineer priced list recommended spares for one and five years of
operation of the Works. The prices advised shall remain valid for any spares ordered
before the issue of the Certificate of Completion of the Works.

During the 'Period of Maintenance'the Contractor may be permitted to use any spare part
provided pursuant to this Clause in order to rectify any defect. If however the defect is
attributable to the Contractor, any spare part so provided is to be expeditiously replaced
by the Contractor.

On the basis that the Employer' s spares requirements for the Period of Maintenance are
advised within three months of the receipt of details by the Engineer, the provision of the
said spares shall represent a pre-requisite of the issue of any Certificate of Completion of
the Works.

1.22 Special Tools

The Contractor shall provide one set of any new and unused special tools not obtainable
from local retail outlets for the maintenance of Works. They shall be contained in clearly
labelled boxes with hasp and staple suitable for padlocking.

Page 18
2. PART 2 MECHANICAL EQUIPMENTS

2. 1 Pumps

2.1.1 General

Materials used in the construction of pumps shall be suitable for the pump duty, the
product to be handled and environment that will exist at the installed location. Cast iron
shall not be used where the daily peak chloride content of the pumped medium is greater
than 1,500 mg/litre.

Pumps shall be arranged for priming by gravity, via normal suction flow path.

Waterways through pumps shall be smooth and free from recesses and obstructions.
Pumps for wastewater and raw water services shall be capable of passing solids:

• Suction pipe work up to 100 mm diameter - equal to the size of the suction pipe
work,
• Suction pipe work between 100 mm and 199 mm – 100 mm diameter
• Suction pipe work 200 mm diameter or greater – 150 mm diameter

Pump speeds shall not exceed 1,500 rpm nominal except for water supply borehole
pumps where 3,000 rpm nominal is acceptable.

The head/flow characteristic of any pump shall be stable under all possible operating
conditions including parallel operation and with maximum sump surcharge.

Velocities in the suction and delivery branches shall be sufficiently low to prevent
hydraulic turbulence and cavitations within the pump and the pipe work and sufficiently
high to prevent settlement of any suspended solids.

The pump and its drive motor shall be suitably rated to allow for any increased head, due
to sliming and so on, of the rising main, during the lifetime of the pump.

Pump suction (except for wet well mounted submersible pumps) and discharge pipe work
for clean water and effluent duties shall be tapped and plugged with 25 mm reducing to
12 mm and fitted with a tee. The tee shall be fitted with an isolating cock, suitable for use
with a pressure gauge having a 12 mm connection and an isolation cock to act as a vent.
The tapping shall be located between two and three pipe diameters from the pump, in
accordance with BS EN ISO 9906.

Pump suction and discharge connections for sludge and un-screened effluent shall be
provided with 50 mm flanged connections fitted with a flanged tee. The tee shall be fitted
with two flanged isolation valves, one for connection of diaphragm type pressure gauge
and the second to act as a vent.

Open ends of valves shall be fitted with blanking flanges or plugs as appropriate.

2.1.2 Centrifugal Open Coupled Sewage Pumps and Cardin Shaft

2.1.2.1 General

Pumps shall be designed for continuous operation. They shall be capable of passing
fibrous matter, rags, paper, plastics and solids.

The pump and motor units shall be continuously rated.

Bearings shall have a design life of 100,000 hours.

Page 19
Components likely to become worn in the course of normal operation shall be capable of
being easily replaced making use of readily exchangeable components. Low
maintenance costs, reliability and trouble-free operation shall be prime considerations
when selecting pump units.

Pump units shall be provided from within manufacturer'


s standard range which shall meet
the quantity/head duty requirements within the high efficiency band of the pump
characteristics. The pump curve shall have non-overloading power characteristics unless
agreed otherwise by the Engineer.

Pump units shall be quiet in operation, free from vibration and the shaft speed shall not
exceed 1,500 rpm.

All rotating parts shall be statically balanced during manufacture and dynamically
balanced after assembly.

2.1.2.2 Pump Volute Casing

The pump casings shall be of close grained cast iron to BS EN 1561 free from blowholes
and other imperfections.

Casings shall be manufactured and pressure tested in accordance with BS EN ISO 9906.

The pump casing shall be fitted with renewable suction wear rings.

Access shall be provided in the pump casings in the form of large hand holes, for
inspection and cleaning of the pump interior.

Pump casings shall be provided with a drainage cock at the bottom of the lower casing
section and an automatic air release valve and cock on the top of the volute casing
section. The discharge from fittings shall be piped to the station drainage system. Small
bore pipes shall be heavy grade copper tubing.

2.1.2.3 Impellers

The impellers shall be cast in one piece from close grained cast iron to BS EN 1561. The
working faces shall be accurately machined and finished smooth with each impeller being
balanced statically and dynamically to ensure smooth running.

The impellers shall be of the single bladed open or spiral vane type or two port single
entry choke resistant type. Where the two port entry type is utilised the vanes shall be
supported on both sides of their entire length by the outer shroud. The impellers shall
have auxiliary vanes on the outside of the shrouds to minimise the recirculation of the
liquid within the pump casing and to reduce the pressure around the shaft seal.

The impellers shall be securely keyed and locked to the pump shaft.

The impeller diameter shall be machined to comply with the required duties and
maximum efficiencies.

2.1.2.4 Fittings

Each pump shall be fitted with the following fittings as standard requirements:-

• A combined automatic air release and syphon breaker valve shall be fitted into the
pump delivery pipe work;
• 25 mm bore gland drainage pipe from the invert of the sill on the top gland cover and
leading down to discharge into the dry well drainage channel to prevent
contamination of the pump casing or walkways.

Page 20
2.1.2.5 Shafts and Sleeves

The pump shafts shall be constructed from high tensile alloy steel and shall be fitted with
a hardened steel sleeve extending through the full length of the shaft seal.

Transmission shall utilise universal joints and a splined slip joint at the pump connection.
Universal joints shall have needle roller bearings. The weight of the transmission shafting
shall be carried by a thrust bearing in the motor stool. The splined shaft shall ensure that
no load is transferred to the pump from the shafting. Normal shaft running speed shall be
well below the first critical speed. The Contractor shall submit his calculations to confirm
this.

2.1.2.6 Glands

Pumps shall be supplied with soft packed glands.

2.1.2.7 Drive Coupling

A suitably sized rubber bushed flexible coupling shall be fitted between each pump and
driving motor. The coupling shall be fixed to the pump and motor shafts using keys and
keyways.

2.1.2.8 Pump Motor

The motor speed shall not exceed 1,500 rpm.

2.1.2.9 Temperature Transducer Pockets

The pump Non-Drive End bearings and the pump Drive End bearings shall be fitted with
temperature pockets for the reception of resistance thermometer probes.

2.1.2.10 Pressure Gauge Tappings

Each pump set shall be provided with both delivery and suction gauge tappings such that
when fitted they are in an upright position. Each tapping shall be isolated with a gun-
metal gauge cock.

2.1.2.11 Pressure Gauges

A pressure gauge shall be provided and installed at the above suction and delivery
tappings. The gauges shall be of the diaphragm operated sewage installation type.

2.1.2.12 Guarding

The Contractor shall include for guards to completely enclose the moving parts of plant.

2.1.2.13 Engraved Nameplates

Each pump shall be provided with engraved nameplates as follows:

• Duty Plate: Indicating the type, impeller diameter, and output at normal duty, normal
duty head, speed, serial number and pump curve number.
• Identification: Corresponding with the pump control panel designation, for example,
'Pump No 1' . The characters shall not be less than 30 mm high.

2.1.3 Split Case Centrifugal Pumps

2.1.3.1 General

Pump units shall be designed to handle the process fluid and for continuous operation.
The pumps shall be electric motor driven.

Page 21
Pump and motor units shall be continuously rated. Components likely to become worn in
the course of normal operation shall be capable of being easily replaced making use of
readily exchangeable components. Low maintenance costs, reliability and trouble-free
operation shall be prime considerations when selecting pump units.

Pump units shall be provided from within manufacturer'


s standard range which shall meet
the quantity/head duty requirements within the high efficiency band of the pump
characteristics. The pump curve shall have non-overloading power characteristics unless
agreed otherwise by the Engineer.

The pump and its driving motor shall be separate machines, open coupled, using a
flexible coupling to form an integral unit mounted on a suitable common rigid base plate
or base frame. A flywheel may also be incorporated in the drive train if required for surge
suppression. Each component shall be dowelled to facilitate re-assembly.

Pump units shall be quiet in operation, free from vibration and the shaft speed shall not
exceed 1,500 rpm.

All rotating parts shall be statically balanced during manufacture and dynamically
balanced after assembly. The rotating parts shall be supported in substantial bearings of
approved design.

2.1.3.2 Pump Volute Casing

The pump casings shall be of close grained cast iron to BS EN 1561 free from blowholes
and other imperfections.

Casings shall be manufactured and pressure tested in accordance with BS EN ISO 9906.

The casing shall comprise of two sections, split to provide complete access to the
impeller and other rotating parts without disturbing the pipe work connections.

The sections of casing shall be secured together using substantial stainless steel studs
and nuts. To ensure accurate re-alignment of the casing section stainless steel dowels
shall also be fitted.

To facilitate the dismantling of the casing halves equally spaced tapped holes shall be
provided in one casing flange to allow jacking bolts to separate the joint.

Renewable suction wear rings and interstage bushes manufactured from zinc free
bronze, or LG4 Bronze to BS EN 1982 shall be provided.

Each pump shall be fitted with a drainage cock at the bottom of the lower casing section
and an automatic air release valve and cock on the top of the upper casing section. The
discharge from each of these fittings shall be piped to the station drainage system via a
tundish. Small bore pipes shall be galvanised mild steel.

2.1.3.3 Impellers

Impellers shall be manufactured from zinc free bronze, or LG4 Bronze to BS EN 1982,
keyed to the shaft and securely locked in position, the whole assembly being both
statically and dynamically balanced. Impeller surfaces shall be machine finished free from
blowholes and imperfections.

The impeller diameter shall be machined to comply with the required duties and
maximum efficiencies.

2.1.3.4 Shafts and Sleeves

Shafts shall be of mild steel protected with renewable stainless steel sleeves, where they
pass through any wear inducing sealing arrangement.

Page 22
2.1.3.5 Bearings

Bearings shall have a design life of 100,000 hours.

2.1.3.6 Glands

Split case pump units shall be supplied with soft packed glands.

2.1.3.7 Drive Coupling

A suitably sized rubber bushed flexible coupling shall be fitted between each pump and
driving motor. The coupling shall be fixed to the pump and motor shafts using keys and
keyways.

2.1.3.8 Pump Motor

The motor shall be sized to allow for the provision of flywheels for surge suppression as
necessary.

2.1.3.9 Temperature Transducer Pockets

The pump non-drive end bearings and the pump drive end bearings shall be fitted with
temperature pockets for the reception of resistance thermometer probes.

2.1.4 End Suction Centrifugal Pumps

2.1.4.1 General

Pump units shall be designed to handle final effluent and continuous operation. Pumps
shall be Electric motor driven.

Pump units and motors shall be continuously rated. Components likely to become worn in
the course of normal operation shall be capable of being easily replaced making use of
readily exchangeable components. Low maintenance costs, reliability and trouble-free
operation shall be prime considerations when selecting pump units.

Pump units shall be provided from within manufacturer'


s standard range which shall meet
the quantity/head duty requirements within the high efficiency band of the pump
characteristics. The pump curve shall have non-overloading power characteristics unless
agreed otherwise by the Engineer.

Tapped holes or other provisions shall be made in the main casting and impeller of the
pump for the insertion of jacking screws or fixing other such drawing gear necessary to
facilitate the dismantling of the pump.

2.1.4.2 Pump Casing

The pump casing shall be of close grained cast iron to BS EN 1561 grade 14, free from
blowholes and other imperfections, suitable for use with final effluent.

2.1.4.3 Mechanical Seals

Pumps shall be fitted with a mechanical seal with both the rotating and stationary faces
being tungsten carbide or other approved materials. The pump mechanical seal design
should he such that prolonged periods of dry running do not affect the pump or
mechanical seal.

2.1.4.4 Pump Motor

The motor speed shall not exceed 1,500 rpm.

Page 23
2.1.5 Submersible Pumps

Pump casings shall be manufactured from close-grained cast iron in accordance with BS
EN 1561 or as defined in the particular specification. An oil filled casing shall separate the
electric motor from the centrifugal pump.

Mechanical seals shall be fitted to the pump shafts which shall prevent water from
entering the oil casing and oil from entering the motor casing. A moisture detection
system shall be provided in the motor stator casing, wired to initiate an external alarm.

Pump units shall be provided from within manufacturer'


s standard range which shall meet
the quantity/head duty requirements within the high efficiency band of the pump
characteristics. The pump curve shall have non-overloading power characteristics unless
agreed otherwise by the Engineer.

The submersible pumps shall be supplied and installed complete with bolt-less self-
aligning duck foot assemblies giving automatic connection, and rising pipe work to the
sump top. All pipe work and fittings inside wet well shall be reinforced thermoset resin.

Each pump shall be provided and installed with stainless steel guide rails, fittings and all
necessary support brackets. A lifting chain made of stainless steel shall be attached to
each pump to enable the pump to be raised and removed from the wet well without the
necessity for personnel entering the well.

Each pump shall be supplied complete with a suitable length of submersible cable. The
length of the cable shall be so as to allow connection to a connection box adjacent to the
wet well.

The submerged cable shall be a multi-core flexible cord, vulcanised rubber insulated with
tough rubber sheath and outer PCP sheath to BS 6500.

2.1.6 Progressive Cavity Pumps

2.1.6.1 General

Progressive cavity pumps shall have an output characteristic that is substantially


independent of change in head.

Pumps shall be designed for continuous operation.

2.1.6.2 Casings

Casings shall be of close grained cast iron to BS EN 1561 capable of withstanding


pressures that may be produced due to normal operating pressure surges. Flanges shall
accord with BS EN 1092: Part 2.

Casings shall be mounted on base plates manufactured from cast iron. Casings shall be
accurately aligned and located by dowels or machined spigots. Holes shall be provided in
the base plates or stools for foundation bolts.

Casings shall not be integral with the stool or base plate, but shall be designed to allow
the ready removal of the pump complete from the stool or base plate. Easy access to
suction pipe connections must be available.

Stools or base plates shall be fixed to concrete plinths.

2.1.6.3 Glands

Casings shall be sealed against leakage along the rotor shaft by a soft packing stuffing
box, which shall contain a bronze lantern ring to facilitate greasing and efficient sealing of
the gland.

Page 24
The gland housing shall be cast iron and split to facilitate packing of the gland.

A grease stauffer shall be provided for lubrication of the gland.

2.1.6.4 Stator

A resilient stator shall be fitted into a rigid housing and be intimately bonded to it.

Stators shall form a double internal helix of constant circular section in which a single
helical rotor shall rotate to form progressive cavities.

Stator materials shall be compatible with the liquids and materials being pumped. Stator
materials shall generally be natural rubber, nitrile rubber or Hypalon depending on the
application.

The stator housing shall be flanged cast iron and jointed to the casing. A flanged delivery
connection at the free end of the rotor shall be flange jointed to the stator housing. The
suction flange may be part of the casing or be an interleaving flanged casting between
stator housing and casing.

Where pumps incorporate long stator housings such housings shall be supported from
the base plate.

2.1.6.5 Rotating Parts

The rotating parts shall have a smooth finish and the materials shall be compatible with
the liquid and materials being pumped. Rotors shall generally be hard chrome plated
stainless steel, tool steel or nitralloy.

Coupling rods shall generally be hard chrome plated mild steel, or hard chrome plated
stainless steel. The rod shall be joined to the rotor and input shaft by flexible joints
preferably of the ball and socket type.

Shaft diameters shall be to BS 4506; shaft keyways shall be to BS 4235: Part 1.

The drive shaft shall be supported in heavy duty ball or ball and roller bearings. Bearings
shall have life of 100,000 hours.

Where variable output is required from the pump, this shall be achieved by a hydraulic
speed variator fitted between pump and drive motor. Where fixed speed output is
required or a compact pump arrangement is required then the drive shall be through anti
static veebelts.

2.1.6.6 Pump Fittings

Pumps shall be equipped with the following fittings as standard requirements:

• A drainage pipe to allow drainage of gland seepage liquid.


• Suction and delivery pressure gauges.
• An engraved nameplate indicating material of rotor and stator, output at normal
speed, and serial number.
• A 25 mm plugged tapping on the suction side for manual flushing the pump.
• A pressure relief valve on the delivery side, the discharge of which shall be piped to
the suction pipe.

2.1.7 Screw Pumps

2.1.7.1 Screws

Screw pumps shall comprise a welded steel fabricated central tube with a free start cold
formed screw fabricated into a smooth continuous form, welded to the centre tube and
designed for minimum deflection.

Page 25
When it is necessary for the central tube to be constructed of more than one length of
plate, a welded joint shall not be positioned in the centre of the flight but shall be
positioned at each end, and all such joints shall be full penetration butt weld with fatigue
design to BS 5400: Part 10C. Tube end plates shall be manufactured from Grade 43 steel
accurately machined to carry bearing stub shafts. The central tube shall be watertight.

The spiral blades shall be formed from steel plate. The blades shall be secured to the
centre tube by a continuous weld and the periphery of the screw blade shall be finished to
ensure a uniform clearance between the screw and trough.

Bearing stub shafts of ample dimensions complete with machined location shoulders and
mounting flanges shall be bolted to the tube end plates. Top stub shaft units shall extend
through the bearing housings to receive the driven half coupling.

Where the upper stub shaft of the screw pump passes through the structure, substantial
removable anti-splash closing plates shall be installed and sealed to the structure. Plates
shall be not less than 3 mm thick mild steel, split for ease of removal.

The screw pump shall have a speed of rotation not greater than that given by the
0.667
equation 50 = ND where N is in rpm and D is the outer diameter of the screw in
metres.

2.1.7.2 Screw Pump Bearings

The top bearing shall be arranged for plinth mounting with all loadings transmitted to the
motor room floor. It shall be self aligning and designed to support all thrust loads and
radial loads at the top of the screw and shall be rated for a life of 100,000 hours under all
combined loadings and, where applicable, speeds imposed by the screw. The service
factor shall be at least two under maximum load conditions. The bearing shall conform to
BS ISO 281.

The bottom bearing shall be designed to withstand all radial forces and end support
loads.

The bottom bearing shall be of bronze or gunmetal sleeve type. The sleeve shall
incorporate positive means to prevent rotation of the sleeve bearing.

The bottom bearing shall be supported in a cast iron or fabricated steel housing mounted
on a horizontal plinth.

The bottom bearing shall be sealed to prevent the ingress of grit and liquid.

Replacement of the bottom bearing shall be possible without the need to remove the
bearing base or the screw or require the use of external carnage.

The bottom bearing shall be suitable for continuous operation either in air or submerged
and it shall be automatically lubricated whilst the screw is rotating.

2.1.7.3 Bottom Bearing Lubricator

A positive displacement metering pump, (lubricator), shall be provided for each screw
pump to provide a return oil lubrication system for the bottom bearing. The lubricator shall
incorporate a means of flow control that shall have a positive minimum setting to prevent
premature failure of the bearing. The flow control device shall be provided with locking
facilities.

The lubricator shall have an independent drive motor interlocked with the respective
screw pump motor.

The lubricator shall incorporate a reservoir which shall hold sufficient lubricant for seven
days continuous operation of the screw at maximum lubrication rate possible from the

Page 26
lubricator. A lubricant contents indicator shall be provided on the reservoir in the form of a
positive depth gauge.

A lubricant flow meter shall be installed within the return pipe work which shall provide a
pulsed output when lubricant is being returned from the bottom bearing. The flow meter
shall operate in conjunction with a pulse continuity relay which shall stop the pump upon
a failure of the lubricant system. There shall also be a visible means of indication of the
return flow. A filter shall be provided between the return oil pipe and the reservoir.

Pressure and return pipes shall be stainless steel throughout.

2.1.7.4 Screw Pump Drive System

The gearbox reducing the speed between the prime mover and the screw pump shall be
of robust construction having the output shaft at right angles to the input and suitable for
mounting on a plinth inclined at the same angle as the screw pumps to the horizontal.
The concrete plinth shall be provided by the Civil Contractor in accordance with the
Contractor's design requirements.

The speed reducer shall be of the totally enclosed oil bath lubricated type fitted with oil
level sight glass, dipstick, filler and drain plug, large inspection covers and an oil breather.

Bearings shall be either splash or forced lubricated.

Efficient long life shaft seals shall be fitted to all external shafts to prevent loss of
lubricant.

The speed reducer shall be rated for:

• Continuous operation, in the climate and temperature of the place of installation.

A gear design life of 100,000 hours at a service factor of 1.5 at the motor full load rating.
All bearings shall be rated for a life of 100,000 hours at speed reducer full torque rating in
accordance with AGMA 6013-A06 Specification and all other combined loadings and
speeds imposed by the screw.

Where speed reducer external cooling equipment is required this shall be a separate
system to any other cooling system.

Screw pumps shall be driven through flexible couplings, of the pin and buffer type to
prevent end thrust and radial loads being transmitted to the speed reducer. Couplings
shall be arranged to allow coupling belts and buffers to be replaced without disturbing the
drive or driven shafts.

A back stop device shall be fitted to the speed reducer shaft to prevent reverse rotation of
the screw pump under the head of liquid in the flights when the screw pump motor is de-
energised.

The screw pump shall be driven by a squirrel cage induction motor. The motor shall be
protected IP55. The motor shall be horizontally mounted.

Power transmission from drive motor to speed reducer shall be through multiple vee
belts. Pulley ratios and centres shall be selected to ensure the maximum belt contact and
bosses shall be a tight fit on the shafts and shall have fitted keys.

Drive motors shall be mounted on slotted slide rails with belt tensioning screws and
locknuts provided for adjustment.

The complete drive system shall be guarded to prevent accidental contact with moving
parts.

Page 27
2.1.7.5 Side Profile Plates

A side profile splash guard on the high liquid side of the screw trough shall be provided to
prevent liquid running back down the side of the trough.

The guard shall be fabricated from steel plate not less than 5 mm thick. The guard shall
be strengthened and returned to the trough side wall to prevent build up of debris behind
the guard and also allow liquid to run back into the screw.

A channel section shall be provided for casting into the screw trough along the full length
of the screw pump.

The guard shall be securely bolted to the channel section cast into the civil structure.

2.1.7.6 Trough Profiling

The screw pump trough shall be profiled by welding a steel strip of suitable thickness
along the complete length of the screw and turning the screw using the Contract motor.

Screeding of the screw pump trough to form the profile will be carried out by the Civil
Contractor acting under the guidance and direction of the Contractor.

Profile, finish and running clearance between screw pump and trough must be in
accordance with the requirements of the Contractor. Should this not be the case the cost
of any remedial work shall be split equally between the Contractor and the Civil
Contractor.

The Contractor shall provide dry running protection for progressive cavity pumps.

The Contractor shall submit details of the proposed system for the approval of the
Engineer.

2.1.8 Chemical Dosing Pumps

Chemical dosing pumps shall be of the piston, piston diaphragm or mechanical


diaphragm type. Pump design shall incorporate positive stroke return. The maximum
stroking speed shall not exceed 100 strokes per minute.

Stroke adjustment shall be manual, or by an electrical or pneumatic controlled stroke


positioner with step less adjustment between zero and maximum stroke length. Where
flow-proportional dosing is required, the variation of output shall be achieved by varying
the speed of the pump motor and not the pump stroke length.

A stroke length indicator and digital stroke counter shall be fitted.

2.1.9 Submittals

Submit to the Engineer shop drawings and product data. Submittals shall include at least
the following, where relevant:

• Certified dimensional drawings of each item of equipment and auxiliary apparatus


are furnished.
• Certified foundation, pump support and anchor bolt plans and details.
• Schematic electrical wiring diagram and other data as required for complete pump
installation.
• Pipe anchors and supports.
• Literature and drawings describing the equipment in sufficient detail, including parts
list and materials of construction, to indicate full conformance with the detail
specifications.
• Total weight of pumping unit.

Page 28
2.1.9.1 Design Data

Manufacturer' s certified rating curves, to satisfy the specified design conditions, showing
pump characteristics of discharge, head, brake horsepower, efficiency and guaranteed
net positive suction head required (NPSHR). Curves shall show the fully recommended
range of performance and include shut-off head. This information shall be prepared
specifically for the pump proposed. Catalogue sheets showing a family of curves shall not
be acceptable.

2.1.9.2 Test Reports

• Certified motor test data.


• Tabulated data for the drive motors including rated Hp, full load rpm, power factor
and efficiency curves at one-half, three-quarters and full load, service factor and KW
input, including when the pump is at its design point. A certified statement from the
motor manufacturer shall be submitted, confirming that the motors are capable of
continuous operation on the power supply without affecting their design life for
bearings or windings.
• A schedule of the date of shop testing and delivery of the equipment to the job site.
• Description of pump factory test procedures and equipment.
• A statement that the pump will function properly as installed with respect to the
suction piping layout as shown on the Drawings.

2.1.9.3 Operation and Maintenance Data

Complete operating and maintenance instructions shall be furnished for all equipment
included under this Section as provided in Division 1. The maintenance instructions shall
include troubleshooting data and full preventative maintenance schedules and complete
spare parts lists with ordering information.

2.1.10 Pumping Ancillaries

2.1.10.1 Pressure Gauge Tapings

Each pump set shall be provided with both delivery and suction gauge tapings such that
when fitted they are in an upright position. Each tapping shall be isolated with a
gun-metal gauge cock.

2.1.10.2 Pressure Gauges

A pressure gauge shall be provided and installed at the above suction and delivery
tapings. The gauges shall be of the diaphragm operated sewage installation type.

Pressure gauges shall comprise of brass or black moulded phenol plastic construction
with acrylic plastic or toughened glass windows. Dials shall be at least 150 mm diameter
except where fitted to small pumps having branch connections 75 mm internal diameter
and below.

100 mm diameter gauges shall be fitted. Internal gauge components shall be of stainless
steel or other corrosion resistant material with an accuracy of at least + 1 per cent of full
scale. Gauges shall wherever possible operate about their mid scale position. No
aluminium shall be used in the construction of the gauges.

Diaphragms shall be fitted to gauges subjected to liquid containing suspended matter.

Scales shall be calibrated in metres head for water and bar for air. Gauges associated
with pumps shall be of the compound type for suction branches and the pressure type for
delivery branches.

Gauges shall be fitted with isolation valves and where measuring water pressure they
shall be equipped with a combined isolating valve and air release vent.

Page 29
If mounted remotely from the tapping point an isolating valve shall also be installed at the
tapping point.

Snubbers shall be fitted to gauges installed on pumps and wherever subjected to


fluctuating pressure pulses.

Pressure gauges are to be with stainless steel diaphragm and PTFE coating.

2.1.10.3 Guarding

The Contractor shall include for guards to completely enclose the moving parts of plant.

2.1.10.4 Engraved Nameplates

Each pump shall be provided with engraved nameplates as follows:

Duty Plate: Indicating the type, impeller diameter, output at normal duty, normal duty
head, speed, serial number and pump curve number.
Identification: Corresponding with the pump control panel designation eg 'Pump No 1' .
The characters shall not be less than 30 mm high.

2. 2 Surge Vessels

The system shall be provided with a hydro-pneumatic pressure vessel of suitable working
capacity to provide surge protection and storage. The vessel shall be of the bladder type.
The bladder shall be polyurethane and shall be precharged with Nitrogen. The vessel
shall be sized to provide sufficient working volume to ensure that the pump starts are
limited, to the requirement in the Particular Mechanical Specification

2.2.1. Vessel

A method statement for the safe charging of the vessel with air shall be included in the
Operation and Maintenance Manuals.

Vessels shall be constructed and tested in accordance with PD 5500:2006 (Specification


for unfired fusion welded pressure vessels) or equivalent International Standard.

Internal weld surfaces shall be dressed for a smooth finish prior to painting.

2.2.2. Bladder

The bladders shall be capable of being readily removed without the need to dismantle the
vessel from the installation. A method statement for the safe removal of the bladder shall
be included in the Operation and Maintenance Manuals.

2.2.3. Fittings

Each vessel shall be fitted with:

• '
Schrader'type valve for gas pressurisation;
• Suitably rated safety valve;
• Water drain valve, complete with plug fitted to the open end;
• 100 mm diameter pressure gauge calibrated in bar and meters head, complete with
snubber and isolation valve;
• Gas bleed valve, complete with plug fitted to the open end;
• Water level indicator, suitably marked with the correct operating levels for pump
stopped and operating with varying numbers of pumps under steady state
conditions;
• Flange connection for connecting to the pumping main;

Page 30
• Two 25 mm threaded bosses for future instrument connections, fitted with suitable
plugs.

The gas charge connections shall be accessible from floor level. The hose assembly for
connecting to pressurising plant shall be provided with each vessel.

The water level indicators shall be suitable for continuous monitoring, i.e. they shall not
allow gas to ' escape'under low water mains pressure conditions without the need to
close isolation valves.

Isolation valves which if accidentally opened allow gas or water to '


escape'shall be
provided with locks.

2.3 Actuators

Actuators shall be well proven for the anticipated environmental conditions. Actuators
shall be suitable for external installation without the need for sunshades.

Isolating actuators shall have short time ratings appropriate to duty cycle S2 10 min to
IEC 34-1, and a maintenance free interval better than 10,000 open/close cycles.

Modulating and inching actuators shall have a rating appropriate to duty cycle type S4
20% 1200 cycles/hour to IEC 60034-1 and a maintenance free interval better than 50,000
hours in normal operation.

Actuated valves and penstocks shall be driven by three phase a.c. electro-mechanical
actuators. Each actuator shall be sized to produce at least 150% of the torque
requirement quoted by the valve or penstock manufacturer.

Valve actuators shall have an index of protection rating IP67 or above and have totally
enclosed drive units and reduction gearing.

Each actuator shall be provided with an integral control and starter system allowing local
and remote operation, control and indication. Control systems shall include facilities for
valve modulation using a 4 mA to 20 mA control signal. Local position indication shall be
provided integral with the actuator housing. Actuators shall have position feedback
circuits giving a 4 mA to 20 mA signal for remote indication. Modulating actuators shall
also have position indication at the local control panel.

The actuators shall also have the facility for hand operation, the use of which will
automatically disengage the electric motor. The hand operation facility shall be capable of
being padlocked in the in-operative state.

Limit switches and torque limiting devices shall be incorporated to prevent over running.

Each actuator drive unit shall be complete with integral starter, anti-condensation heater,
local operating buttons, local and remote selector switch. A separate termination section
shall be provided for the glanding and terminating of the supply, control and indication
cables.

A phase discriminator and monitor relay shall be provided.

Cable entries shall be suitable for conduit and fittings to BS EN 61386: Part 1. Cable
glands shall be provided for each actuator.

The actuator shall have volt free contacts to indicate when the valve is fully open, fully
closed or has failed.

2.4 Blowers

Blower sets shall be provided to supply the biological treatment process air requirements.

Page 31
The number of blower sets provided shall be sufficient to ensure the range of process air
requirements can be met, and that at peak process airflow requirements one unit is still
available as standby.

Blower sets shall be the same model with the same rated capacity.

Each blower set shall be provided with an acoustic enclosure and a surge protection
system. The acoustic enclosure shall limit the noise level to not more than 80 dB(A) when
measured at 1 m distance from any point. The enclosure shall be designed to ensure that
adequate cooling of the blower is maintained. The enclosure shall be designed to allow
for ease of access to the blower set without the necessity to lift the complete enclosure,
to allow for routine inspection and maintenance procedures.

The blower sets shall be of a proven design with at least five years operational
experience in similar applications. In addition to single duty applications, the design shall
be proven in applications where two or more units are automatically controlled to meet
the varying air demand.

Materials and equipment of construction shall give a design running life of at least
100,000 hours before major maintenance is necessary. Gearbox bearings may have a
reduced operational life, which shall not be less than 18,000 hours, provided the work
necessary to change the bearings can be safely carried out by general maintenance
technicians who have limited skill and the work does not involve the precision setting of
tolerances.

The impeller, gears and shafts shall be dynamically balanced. The first responsive critical
speed of the rotating assembly shall be at least 10% above the maximum operating
speed.

The gears shall have a minimum AGMA service factor of 1.5. A labyrinth oil seal shall be
fitted to each shaft to prevent oil seepage from the casing under operating and static
conditions. The seals shall be designed to ensure there is no contamination of the
process air.

The baseplate shall be provided with lifting points to allow the complete set to be handled
via the use of chain slings.

Instrumentation for the safety monitoring of air blowers shall include oil temperature, oil
level, air temperature at inlet to the blower, air pressure in the blower casing, surge
conditions, bearing vibration and motor running current. The instruments shall provide
signals for the shutting down of air blowers if unsafe conditions arise and for visual
indication of the fault.

Each blower shall be performance tested at the manufacturer'


s works, using the contract
motors, to BS ISO 1217. Air flow measurement for these tests shall be carried out in
accordance with PD ISO/TR 12767. Blower casing shall be works hydrostatically tested
to 1.5 times the maximum working pressure.

2.5 Air Conditioning and Ventilation Installations

2.5.1 Air Handling Units

2.5.1.1 General Requirements

All individual components of packaged air handling units shall comply with the
appropriate Sections of this Specification unless otherwise specified within the Schedules
or on the drawings.

Page 32
2.5.1.2 Construction

Each assembly shall be of compact construction and shall consist of a rigid metal
framework, with insulated double skin sheet metal panels. The metal shall be 1.2 mm
minimum thickness strengthened as necessary to prevent distortion and drumming. The
insulation shall be 25 mm thick and comply with the relevant clauses in the section
covering insulation. The panels shall be easily removable using quick release fasteners to
obtain access for inspection and maintenance. All items shall be assembled by means of
bolts, anti-vibration lock washers and nuts or accepted quick release fastenings.

All units shall be mounted on accepted type anti-vibration mountings.

2.5.1.3 Dampers, Filters and Fans

Where air mixing sections are required the damper controls shall be suitable for
connection to a single damper motor; a motor mounting bracket shall be provided. The
arrangement of dampers shall ensure adequate mixing. Dampers shall be of the opposed
blade multi-leaf type.

Unless otherwise indicated in the Particular Specification, a flat panel pre-filter and bag
type main filter shall be provided, each in accordance with this Specification.

Both fresh air and recirculated air shall be filtered.

Fans shall be of either forward or backward bladed centrifugal type; unless otherwise
indicated fan motors shall be mounted internally in the unit and there shall be means of
adjusting the motor position. The fan and motor assembly shall be provided with anti-
vibration mountings to isolate vibration from the casing.

Fans fitted to all air handling units shall be provided with external lubricators arranged to
terminate adjacent to the access door to the fan section of the air handling unit.

2.5.1.4 Anti-Condensation Features

Where units incorporate humidifying plant and/or cooling coils the internal surfaces of the
units liable to be affected by any free water produced shall be protected by anti-corrosion
paint or a similar finish. Such units shall have adequate drain trays to collect water; the
drain trays shall be extended, or other means of collection shall be provided, to ensure
the removal of any water deposited or condensed in adjacent sections. Trays collecting
cooled water shall be insulated to prevent condensation on the outer surface, and shall
be provided with a trapped outlet to drain.

2.5.1.5 Thermal Insulation

Thermal insulation shall be provided between the inner and outer members of the double
skin panels and in any hollow members of the framework. The insulation shall be of the
closed-cell foamed plastic type, with a minimum thickness of 25 mm, and a maximum
o
conductivity of 0.036W/m C.

Additional insulation shall be provided as required to prevent any risk of condensation on


the external surfaces.

2.5.2 Fans

2.5.2.1 General Requirements

Fans shall be capable of giving the specified performance when tested in accordance
with BS 848. Although estimated values of the resistance to airflow of items of equipment
may be indicated this does not relieve the Contractor of the responsibility for providing
fans capable of delivering the required air volume through the system.

Page 33
The make and design of fans shall be accepted by the Engineer and evidence supporting
claimed noise levels and fan efficiencies shall be submitted for acceptance prior to
placing the order. Where fans are supplied with noise attenuators full details of the
attenuators shall be given.

Belt driven fans shall be fitted with pulleys suitable for V-belts; pulleys of the taper lock
type may be used for drives up to 30 kW output. Alternatively, and in any case above
30 kW output, pulleys shall be secured to the fan and the motor shafts by keys fitted into
machined keyways. Pulleys shall be keyed to the fan shaft in the overhung position. Keys
shall be easily accessible so that they can be withdrawn or tightened and they shall be
accurately fitted so that the gib head does not protrude beyond the end of the shaft.

Machined bolts, nuts and washers only shall be used for the assembly of fans; all bearing
surfaces for the heads of bolts or washers shall be counterfaced. Holding-down bolts for
fans and motors shall be square section under the head or be fitted with lugs to prevent
them turning in the fan base plate when the nuts are tightened. Any fan which is too large
or too heavy for safe manhandling shall be provided with eyebolts or other lifting facilities
to enable mechanical lifting equipment to be used.

2.5.2.2 Centrifugal Fans

Unless otherwise indicated centrifugal fans larger than 7.5 kW output shall be of the
backward curved blade type having fan total efficiencies of not less than 78%. Below
7.5 kW fans may be either forward curved or backward curved type. Fan casings shall be
constructed of mild steel plates with angle stiffeners and base angles to ensure freedom
from drumming and shall be suitable for operation at the maximum static pressure of the
system. Fan casings shall be constructed so that impellers can be easily withdrawn after
installation. Outlets shall be flanged and inlets shall be flanged or spigotted as indicated
except that for suction pressures greater than 1,000 Pa inlets shall be flanged.

A drain and plug shall be fitted to the fan casing at its lowest point. For all kitchen extract
ventilation fans an access door, for inspection and cleaning, shall be fitted to the scroll
casing in an accessible position; it shall be the full width of the impeller.

Impellers shall be of mild steel (or aluminium where indicated) of riveted or welded
construction, with spiders or hubs of robust design, and shall be capable of running
continuously at 10% in excess of normal speed. Impellers shall be keyed to a substantial
mild steel shaft and the impeller with shaft shall be statically and dynamically balanced
and tested for over speed before leaving the maker' s works.

Shaft bearings of belt driven single inlet fans shall be truly aligned and rigidly mounted on
a pedestal common to both bearings. Double inlet, double width fans shall have a
pedestal mounted bearing at each side of the fan.

Fan bearings shall be ring oiled sleeve bearings, or ball or roller type. e
V-belt drives.

The maximum fan outlet velocity shall be 10 m/s.

2.5.2.3 Axial Flow Fans

Axial flow fans shall be either the single stage type or the multi-stage contra-rotating type
with each impeller mounted on an independent motor, and having an efficiency of not
less than 60%. Casings shall be rigidly constructed of mild steel stiffened and braced to
obviate drumming and vibration. Cast iron or fabricated steel feet shall be provided where
necessary for bolting to the base of supports. Inlet and outlet ducts shall terminate in
flanged rings for easy removal. The length of the duct casing shall be greater than the
length of the fan(s) and motor(s) in order that the complete section may be removed
without disturbing adjacent ductwork. Electrical connections to the motor(s) shall be
through an external terminal box secured to the casing.

Page 34
Impellers shall be of steel or aluminium; the blades shall be secured to the hub or the
blades and the hub shall be formed in one piece. The hub shall be keyed to a substantial
mild steel shaft and the whole statically balanced. Blades shall be of aerofoil section.
Shafts shall be carried in two bearings which may be ball, roller or sleeve type.
Lubricators shall be extended to the outside of the casing.

Where axial flow fans are driven by a motor external to the fan casing the requirements
for pulleys and V-belt drives and guards as specified elsewhere shall be met. Unless
otherwise indicated a guard is not required for any part of a drive which is inside the fan
casing. An access door of adequate size shall be provided.

Where axial flow fans of the bifurcated type are indicated the motors shall be out of the
airstream. Motors may be placed between the two halves of the casing in the external air
or may be placed within the fan casing provided that effective ventilation is given to the
motor. Where hot gases or vapours are being handled the motor and the bearings shall
be suitable for operation at the temperature they may experience.

Fans which do not connect to a suction duct shall be supplied with a bellmouth inlet.

2.5.2.4 Propeller Fans

Impellers shall be of steel or aluminium; the blades shall be fastened to the hub or the
blades and hub shall be formed in one piece. The bearings may be ball, roller, or sleeve
type.e Propeller fans may be ring mounted or diaphragm mounted in a casing, as
indicated. Where they are mounted in a casing the casing shall be longer than the length
of the fan and motor. The casing shall be of steel, shall have flanged ends and shall
incorporate an inspection door. A terminal box shall be mounted externally on the casing.
The tip speed of fans shall not exceed 20 m/s.

Propeller fans shall not be installed to work against a resistance of more than 50 Pa.

2.5.2.5 Protectively Coated Fans and Special Enclosures

Protectively coated fans shall meet the appropriate requirements of the preceding
clauses relating to fans generally and to particular types of fans; the form of protection
shall be as indicated. Where a protective coating is required for use with corrosive gases
the coating shall cover all parts of the complete fan, motor and casing assembly which
will be in contact with the corrosive gases. No fan shall be installed if the protective
coating has been damaged in any way. Flame-proof enclosures shall comply with the
requirements of BS EN 60079 for the appropriate gas group.

2.5.2.6 Mechanical Roof Extract Units

The fans used in roof extract units shall meet the appropriate requirements of the
preceding clauses relating to fans generally and to particular types of fans. Cowls and
bases shall be of aluminium construction unless otherwise stated in the Particular
Specification. Cases shall be formed so as to ensure a weatherproof fitting to the building
structure.

Adequate access to motor terminals and lubricating points shall be provided by means of
hinged cowls or otherwise as appropriate. Backdraught dampers and/or fire release
dampers shall be provided where indicated.

2.5.2.7 In-Line Centrifugal and Mixed Flow Fans

In-Line centrifugal and mixed flow fans may be incorporated subject to the acceptance of
the Engineer provided that full details of ratings, noise level, dimensions and construction
are given in the tender. Fans of these types above 7.5 kW output will not normally be
accepted.

Page 35
2.5.2.8 Twin Fan Units

Duplicate fan assemblies shall comply with the appropriate sections of this Specification
for the fans themselves and shall incorporate an automatic or manual changeover facility
as indicated.

A non-return damper arrangement shall be fitted to prevent short circuiting.

2.5.3 Cooling Coils

2.5.3.1 General

All air cooling coil casings shall be of sheet steel not less than 1.2 mm thick with angle
framing at each end drilled ready to receive the counter flanges on the connecting
ductwork and shall be galvanised after manufacture. Cooler batteries shall be constructed
of copper tubes with aluminium fins, unless otherwise stated in the Particular
Specification. The secondary extended cooling surfaces shall be bonded to the primary
cooling tubes. Headers for copper tube batteries shall be of copper or bronze. The bottom
of a casing shall be made in the form of a watertight drip tray complete with drain
connection. The drain shall be fitted with a water seal to prevent the ingress and
discharge of air to and from the system; the drain pipe shall be run to the nearest sump or
gully.

A separate drain trough shall be provided for at least each 1.2 m height of coil. Water
shall not be carried over from a cooler into the airstream; an eliminator section shall be
fitted where necessary to prevent carry-over.

The resistance to air flow shall not exceed 125 Pa and the face velocity shall not exceed
2.5 m/s. Before leaving the maker' s works coolers shall be tested to 1½ times the working
pressure or to 7 bar whichever is the greater.

Eliminator plates shall be fitted if the face velocity exceeds 2.25 m/s.

Cooling Coils shall be supported so that their weight is not transmitted to ductwork and so
that they can be removed without disturbing adjacent ductwork. Inspection doors shall be
provided on both the upstream and downstream sides of the cooler. On any system
where the air static pressure at the cooler exceeds 750 Pa airtight cover boxes shall be
provided over the headers and bends; provisions shall be made for draining the cover
boxes.

Coils with fins which have been badly damaged during transport or erection or which
have become fouled or coated with builders materials will not be accepted.

2.5.3.2 Chilled Water Coils

Coils shall be arranged in a contra-flow pattern, with the flow of chilled water entering at
the leaving air end and leaving at the entering air end. The flow and return connections
and headers shall be so arranged to ensure an equal flow of water through all the tubes.
Provision shall be made for expansion of the tubes, for effective venting of the cooler
battery and connections and for draining of the cooler battery headers and tubes.

Connections up to and including 65 mm bore shall be screwed or flanged; connections


80mm diameter and above shall be flanged. Isolating valves shall be provided on inlet
and outlet connections, arranged so as to facilitate removal of the cooler.

2.5.3.3 Refrigerant Direct Expansion Air Cooling Coils

Coils shall be provided with refrigerant distributors, and connections to the tubes shall be
designed to ensure an equal flow of refrigerant to each tube. Return (or suction)
connections shall be arranged so as to ensure complete drainage of any oil in the cooler.
Coolers shall be dehydrated and sealed after manufacture.

Page 36
The thermostatic expansion valve which shall incorporate an external equaliser line shall
maintain the design degree of superheat at the evaporator outlet; the remote sensing
bulb shall be securely fixed to the evaporator outlet piping in a position where the degree

All refrigerant spaces shall be tested at the maker' s works to 1,400 kPa for use with
refrigerant 12 and to 2,100 kPa for use with refrigerant 22.

2.5.4 Air Heater Batteries

2.5.4.1 General

Casings shall be of galvanised sheet steel no less than 1.2 mm thick with angle framing
at each end drilled ready to receive the counter flanges on the connecting ductwork.
Heaters shall be supported so that their weight is not transmitted to ductwork and so that
they can be removed without disturbing adjacent ductwork. Inspection doors shall be
provided on both the upstream and the downstream sides of the heater.

The casing shall be airtight to meet the air pressure requirements of the system with
appropriate arrangements to accommodate expansion where applicable.

2.5.4.2 Electric Type

Electric air heaters shall consist of a number of heating elements of the enclosed non
corrodable type mounted in a steel casing. The elements shall be so installed that they
can be removed for cleaning or renewal without dismantling ductwork. The surface
temperature of the elements shall not exceed 150ºC. A high-temperature limit device with
hand reset button shall be incorporated.

Each element shall be complete with a second set of terminals to operate a failure
warning light.

The control of electric air heaters shall be interlocked with an air flow control of the vane
or pressure type which shall isolate the heating elements from the electricity supply in the
event of failure of air flow.

The heater shall be arranged with elements of the same number, or a multiple of the
number, of steps as the control required. All heaters and heater sections of more than
3 kW loading shall be balanced over three phases and the complete heater bank shall be
arranged for balanced operation on a 3-phase 4-wire system and be stepped by he
controller in 3 kW stages, unless otherwise indicated in the Schedules.

Below 3 kW the stepped loadings shall be in 1 kW increments.

The connections from each element shall be taken to a readily accessible terminal box
arranged for conduit entry. Each heater section shall be separately fused and the neutral
point of all 3-phase star-connection sections shall be brought out to a link in the terminal
box. Near any hot areas the wiring insulation shall be of appropriate quality.

The total resistance of the heater to air flow shall not exceed 25 Pa and the velocity
through the free area shall not exceed 6 m/s.

The installation of electric heater batteries shall comply in all respects with the
requirements of the local Fire Authority.

2.5.5 Air Filters

2.5.5.1 General

Filters shall operate to at least the efficiencies specified in this Section. They shall be
complete with holding frames sufficiently robust to ensure that no distortion occurs in
operation. All filters shall be installed with edge seals which shall prevent air bypassing

Page 37
the filters. The seals shall, remain effective even though the cells are periodically
removed and refitted. Filters shall be arranged so that there is easy access for cleaning
and/or removal. A differential pressure gauge of the dial or inclined manometer type shall
be provided for each filter bank and shall be fixed in such a position outside the duct
system that it is accessible and easily read. The gauge shall be marked to show
maximum pressure differential indicating a filter change requirement. Air velocity through
filters shall be such that the clean resistance (or operating resistance of automatic filters)
as indicated is not exceeded and that filter fabric or oil is not carried over into the system.

Filter assemblies shall be of a standard type and dimensions and shall be such that
replacement filter medium is readily available from a number of manufacturers.

2.5.5.2 Fire Precautions

Where a flameproof filter medium is specified the material shall comply with the following
requirements when tested in accordance with the relevant standard.

(1) Duration of flaming

No test specimen shall continue to flame for more than 8 seconds after the igniting flame
has been removed.

(2) Extent of after-glow

After-glow shall not spread beyond the area of material damaged by flaming.

(3) Length of material which chars or melts

The average length of material which chars or melts on the six specimens shall not
exceed 85 mm and the maximum length of the charred or melted material in any one
specimen shall not exceed 115 mm.

Where washable type flameproof filters are offered or specified the filter medium shall
comply with the requirements of Clause (ii) above both before and after the washing
treatment prescribed in BS 3120 Appendix A.

Where the filter medium is required to be flameproof the casing shall be not less than
1.6mm thick for at least 1.8 m upstream and 1.8 m downstream of the filter; the
immediate frames or cases of the filter elements shall be of material complying with BS
746 Part 1, Clause 7, Class 1.

2.5.5.3 Dry Replacement Media Type Filters

The filter shall be of the flat panel type contained in a galvanised steel front or side
withdrawal frame. Each cell shall comprise a pad of glass fibre or synthetic fibre filter
media, 50mm thick, retained within a rigid frame of durable cardboard.

The filter shall have an efficiency of not less than 92% based on the tests specified in
BS 2831 with test Dust No. 2, a maximum face velocity of 2 m/s and an initial pressure
drop not exceeding 70 Pa.

Sufficient spares cells shall be provided to replace all of the filter bank.

2.5.5.4 Regenerative Filters

The filter medium shall be processed washable open cell foamed plastic or plastic
bonded synthetic fibre and shall have a minimum thickness of 15 mm. The element shall
be supported on plastic coated steel wire formers with a metal frame. The face velocity
shall not exceed 2.25 m/s. Filters of this type shall have an efficiency of not less than
90% based on the tests specified in BS 2831 with test dust No. 2.

Page 38
2.5.5.5 Bag Filters

The filter shall comprise one or more 600 x 600 filter bag modules fitted into a purpose
made galvanised steel side or front withdrawal frame.

Each module shall comprise a minimum of four separate bags banded or clipped into a
galvanised steel header.

The bags shall have a minimum length of 600 mm. and shall be of the fine medium to
give an efficiency of not less than 99.6% based on the tests specified in BS 2831 with test
dust No. 2.

The medium shall be of multi-layer type with high mechanical strength. The maximum
initial resistance shall be 100 Pa. One complete set of spare bags shall be supplied.

2.5.5.6 Automatic Fabric Roll Type Filters

The filter shall comprise the complete assembly of filter frame, motor and drive and filter
medium. The filter shall operate automatically, with provision for manual starting and
stopping of filter movements; unless otherwise indicated automatic filter movement shall
be controlled by the resistance across the filter. Provision shall be made for visual
warning that the end of the clean filter medium is approaching. The driving motor shall be
automatically switched off when the end of the filter medium is reached.

Unless otherwise indicated the resistance of the filter shall not exceed 125 Pa under
normal operating conditions; the air velocity through the filter medium shall not exceed
2.5 m/s. Filters of this type shall have an efficiency of 95% based on the tests specified in
BS 2831 with test dust No. 2.

Where the motor and/or gearbox is mounted in the air stream the electrical insulation
and/or lubricants shall be suitable for the temperature range experienced.

A spare roll of filter medium shall be provided for every installed roll.

2.5.5.7 Grease Eliminators

Grease eliminators shall be of the impingement type comprising fluoropolymer coated


adjustable vertical baffles contained within a stainless steel casing.

2.5.6 Fan Coil Units

2.5.6.1 General

Fans, filters, cooling coils, heating coils, motors and thermal and acoustic insulation shall
comply with the appropriate Sections of this Specification, with the following exceptions or
alternatives:

(1) Fans shall be of the forward curved centrifugal type and may be of aluminium,
reinforced glass fibre or rigid plastic material.

(2) Air Filters may be of washable synthetic fibre or cellular plastic material with a
minimum thickness of 15 mm and shall have a minimum efficiency of 90% when tested in
accordance with BS 2831 using test dust No. 2.

(3) Motors shall be quiet running and shall have sleeve bearings factory lubricated
for life. Motor windings and electrical components shall be impregnated or protected to
avoid trouble from condensation.

2.5.6.2 Casings

Casings shall be of sheet steel not thinner than 1.2 mm and shall be protected against
corrosion and finished inside and outside with stoved primer.

Page 39
Casings of exposed units shall provide sufficient internal space to accommodate valves,
controls etc. and shall incorporate return air grille and directional supply grille. The front
panel shall be readily removable for access.

Concealed units shall be complete with supply air duct spigot and return air plenum.
Valves and controls shall be external to the casing.

2.5.6.3 Components

Cooling and heating coils shall be at least two-row and shall include an air cock. All units
shall include an easily removable and replaceable air filter capable of treating the total air
volume. Drain pans shall be either of sheet steel protected against corrosion or of plastic
or reinforced glass fibre material and shall be arranged, and insulated where necessary,
so as to ensure that no condensation is formed on the underside. Drain pans shall be
large enough to collect all condensate from the coil, return bends and pipe work
connections; they shall be removable and shall have a slight fall to the drain connection.

2.5.6.4 Arrangement of Units

The arrangement of units, i.e. whether they be wall, floor or ceiling mounted, the position
of inlet and outlet grilles if any, the need for sheet metal casing and so on, shall be as
indicated elsewhere.

Where units are concealed, the Contractor shall ensure that adequate access is provided
for the removal of a complete unit.

2.5.6.5 Controls and Grilles

Fan coil units shall have a control giving three running speeds and an '
OFF'position. The
specified duty shall be achieved using medium or low speed. Outlet grilles shall be
adjustable to enable the direction of airflow to be reset. On floor mounted units, supply
grilles shall be on the top of the unit.

2.5.6.6 Noise Levels

Casings shall be lined with material to act as both thermal and acoustic insulation
(Sections 10 and 11). Fan and motor assemblies shall be complete with anti-vibration
mountings.

Noise data shall be provided and shall be based on tests in accordance with the HVRA
Test Code, or similar tests; full details of the testing technique and procedure shall be
given. The data given shall include an octave band analysis of the sound power level of
the unit.

2.5.7 Roof Mounted Air conditioning Units

Roof mounted packaged air conditioning units where specified shall be thermostatically
controlled from the respective MCC room. The system shall handle predominantly
recirculated air with a controlled quantity of fresh air introduced at the unit. Supply and
return air distribution ducts shall be located in the suspended ceiling serving supply and
return air diffusers.

Supply air handling plant shall include sand trap fresh air intake louvre, insect screen, pre
filter, bag filter, electric air heater battery, fan and distribution ductwork.

External conditions for the calculation of duties for the mechanical services plant shall be
with mean monthly maximum and minimum values as detailed elsewhere.

All items of plant and equipment for building services shall be designed to operate without
malfunction up to a maximum ambient condition of 52°C dry bulb and a minimum ambient
condition of 1°C dry bulb with instances of 100% relative humidity.

Page 40
The air conditioning system shall be capable of maintaining internal conditions in the
respective buildings within the following bands:

22°C ± 1°C dry bulb


40% - 55% relative humidity

The air conditioning shall be arranged to introduce a fresh air quantity equivalent to 10%
of the total air volume handled with a minimum of six air changes per hour. The system
shall maintain a positive pressure internally of 6 mm water gauge. The grills and diffusers
shall be arranged in such a way that a uniform air supply is maintained throughout the air-
conditioned areas. The supply and return air ducting system installation shall be in
accordance with Duct work Specifications DW 142 and all testing to follow DW 143 and
CIBSE Guides.

The air-conditioning CIBS guides is valid for package units only.

The maximum acceptable sound level in the air-conditioned space shall have a Noise
Rating (NR) of 40.

The Contractor shall be responsible for the complete and proper closure of the openings
provided by the Civil Contractor for ventilation purposes.

The refrigerant used in air conditioning plant shall be HFC-134a.

Condensated water shall be piped from air conditioning units to approved drainage
points. The free discharge of condensation onto the ground shall not be permitted.

External ducting shall be protected by aluminium cladding.

Final connections to the diffuser shall be by flexible ducting of maximum length 1 m.

Volume control dampers shall be provided at readily accessible locations, at all branches,
and where necessary to adjust the flow to achieve satisfactory distribution.

Unless restricted by the dimensions of the ducting, duct access panels shall be minimum
450 mm x 300 mm.

Fire dampers compliant with BS 476, and 2 hour rated, shall be provided.
Extract grills and diffusers shall be anodised aluminium, to match the existing finish.

Where required, fibreglass insulation shall be minimum thickness 50 mm, and secured to
the ducting with non-corrosive metal pins.

Where incorporated in air conditioning units any copper parts shall be coated for
protection against corrosion.

2.5.8 Split AC Unit

Split AC unit shall be quick cooling by high output and of the energy saving type.

Compressor shall be of robust design with increased hardness of compressor drive


material, and provided with gas leak protection, overload protection, temperature rise
prevention device, and so on.

Compressor shall comprise a high-efficiency, high-torque motor with high-durability


crankshaft.

Split AC unit shall be provided with following features

• Auto restart
• Double swing automatic complex action of flaps

Page 41
• Moisture removal
• Auto shut louvers
• Program digital timer
• Auto changeover for various cooling mode
• Sleep timer
• Automatic air flow adjustment to suit room temperature
• Up/down swing louvers
• Remote control unit
• Automatic filter cleaning function.
• Antibacterial dust box
• Sterilizing countermeasure by photo catalytic filter to remove odours and
bacterial
• UV illumination to refresh air

Indoor unit shall be either floor/wall or ceiling mounted and super quiet type and
evaporator motor shall generate high power which confronts very wide magnetic
attraction with respect to narrow from conventional motors.

Copper parts within the unit shall be coated for protection against corrosion from rust and
salt damage.

2.5.9 Window AC Unit

AC unit shall be horizontal application operated on 240 V AC supply with capacity of


18,000 to 30,000 Btu/h.

Compressor shall be of robust design of smooth rotary type operating up to 56ºC, with
internal thermal protector and capacitor, suitable to operate with R22 refrigerant at design
pressure of 2.6 MPa. Compressor shall have 5-year warranty.

Fan motor shall be of the 3-speed type and unit shall be of the low outdoor noise type to
64 dB(A).

Evaporator fin shall be hydrophilic aluminium type and condenser fin shall be non -
hydrophilic aluminium type.

Copper parts within the unit shall be coated for protection against corrosion from rust and
salt damage.

Unit shall be comprise of Fresh air switch, moisture removal, twin drainage methods,
sliding chassis and easy to remove panel and remote operated unit.

Unit shall be provided with anti-bacterial and washable type, filter , with energy-saving
operation and easy to maintain type.

2.6 Refrigeration Plant

2.6.1 General Requirements

This section deals with mechanical refrigeration plant and ancillaries for vapour
compression refrigeration plant using halogenated fluorocarbon refrigerants.

All items of plant whether supplied separately or as a factory assembled package unit
shall comply with the following sub-sections unless superseded by the Particular
Specification.

The refrigeration plant shall include compressor(s), evaporator(s) and condenser(s) all as
indicated to suit the application. The items shall be correctly matched to ensure
satisfactory operation. The heat rejected at the condenser under maximum design

Page 42
conditions shall include the design heat load absorbed at the evaporator, the heat
equivalent of the work done by the compressor and any other heat gains of the system.

A full charge of refrigerant and lubricating oil shall be supplied together with all items
necessary for the satisfactory functioning of the system.

Complete control and instrumentation equipment including safety devices shall be


included.

Packaged assemblies shall be resiliently mounted on a combined base plate and tubular
framework requiring only the external water and electrical connections to be made on
site.

Complete data of plant operation and maintenance should be made available to the
Engineer together with a Schedule of Spare Parts and Repair Information.

2.6.2 Compressors

Hermetic compressors may be used up to 10 kW; where they are supplied, the entire
refrigeration system shall be completed and tested at the Factory.

Semi-hermetic and open type compressors shall be suitable for the type of refrigerant
specified in the Particular Specification. Where a direct expansion cooler is employed the
refrigerant shall be non-toxic.

All compressors shall be driven by electric motors and may be of the reciprocating,
centrifugal, rotary or screw type. Speed shall be such that the noise is kept to a
reasonably low level consistent with the application and location of the machine. The
complete compressor unit shall be mounted on an anti-vibration base reducing
transmissibility from compressor to structure to below 10%. The Contractor shall supply
all necessary foundation bolts.

When one compressor is specified it shall be designed for the maximum cooling load;
where two or more compressors are required the maximum cooling load shall be divided
equally between the number of compressors.

Lubrication shall be automatic and so arranged that the compressor may be started
frequently (under thermostatic control) or be run for prolonged periods without inspection.
An oil separator shall be fitted to the compressor discharge line and shall be of the float
and needle valve type and shall have an automatic return to the compressor crank case.
Crank case oil heaters shall be provided and shall operate when the compressor is shut
down.

Semi-hermetic compressors shall include the following features:

All parts of the electric motor shall be proof against contact with refrigerants and the
associated lubricating oils. Additional motor protection shall be provided against failure or
partial failure of the gas cooling system. All valves on the refrigerant circuits shall be
located in a readily accessible position and shall be provided with seal caps.

A rotary mechanical seal shall prevent loss of refrigerant at the driving shaft. The seal
shall be effective for long operating periods and short rest periods without leakage.

All compressors of duty in excess of 35 kW shall incorporate capacity control and shall
start unloaded. Hot gas by-pass capacity control shall not be used unless indicated.

When called for in the Particular Specification the low pressure cut outs shall be used to
control the operation of the compressor, in which case it is to be the self restoring type
with adjustable working differential.

Page 43
Liquid receivers with inlet and outlet service valves shall be provided where required. A
liquid sight glass shall be mounted vertically in the liquid line with integral filter.

Means shall be provided for oil to return to the crank case from the suction gas header
and for refrigerant gas (but not oil) to return to the suction manifold from the crank case.
Crank case oil heaters shall be provided and shall operate when the compressor is shut
down. An oil pressure relief valve or a bleed from the oil pump discharge back to the
crank case shall be provided.

Suction gas entry to the compressor shall be designed to reduce gas velocity so as to
assist in releasing any entrained oil or dirt; suction gas strainers shall be fitted. The
following fittings shall be provided:-

(a) Suction and discharge stop valves.

(b) Suction and discharge refrigerant gas pressure gauges with means of isolation.

(c) Oil pressure gauge.

(d) Oil sight glass.

(e) High and low gas pressure adjustable safety controls.

(f) Semi hermetic compressors shall include the following features:

(i) All parts of the electric motor shall be proof against contact with halocarbon
refrigerants and the lubricating oil associated with halocarbon refrigeration
systems.

(ii) The oil pump shall operate equally well under either direction of rotation.

(iii) Where the motor rotor is overhung a support bearing of adequate width shall
be provided.

(iv) Additional motor protection shall be provided against failure or partial failure
of the gas cooling system.

2.6.3 Evaporators

Evaporators are to be designed in accordance with the current standard practice being
suitable for direct expansion, chilled water or brine as required.

Evaporators for water chilling installations unless otherwise indicated shall be of the shell
and tube heat exchanger type. The evaporator shell, tube plates and end covers shall be
of steel or cast iron; the tubes shall be of copper and may be extended surface piping.
The end covers shall be removable and the plant shall be arranged so that there is
adequate space for cleaning and removal of the tubes. Isolating valves and flow and
return connections shall be provided. Unless otherwise indicated, the fouling factor shall
be 0.000088 m2 oC per W.

Evaporators may be of either the flooded type or the dry expansion type. The flow of
refrigerant to dry expansion type evaporators shall be controlled by a thermostatic
expansion valve; the flow of refrigerant to flooded type evaporators may be controlled by
either a float level or a thermostatic expansion valve. In dry expansion type evaporators
the velocity of refrigerant and the design of the refrigerant passages shall ensure that any
oil present is carried over to the compressor. In flooded type evaporators special
provision shall be made to return oil from the evaporator to the compressor. Unless
otherwise indicated the design evaporating temperature for direct expansion air coolers
and for dry expansion shell and tube water chillers shall not be less than -1ºC; for flooded
evaporators it shall be not less than + 1ºC.

Page 44
A thermostatic expansion valve shall maintain the design degree of superheat at the
evaporator outlet; the remote sensing bulb shall be securely fixed to the evaporator outlet
piping in a position where the degree of superheat can be correctly sensed. Thermostatic
expansion valves shall incorporate an external equalizer line.

Refrigerant spaces shall be tested at the maker’s works to 1,400 kPa for use with
refrigerant 12 and 2,100 kPa for use with refrigerant 22. The water side of heat
exchangers shall be tested to 700 kPa.

2.6.4 Condensers

Air cooled condensers shall be tested at the maker’s works to 2,000 kPa for use with
refrigerant 12 and to 2,750 kPa for use with refrigerant 22. Condensers shall have copper
tubes with aluminium fins or, where indicated, they shall have copper tubes with copper
fins. Condensers with fins which have been badly damaged during transport or erection
or which have become choked or coated with builder' s material will not be accepted.
Minor irregularities in the fins shall be combed straight.

Where air cooled condensers are sited within a building and serve a compressor larger
than 2.25 kW the air outlet shall be ducted to the external air; condenser fans shall be
capable of overcoming the extra resistance of this ducting. The condenser frame
supports and enclosure shall be of galvanised steel. For saline, sand laden or corrosive
atmosphere extra protective finishes shall be provided.

Where air cooled condensers are mounted outside buildings, weatherproof motors shall
be provided and the condenser enclosures shall be designed to protect the fan, motor,
drive and finned coils from the weather, including solar radiation. Externally mounted
condensers shall discharge air vertically upwards unless they are protected by an integral
wind deflection shield or a purpose made builders work baffle.

Where an air cooled condenser will have to operate under conditions of much lower air
temperatures than the design maximum a means of maintaining condenser pressure
shall be incorporated. This may be achieved by modulation of the outlet dampers and/or
by-pass dampers by condenser flooding or by fan volume control. Where there are three
or more condenser fans, control may be effected by sequencing of these fans. Where
modulation of the outlet damper only is used the fan motor shall be of adequate size to
deal with the minimum extra load and shall in any cased be switched off by the dampers
when they are closed. Fans shall comply with the relevant Section of the Specification.

2.6.5 Condensing Units

Condensing units may be water cooled or air cooled as indicated.

Sub-components, that is, compressors, and so on, shall be in accordance with the
appropriate sections of the Specification.

The components shall be constructed within a robust steel framework with all internal
piping and wiring completed. Where the unit is exposed to weather it shall be suitably
treated to avoid corrosion and damage.

A control panel shall be provided and shall include starters for all compressors and fans
complete with overload protection. The panel shall be pre-wired but allow for connections
for external interlocks and shall also include a control circuit fuse. Anti-condensation
heaters and oil failure switches shall also be provided.

Capacity control shall be as indicated in the Particular Specification or as shown on the


contract drawings.

2.6.6 Refrigeration Plant Accessories

Every refrigerating system shall be protected by a pressure relief device.

Page 45
Each system with an air cooled or evaporative condenser shall have a liquid receiver
complete with two stop valves, a sight glass, charging connection and a purge valve.
Relief valves shall be fitted on liquid receivers and water condensers for plant larger than
17.5 kW. Liquid receivers on plant smaller than 17.5 kW capacity may, alternatively, have
a fusible plug.

Water cooled condensers on systems larger than 17.5 kW shall have a liquid receiver
capable of holding a complete charge. Either the water cooled condenser or the
associated liquid receiver shall have a purge valve. A capped valved connection shall be
provided for refrigerant charging.

All major items of plant shall be dried at the factory and filled with a holding charge of
refrigerant or inert gas; all openings shall be sealed. During erection care shall be taken
to prevent the entry of moisture. A dehydrator shall be fitted in the refrigerant pipe work.

In addition to the suction gas and lubricating oil strainers fitted to the compressor, a liquid
line strainer shall be fitted to protect the expansion valve or float valve; any pressure
regulating device fitted in the suction line shall also be protected by a strainer. Where an
evaporator pressure regulating device is fitted, an additional gauge indicating evaporator
pressure shall be provided, complete with means of isolation.

Each compressor of more than 10 kW capacity shall have a discharge gas silencer.

In dry expansion type systems the liquid leaving the condenser shall be sub-cooled and
the refrigerant gas leaving the evaporator shall be super-heated. For compressors
greater than 200 kW capacity this shall be achieved by means of a purpose made heat
exchanger.

2.6.7 Pipe Work, Valves and Ancillaries

All refrigerant pipe work and all necessary fittings and ancillaries shall be supplied for the
complete erection of the plant(s) at site.

Pipe work for refrigerant circuits shall be of refrigeration quality copper tube. Joints shall
be flanged, brazed, welded or made with soldered capillary fittings. Pipelines shall be
firmly secured and measures shall be taken to prevent vibration weakening joints and
connections. In particular, the suction and delivery pipes from the compressor shall
incorporate an adequate length of flexible piping of the armoured bellows type.

Pipe work shall be designed and run so that any oil in the compressor discharge
refrigerant which passes through the oil separator (where fitted) is carried through the
system and returned. At any point where a large quantity of oil may accumulate an oil
separator and means of returning the oil to the compressor shall be provided.

All necessary suction, delivery, liquid, gauge and charging valves shall be provided so
that all major portions of the system may be isolated for maintenance. In particular the
refrigerant circuit shall be arranged so that any thermostatic expansion valve may be
removed without the necessity of “pumping-down” the system.

Valves required for compressors, liquid receivers, and so on, shall be of either diaphragm
or bellows type or be packed valves complete with a back seating and a seal cap.

The liquid refrigerant regulating valves shall be of the thermostatic expansion type
preferably multi-outlet with pressure distribution and shall be provided with thermal
elements of the “liquid charged” type and removable fine wire-mesh liquid strainer.

Magnetic liquid valves shall be installed in the liquid line before the expansion valves. The
magnetic valves shall be provided with manual lifting screw or alternatively a valved by-
pass.

Page 46
Compressors shall not be connected to run in parallel unless specified in the Particular
Specification, in which case all major plant items that are cross connected shall be valved
for isolation.

When the refrigeration plant is used to provided a storage of chilled water or brine, the
temperature of the liquid is to be maintained and controlled by capillary tube immersion
type thermostats. A thin walled metal sleeve phial pocket is to be fixed securely in the
side of the tank to receive the phial and isolate it from the contents of the tank.

2.6.8 Insulation

Refrigerant discharge and liquid lines need not normally be insulated, but where
exposure to solar radiation is likely they shall be shielded or insulated with a 19 mm
thickness of material having a thermal conductivity of less than 0.036 W/mºC and
weatherproofed with a material having a reflective or light coloured finish.

The suction line from the evaporator to the compressor shall be insulated with a material
having a thermal conductivity of less than 0.036 W/mºC and least 19 mm thick for pipes
of up to 76 mm diameter and 25 mm thick for pipes of 108 mm diameter and above. This
insulation shall be protected by a vapour barrier which shall not be broken between joint
of sectional material or at discontinuities at valves or brackets.

Shell and tube evaporators shall be insulated with at least a 25 mm thickness of material
having a thermal conductivity of less than 0.036 W/mºC. This material shall be protected
by a vapour barrier and further protected by a painted sheet metal casing. The insulation
and protection shall be so arranged that the end covers can be removed without damage
to the insulation.

2.6.9 Controls

A solenoid valve shall be fitted in the liquid line to each evaporator, except high-pressure
float controlled flooded evaporators, to prevent the flow of liquid refrigerant to the
evaporator when the compressor is not running.

Each compressor of 35 kW capacity and above shall be provided with an oil pressure
failure control.

Compressors in tropical latitudes subject to time controlled operation shall be fitted with
suction pressure regulating devices to limit the maximum suction pressure.

Where the stopping of a compressor of more than 35 kW capacity (or less where
indicated) is not controlled by suction pressure, that is, it is controlled by air or water
temperature criteria, and the evaporator is at a higher level than the compressor, a pump-
down cycle shall be incorporated. The control signal shall initially close the liquid line
solenoid valve and the compressor shall then pump down to a pre-determined suction
pressure.

For each shell and tube evaporator a flow switch shall be fitted in the chilled water
pipeline. The flow switch shall prevent the compressor(s) starting unless the chilled water
is flowing and shall stop the compressor(s) if the flow falls below a safe minimum.
Additionally a chilled water low temperature limit thermostat shall be provided and shall
stop the compressor(s) if the leaving water temperature drops below a set value. The flow
switch and the thermostat shall each be connected in a separate circuit independent of all
other control circuits; they shall not be wired in series.

2.6.10 Pipe Work, Fittings and Valves

2.6.10.1 Pipe Erection

All pipe work shall be installed in a neat and workmanlike manner by skilled tradesmen.

Page 47
All adjacent pipes shall be fitted mutually parallel, all vertical pipes fitted plumb, and all
horizontal pipes shall have a continuous fall to low points of 1:240 except where such an
arrangement would make it difficult to provide a neat installation. In such cases, a ruling
from the Engineer shall be sought.

Generally pipes shall follow the line of walls as indicated on the drawings, including sets
around columns as required, and shall be fitted to give a minimum clearance of 25 mm
from walls, 100 mm from floors, and 75 mm between pipes.

Where pipes are to be insulated, they shall be fitted in such a manner as to give the
prescribed clearance between the insulation and the walls, floors or adjacent pipes.

All sets or pulled bends shall be free from flattening or distortion, and all burred and cut
ends of pipes shall be well reamered or filed to ensure that the full diameter of the pipe is
maintained. Any sets or pulled bends on PVC-U pipe work shall be factory fabricated.

No pipe joints shall be embedded in the thickness of walls, floors or ceilings, or in any
inaccessible position.

Special care shall be taken before final assembly and closing up to ensure that all pipes
are properly cleaned out and free from flux, grit, scale and jointing materials. Ends of
pipes temporarily unconnected for any reason shall be closed with plastic caps.

All reductions in the diameter of pipes shall be made by the use of eccentric reducing
sockets. Bushed fittings will not be permitted.

All tees shall be swept, and all bends long radius, unless otherwise agreed with the
Engineer.

2.6.11 Pipe Supports

Pipe work shall be supported at intervals not exceeding the following:

(a) Mild Steel

Nom. bore Vertical pipes Horizontal pipes


15 mm 2.50ºm 1.80ºm
20 mm – 25ºmm 3.00ºm 2.50ºm
32ºmm 3.00ºm 2.70ºm
40 mm – 50ºmm 3.60ºm 3.00ºm
65 mm – 100ºmm 4.50ºm 4.00ºm
125 mm – 150ºmm 5.50ºm 4.50ºm
200ºmm & above 8.50ºm 6.00ºm

(b) Copper

Nom. bore Vertical pipes Horizontal pipes


15 – 22ºmm 1.80ºm 1.20ºm
28ºmm 2.40ºm 1.50ºm
35 – 54ºmm 3.00ºm 1.80ºm
67 – 108ºmm 3.70ºm 2.40ºm
133ºmm 3.70ºm 3.00ºm
159ºmm & above 3.70ºm 3.70ºm

Page 48
(c) PVC-U

Nom. Bore Vertical and Horizontal Pipes


Classes B & C Classes D & E
15ºmm - 0.90ºm
20 mm – 25ºmm - 1.05ºm
32 mm – 40ºmm - 1.20ºm
50ºmm 1.05ºm 1.35ºm
65ºmm 1.20ºm 1.50ºm
80ºmm 1.35ºm 1.65ºm
100ºmm 2.50ºm 1.80ºm
150ºmm 2.00ºm 2.25ºm
200ºmm & above 2.40ºm 2.70ºm

All pipe supports or clips shall be adequate for the weight to be carried, and shall allow
free movement for expansion and contraction.

Pipe supports shall generally be fabricated from mild steel, but ring clips shall be cast
brass for copper pipe and PVC-u lined for PVC-u pipe.

Visible supports in occupied rooms shall generally be split ring clips with back-plate for
screw fixing for copper and steel pipes, and moulded plastic clip-in type for PVC-u pipe
work.

Pipe work in ceiling voids, plant rooms etc. shall be generally supported from accepted
type multiple pipe supports comprising mild steel channel bolted to the underside of the
slab, with drop rods and split ring clips. All drop rods shall be fitted with cup washers, nut
and locknut. All holes for drop rods shall be drilled, not flame-cut.

Pipe work in horizontal ducts shall be generally supported as for pipe work in ceiling
voids, but with the channel iron built into the duct walls.

Where the calculated maximum linear expansion in any straight pipe exceeds 20 mm, the
pipe shall be supported on rigid welded channel iron frames with rollers and chairs, and
semi-circular flat iron hoops to act as pipe restraints and guides.

Pipe work in vertical ducts shall be supported from channel iron built into the duct walls,
with “U” bolts.

Supports shall be provided either side of heavy items of pipeline equipment such as
flanged valves, strainers etc. to avoid any strain on or distortion of the equipment.

2.6.12 Welding

All welding on pipe work of 80 mm and above shall be by the electric arc method, but for
pipe work of 65 mm and below oxy-acetylene welding may be used as an alternative.

All welding shall be carried out in accordance with current good practice by operatives
skilled in this trade.

Care shall be taken to ensure that welding material or flux does not project into the bore
of the pipes. All welds shall be of good clean metal free from slag or porosity of even
thickness and contour, well fused with the parent metal, hammered on completion and
finished smooth.

The Engineer reserves the right to have cut for examination 2% of all welds made.

Page 49
All bends, branches, reducers etc. shall be seamless steel butt-welding fittings. Site
fabricated fittings are not permitted.

2.6.13 Unions and Flanges

Removable joints shall be formed on all steel and copper pipe work at intervals of
approximately 15 m or wherever necessary to facilitate dismantling.

Removable joints shall be formed by screwed unions on all pipe work up to and including
54 mm, and by flanges of the appropriate pressure rating on pipe work above 54 mm.

All unions shall have two bronze tapered seats. Unions and flanges shall be galvanised
when used on galvanised pipe work and gunmetal when used on copper pipe work.

Flanged joints shall be made with an accepted type nickel alloy or composition joint ring.

2.6.14 Pipe work and Fittings

2.6.14.1 Black Mild Steel

Pipe work shall be to BS EN 10255 Heavy Quality, or ASTM A53/A53M Grade B


Schedule 40, assembled by means of screwed joints and heavyweight beaded malleable
iron fittings, or welded.

Screwed joints shall normally be used on sizes up to 32 mm, and welded joints on 65 mm
and above. On sizes 40 mm and 50 mm, the choice is at the discretion of the Contractor
in agreement with the Engineer.

Screwed joints shall be BSP taper threads to BS 21, clean threaded, pulled up tight, and
made with either fine stranded hemp and an accepted jointing compound, or PTFE tape.
Excess jointing materials shall be removed after the joint has been made.

On pipe sizes 15 m – 40 mm inclusive, hot pulled bends formed on site may be permitted
providing their radius is not less than 2½ times the internal diameter of the pipe.

2.6.14.2 Galvanised Mild Steel

Pipe work shall be to BS 1387/1967 Heavy Quality, or ASTM A53/A53M Grade B


Schedule 40, assembled by means of screwed joints and galvanised heavyweight
beaded malleable iron fittings. The welding of galvanised tube will not be permitted.

Screwed joints shall BSP taper threads to BS 21, clean threaded, pulled up tight, and
made with either fine stranded hemp and an accepted jointing compound, or PTFE tape.
Excess jointing materials shall be removed after the joint has been made.

2.6.14.3 Copper

Pipe work shall be to BS 2871, of one or more of the following grades as indicated in the
Particular Specification :

(i) Part 1 Table X Condition ½H

(ii) Part 1 Table Y Condition O

(iii) Part 1 Table Y Condition ½H

Copper pipe work up to and including 54 mm shall be assembled by means of integral


solder ring capillary fittings to BS 864 Part 2. The solder used shall comply with BS 219,
and the method of assembly shall be to the fitting manufacturers recommendations.

Fittings of 67 mm and above shall be brazed or bronze welded.

Page 50
2.6.14.4 PVC-u (Pressure Type)

Pipe work shall be to BS 3505, of adequate grade for the service to which it is to be
applied, and shall have a tensile strength at 20ºC of 34,500 kPa. In all cases particular
attention shall be made to the operating pressure when related to the temperature of the
medium, and the manufacturers recommendations must not be exceeded.

Joints generally shall be made using an accepted solvent cement of the gap filling type,
and following the manufacturers recommended procedures.

Integral mechanical rubber ring joints may be used on pipe work of 65 mm and above
where buried underground. The Contractor shall allow for all necessary thrust blocks
where such joints are used.

Care shall be taken with all PVC-u pipe work to allow for the high coefficient of
expansion.

All bends and fittings shall be of the same materials specification as the tube, and shall
conform to BS 4346 Part 1.

2.6.15 Air Venting and Drainage

All pipes shall be run with appropriate gradients to ensure the free release of air and
drainage at suitable points on the system.

Where high points occur and Automatic Air Eliminators are not specifically indicated the
venting of the pipe shall be effected by the formation of a collecting pocket of not less
than 50 mm bore and 100 mm in length welded to the top of the pipe. Where the main
pipe bore is less than 50 mm size the connection shall be the same size as the main
pipe.

The trapped air shall to be released to atmosphere by way of a 15 mm tube carried to low
level and terminating with a 6 mm bronze vent cock.

Drain outlets shall be provided at all points of the system necessary to empty the system
and to facilitate maintenance and repair of the pipe work. Collection pockets of ample
size for rust, scale or welding pellets are to be provided at each drain point and shall be
fitted with a 15 mm bronze draining tap.

2.6.16 Test Points

Pressure and temperature test points shall be provided where required to assist the
balancing testing and commissioning and additionally where indicated on the drawings.

Unless otherwise indicated pressure and temperature test points shall comprise a welded
socket, into which shall be screwed a self-sealing test plug, with removable cap.

2.6.17 Expansion Joints

Provision for movement due to expansion and contraction shall be made either by loops,
bellows expansion joints, or by change in direction of the pipe work. Supports at such
points shall be arranged to ensure that all movement is taken up by the loop, joint, or
change in direction of the pipe work. Where pipe work is required to be pre-stressed for
the purpose of reducing expansion stress under working conditions, the extent of the cold
draw shall be calculated as half the total expansion.

Expansion bellows shall be of axial pattern or as indicated and shall be provided with
screwed or flanged ends as appropriate to facilitate replacement, unless otherwise
accepted. They shall incorporate internal liners if required and shall be manufactured
from 18/8 stainless steel or other accepted material appropriate to the duty and shall be
designed to withstand the test pressure of the system. Bellows shall be capable of not

Page 51
less than 2,000 complete cycles of movement over the designed working range without
failure.

Expansion bellows for angular movements shall be arranged as indicated. They shall be
provided with tie rods or hinges to take end thrust.

All bellows expansion joints shall be provided with external protection where exposed to
damage. For axial bellows this shall comprise an external sleeve.

Bellows shall be installed so that they are not subjected to stresses other than those for
which they are designed. Unless otherwise indicated they shall be installed so that they
are in their free position at a temperature midway between the high and low limits of
normal service.

Pipe work either side of the bellows expansion joints shall be provided with guides to
ensure that all movements are taken up in the designed manner. The manufacturer' s
recommendations shall be closely followed. Guides shall be secured rigidly and shall
provide free movement for expansion without undue tolerance. Means of lubrication shall
be provided where necessary.

On mild steel pipe work, mild steel anchors capable of resisting the maximum stresses
shall be provided and preferably shall be welded to the pipe work. Where it is
impracticable to weld the anchors to the pipe work, cast iron chairs with at least two
wrought iron stirrup bolts shall be used, the bolts being provided with sufficient thread to
ensure an effective grip on the pipe. For copper pipe work the anchors shall be provided
by wide copper straps secured to the pipe work in such a manner that the pipe is not
damaged. The Contractor shall supply, and fix in position ready for building in, all cleats,
brackets and steelwork required for anchor points. Anchor points where secured to the
bottoms of ducts or trenches shall be sealed with hot poured bitumen.

2.6.18 Pipe Sleeves

Where pipes pass through walls, floors and ceilings, sleeves of the same material as the
service pipe shall be used. All sleeves shall project 2 mm clear of the finished surfaces of
walls and floors.

The Contractor shall be responsible for ensuring that the sleeves are in the correct
position at the time they are built in.

The space between the pipes and sleeves shall be packed with a suitable flexible
material to maintain the fire rating of the walls and floors.

2.6.19 Protection of Buried Pipelines

All metal pipe work buried underground or embedded in the building structure shall be
protected by two layers of a bituminous or petrolatum tape formulated for tropical
application.

The tape width shall be 100 mm, applied with a 25 mm overlap, and the second layer
shall be applied in the opposite direction to the first.

The minimum cover over buried pipes shall be 600 mm for copper and steel, and 900 mm
for PVC-u.

2.6.20 Refrigerant Systems

Pipe work for refrigerant systems shall be of refrigeration quality copper. Joints shall be
flanged, brazed, welded or made with soldered capillary fittings.

Page 52
Pipelines shall be firmly secured and measures shall be taken to prevent vibration
weakening joints and connections. Pipe work shall be designed and run so that any oil in
the compressor discharge refrigerant which passes through the oil separator (where
fitted) is carried through the system and returned. At any point where a large quantity of
oil may accumulate an oil separator and means of returning the oil to the compressor
shall be provided.

Valves required for compressors, liquid receivers, and so on, shall be of either diaphragm
or bellows type or be packed valves complete with a back seating and a seal cap.

Compressors shall not be connected to run in parallel (that is, with common discharge
and/or suction lines). Where, to increase availability, it is required that any compressor
shall be capable of working with any condenser or evaporator, cross connections shall be
provided and all major plant items shall be valved for isolation.

After erection the whole of the refrigeration pipe work shall be pressurised and tested for
leaks.

All fittings for use with refrigeration systems shall be suitable quality copper with all joints
being made either by flanges, brazing, welding or soldered capillary fittings.

The Contractor shall ensure that the correct quality of brazing or soldering filler rod,
together with the correct flux is used for the type of joint with due consideration for the
temperature and pressure of the media flowing in the pipe work.

2.6.21 Compressed Air System

Compressed air systems and their components shall be designed, manufactured and
tested according to the relevant Standards and Codes.

All branches shall be taken from the top of the mains. Each branch pipe to compressed
air points shall terminate in a standard fitting provided with chained cover.

The system shall be self draining in the direction of flow (where possible) and fitted with
drain traps and the necessary isolating and bypass cocks. Each air receiver shall be fitted
with its own drain.

Fusible plugs shall be fitted as close to compressor outlets as possible to safeguard the
installation in the event of the air temperature reaching the lubricating oil flash point.

Fusible plugs shall also be fitted directly into any receivers which are capable of being
isolated from the safety valve to prevent an explosion in the event of fire.

The position of the plugs shall be such that their discharge will not cause injury to
personnel nor damage to other equipment.

Safety valves shall be provided to permit air to escape from the system without increasing
the pressure beyond 10% above the blow off pressure when the compressor(s) are
delivering their full output and all other valves are closed.

Safety valves shall be fitted with hand operated easing gear.

Where reducing valves are installed in a system the low pressure, high pressure and any
intermediate pressure systems shall be separately protected by safety valves set to
release air as soon as the design pressure of that part of the system is reached.

Safety valve outlets shall be positioned such that escaping air will not cause injury to
personnel or damage to equipment.

A pressure gauge shall be fitted to each air receiver, and at each pressure reducing set.

Page 53
2.6.22 Thermometers and Altitude Gauges

Thermometers shall be vapour pressure type with 100 mm. dia. dial, chrome bezel, clear
acrylic window and black indicating pointer.

Water thermometers shall be provided with separate pocket, and air thermometers shall
be back flange mounting. The operating range shall be such that the normal operating
temperature is approximately halfway round the scale.

Remote reading thermometers shall be provided where indicated, and shall be back-
flange mounted onto a polished hardwood gauge board.

Altitude gauges shall be of the Bourdon tube type with 100 mm. diameter dial, chrome
bezel, clear acrylic window, black indicating pointer and red adjustable pointer. The
operating range shall be such that the normal operating pressure is approximately
halfway round the scale. Each gauge shall be fitted with lever handle control cock, and
shall be calibrated in kPa and Bar.

2.6.23 Isolating and Regulating Valves

Valves shall be provided as indicated on the drawings and as required for regulation and
isolation. All valves shall have a pressure/temperature rating suitable for the intended
service.

2.6.23.1 Chilled Water

Isolating valves up to and including 50 mm shall be bronze or cast gunmetal screwed


gate valves with non-rising stem, screwed bonnet, one-piece wedge disc and cast alloy
hand wheel.

Isolating valves of 65 mm and above shall be cast iron flanged gate valves with inside
screw non-rising stem, bronze trim, wedge disc and cast iron hand wheel.

Regulating valves up to and including 50 mm shall be bronze screwed lockshield globe


valves, with rising stem, screwed bonnet, metal to metal seat and regulating disc.

Regulating valves of 65 mm and above shall be cast iron flanged oblique orifice valves
with outside screw, rising stem, copper alloy trim, regulating disc, indicator and cast iron
hand wheel.

Double regulating valves up to and including 50 mm shall be bronze screwed key-


operated oblique globe valves, with rising stem, screwed bonnet, metal to metal seat,
regulating disc, double regulating device and four bosses tapped ¼" B.S.P.

Double regulating valves of 65 mm and above shall be cast iron flanged oblique orifice
valves with outside screw, rising stem, copper alloy trim, regulating disc, double
regulating device, indicator, four bosses tapped ¼" B.S.P. and cast iron hand wheel.

2.6.23.2 Domestic Hot and Cold Water and Fire Protection Services

Isolating valves on the general domestic water and fire services distribution system shall
be as for chilled water services, but the final connections to sanitary fittings or ranges of
sanitary fittings shall be provided with gunmetal stopcocks to BS 1010. Stopcocks shall
be chromium plated easy-clean pattern where exposed to view.

Regulating valves on hot water circulations shall be as for chilled water services.

2.6.23.3 Mains Cold Water Services

Isolating valves up to and including 54 mm shall be gunmetal screwed stopcocks to


BS 1010, with crutch head.

Page 54
Isolating valves of 67 mm and above shall be cast iron flanged waterworks sluice valves,
with inside screw, non-rising stem, bronze trim, wedge disc and cast iron hand wheel.

2.6.23.4 Gas and Compressed Air Services

Isolating valves shall be full-bore ¼-turn ball plug valve with stainless steel body, ball and
spindle, PTFE seat, and cast iron lever handle.

Bodies shall be screwed for sizes up to and including 50 mm and flanged for sizes 65 mm
and above.

2.6.24 Check Valves

Valves up to and including 54 mm shall be bronze screwed swing pattern, with screwed
bonnet and metal to metal seat.

Valves above 54 mm shall be cast iron flanged swing pattern, with bolted cover and
copper alloy trim.

All valves shall be suitable for mounting in horizontal or vertical pipelines, and shall have
a pressure/temperature rating suitable for the intended service.

2.6.25 Strainers

Strainers up to and including 54 mm shall be of the bronze screwed Y type, with screwed
cover and stainless steel screen with 0.8 mm diameter perforations.

Strainers above 54 mm shall be of the cast-iron flanged Y type, with bolted cover and
stainless steel screen with 1.6 mm diameter perforations.

All strainers shall have a pressure/temperature rating suitable for the intended service.

2.6.26 Ball Float Valves

All ball float valves fitted on the mains water connection to water storage tanks shall be of
the “equilibrium” pattern to minimise the effect of varying mains pressures.

All ball float valves fitted on the pressure boosted supply to secondary water storage
tanks shall be of the “Portsmouth” pattern to BS 1212 Part 1, for high pressure use.

Floats for ballvalves may be copper to BS 1968 or plastic to BS 2456.

2.6.27 Pressure Relief Valves

Pressure relief valves shall be as required by the British Standard relevant to the boiler,
calorifier or pressure vessel to which the valve is connected.

They shall generally be of the totally enclosed spring loaded type, with padlock, and with
full bore discharge to a safe but visible position to be agreed with the engineer.

2.6.28 Automatic Air Eliminators

Automatic air eliminators shall be installed only where indicated on the drawing. These
shall be of the float operated type with bodies of bronze designed to operate on the
maximum pressure and temperature of the service on which they are used.

Each air eliminator shall be preceded by an isolating valve. A 15 mm dia. copper pipe
shall be run from the discharge connection of the eliminator to atmosphere or to the
position indicated on the drawing.

Page 55
2.6.29 Labelling of Valves

All plant room valves and every circuit control valve shall be provided with a brass,
stainless steel or accepted plastic label 75 mm x 50 mm and 1.6 mm thick stamped or
engraved with a reference number. Wherever practicable the label shall be fixed in a
prominent position to identify the valve concerned. Elsewhere purpose-made lightweight
steel brackets for carrying the labels shall be welded to the pipe work supports adjacent
to the valves.

The Contractor shall provide and fix in a glazed hardwood frame, in a position to be
indicated by the Engineer, on site, a circuit control diagram showing the positions and
numbering of the valves, and indicating valve type and purpose.

On insulated pipe work an additional plastic valve label shall be fixed to the outer
covering of insulated valve boxes or jackets.

2.7 Ductwork, Grilles and Diffusers

2.7.1 Ductwork

The Contractor shall supply deliver and erect the whole of the ductwork system complete
with dampers, supports, insulation and fixings and shall adhere to the duct runs shown on
the drawings except where local conditions prevent or where variations are necessary to
suit any revisions to plant layout. All leading dimensions and positions of plant shall be
checked on site by the Contractor who will be responsible for ensuring that the ductwork
shall conform with the equipment to be installed, also with the building details and
structure.

It is the responsibility of the Contractor to submit to the Engineer for his acceptance, fully
dimensioned detailed drawings of ductwork before manufacture.

All metal ducting shall be constructed of galvanised cold rolled close annealed, patent
flattened steel sheets.

Low-velocity, low-pressure air system rectangular ducts shall be manufactured and


installed in accordance with Specification DW 144 as issued by the Heating and
Ventilating Contractors Association, London.

Cross joints shall be constructed from profile rolled galvanised steel strip forming
complete angle sections with a pressed form reinforcing bracket spot-welded to each
corner. An extruded gasket shall be applied to the face of the flanges and the joint made
with galvanised rolled section cleats.

High-velocity, high-pressure air system circular ducts shall be manufactured in


accordance with Specification DW 144 as issued by the Heating and Ventilating
Contractors Association, London.

Bolts shall be 8 mm for angles up to and including 32 mm and shall be 10 mm for angles
above 32 mm. All joints both longitudinal and lateral shall be made with an accepted
sealer and shall be air-tight, to the maximum system pressure.

All ductwork exposed to external atmosphere or corrosive fumes shall be suitably painted
or otherwise protected, internally and externally as required. Where ducts are lined
internally for acoustic attenuation the internal area shall be maintained and the sheet
metal size increased accordingly.

Flexible ducting shall be used only where specially accepted and full details and samples
shall be submitted when seeking acceptance.

Page 56
All PVC ducting shall comply with Specification DW 154 as issued by the Heating and
Ventilating Contractors Association, London.

Where headroom clearances are given on the drawings or elsewhere these shall be to
the lowest point of the supporting structure.

2.7.2 Ductwork Supports

Ductwork will not be permitted to rest directly on portions of the building except on
concrete slabs or substantial brick walls and then only with the acceptance of the
Engineer. Adequate thermal insulation shall be applied as necessary.

The welding or bolting of supports to structural steelwork will not be permitted without
written authorisation from the Engineer.

2.7.3 Dampers – General Requirements

Sufficient dampers shall be provided to regulate and balance the system. Dampers on
grilles or diffusers shall be used for fine or secondary control only. All dampers shall be
sufficiently rigid to prevent fluttering. Unless otherwise indicated the air-leakage past
dampers in the fully closed position shall not exceed 5% of the maximum design air flow
in the duct. All duct dampers except fire dampers and self-closing dampers shall be fitted
with locking devices and position indicators.

Each primary control damper shall be fitted with a non-corrodible label stating the actual
air flow in m3/s and the cross sectional area; position of a damper as set after final
regulation and balancing shall be indelibly marked on the damper quadrant.

2.7.4 Flexible Joints

Flexible joints shall be provided on fan inlet and outlet connections and elsewhere on the
ductwork where indicated. They shall be of the full cross sectional area of the mating fan
inlet or outlet or duct section. The ends of the ducts or the duct and the fan connection
shall be in line.

Flexible joints shall consist of, or be protected by, material having a fire penetration time
of at least 15 minutes when tested in accordance with BS 476.

Flexible joints shall be constructed of material which is dimensionally stable and


impervious to moisture.

2.7.5 Air Intakes and Outlets

Fresh air intake and exhaust air louvres shall have fixed blades angled to give adequate
weather protection. Unless otherwise indicated louvres shall be constructed of aluminium
with blades not less than 3 mm thick braced as necessary to ensure complete rigidity.

Where louvres are required to be supplied under this Contract they shall be handed to the
main Contractor for fixing.

A galvanised steel wire screen of 6 mm mesh complete with a frame of galvanised steel
rod with securing lugs or of flat iron shall be provided and fixed by the Contractor on the
inner side of the louvres.

2.7.6 Kitchen Extract Canopies

Canopies are to be provided to the sizes indicated on the drawings.

Canopy and valance framework shall be formed from extruded sections of aluminium
alloy, jointed by welding into assemblies of convenient size for delivery to site, and/or
otherwise connected by non-ferrous fastenings.

Page 57
All internal surfaces of the canopy and supports shall be arranged at an angle greater
than 60º to the horizontal to prevent condensation drips.

At junctions between canopies and walls or ceilings the Contractor shall seal all gaps with
an accepted sealant to exclude vermin.

Hoods for kitchen equipment and for the extraction of condensible vapours shall have a
watertight extruded section channel gutter not less than 50 mm wide or more than 25 mm
deep (40 mm x 20 mm for “single appliance” canopies) at the bottom edge. Draining
points shall be formed by a tapped hole into which a cleaning eye and washer (of the type
fitted to sink waste traps) is screwed finger tight. Such draining points shall be provided in
the gutter at intervals of not more than 6 m.

Canopies shall be fixed so that the bottom edge is not more than 2.0 m from floor level.
They shall be supported from above by suspension rods each having a turn-buckle for
levelling and load adjustment. Canopies and connected ductwork shall be so supported
that no part of the weight of one is imposed on the other.

The Contractor' s attention is drawn to any supply ducting which is to be installed within a
canopy. All joints between the canopy and ductwork shall be sealed against vermin as
previously described.

2.7.7 Kitchen Extract Air Ductwork

Adequately sized cleaning doors shall be provided, regardless of whether grease filters
are fixed at the entry points, so that access for interior cleaning is possible at intervals of
not more than 3.0 m.

Precautions must be taken against possible leakage of condensate and/or grease from
the ducts by avoiding longitudinal seams along the bottom face, and employing suitable
gaskets material at the joints between sections.

The ducts shall be fixed with a slight fall, preferably in the direction of air flow, and at low
points such as at the bottom of risers there should be plugged drainage points suitable for
the later connection of a permanent trapped drainage pipe if operating conditions
demonstrate the need.

2.7.8 Access Doors

Access doors shall be provided adjacent to all items of equipment requiring maintenance
or inspection. Access doors having the dimensions up to and including 460 mm x
460 mm shall be of the bolt-on-type manufactured from 1.65 mm thickness galvanised
sheet steel, secured to 32 mm x 6 mm flat iron frames riveted to the ductwork.

Access doors having dimensions greater than 460 mm x 460 mm shall be of the hinged
type manufactured from 1.65 mm thickness galvanised sheet steel suitably stiffened. The
doors shall be provided with robust hinges on one vertical side and a suitable handle
operated lock on the other vertical side. All hinges and handle operated locks shall be
cadmium plated or treated with a similar corrosion resistant finish. All access doors shall
be made air tight by the use of plastic or felt strip.

2.7.9 Ductwork Test Points

At points throughout the ductwork system, test points suitable for pitot tube insertion shall
be provided in accordance with the HVCA DW 144 and the C.I.B.S. commissioning code
“A” on two adjacent sides of rectangular ducts as determined by the access available.
They shall consist of 25 mm diameter holes, fitted with a cover secured by large headed
set screws, one hole being slotted to allow the cover to swing clear without being
removed. The use of plastic or rubber plugs will not be accepted. Test points shall be
positioned at points where the air flow is stable and shall include each branch duct as
well as suitable locations in the main duct.

Page 58
2.7.10 Ductwork Protection

Any part of galvanised ductwork where the galvanising is damaged during manufacture or
erection shall be painted with two coats of aluminium, zinc rich or other corrosion-
resisting paint. In kitchens and dining rooms the outer-most surface of exposed ductwork
or insulation shall be not less than 30 mm away from walls and ceilings to permit access
for cleaning.

2.7.11 Grilles

Grilles shall be of steel or aluminium as indicated. Steel grilles shall be protected against
rusting and supplied in fully finished condition. Grilles shall be not less than the size
indicated; where no size is given they shall be capable of dealing with the air flow and
distribution as indicated. All grilles except those on exposed ducting shall incorporate an
edge seal.

The drawings show provisional locations but in each instance outlets shall be installed in
accordance with architectural final detail drawings and reflected ceiling plans.

Velocities, nett airways and distribution patterns shall give satisfactory air distribution, and
be free of draughts, stratification or noise nuisance. The Contractor shall make final
adjustments to air patterns when balancing.

Damper assemblies and internal surfaces of outlets and take-off ductwork where visible
through outlet faces, shall be painted matt black.

All outlets shall be fitted truly square and in alignment. Perimeter trims shall seat hard
against wall or ceiling finishes as applicable and shall properly mask the trimmed
openings. Unless otherwise accepted, all fixings shall be concealed.

Each supply air grille shall be complete with an opposed blade multi-leaf damper.
Alternatively, in lieu of the opposed blade multi-leaf damper a rhomboidal air controller
may be provided; this air controller shall control both the volume of air passing and the
distribution of air across the grille face. Each supply air grille shall have two sets of
separately adjustable louvres one set horizontal and one set vertical, all adjustable from
the front or the grille. For up to ten grilles, one set of any tools required for adjusting the
louvres and dampers or air controllers shall be provided; from eleven to twenty-four
grilles, two sets; above twenty-five grilles, three sets.

Return air grilles may have either a single set of louvres or bars (either vertical or
horizontal) or a lattice or egg crate front, as indicated in the Schedules. Each return air
grille shall be complete with an opposed blade multi-leaf damper or a rhomboidal air
controller operable from the front.

For Kitchens and Dining Rooms both supply and return air grille shall have quick-release
sub-frames.

2.7.12 Diffusers

Diffusers shall be of steel or aluminium and supplied in a fully finished condition.


Diffusers, except on exposed ductwork, shall incorporate an edge seal; diffusers mounted
on ceilings shall have anti-smudge rings. Pan type diffusers may be provided except
where cone type diffusers are indicated.

Circular diffusers shall be provided with volume control dampers of the iris, flap or sleeve
type. Rectangular diffusers shall be provided with opposed blade dampers. Dampers
shall be adjustable from the front of the diffuser. Where the length of a vertical duct to a
diffuser is less than twice the diameter of the diffuser an equalizing deflector shall be
fitted.

Page 59
For Kitchens and Dining Rooms diffusers shall have a quick-release centre to facilitate
easy cleaning.

Linear diffusers shall include a control damper at the rear of the vanes giving volume
control down to complete shut-off and operated from the face of the diffuser. Linear
diffusers for supply air shall have adjustable blades to give directional control of air flow.
Where linear diffusers are mounted in a continuous line there shall be means of ensuring
alignment between consecutive diffusers and of equalising pressure behind the vanes.

2.7.13 Sand Trap Louvres

Sand trap louvres shall be constructed from aluminium sheet, 1.5 mm thick for blades
and 2.0 mm thick for casing, with mill finish.

The base member of the box shall incorporate sand drain holes.

The louvres shall be of the labyrinth type designed to achieve velocity changes of the air
passing through it inducing the sand to drop out.

The louvre shall incorporate a galvanised wire mesh insect screen at the rear.

2.7.14 Air Valves

Extract air valves shall be of the sizes indicated on the Schedules and be manufactured
from pressed steel sheet with stove enamel finish. The valve shall be supplied complete
with a mounting ring of the bayonet fitting type, and screw adjustment with locknut for
volume control.

2.7.15 Fire Dampers

Fire dampers shall be provided in each duct passing through all structural fire
compartment walls and each floor level slab, and also where shown on the Air
Conditioning and Ventilation drawings and shall be of the spring loaded stainless steel
folding shutter type, unless otherwise accepted in writing by the Engineer.

The fire dampers shall have a fire rating at least equal to the barrier through which they
are passing and in any event shall be at least two hours (BS 476: Part 1).

The damper shall comprise a casing fabricated from not less than 1.2 mm thick
galvanised rolled steel section and 0.8 mm stainless interlocking hinged blades tensioned
by two constant force coiled band stainless steel springs.

Damper blades shall be held in the open position by a fusible link to fuse at 69ºC, care
being taken to ensure that on fusing the links and fixings shall not prevent complete
seating of the damper blades.

The damper blades shall be out of the airflow when open. External indication shall be
provided to indicate fire damper “open” and fire damper “closed”.

All parts used in the construction of fire dampers shall be galvanised after manufacture or
stainless steel.

Access doors shall be provided in the ductwork adjacent to all fire dampers to permit
inspection and replacement of fusible links.

The fire dampers shall have a free area of not less than 90% of the cross sectional area
of the ducts to which they connect, and if necessary, the fire damper casings shall be
increased in size above that of the ducts in which they are installed to comply with this
requirement.

Page 60
All fire dampers shall be built into the appropriate fire compartment walls strictly in
accordance with the manufacturers instructions.

All fire dampers shall be to the approval of the relevant local Fire Authority.

2.8 Odour Treatment Technologies

2.8.1 Summary Matrix

A number of treatment technologies are considered suitable for the treatment of odour
emitting from a new inlet works and pump station. The selection of the most appropriate
system shall be determine by the use the matrix below as a mechanism to select a
technology or combinations of technologies that will

• meet the discharge requirements


• offer the most advantageous whole life cost
• suit the current building design including space allocation for the odour control plant.

Careful consideration should be given to minimising odour released during the


commissioning phase of the project when tanks are filling and plant operation has not
been optimised.

Table 2 - Odour Abatement Technology Summary Matrix

Process type (Generic Odorants treated Maximum feed Air flow range Maximum H2S
Name) air H2S removal in
Concentration design

Impregnated Carbon VOCs, H2S, broad <50ppm 0–500 m3h-1 99%


Adsorber range of compounds

Biofilter VOCs, H2S <30 ppm 0–4,000 m3h-1 98% to minimum


of 0.5 ppm

Bioscrubber VOCs, H2S <200 ppm 500–4,000 m3h-1 95%

Catalytic iron filter Sulphides, H2S <250 ppm 0–4,000 m3h-1 70% - 90%

3 -1
Dry scrubbing (DS) – VOCs, H2S, broad <300ppm (subject 0–500 m h 99%
non-carbon media. e.g. range of compounds to economics)
peacemaker

Ionisation/carbon filter Sulphides, H2S <250 ppm 0–2,000 m3h-1 99%

3 -1
Chemical scrubber 2 or soluble odorous >100 ppm >4,000 m h 99.9%
3 stage final to remove compounds
Residual chlorine including NH3

Page 61
2.8.2 Wet Chemical Scrubber Plant Configuration

Plant installations shall comprise a number of treatment units designed/configured to


satisfy the process performance detailed in the Specification or as revised by the
Contractor’s odour survey and model.

Each treatment unit shall incorporate or be provided with the following ancillary systems:

• A scrubbing liquid dosing system;


• A scrubbing liquid re-circulating system;
• A scrubbing liquid discharge system;
• A number of pre-filters (detail to be provided, for example, dust filters, de-misters,
and so on);
• A mist eliminator.

The duty/standby requirements for the treatment units and ancillary components/systems
comprising the installation shall be as specified above.

The Contractor’s design shall include for the installation of bypass ductwork to allow
odorous air to be removed from its source(s) with the treatment unit offline.

All materials that come into contact with the scrubbing liquid shall be compatible with
and/or resistant to the scrubbing liquid.

2.8.3 Treatment Stage(s)

Each treatment unit shall consist of a multi-stage wet chemical (acid and alkali) scrubbing
system.

Each treatment stage shall comprise a random or structured porous bed of inert media
and its associated support structure. The volume and arrangement of the inert media
shall be such that the rates of mass transfer of odorants from the gas to the liquid phase
within each treatment stage are optimised.

The type and composition of the inert media shall be determined by the Contractor.

The inert media shall be compatible with and/or resistant to the scrubbing liquid and have
sufficient compressive strength to resist all operational loads without excessive
deformation.

Internal and external support structures for each treatment stage shall be designed to
consider the treatment stage full of water.

2.8.4 Scrubbing Liquid Re-Circulating System

Liquid distributors shall be of the pipe manifold or weir trough type (that is, spray nozzles
are not acceptable).

The chemical consumption of the scrubbing liquors shall be minimised by the use of
sustainable ‘roughing’ stages.

A water softening system shall be provided allowing only fully softened water to be used
in each scrubbing phase.

2.8.5 Scrubbing Liquid Discharge System

Excess/waste scrubbing liquid shall be discharged to the pumping station wet well.

2.8.6 Mist Eliminators

Mist eliminators shall be of the inclined plate type or equal. Mesh type mist eliminators
are not acceptable.

Page 62
2.8.7 Catalytic Iron Filter (CIF) Installations

Plant installations shall comprise a number of CIF units designed/configured to satisfy the
process performance detailed in the Specification or as revised by the Contractor’s odour
survey and model of a roughing system only.

Each CIF unit/the installation shall also incorporate the following ancillary components:

• A number of pre-filters (for example, dust filters, de-misters, and so on);


• An inlet air humidifier; and
• A media irrigation system.

The duty/standby requirements for the CIF units and ancillary components comprising the
installation shall be as specified above.

The Contractor’s design shall include for the installation of bypass ductwork to allow
odorous air to be removed from its source(s) with the treatment unit offline.

CIF units for use with dry scrubbers may be integral with the dry scrubber or may be free-
standing units. CIF units for use with bio-filters shall be free-standing units, completely
separate from the bio-filters.

2.8.8 Dry Installation (Dry Scurbbers, GAC Units and carbon filter)

The installation shall comprise a number of treatment units designed/configured to satisfy


the process performance detailed in the Specification or as revised by the Contractor’s
odour survey and model.

It is considered unlikely that a single stage dry scrubber will be considered suitable for
treatment at the principal pump stations. Provision of two-stage systems is considered
most appropriate.

Each installation should incorporate the following ancillary components/systems:

• A number of pre-filters (for example, dust filters and/or de-misters);


• A media re-generation system (for GAC Units); and
• An inlet heater.

The duty/standby requirements for the treatment units and ancillary components/systems
comprising the installation shall be as specified above.

The Contractor’s design shall include for the installation of bypass ductwork to allow
odorous air to be removed from its source(s) with the treatment unit offline.

2.8.9 Treatment Unit(s)

Each treatment unit shall be designed so that the volume of condensate accumulating
within it is minimised. Facilities shall be provided for the collection and drainage of
condensate to a single point and thence into the pump wet well.

Drainage systems shall incorporate water traps to prevent the escape of odorous air.
Each treatment stage shall comprise a porous bed of media and its associated support
structure.

The volume and arrangement of the media shall be such that the rates of chemical and
physical reaction between the media and odorants within each treatment stage are
optimised to achieve the specified performance.

The maximum pressure drop across each treatment stage shall be 1 Pa/mm.

Page 63
Cartridge trays, if provided, shall be made of corrosion resistant materials and be
effectively sealed to their support structure.

The type and composition of the media shall be non carbon dry scrubbing media
(Peacemaker or equal), Iodide or Poly aluminium chloride impregnated activated carbon,
regenerable activated carbon or high surface area activated carbon. The accepted air
flow range and performance for each type is detailed above in the matrix selection chart.

The media shall have sufficient compressive strength to resist all operational loads
without excessive deformation or bed settlement.

A media sampling facility shall be provided and media analysis service to provide
information on percentage media life remaining.

2.8.10 Media Re-Generation System (for GAC Units)

The method of disposal and pH of the liquid waste shall be stated.

Excess/waste re-generating liquid shall be discharged to the pumping station wet well.

Drainage facilities shall incorporate a water sampling point and a water trap to prevent
the escape of odorous air.

2.8.11 Inlet Heater

The heater housing shall be insulated to minimise heat losses.

2.8.12 Media Disposal

The safe and sustainable method of disposal and waste classification of the spent media
shall be stated.

The time required to completely remove all the spent media from the unit and replenish it
with fresh media shall be stated.

2.8.13 Biological Treatment

Plant installations shall comprise a number of bio-filter units designed/configured to


satisfy the process performance detailed in the Specification or as revised by the
Contractor’s odour survey and model.

Each bio-filter unit shall incorporate or be provided with a media irrigation system (re-
circulating or single pass as required). If a re-circulating media irrigation system is
provided, each bio-filter unit shall incorporate or be provided with a sump with readily
accessible drainage facilities.

If required, each bio-filter unit/the installation shall also incorporate the following ancillary
components:

• A number of pre-filters (detail types of pre-filters required/provided, for example, dust


filters, de-misters, and so on); and
• Covers (for open-topped, up-flow bio-filter units).

The duty/standby requirements for the bio-filter units and ancillary components/systems
comprising the installation.

The Contractor’s design shall include for the installation of bypass ductwork to allow
odorous air to be removed from its source(s) with the treatment unit offline.

2.8.14 Bio-Filter Unit(s)

The housing material and type of construction shall be as required.

Page 64
The number of treatment stages provided shall be as required.

Each treatment stage shall comprise a porous bed of media and its associated support
structure.

The volume and arrangement of the media shall be such that the rates of chemical
reaction between the media and odorants within each treatment stage are optimised to
achieve the specified performance.

The arrangement/configuration of the media bed(s) shall be as required.

The type and composition of the media shall be as required. The media shall possess the
following attributes:

• Support bio-film formation;


• Not leach chemicals detrimental to the process or effluent quality;
• Have sufficient strength to resist excessive deformation under self/bio-mass loading;
and
• Be homogeneous in structure, to promote uniform gas flow through the treatment
stage(s).

2.8.15 Media Irrigation System

The media irrigation system shall incorporate the following components:

• An irrigating liquid flow monitoring device;


• An irrigating liquid overflow or pressure relief device; and
• An irrigating liquid level monitoring device, for example, sight glass.

The source and type of irrigating liquid and the frequency and duration of the irrigation
cycle shall be as required.

Excess/waste irrigating liquid shall be discharged to the pumping station wet well.
Drainage facilities shall incorporate a water trap to prevent the escape of odorous air.

The system shall incorporate a sampling point and tundish to enable verification of the
irrigating liquid composition and correct operation of the make-up system.

2.8.16 Media Disposal

The method of disposal and waste classification of the spent media shall be as required.

The time required to completely remove all the spent media from each unit and replenish
it with fresh media shall be as required

2.8.17 Bio-Scrubber Installation

The installation shall comprise a number of treatment units designed/configured to satisfy


the process performance requirements.

Each treatment unit shall incorporate or be provided with the following ancillary systems:

• A scrubbing liquid make-up system;


• A scrubbing liquid re-circulating system; and
• A scrubbing liquid discharge system.

If specified/required, each treatment unit/the installation shall also incorporate or be


provided with the following ancillary components/systems:

Page 65
• A number of pre-filters (detail types of pre-filters required/provided, for example, dust
filters, de-misters, and so on);
• A nutrient dosing system; and
• A pH control system.

The duty/standby requirements for the treatment units and ancillary components/systems
comprising the installation.

The Contractor’s design shall include for the installation of bypass ductwork to allow
odorous air to be removed from its source(s) with the treatment unit offline.

All materials that will come into contact with the scrubbing liquid shall be compatible with
and/or resistant to the scrubbing liquid. The minimum pH value that the materials are
designed to withstand, without excessive corrosion, shall be stated in the Tender.

2.9 Pipe work Systems for Sewerage Works

2.9.1 General

Except where operating pressure dictates that higher pressure ratings are required, the
flanges of pipe work and fittings shall conform to the requirements of BS EN 1092: Part 3.

In arranging pipe work systems, provision must be made for the convenient removal of
plant from the pipe work system by the use of flange adaptors, unions or conveniently
placed bends. Flange adaptors shall not be used simply to accommodate misalignment in
the fixing or building in of pipe work systems. Flange adaptors shall be supported or tied,
or the pipe work anchored, to withstand maximum possible system pressure.

Where flanged puddle pipes are provided by the Contractor the minimum length shall be
such that the length of the pipe shall be at least 400 mm more than the wall thickness.
Puddle pipes shall be installed such that any flanges are at least 200 mm away from the
wall to allow good access for installation and maintenance.

Where more than one item of plant is served by a common pipe work system, the pipe
work shall be arranged so that when a single item of plant has been removed the
remaining items can be operated safely without the need to provide any special fixings
and supports for the pipe work system.

To allow isolated sections of pipeline to be drained to remove items of plant, and primed
to remove air before being brought into service, ½" vent and 1" (minimum) drain tappings
shall be provided as directed by the Engineer. The tappings shall be fitted with gunmetal
isolation cocks and the open end shall be fitted with a plug. Bright or black finished
carbon steel barrel nipples shall not be allowed.

Pipe work shall be adequately supported and anchored so that strain is not placed on any
pump casing or other associated plant due to the weight of fixing of the pipe work.

Necessary anchors, supports, saddles, slings, fixing bolts and foundation bolts to support
the pipe work and its associated equipment shall be provided by the Contractor. The
Contractor shall also provide galvanised steelwork pipe supports, where their inclusion
represents the most appropriate technical solution.

Adequate provision shall be included to cater for settlement of rigid structures/pipe work
systems.

2.9.2 Ductile Iron

Iron pipe work shall be ductile iron to BS EN 598 of a suitable grade and class to suit the
design. Ductile iron pipes and fitting shall be rated for 16 bar or the working pressure of
the system whichever is greater.

Page 66
For underground applications, Ductile iron pipe work shall be protected with a standard
bitumastic finish. Internal cement lining shall be applied.

Upon completion and testing of the installation, the Contractor shall apply on site a further
external painted finish to all ductile iron pipe work with a standard bitumastic finish.

For Ductile Iron pipe installed inside chambers or pump drywells, fusion bonding epoxy
powder coating shall be applied for pipe protection internally and externally.

2.9.3 Reinforced Thermosetting Resin (RTR)

“RTR’ – Reinforced Thermosetting Resin to include Fibre Reinforced Plastic (FRP), Glass
Reinforced Plastic (GRP) and Reinforced Plastic Mortar or matrix (RPM)

The supply, manufacture, installation, and testing of RTR pipes and fittings manufactured
from thermosetting resins reinforced by glass fibres shall be the responsibility of the
Contractor. Pipes shall be manufactured in accordance with BS EN 14364 and installed
in accordance with BS 8010 or other approved National Standards. Pipes that are
permanently exposed to sunlight shall be UV resistant.

Reinforcement for pipes manufactured by a centrifugal casting or conventional filament


wound method shall be standard E glass or an approved acid resistant glass.
Reinforcement for pipes manufactured by a continuous filament wound process shall be
an approved acid resistant glass. Veiling used in surface areas shall be Class C glass or
an approved high acid resistant glass.

The thermosetting resin shall be isophthalic polyester , bisphenol-A polyester or vinyl


ester. The use of additives to modify the resin viscosity prior to cutting is permissible, but
the incorporation of pigments is not permitted. The resin material shall be stabilized
against ultraviolet light. Cured resin must have a minimum 4% elongation to break.

The aggregate if used in RTR pipes shall be graded silica sand, or granules of approved
glass, of size between 0.05 mm and 3 mm.

The incorporation of sand into the outside resin rich layer is permitted but otherwise fillers
or extenders shall not be used in the resin rich layers.

Resin rich layers shall be provided on the outside and inside surfaces of the pipe.

The resin rich layer on the inside surface of the pipe shall have an average thickness of
2.0 mm with a minimum thickness of 1.5 mm and maximum thickness (except at local
overlaps in reinforcement) of 2.5 mm. This liner shall comprise a surface layer of between
0.25 mm to 0.75 mm thickness containing 10% by weight of veil reinforcement, and a
barrier layer containing 20% to 35% by weight of chopped strand standard E glass or
approved high acid resistant glass.

The resin rich layer on the outside surface of the pipe shall be of the same construction
as the inner liner, except that the overall thickness shall be 1mm and the minimum
thickness 0.5 mm.

No structural reinforcement shall be allowed to penetrate the barrier layers and where
pipes are made by the filament wound process a method statement shall be submitted
describing how compliance with this requirement will be ensured.

All RTR gravity pipes shall be of sufficient stiffness compatible with loading, backfill and
soil materials and shall be supplied in minimum lengths of 6.0 m. Generally pipes shall
have a minimum stiffness of 5,000 N/m2.

RTR Rising Main pipe work shall have a pressure rating of 12 bar, and a minimum
2
specific initial stiffness of 10,000 N/m .

Page 67
When pipes pass through an anchor/thrust block, wrapping of pipe shall be carried out
using suitable compressible filler to prevent contact with sharp edges.

Pipes and fittings shall be jointed with a double bell coupling and rubber rings. Couplings
shall be of similar material as that of the pipes and fittings unless otherwise required or
directed.

Pipes and fittings shall effectively resist the corrosive effects of septic sewage or effluent
with a normal maximum temperature of above 40ºC.

The Contractor shall supply the pipes for a life of not less than 50 years. Copies of the
design calculations shall be submitted to the Engineer for approval.

Pipes shall be joined by GRP double socket coupling type joints, all with EPDM synthetic
rubber rings to BS EN 681. Joints shall allow at least 3 degrees of deflection for sizes up
to and including 500 mm, 2 degrees for sizes up to and including 900 mm and 1 degree
for larger sizes, all with no loss of water tightness. The design of the joints shall be in
accordance with ASTM D4161.

Rubber Lined Stainless Steel Grade 316 L couplings shall be used at changes of pipe
material. After installation and before backfilling the stainless steel couplings shall be
wrapped with Denso tape or equal approved.

The Contractor will comply with the pipe manufacturer'


s handling/laying specification at all
times, unless otherwise ordered by the Engineer's Representative.

All cutting, machining, chamfering, on site repairs etc., of RTR pipes are to be carried out
as per the pipe manufacturer’s instruction, and are to be to the approval and satisfaction
of the Engineers Representative

The Contractor shall submit to the Engineer for approval details of proposed trench
construction, pipe bedding material, method of bedding, pipe laying, backfilling and
compaction. The choice of design parameters, will be subject to the approval of the
Engineer. When Class 1 material is used as a bedding material a Geo-Textile filter
membrane shall be used to line the trench bottom and walls to prevent migration of the
native soil into the bedding and backfill.

A field representative of the Manufacturer shall be present during installation.

The design of pressure pipes shall incorporate a surge allowance of 40% above the
working pressure of the pipe.

Ultra Violet Stabilizers shall be incorporated in the pipe and fitting construction. The GRP
pipe shall have a minimum total wall thickness of 10 mm

2.9.4 PVC-u

PVC-u pipe work shall be Class E in accordance with BS 3505, BS 4660 and
BS EN 1401: Part 1 as applicable.

Sealing rings where used shall be ethylene-propylene elastomer (EPDM).

2.9.5 ABS pipes and fittings

ABS pressure pipes and fittings shall comply with the relevant provisions of
BS 5391: Part 1 and BS 5392 : Part 1 respectively.

2.9.6 Chlorination Pipe Work

All pipe work used in the conveyance of gas (either under positive pressure or vacuum)
shall be colour coded in accordance with current European or British Standards and shall

Page 68
be labelled throughout its length with the material of manufacture and pressure rating..
Materials shall be suitable to withstand pressures, including surge, and have an inherent
resistance to the corrosive nature of chlorine. Where it is capable of withstanding the
system pressures, PVC-u shall be the preferred material.

Joints in the system pipe work are to be kept to an absolute minimum.

All pipe work shall be installed in such a manner that it is protected against mechanical
damage, including adequate support to prevent sagging and undue strain. Rigid vacuum
pipe work outside buildings and chambers shall be installed either in suitably covered
concrete channels allowing access from above for replacement and affording adequate
protection against mechanical damage, ingress of water and exposure to sunlight, or in
buried ducts with regular inspection chambers such that no joints or fittings are beyond
ready access by operatives.

2.9.7 Pipe Supports

All Pipe work shall be designed and installed so that no dead weight loads are
transmitted to machinery casings and pipes shall not be sprung into place. Pipelines shall
be supported by external means at regular intervals to prevent them from sagging due to
their self weight and the weight of the fluids inside the pipe. Pipe lines not supported at
regular intervals will lead to sagging, causing stress at welded joints, flanges, and so on,
which may end in leaks and ultimately lead to failure or rupture in the line. Pipes shall be
supported from the bottom or hung from the supporting structure depending upon the
layout and availability of supporting locations and structure.

Pipe supports and hangers shall be designed and manufactured comply with the
standards MSS – SP - 58.

Riser pipe work shall be supported independently of connected horizontal pipe work. The
contractor should ensure that none of the component parts are stressed due to
misalignment of the pipes or other items.

The Contractor shall provide all fixing brackets and holding down bolts for the plant and
pipe work supplied within the scope of his works. Pipes shall be installed to provide a
minimum spacing as per the standards between finished covering and adjacent work.

Prior to tightening all bolt threads shall be treated with graphite paste. Nuts shall be
tightened evenly in diametrically opposite pairs.

An expanding grout shall be used for grouting in any duck foot bends and the Contractors
shall comply with the appropriate period stipulated by the manufacturer before any
equipment is run on this grout and shall in any case not run any equipment for at least
two weeks.

The same stipulation shall apply for all other holding down bolts and brackets fixed by
grout.

All holding down bolts, pipe and support brackets within the works shall be sterilized or
electro-galvanised before any painting is carried out of these items.

2.9.8 Gate Valve

Gate valves shall have resilient seats which shall comply with the requirements of BS
5163: Table 6 (b): Class PN 16 with flanges to BS EN 1092: Part 2: PN 16. Valves shall
be anti-clockwise opening with non rising spindles and shall be of straight through type
with resilient seating. Valve bodies shall be manufactured from ductile iron. Valve gates
shall be manufactured from ductile iron faced with moulded EPDM rubber.

Handwheels shall clearly indicate direction of closure in accordance with BS 5163:


Clause 17.4. Markings shall be cast into the rim of the valve.

Page 69
Valve caps and key heads shall be in accordance with BS 5163: Table 5.

Valves shall be ' open end'tested before delivery and copies of manufacturer'
s test
certificates shall be supplied to the Engineer before installation.

Gate valves shall typically be protected via the supplier'


s standard finish. However any
valve associated with pipelines designed to convey sludge shall receive a fusion bonded
coating in accordance with the Specification.

Upon completion and testing of the installation the Contractor shall apply on site a further
external painted finish to all gate valves provided with the standard finish.

2.9.9 Butterfly Valve

Butterfly valves shall comply with BS EN 593 and be suitable for mounting in any
position. The materials of construction shall be as follows:

Body – Ductile iron.

Disc – Zinc-free bronze or stainless steel having edges machined with rounded corners
and polished to a smooth finish. The valve disc shall rotate through an angle of 90° from
fully open to closed.

Shaft – Machined from stainless steel.

Valves that are to operate in throttled positions shall be metal seated. Leakage rates shall
not be greater than Rate D for low leakage valve application, as referred to in BS EN 593.
For all other duties, butterfly valves shall be of the resilient seated type and shall be
airtight when shut off at all operating pressures. Seat materials shall be suitable for use in
contact with potable water.

2.9.10 Non Return Valves (Reflux Check Valves)

Single door reflux valves shall be of the swing check type in accordance with BS 5153:
Class PN 16. Valves shall be double flanged to BS EN 1092: Part 2: PN 16 with external
handles to permit manual operation. Bodies shall have renewable gunmetal seal faces,
bronze bushed hinges and gunmetal hinge pins. Discs shall be of gunmetal and when in
the fully open position shall offer a clear in line passage of the same diameter as the
connecting pipe work.

Non-return valves shall typically be protected via the supplier'


s standard finish. However
any valve associated with pipelines designed to convey sludge shall receive a fusion
bonded coating in accordance with the Specification.

Upon completion and testing of the installation the Contractor shall apply on site a further
external painted finish to all non-return valves provided with the standard finish.

2.9.11 Air Valves

Air relief valves shall be a double ball type with large and small air outlet orifices for
starting and normal running conditions. Air valves shall be specifically designed for use
with the normal fluid within the pipe.

The air relief valve body shall be cast iron, the floats grade 316 stainless steel or
polycarbonate, the elevator and tappet grade 304 L stainless steel, and the orifice, orifice
levers, float guide and guide sleeve a suitable plastic.

The valves shall be pressure tested to 10 bar and have BS EN 1092: Part 2: PN 16
flanges. An isolating gate valve shall be provided with each air relief valve.

Air valves shall typically be protected via the supplier'


s standard finish.

Page 70
2.9.12 Pressure Reducing Valves

Pressure reducing valves (PRV) shall be constructed of cast iron to BS EN 1561 Grade
220/260 or ASTM A 126 Class B. The ported guide, seat ring and trim shall be of
gunmetal to BS EN 1982 Grade LG2C or stainless steel to AISI Grade 303. The valve
shall be capable of operation in any position and shall incorporate only one flanged cover
at the valve top from which all internal parts shall be easily renewable. Valves shall be
double flanged. All controls and piping shall be of non-corrosive construction.

2.9.13 Ball Valves

Ball valves shall be permitted on pipeline diameters of 50 mm or less, for example,


air/gas dosing lines, and so on. Ball valves shall be fitted with limit stops.

The ball and body shall be arranged to provide straight through flow when the valve is
fully open

Ball valves shall be in accordance with BS ISO 7121:2006. Valve bodies shall be
stainless steel. Cast iron bodies are permitted provided they are fitted with a stainless
steel liner or are rubber lined. The ball and stem shall be stainless steel and seats shall
be PTFE. The valve stem shall be designed such that thrust is taken by the shaft and not
via the ball and seats. Body material shall be suitable for the chemical being handled.

Non-metallic ball valves of PVC-u or ABS are permitted in association with pipe work of
the same material.

Both metallic and non-metallic valves shall be three-piece pattern to facilitate


replacement of the ball, seat, backing ring etc. without dismantling of the pipe work.

2.9.14 Flap Valves

Flap valves shall be designed to be mounted be on a vertical wall or flange (PN16) and is
suitable for static on-seating heads up to 6 m. Flap valves shall be designed for fixing to
BS EN 1092-2: 1997 PN16 flanges.

Flap valve frames and hinge links shall be manufactured from ductile iron Grade 420/12
to BS EN 1563: 1997, for wall, pipe or thimble mounting applications.

The door shall be manufactured from ductile iron Grade 420/12 to BS EN 1563: 1997,
designed to withstand static seating heads up to 6 m.

Sealing faces shall be of Phosphor bronze to BS EN 12167: 1998

Hinge pins shall be manufactured from stainless steel Grade 1.4401 to BS EN 10088:
1995 (316).

2.9.15 Penstocks and Stoplogs

Penstocks shall be installed in locations as shown on the layout drawings. The penstocks
are either hand operated by handwheel, square cap and gearbox or power operated by
electromechanical actuators. In both these applications due care is necessary to
establish the ability by the equipment to sustain a working head of liquid is one or both
the directions.

The installations shall be as follows:

a) Wall Mounted

Page 71
Wall mounted penstocks where indicated on the Drawings shall manufactured from the
following materials :

Frame Cast iron


Spindles Stainless Steel Grade 316L
Seating Face Bronze to BEAWA Standard P.12.92
Door Cast iron
Wedges and Wedge Bars Cast Iron

All spindles shall be of the rising type.

b) Channel Mounted

Channel mounted penstocks where indicated on the Drawings shall be manufactured


from the following materials :

Frame Stainless Steel


Spindles Stainless Steel Grade 316L
Sealing Face Coplastix-S with Coplastix-N backing
strip (or equivalent approved)
Door Carbon steel reinforced Coplastix-B
and Coplastix-D
(or equivalent approved)

All spindles shall be of the rising type.

Stoplogs where indicated on the Drawings shall be manufactured from the following
materials:

Frame Stainless steel frame to be either


recessed or wall mounted as indicated on the Drawings

Logs Coplastix B bonded to and enclosed


by Coplastix D (or equivalent
approved)

Seals Sealing of logs to be agreed and


approved by the Engineer

Care should be taken while installing penstocks and stoplogs. The manufacturers
installation procedure shall be fully complied with and special fixing accessories such as
anchor bolts etc. shall be used wherever applicable.

Before final assembly all seating shall be cleaned thoroughly of all foreign materials and
final adjustments made with the gate fully closed, the clearance between seating gates
shall be checked. The gate shall then be field operated from the fully closed to the fully
open position to verify that the assembly is workable.

Under the design seating heads, penstock leakage shall not exceed the permissible limit
of 2.07 x 10-5 m3/s per metre of seating perimeter.

Proprietary lifting equipment shall be supplied by the Contractor where the removal of
long stop-logs is potentially difficult.

2.9.16 Pressure Gauges

Pressure gauges shall comprise of brass or black moulded phenol plastic construction
with acrylic plastic or toughened glass windows. Dials shall be at least 150 mm diameter
except where fitted to small pumps having branch connections 75 mm internal diameter
and below.

Page 72
For such pumps 100 mm diameter gauges shall be fitted. Internal gauge components
shall be of stainless steel or other corrosion resistant material with an accuracy of at least
+ 1% of full scale. Gauges shall wherever possible operate about their mid scale position.
No aluminium shall be used in the construction of the gauges.

Diaphragms shall be fitted to gauges subjected to liquid containing suspended matter.

Scales shall be calibrated in metres head for water and bar for air. Gauges associated
with pumps shall be of the compound type for suction branches and the pressure type for
delivery branches.

Gauges shall be fitted with isolation valves and where measuring water pressure they
shall be equipped with a combined isolating valve and air release vent.

If mounted remotely from the tapping point an isolating valve shall also be installed at the
tapping point.

Snubbers shall be fitted to gauges installed on pumps and wherever subjected to


fluctuating pressure pulses.

Pressure gauges are to be of the BUNDERBURG make with stainless steel diaphragm
and PTFE coating.

2.10 Cast Iron Covers and Frames

Cast ductile iron covers and frames shall be of the size, type and grade shown on the
Drawings and shall comply with BS EN 124 or DIN 1229. They shall be lockable unless
noted otherwise. If specified elsewhere to be airtight, they shall be capable of resisting an
2
internal pressure of 100 kN/m . All covers shall be obtained from approved manufacturers
to the sizes, grades and pattern numbers as detailed. Where no grade is detailed, Class
D400 shall be used in paved areas and Class C250 in areas where there is no vehicular
access.

Covers shall be supplied complete with 5 sets of lifting keys obtained from the cover
manufacturer. Frames and covers for sewers shall have a removable self-sealing GRP or
similar corrosion-resistant plate that fits securely between cover and frame such that the
minimum surface area of the frame is exposed to the atmosphere within the manhole.
The design of the frame, cover and plate shall be to the approval of the Engineer. Covers
and frames to air valve chambers shall be of ventilated type.

2.10.1 Protection to Cast Iron Manhole Covers, Gratings and Frames

Gratings, covers and frames shall be prepared in accordance with the relevant clause for
preparation of steelwork prior to protective treatment and shall be coated with heavy duty
abrasion resistant epoxy paint to a minimum DFT of 375 microns prior to installation.

Contact surfaces of covers and frames (other than machined covers) shall be coated with
approved heavy duty grease immediately prior to final fitting of covers. Surfaces of
machined covers and frames shall be coated with approved graphite grease immediately
prior to final fitting of covers.

2.11 Electric Overhead Travelling Crane

2.11.1 General

Cranes shall be designed in accordance with BS EN 13001 and BS 466 Class 2 Medium
duty operation. The power driven motions shall be based on BS 466.

The crane Safe Working Load shall be sufficient to lift the heaviest individual component
of the main pumps, with an additional allowance of 10%, but shall not be less than 3 t.

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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.

Subject to the hazardous area classification rating, down shop conductors shall be of the
fully insulated shrouded busbar type with renewable current collection contact pieces.
Festoon cables may be used for the cross travel.

The crane and all associated slings, ropes and shackles shall be tested at 125% of Safe
Working Load when fully assembled. The safe working load shall be marked on each of
the individual items.

The Contractor shall provide all access ladders and platforms necessary for maintenance
and repairs.

The crane dimensions shall be such that the largest item of plant to be lifted clears
adjacent plant or fittings by at least 500 mm.

Rail wheels shall be of the double flanged type to BS 3037. Multi-strand wire ropes shall
comply with BS EN 12385.

End stops shall be fitted at the ends of the runway beams. Pendant controls shall be
provided.

Rating plates shall be provided, stating the safe working load in characters, which shall
be easily legible from the working floor level.

2.11.2 Installation and Testing

The Contractor shall provide the services of a factory-trained Service Technician,


specifically trained on type of equipment specified to supervise installation, functional and
performance testing. The Service Technician must have a minimum of five years of
experience, all within the last seven years, on the type and size of equipment specified.

The service Technician must be present on site for all items listed below. Person-day
requirements listed are exclusive of travel time, and do not relieve Contractor of the
obligation to place equipment in operation as specified.

Installation: Inspect location of anchor bolts; setting, levelling, alignment, field erection;
coordination of supports, rails, electrical and control connections: 1 person-day.

Functional Testing: Calibrate, check alignment and perform a functional test. Tests to
include all items specified: 0.5 person-day

Field Performance Testing: Field performance test equipment specified: 0.5 person-day

Person-day is defined as one 8-hour day, excluding travel time.

Any additional time required of the factory trained service technician to assist in placing
the equipment in operation, or testing or to correct deficiencies in installation, equipment
or material shall be provided at no additional cost to the Employer.

Installation of all items shall be in accordance with manufacturer' s printed instructions and
as indicated and specified. All field testing shall be performed with the motor controls.

After installation of the crane and after inspection, operation, testing and adjustment have
been completed by manufacturer' s field service technician; a running test shall be
conducted in the presence of the Engineer to determine the ability of the crane to operate
at its rated capacity under specified conditions. During the tests, the capacity and motor
inputs shall be recorded. All defects or defective equipment revealed by or noted during
tests shall be corrected or replaced at no additional cost to the Employer, and tests shall

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be repeated until specified results and results acceptable to the Engineer are obtained.
The Contractor shall provide labour, weights and materials for conducting the tests.

2.11.3 Crane Structural Steel Work

End stops shall be provided on structural steel at the ends of the crane and trolley runs
capable of withstanding impact imposed by motion of fully loaded hoist and trolley or
crane. All stops shall be securely anchored to the structural steel, and positioned to
protect adjacent construction, materials, equipment, or similar obstructions.
The crane shall be fully compliant with the following:

2.11.3.1 Hoist and Trolley

The Electric Hoist shall be of the low headroom type and shall be a non-sparking system.
The hoist shall incorporate spur, helical or herringbone gearing throughout and anti-
friction bearings shall be provided on all shafting. The hoist shall be provided with both
electrical and mechanical load brakes.

The shafts of the motor drum and drum pinion shall run in grease lubricated ball or roller
bearings.

The gear train and bearings shall be oil bath or splash lubricated.

Trolley wheels shall be similar to bridge truck wheels.

The trolley drive shall be a fully enclosed UL listed electric motor driving through spur or
worm gears driving one wheel on each side of trolley. The gear transmission shall be
completely enclosed in oil-tight housing and ball or roller bearings shall be provided
throughout.

The drum shall be steel or high-grade cast iron and shall be capable of withstanding
combined crushing and bending loads, and not less than two complete wraps of hoisting
rope should remain in the grooves when hook is at lowest position for the lift specified.
There shall be no overlapping of the rope when hook is at highest point

A limit switch shall be provided at the upper and lower limits of hook travel, with overload
cut off to prevent application of forces greater than the rated capacity of the hoist
including accelerating load.

Load block frames shall be of steel construction.

The brake assembly shall be located on the driving motor shaft or gear train to stop
rotation of armature without causing driving wheels to lock quickly. Electric brakes shall
be provided for bridge and trolley motion.

The hoist motor shall be of the AC type with oil encapsulated disc brakes which holds the
load and is applied automatically on power removal.

A mechanical load brake shall be provided for hoist motion to prevent over-speeding. The
brakes shall be accessible for external adjustment by removing the cover plates.

2.11.3.2 Motors

Motors for the hoist, trolley and bridge shall be of the enclosed, reversible, induction
motors type especially adapted to the crane service current. Motors shall be two speed
hoist motors with a maximum speed of 1,500 rpm (synchronous).

Motor insulation shall be minimum Class “F” with Class “B” temperature rise, 50ºC
ambient unless otherwise indicated or specified.

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Motors shall have a Service Factor of 1.15.

Motor capacity shall be sufficient to start the crane, hoist and trolley at maximum speed at
design capacity without exceeding the nameplate ratings for current and power and
without operating in the service factor.

Ball or roller bearings shall be provided with a minimum L-10 life to 100,000 hours.

2.11.3.3 Electrical Controls

Complete integral electrical control system shall be provided with the electric bridge crane
equipment consisting of starters, circuit breakers, overload relays, limit switches, control
transformer for a 240 V control circuit, control relays, and controlling devices.

Magnetic controls for motors shall be provided. Controls shall be provided to permit
"inching" in both forward and reverse directions under full load.

Electrical equipment including motors, controls, resistors, brakes, conduit, wiring, panels,
and enclosures shall be made with applicable requirements for materials, workmanship,
construction, and installation of latest IEE Codes.

Enclosures shall be provided as indicated.

2.11.3.4 Pendant Control

Crane shall be operated from a manually operated travelling pendant push-button control
station as a part of festooned flexible cable messenger system suspended from anti-
friction bearing trolleys operating on a rigid metal track.

System shall be provided so that the crane, trolley, and hoist can be moved to any
position when operating the unit from the operating floor level.

A torque reel shall be provided, which will permit raising and lowering of the pendant
push-button station.

Pendant push-button control station shall be provided with the following push buttons.
Each push button shall be clearly marked to indicate its function:

Hoist:
High Speed
Up
Down
Low Speed
Up
Down

Trolley:
Forward
Reverse

Underside of crane shall be marked with arrows indicating forward direction.

A grounding conductor shall be provided between a ground terminal in the Pendant push-
button station and the crane.

Control equipment shall be mounted in an enclosed compartment, which forms an


integral part of bridge crane and includes transformer for a 240 V control circuit.

2.11.3.5 Conductors and Collectors

Equipment and accessories associated with the conductors and collectors shall be
approved by Lloyds Underwriter'
s Laboratories.

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Conductors for electric current supply to travelling bridge shall be of the safety type shield
conductor with a moulded-plastic cover that surrounds conductor except for a slotted
opening shaped to the contour of the collector head.

A separate conductor shall be provided for each phase. Dual conductors in a single
insulating shield are not acceptable. The conductors shall be of the Copper and shall be
suitable for carrying the maximum current.

The moulded-plastic shield shall have high dielectric strength and shall be resistant to
corrosion and deterioration from sunlight or weather.

Insulated supports shall be provided and spaced not over 1.5 m.

Collectors shall be of the sliding shoe type with an adjustable spring-load arm capable of
horizontal or vertical movement to automatically adapt to irregularities of the conductor.

Shoes shall be set in a moulded-plastic head that will prevent external contact with the
shoe when it is running on a conductor.

Exposed bare current-carrying surfaces or wires in collector or arm where the shoe is in
contact with the conductor are not acceptable.

A bridge fastened span conductor system shall be provided for trolley electrification.

A junction box shall be provided to connect conductors to the power supply circuit.

2.11.3.6 Cable Reels

Feed cable reel for electric current supply for all electric hoists with trolleys, except as
otherwise indicated, through a single flexible, multi-conductor power cable from a self-
winding spring-operated reel located near mid-point of trolley travel or where indicated on
drawings.

The cable shall have at least 4 conductors.

The reel shall have a swivel base.

The reel shall have a roller outlet.

The reel shall have an explosion proof enclosure for classified areas.

An approved junction box shall be furnished to connect cable reel to power supply circuit
with hoist.

2.11.3.7 Shop Painting

Primer and Finish Paint shall be shop applied to all exterior ferrous surfaces with a high-
solids epoxy with the following characteristics:
• Solids by Volume: Minimum 69% (percent 2)
• Type: Polyamidoamine, self priming.
• Dry Film Thickness: 4 ml to 8 ml per coat.
• No. of Coats required: Three.
• VOC Requirement: 2.79 max.
• Colour: As specified elsewhere in the Contract documentation or as selected by
the Engineer.
A Topcoat shall be shop applied over the finish paint which shall be an aliphatic acrylic
polyurethane coating with the following characteristics:

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• Solid by Volume: Minimum 58% (percent 2).
• Dry Film Thickness: 4 ml.
• Number of Coats Required: One.
• VOC Requirement: 3.5 max.
• Colour: As specified elsewhere in the ADWEA Specification or as selected by the
Employer.
The topcoat and finish paint shall be compatible and from the coating manufacturer.

Surface preparation, mixing and application and safety requirements shall be in


accordance with the paint manufacturer'
s printed instructions.

Ferrous surfaces not to be painted shall be given a shop applied coat of grease or rust
resistant coating.

2.11.3.8 Spare Parts

Spare parts shall be provided that is identical to and interchangeable with parts installed.
The following shall be provided:

• One set of all special tools required;


• Manufacturers recommended list of spares

2.11.3.9 Installation

Install items in accordance with manufacturer'


s printed instructions and as indicated and
specified.

2.11.3.10 Field Testing

All tests shall be performed with motor controls.

After installation of cranes, and after inspection, operation, testing and adjustment have
been completed by manufacturer' s field service technician, conduct running test for each
cranes in the presence of the Engineer to determine its ability to operate at its rated
capacity under specified conditions. During tests, observe and record capacity and motor
inputs. Promptly correct or replace all defects or defective equipment revealed by or
noted during tests, at no additional cost to the Employer, and repeat tests until specified
results and results acceptable to the Engineer are obtained.

Contractor shall provide all labour, weights and materials for conducting the tests.

A 30-minute test shall be conducted at the rated capacity.

Make all adjustments to place equipment in specified working order at time of above
tests.

Remove and replace equipment at no additional cost to the employer with equipment that
will meet all requirements specified and indicated if unable to demonstrate to satisfaction
of the Engineer that all units will perform the service specified and indicated.

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3. PART 3 ELECTRICAL EQUIPMENTS

3.1 Electric Motors and Ancillaries

3.1.1. Motors

Motors shall be three phase, fan cooled, totally enclosed squirrel cage, induction type to
BS EN 50347, continuously rated for the heaviest specified duty, and suitable for
operation on the electricity supply specified. Power output from the motor shall not be
less than 10% greater than maximum demand imposed by the drive.

Motors shall be of the ‘High Energy Efficiency’ type.

Motors outdoors shall be fitted with GRP or mild steel/aluminium sunshades. Motors are
to be de-rated to suit ambient conditions.

Submerged motors shall be IP 68 rated.

3.1.2. Insulation

Class ' F' Insulation shall be provided in accordance with the requirements of
BS EN 60034: Part 5, IEC 60034: Part 5. The limit of temperature rise shall be as for
class B insulation. Ambient temperature shall be taken as 49 °C.

3.1.3. Thermistors

Thermistors shall be provided for all submersible motor pump sets, suitable for
connection to a monitoring unit in the motor control circuit, to afford protection against
winding failure due to overheating.

3.1.4. Bearings

The grease lubricated bearings shall be supplied and shall be charged using hydraulic
type nipples which are freely accessible, without any dismantling, or otherwise piped out
to a readily accessible location.

“Sealed for Life” bearings shall not be used.

3.1.5. Anti Condensation Heaters

Continuously rated anti condensation heaters shall be installed in motors. They shall be
sized by the equipment manufacturer/supplier according to the motor frame size.

Heaters shall be located within the motor so that the heat dissipated does not damage
the insulation of any of the windings or associated cables.

3.1.6. Terminal Boxes

Terminal boxes shall be separate from the frame and rotated 180 degrees to allow cable
entry at the top, bottom or either side, and shall be suitable for cable glands.

Terminal mountings shall be arranged such that the motor supply wiring can be
disconnected without disturbing its internal connections.

The end of each winding shall be brought out to a separate terminal, connecting links
being provided to facilitate interconnection of individual terminals.

A diagram of connections shall be fixed inside the terminal box and cover shall be
provided with watertight, oil resisting gaskets.

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Terminal boxes shall be provided with Earth terminal suitable to allow cable lug
connection.

For anti condensation heaters additional terminals and a separate cable gland entry shall
be provided.

A notice shall be fitted within the terminal box engraved: 220 V Heater Supply - Isolate
Elsewhere.

3.1.7. Labels

Plates shall be fixed on each motor, giving the following information:

BS No ............... No of Phases .....................


Manufacturer ............... kW .....................
Serial No ............... Voltage .....................
Insulation Class ............... R.P.M .....................
Frequency ............... Current at FL .....................
Model/Type ............... Power Factor .....................
Origin ............... Duty .....................
Ambient ............... .....................

3.2 Standby Generators

3.2.1. General

The Contractor shall provide a generator driven by a diesel fuelled engine. The engine
and generator shall have a standby rating and output as detailed in the Particular
Specification.

The set shall be designed, manufactured, tested and certified to be compliant with the
relevant BS, ISO and IEC standards.

3.2.2. General Arrangement

The engine, radiator and generator shall be mounted on a common base frame, via anti-
vibration mountings.

3.2.3. Generator Controls

The controls for the generator set shall be fitted in a set mounted control panel. The panel
shall be mounted on the set via anti-vibration mountings.

The panel shall provide the following controls and instrumentation:

The set shall have three modes of control.

• Automatic – in automatic mode the generator shall start automatically when a mains
failure is detected on the live side of the Motor Control Centre mains incoming circuit
breaker.

If the mains failure lasts for more than 5 seconds the Motor Control Centre mains supply
breaker shall trip and a start signal shall be sent to the standby generator system. The
generator shall start and when the output volts have stabilised the Motor Control Centre
panel incoming standby generator supply breaker shall close.

The generator shall continue to supply the Motor Control Centre loads until the mains
supply is restored and remains stable for more than 30 seconds. After this time the Motor
Control Centre incoming standby generator supply breaker shall open and the incoming

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mains supply breaker shall close. The generator shall continue to run for 10 minutes on
no load before shutting down automatically.

Test – when test mode is manually selected a mains failure is automatically simulated
and the generator runs on load for an hour before automatically changing back to standby
mode.

Manual – in manual mode the generator is started and stopped manually, there is no
automatic changeover or switching of circuit breakers.

The following controls shall be provided:

• Key-operated four position, AUTO – OFF – MANUAL - TEST engine control switch.
The set protection shut downs shall operate in all modes of operation.
• Key-operated START – STOP switch, this shall be operable only when the control
selector switch is in the MANUAL position.
• Fault reset pushbutton.
• Emergency STOP pushbutton – mushroom head, twist-to-release type.
• Engine lubricating oil pressure gauge and low pressure warning light. Alternatively
the oil pressure gauge may be mounted on the engine.
• Water temperature gauge.
• Engine hours run indicator.
• Battery charging ammeter.
• Battery voltmeter, selected by pushbutton.
• Engine speed trimming control and tachometer.
• Triple-pole circuit breaker, with thermal and magnetic overload protection set up as
appropriate to the rating of the set, and fitted with a 300 mA residual ground leakage
current trip unit and tripping circuit.
• Ammeter and selector switch permitting display of the three phase currents.
• Voltmeter and selector switch permitting display of line to line & line to neutral
voltages from alternator.

3.2.4. Noise Level

The noise level as measured 2 m in any direction from the exterior of the standby
generator building at 1 m above ground level shall not exceed 85 dBA when the engine is
running at full load. The Contractor shall carry out a test on Site to demonstrate
compliance with this requirement.

3.2.5. Alternator

The alternator shall be the brushless, self-exciting type with salient rotating poles,
damping windings and single end shield bearings. Radio interference suppression to BS
EN 55014: Part 1 or equivalent shall be provided. Protection shall be built in to the
alternator to prevent damage in the event of sustained low speed operation due to an
engine control fault. The winding insulation shall be a minimum of Class F.

The output voltage shall be maintained to ± 2.5% from no load to full load. The alternator
and engine shall be suitable for continuous operation at a power factor between unity and
0.8 lagging at full load.

The alternator shall be dust and moisture protected to IP 23, or above. The alternator
shall be fitted with an anti-condensation heater, which shall be provided with a manual
operation switch.

The alternator shall be capable of running at 110% full load for 1 hour every 6 hours in
the maximum ambient temperature. It shall be supplied with thermistors in each phase
winding, which shall give early warning of the temperature rising above the normal full
load operating temperature.

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The full load temperature rise of the windings shall be limited to a maximum of 80°C. The
thermistor relay shall trip the alternator output circuit breaker. The set shall then be shut
down after the preset cooling period has elapsed.

The output from the alternator shall be connected to outgoing terminals via a suitably
rated manually operated moulded case circuit breaker. The outgoing terminals shall be
located within a separate enclosure. This enclosure shall be fitted with a suitably sized
removable gland plate arranged for bottom entry cabling. A separate enclosure with its
own gland plate shall be provided for control cables.

3.2.6. Diesel Engine

The engine shall be of the diesel fuel powered internal combustion type, continuously
rated, with the engine flexibly coupled to the alternator.

The engine shall be governed within the limits during running according to BS ISO 3046:
Part 1.

The engine speed shall not exceed 1,800 rpm.

Automatic shutdown facilities shall be provided to operate in the event of low lubricating
oil pressure, high cooling water temperatures or high engine speed. In addition a fusible
link emergency fire shut down system shall be provided within the generator enclosure,
complete with wires, pulleys and fusible link. An emergency stop button shall also be
provided on the exterior of the enclosure.

The engine shall be provided with fuel and lubricating oil filters, air cleaner and exhaust
silencer. The set shall be supplied with the correct quantity and grade of lubricating oil.

3.2.7. Integral Fuel Tank

The fuel tank shall be constructed in accordance with BS 799: Part 5 with seams fillet
welded both internally and externally. Prior to dispatch from works the tank shall be
cleaned internally and externally.

An integral fuel tank with a capacity sufficient to give a minimum six hours full load
running of the set shall be provided in the base of the set. When deriving the usable fuel
capacity of the tank, allowance shall be made for usage and for collection of debris in the
bottom of the tank.

The tank shall be provided with the following fittings and connection points:

• Filling point pipe


• Drain Cock
• Access point for dip tape.
• 100 mm diameter level gauge graduated “empty”, ”¼ full”, ”½ full”, ”¾ full” and “full”,
adjacent to the filling point.
• A fuel oil tank low level switch shall be provided to give a low level alarm on the
engine control panel.

3.2.8. Engine Protection

The engine shall be provided with suitable engine protection systems which will shut the
engine down automatically in the event of a fault or abnormal operating conditions.

The engine shall be fitted with an over speed trip which shall cut off the fuel supply when
the engine speed rises above 120% of the normal running speed.

In the event of a shutdown occurring due to a fault condition arising, the relevant fault
lamp shall remain illuminated and restarting shall be inhibited until some reset action has
been taken.

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3.2.9. Starter

An electric starting system utilising heavy-duty lead-acid batteries shall be supplied. An


engine driven alternator and control unit shall be fitted for automatically recharging the
starting batteries when the set is running.

A minimum of three sequential attempts to start from cold over a six-minute period and a
maximum of six starts per day shall be possible without the assistance of a supply of
mains electricity. The starting system shall be fully recharged within 12 hours of
continuous engine operation following the most arduous of the above starting sequences.

If the engine fails to start after three sequential attempts the start sequence shall be
locked out and a “Failed to Start” alarm condition indicated.

3.2.10. Exhaust and Silencer

The engine shall be fitted with an exhaust and silencer system. The exhaust shall
terminate outside of the building above roof level. Within the building the exhaust shall be
suitably lagged and finished with polished stainless steel cladding. Exhaust pipes shall be
supported on rollers or pipe hangers. The exhaust pipe work shall be connected to the
engine via a bellows type expansion joint on the manifold flange. The exhaust pipe work
shall be fabricated from a minimum of “3/16” thick 316 grade stainless steel.

Insulation shall be fitted to those parts of the exhaust system within the generator
enclosure or elsewhere, that are likely to come into contact with operatives.

3.2.11. Cooling System

The engine cooling system shall consist of a forced air cooled radiator utilising an engine
driven cooling fan. The exhaust air shall be discharged directly to the outside of the
building via ductwork. The incoming air will be taken from outside of the building and first
pass over the alternator before passing over the engine and radiator.

The Contractor shall be responsible for the design and provision of adequate cooling
facilities for the alternator, engine and radiator, taking into account the high ambient
temperatures of the location. This shall include the provision of a noise attenuated intake
and exhaust baffles and corrosion resistant ducting required within or external to the
enclosure.

The Contractor shall submit calculations to demonstrate that adequate cooling of the
generating set shall be achieved under all conditions up to the maximum ambient
temperature.

The Contractor shall ensure that hot air produced by the engine running continuously at
full load shall be satisfactorily dissipated with no risk of short circuit to the cooling air inlet.

3.2.12. Generator Enclosure for Mobile Generator.

The enclosure shall be factory built, with stainless steel hinges and fasteners.

The enclosure body shall be made of steel, pre treated with zinc phosphate and polyester
powder coated. Doors shall be wide enough for easy maintenance and placed on either
side. Service points like drain, coolant fill, and so on, shall be extended to exterior of the
enclosure. The control panel viewing window shall have a lockable access door. There
shall be an emergency stop button mounted on the exterior of the enclosure. Fuel fill
point and battery shall be protected by a lockable access door. Engine exhaust muffler
shall be suitably protected for operator’s safety and terminated at the top with a rain cap.

Page 83
3.3 Cabling

3.3.1. Types of Cables

Cables shall be 600 V to 1,000 V grade for LV applications. The following types of cables
shall be used:

• Cables for general power distribution within buildings, and all cables underground,
shall be wire armoured, stranded copper cored, XLPE insulated, PVC sheathed
cables, complying with BS 5467 characteristics.
• Cables run in conduits and trunking systems shall be stranded copper cored PVC
insulated cables, complying with BS 6004.
• Unless otherwise specified by the equipment manufacturer, signal cables shall be
PVC/SWA/PVC multi-pair cables complying to BS 5308: Part 1 and Part 2 and shall
be used for instrumentation/telemetry circuits. Conductors shall be single strand 0.9
mm diameter. An overall screen shall be provided.

3.3.2. Cable Design

The applicable de-rating factors for ambient temperature and method of installation shall
be applied when selecting cable sizes. Cable routes and cable lengths shall be
determined by the Contractor subject to the Engineers approval. Cable sizing calculations
shall be submitted to the Engineer for approval.

Cables shall be selected such that the voltage drop does not exceed the maximum value
defined in BS 7671 (Requirements for electrical installations. IEE Wiring Regulations.
Seventeenth edition).
2
The minimum size of conductors used shall be 1.5 mm for control circuits including
programmable controller wiring and 2.5 mm2 for power circuits. These minimum
conductor sizes will not apply in the case of instrumentation/telemetry circuits where
smaller conductor sizes and special cables may be appropriate.

Segregation of cables in trenches, on cable trays, in conduit, in trunking, or in ducts shall


be in accordance with BS 7671. Particular attention shall be taken to ensure the correct
segregation of intrinsically safe circuits.

3.3.3. Cable Supports

Cables, except those laid in ground, run in horizontal cable troughs or in ducts, shall be
firmly supported and fixed.

Single runs of PVC sheathed armoured cables shall be supported using PVC cable clips.
Multi-cable runs of PVC sheathed armoured cables shall be fixed onto heavy gauge hot
dipped galvanised steel cable trays and supporting steelwork.

Non armoured PVC cables shall be installed in conduits or trunking.

3.3.4. Trunking and Cable Trays

The trunking and perforated cable tray shall be selected to form a continuous support for
cables. The trunking and tray shall be installed to form a complete, continuous system by
the use of manufacturer’s standard fittings and devices where there are any changes in
direction, elevation or branches. The manufacturer shall supply all cable trunking/tray
risers fittings such as flat bends, equal and unequal tees, four way cross pieces and
offset reducers. Also any accessory items required such as dividers, brackets, clips, earth
continuity connectors, flexible (expansion) couplers and covers shall also obtained from
the same manufacturer.

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Trunking is to be manufactured from either mild steel or PVC and shall confirm to BS EN
50085: Part 1, BS EN 50085: Part 2-1, BS 4678: Part 4 and BS 4678: Part 2. Cable trays
shall be manufactured from mild steel. Mild steel trunking and cable trays shall be hot dip
galvanised.

Where the trunking or cable trays are cut, drilled or where the galvanising is damaged in
any way the surfaces shall be adequately treated to restore them to the original
galvanised standard. The number of cables installed in the trunking shall not exceed that
recommended in BS 7671 (IEE Regulations), and the resulting space factor shall not
exceed 45%.

The fixing of trunking and cable trays and the installation of cables into or on trunking and
cable trays shall be carried out using the manufacturer' s approved accessories and
fixings only. Such accessories and fixings shall be either manufactured from non-
corrodible materials or supplied suitably coated to render them non-corrodible.

3.3.5. Conduit Systems

Conduits for occupied areas to be concealed; conduit for unoccupied areas to be surface
mounted and GS conduit pipe for Plant-Rooms.

Conduits within buildings and structures shall be extra-super-high-impact heavy-gauge


PVC-u conduit, installed with solvent welded joints and shall be installed with screwed
fittings.

Conduit systems shall conform to BS 4607: Part 1, BS 4607: Part 5, BS EN 61386: Part-
1, BS 4568: Part 1 as appropriate, and the number of cables installed shall not exceed
those recommended in BS 7671 (IEE Regulations).

The conduit system where it passes through the building structural expansion joints,
suitably rated/sized expansion couplers shall be used in order to absorb the
expansion/contraction.

Fixings and accessories associated with conduit systems shall be either manufactured
from non-corrodible materials or suitably coated to render them non-corrodible. No
conduit shall be smaller than 20 mm diameter.

Cable runs shall be continuous throughout. Jointing shall not be carried out in conduits or
at drawing points under any circumstances.

Draw-in boxes shall be spaced so that there is not more than two solid bends, or their
equivalent, or more than nine metres of straight run between draw-in boxes.

Flexible conduit for connection to mechanical equipment.

3.3.6. Cables Laid Directly in Ground

The Contractor shall be responsible for all work associated with cabling including
trenching, ducting under roadways and backfilling of trenches.

Cables shall be laid at a depth of not less than 500 mm or not more than 1,000 mm below
the surface of the ground.

The bottom of the trench and the first 250 mm of backfill shall be fine sand free of stones
or other sharp objects.

Where cable trenches pass through stone fill, the cable shall be laid on an 80 mm bed of
sand. After laying, the cable shall be covered by a further layer of sand to a depth of
80 mm above the top of the cable. Where sand is likely to leach away, a suitable
membrane shall be fitted.

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Interlocking PVC cable tiles shall be laid after backfilling a layer of sand at a depth of
400 mm from the finished ground level throughout the cable length and a continuous
warning tape shall be laid over the width of the cable trench 250 mm below ground level.
The tape shall be heavy gauge polythene marked ' CAUTION ELECTRIC CABLE
BELOW' , in English and Arabic.

Cable route markers shall be installed at all changes of direction and at road crossings,
and shall have their positions marked and identified by co-ordinates on the ' as installed'
cable route drawings. Each marker shall be a block of concrete approximately 300 mm
square by 150 mm, permanently marked ' ELECTRIC CABLES' , in English and Arabic,
with arrows showing the directions of the cable route.

Cables laid under or through roadways, footpaths, structures or buildings shall be


installed in ducts. 50% spare duct capacity shall be provided subject to a minimum of one
spare duct, and a maximum of five spare ducts at each duct installation.

Cable trenches shall be adequately supported and kept free of water whilst cable laying
proceeds.

Where cables pass from made up ground into a fixed structure, sufficient allowance shall
be made to cater for subsidence and ground movement.

3.3.7. Cables Run in Ducts

Cable ducts supplied under the Contract shall be rigid Class E PVC-u pipe with rubber
ring joints and be not less than 100 mm diameter. Cable ducts shall be complete with
nylon draw wires (min 1 kN). The draw wire shall be retained in the duct after installation
of the cables.

Cable ducts shall be laid at a depth of not less than 500 mm or not more than 1,000 mm
below the surface of the ground. Draw pits shall be provided at road crossings, changes
in direction, or at 30 m intervals on straight runs. At road crossings ducts shall be
encased in concrete.

A minimum of one spare duct or 10% of the total ducts installed in each duct route,
whichever is the greater, shall be provided for future installations.

Cable ducts shall be sealed at both ends where they enter buildings in draw pits, or
where the end of the duct is visible, using an expanding polyurethane foam impervious to
water, gas and vermin on completion of the installation. The length of the foam plug shall
be a minimum of 300 mm.

3.3.8. Cable Troughs

Where cable troughs are provided they shall be shown on the cable routing drawings.
The Contractor shall include for removing and replacing covers as necessary for the
installation of the cables. On completion of the cable installation all entries and exits to
the troughs shall be sealed using an expanding polyurethane foam.

Cables to be laid with suitable spacing.

3.3.9. Cable Identification

Cables and cable cores shall be identified at both ends by means of sleeve bands
bearing the cable/core reference number which shall relate to the reference number
shown on the drawings. Where multiple cables are laid in troughs, ducts, clipped on tray
over long runs or laid in ground close together, intermediate markings to identify specific
cables shall be applied.

Where cables are installed in ducts, the cables shall be identified with the cable reference
number within each cable draw chamber or at each end of the duct.

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Identification and markers to be approved by the engineer.

3.3.10. Termination

Armoured cables shall be terminated at plant and equipment using brass armour lock
glands which conform to BS 6121: Part 1 and Part 5, BS EN 50262. All glands shall be
fitted with PVC shrouds. For external applications all glands shall be type E1W and for
internal applications type CW.

Cable cores shall be terminated by solder less compression fittings appropriate to the
core being terminated. Compression tools shall be designed for specific use with the
connectors used

Where the above type of glands are not suitable for a particular application the
requirements shall be as detailed in the Particular Specification.

Fire Barrier – All apertures and ducts to be sealed with approved fire-resistant filling.

3.3.11. Bus Ducting

Connections from the low-voltage terminals of the supply transformers to the incoming
circuit breakers shall be either cable or bus ducting. If bus ducting is selected by the
Contractor then the bus ducting shall comply with the following requirements.

• The bus ducting shall be of the feeder type suitable for indoor application.
• The conductors shall be copper, with silver plated joints.
• The conductors shall be insulated with epoxy, and rated for Class B 130°C
temperature rise.
• The insulated conductors shall be housed within a non-ventilated metallic enclosure.
• In addition to the phase conductors a ground conductor shall be provided.

3.4 Plant Earthing

For the earthing of electrical systems, equipment and structures, each installation shall
have one common earth bar connected to at least two groups of earth electrodes.

The earth resistance of the electrode shall be as low as is practicable but shall in any
event be such that the electrical resistance between the main earth grid and the general
mass of earth shall not exceed 4Ω when any one group of electrodes is disconnected.

The earth grid shall extend throughout the installation in the form of a main earth ring with
branch interconnections to the equipment and structures to be earthed. The earth
connections shall comprise earthing conductors made up of wires of stranded copper with
overall green/yellow PVC covering.

Earth electrodes shall be suitable material which guarantees low resistance and long life.
Copper electrodes shall not be used in areas with impressed current Cathodic protection.

The connections between electrode heads and conductors shall be so executed that easy
inspection and testing of the earth resistance of individual electrodes is possible.

All bare parts of underground earthing conductors shall be suitably protected against
direct contact with the soil so as to prevent electrolyte corrosion of plant equipment. All
earthing terminations shall be made with compression-type cable lugs. Interconnections
shall be directly clamped with compression-type branch connectors or ' cad-welded'.

The main earth conductor shall have a cross sectional area such that it can act as the
circuit protective conductor on all plant and equipment connected to it. At the point of
electricity supply it shall be solidly connected to the earth terminal conductor or site earth
terminal to achieve a TN-S system.

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External to the Switchgear and Control Rooms electrical plant and equipment shall be
connected to an extended main earth conductor. Cross bonding between extraneous
metalwork, and metal supporting structures for the plant and equipment shall also be
connected to this main earth terminal conductor.

The conductors from electrical plant and equipment to the main earth conductor shall be
treated as circuit protective conductors as described in BS 7671 (IEE Regulations) as
applicable.

The cross bonding conductors shall be as described in BS 7671 (IEE Regulations) as


applicable.

Cable Armouring and cable sheaths are not acceptable as the CPC where equipment is
installed.

Pre-cast chambers with removable cover and installed flush with the finished ground level
shall be provided at each earth electrode. These should be commercial quality and fitted
around approved earth rods.

3.4.1 Connections

Sub circuit protective conductors (CPCs) and bonding conductors shall be continuous
throughout their lengths wherever possible.

Joints from sub circuit protective conductors to the main earth/CPC shall be made with
compressed joints. Every joint shall have a warning plate securely attached which shall
state, in English and Arabic:

• “Safety Earth and Circuit Protective Conductor. Do Not Remove.”

Joints shall be readily accessible for inspection.

Where cable troughs are used for installation of the CPC, the joints may be made within
the trough.

Where the cable installation and CPC are installed underground, CPC joints shall be
made in above ground link boxes.

The minimum size of conductor for any external earthing connection, that is, outside of an
2
equipment enclosure is 6 mm .

3.4.2 Extraneous Metalwork

Metalwork within 2.5 m of any other metalwork, plant and equipment which can be
energised, or forms part of any other equipotential zone, shall be bonded to the
CPC/Earth System, and shall have a warning notice securely fixed accordingly.

On test, supplementary bonding conductors may be required to ensure integrity of the


equipotential zones, the installation of which shall be agreed with the Engineer.

3.4.3 Special Earthing Systems

• Instrumentation Clean Earth Facility:

Special regard shall be made, where earthing of instrumentation, transducers and


transmitters is concerned, so that all installations are earthed to the manufacturer'
s
instructions.

• Lightning Protection Units for outdoor instruments:

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A separate earth to that of the panel and associated equipment shall be provided for the
Lightning Protection Units or suppressors as suitable.

3.5 Outdoor Equipment

Outdoor equipment shall be weatherproof to a minimum standard of IP 65.

3.5.1 Socket Outlets

Refer to the Particular Specification for details of socket outlets to be provided.

Socket outlets types shall conform to BS EN 60309: Part 2, IEC 60309: Part 2, BS 1363:
Parts 1-5 and be complete with enclosures for surface mounting thus:

• 415 V - shall be 3 P+N+E and be complete with a plug interlocked on/off switch and
a 30 mA four pole residual current earth leakage circuit breaker.
• 240 V - shall be 2 P+E and be complete with a plug interlocked on/off switch and a
30 mA residual current device.
• 110 V - shall be 2 P+E and complete with a plug interlocked on/off switch.
• 50 V - shall be 2 P+E.

Scraping earth connections will not be acceptable.

A suitable plug shall be supplied for each outlet.

• 110 V - (for use with portable tools):

This shall comprise a 240 V/110 V isolating safety transformer with centre tap earthed
secondary providing no greater than 55 V to earth. Both secondary connections to the
transformer shall be fitted with fuses.

• 50 V - (for use with hand lamps):

This shall comprise a 110 V/50 V isolating safety transformer with centre tap earthed
secondary providing no greater than 25 V to earth. Both secondary connections to the
transformer shall be fitted with fuses.

3.5.2 Distribution Boards

Distribution boards shall comply with BS EN 60439, and distribution elements shall be as
specified, miniature circuit breakers which shall comply with BS EN 60898. A minimum of
one spare way shall be provided.

Live metalwork within distribution boards shall be fully insulated from the enclosure. The
neutral bar shall have at least one connection point for each distribution way of the unit
(for example, a 3-way TP&N unit shall have nine neutral connection points).

Distribution boards shall be complete with an isolator and a full complement of MCB
and/or RCCD units.

Domestic distribution boards shall be complete with a suitable rated isolating switch. A
30 mA residual current device shall be fitted on each socket outlet, or on the circuit for the
socket outlets.

A circuit schedule printed on a non-combustible sheet shall be permanently fixed within


the door of each distribution board.

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3.6 MCCs and Control Panels

3.6.1 General Requirements

The equipment shall conform to all relevant Bahrain, British or equivalent International
Standards, in particular those detailed below. Where a Standard or reference has been
updated or superseded the Contractor shall comply with the latest edition or equivalent
standard.

• Regulations for Electrical Installations published by the Kingdom of Bahrain, Ministry


of Electricity and Water, Electricity Distribution Directorate (Document Ref EDD/R-1).
• BS 88 Low-voltage fuses.
• BS 89 Direct acting indicating analogue electrical measuring instruments and their
accessories.
• BS 90 Specification for direct-acting electrical recording instruments and their
accessories.
• BS 142 Electrical protection relays.
• BS 1650 Specification for capacitors for connection to power-frequency systems.
• BS 3939 Graphical symbols for electrical power, telecommunications and electronics
diagrams.
• BS 4293 Specification for residual current-operated circuit breakers.
• BS 5164 Specification for indirect-acting electrical indicating and recording
instruments and their accessories.
• BS 5499 Graphical symbols and signs. Safety signs, including fire safety signs.
• BS 6231 Electric cables. Single core PVC insulated flexible cables of rated voltage
600/1000 V for switchgear and control gear wiring.
• BS 6423 Code of practice for maintenance of electrical switchgear and control gear
for voltages up to and including 1 kV.
• BS EN 60073 Basic and safety principles for man-machine interface, marking and
identification. Coding principles for indicators and actuators.
• BS EN 60309 Plugs, socket-outlets and couplers for industrial purposes.
• BS EN 60439 Low voltage switchgear and control gear assemblies.
• BS EN 60445 Basic and safety principles for man-machine interface, marking and
identification. Identification of equipment terminals and conductor terminations.
• BS EN 60447 Basic and safety principles for man-machine interface, marking and
identification. Actuating principles.
• BS EN 60529 Specification for degrees of protection provided by enclosures (IP
code).
• BS EN 60664 Insulation coordination for equipment within low-voltage systems
• BS EN 60898 Electrical accessories. Circuit breakers for overcurrent protection for
household and similar installations.
• BS EN 60947 (all relevant parts) Low-voltage switchgear and control gear.

Motor control centres (MCCs) and control panels, unless stated otherwise in the
Particular Specification, shall comply with BS EN 60439 Form 4 Type 7 IEC 439, and be
rated to the levels specified in the Equipment Specification for operation on a 415 V 3-
phase, 4-wire 50 Hz supply.

MCCs and control panels that are to be ASTA certified are detailed in the Particular
Specification.

MCCs and control panels shall be constructed so that normal maintenance may be
carried out from the front.

Cable entry and other access will be as detailed in the Particular Specification.

MCCs and control panels for outdoor use shall be fitted within a non corrodible GRP
enclosure. The enclosure to provide a minimum protection of IP 65, and to allow a
minimum of 1,000 mm in front of equipment.

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GRP enclosures shall be provided with internal door operated fluorescent lamp and
external strobe alarm light, air conditioning split units.

3.6.2 Construction

MCCs and control panels shall be of multicubicle pattern design, such that each section
within a panel is segregated from the adjoining sections and be complete with its own
access door capable of being opened through a minimum of 90°. Each panel shall be
lockable with a common key for all panels provided under the Contract. A minimum of two
keys shall be provided for each panel. All other access covers shall be bolted.

Front access only panels shall be fitted with cable ways complete with bolted front
covers. Routing of cables direct between sections or behind sections will not be
permitted.

All bolting used for assembly of the panel, mounting of components and connections shall
be 316 L grade stainless steel. Door hinges and catches shall be plastic and catches
shall be 316 L stainless steel, door handles shall be coated to inhibit corrosion, the
method of coating shall be subject to the Engineers approval.

MCCs and control panels shall be manufactured from sheet steel, and shall be of uniform
height and rigid construction to BS EN 60947/BS EN 60439 providing an enclosure to
IP 54 as defined in BS EN 61061: Part 1.

Minimum thicknesses of MCCs and control panels shall be as follows:

Carcass 2.5 mm
Doors 2.0 mm
Boxes 1.5 mm

Solid barriers shall be provided to segregate each load compartment from all others and
the busbar chamber, to prevent objects falling into lower live compartments, and to
restrict fault travel to other compartments.

The overall height of MCCs and control panels, including plinths shall not exceed
2,500 mm. Isolator handles, control switches, push buttons, indicator lamps and
instrumentation shall not be less than 500 mm and not more than 1,900 mm above
finished floor level.

Panels shall be supplied with a purpose made plinth 125 mm high of fabricated and
corrosion protected sheet steel or rolled steel channel. The plinth shall be inset from the
vertical face of the panel by 12 mm such that a continuous flat vertical surface faces
outwards.

A minimum of 250 mm shall be provided between finished floor level and the gland plate,
and a minimum of 250 mm between the gland plate and the connection terminals.

Internal components shall be fitted on mounting plates. These plates shall be fitted at the
back of the individual sections on stand off pillars if required, to provide easy access for
maintenance.

A minimum space of 45 mm shall be allowed between internal cable trunking and the
terminals or other termination points within the section.

The number of cables installed in internal trunking shall be such that the resulting space
factor does not exceed 45%.

3.6.3 Busbars

Busbars shall be of tinned, hard drawn, high conductivity copper. They shall be insulated
throughout their lengths by means of phase colour sleeving to comply with BS 159. The

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busbar assemblies and joints shall be in accordance with the manufacturers/suppliers
recommendations.

The dimensions of the busbar copper work shall be of one size throughout the complete
panel.

Busbars shall be enclosed in a separate chamber to comply with BS EN 60439 and shall
be continuous over each shipping section.

Riser bars shall be of the same construction and be fault rated to the same level as the
main busbars.

Live connections to and from busbars shall be either fully insulated or suitably screened
and all covers screening the busbars and connections shall be provided with adequate
warning labels.

Easy access shall be available to the busbars for future connections at both ends of the
panel.

The rating, supports and bracing of all main connections between all main circuit
switching mechanisms and busbars shall be designed for operation at the same short-
time withstand current rating as that specified for the busbars.

Current transformers shall be bar type, to BS EN 60044: Part 1, IEC 60044: Part 1
accuracy and output mounted on the cabling side of the ACB or MCCB.

Busbar joints are to be sleeved.

3.6.4 Heaters

Each panel compartment shall be fitted with an anti-condensation heater with easily
accessible on/off switch controlled via a thermostat. The switch shall be fitted inside the
compartment.

3.6.5 Internal Panel Wiring

Internal wiring shall be PVC insulated conforming to BS 6231, 600 V grade. The wires
shall have stranded copper conductors. The minimum conductor size shall be 1.0 mm2.
2
The maximum conductor size for door mounted equipment shall be 2.5 mm , wiring
subject to flexing or movement shall be multi-stranded.

Voltage Colour

25 AC Violet (Live)

24 DC Positive (+) Brown, Negative (-) Pink

50 AC (Not allocated)

110/130 Yellow (Where centre tapped both live to be yellow)

280/460 Red (Live with Phase colour marker sleeves)

mA signals Grey (With polarity markers)

Neutral Black (415, 230, 110, 50, 25 AC) with level markers

Earth Yellow/Green

Telemetry cabling shall be coloured Violet.

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Current transformer cabling shall be white with phase identification and polarity markers.

Power circuits shall be segregated from low voltage signal cables.

Phase identification shall be by an appropriate colour, that is, red, yellow or blue plastic
sleeve not less than 10 mm long, and not adhesive tape.

Wiring shall have crimped insulated type terminations and shall be identified by means of
ring type plastic wire markers at both ends.

Where more than one panel is fitted within a station or works, the identification shall be
unique to each panel.

Wire markers shall be cross-referenced 3-digit numbering system to their relevant


schematic and wiring diagrams.

3.6.6 Cable Termination

Cables shall be terminated on rear cable boxes with integral gland plates. The gland
plates shall be of adequate size to ensure that any cable can be removed without
removing other cables.

A minimum of 150 mm clear space shall be available above and below the gland plate,
for access to the glands.

Where necessary, tray work or cable ladder shall be provided for supporting and fixing
cables.

Only one wire shall be connected to each side of a terminal.

Where different voltages are terminated on a common rail, they shall be segregated by
using insulated partitions, and marked with individual voltages.

Cable terminations shall be arranged to ensure that they are not overstressed
mechanically during normal tightening of the mountings and connection fittings.

The cables and cable cores shall be identified using plastic sleeve bands at both ends.

All spare cores shall be terminated in suitable terminals.

MCC shall be suitable for bottom cable entry. Incoming power cables shall be terminated
by the Contractor and shall be inclusive of cable gland and accessories as required.

3.6.7 Terminals

Terminals shall be of a type providing a positive mechanical clamp on connection, fully


shrouded and suitable for mounting on DIN standard rail. Double banked terminals in one
composite moulding shall not be used.

Telemetry cables shall be terminated in hinged link type terminals.

Instruments using flat cable plugs, D-sub plugs and DIN plug strips for their connection
shall be terminated in a DIN rail mounted interface unit comprising electronic plug
connections and screw connection terminal block with identified terminals.

Where separate power supplies are required for instruments, these must be capable of
being isolated individually using fused, hinged link type terminals.
2
Cables of 10 mm and above shall be terminated on stud type terminals.

Page 93
Main incoming power terminals, and terminals used for voltages of 110 V or above, shall
be fitted with appropriate '
Danger'labels.

Terminals which may be live, when a section is isolated by its own isolator, shall be
shrouded using clear plastic with warning notices marked ' DANGER LIVE TERMINALS,
ISOLATE ELSEWHERE'and with the voltage clearly marked on the shroud. The shrouds
shall be secured by screws and sufficient to cover terminal lugs.

Separate terminals shall be provided in the vicinity of the gland plate for incoming and
outgoing connections.

Terminals and terminal boards shall be identified and shall correspond with the
appropriate schematic or wiring diagram.

Provisions shall be made for installation of a minimum of 10% or 15% (whichever is the
greater) additional terminals to be fitted in future on each terminal block.

3.6.8 Panel Earthing

Panels shall be provided with a hard drawn, tinned, copper earth bar located clear of any
gland plate or cable access. The earth bar shall have a minimum cross-sectional area of
120 mm2. The earth bar shall be the full length of the panel and split only at sections used
for transport and installation purposes. Where splits occur, the bar shall be joined by a
minimum of two bolted connections. Provision shall be made at each end of the earth bar
for connection to a main earthing system.

The component parts of all enclosures forming the panel, and all non-current carrying
metal parts, shall be effectively connected to the earth bar. Connections to steelwork
shall be made via welded studs.

Panel doors shall be electrically connected to the main enclosure earth using the
correctly sized flexible earthing conductor.

The main earth terminals shall not be less than M 8 or equivalent.

The surfaces of all equipment to which earthing bonds are fixed shall be cleaned free
from paint and other non-conducting materials.

3.6.9 Enclosure

All MCCs shall be in an air conditioned room or kiosk, and as such all enclosures shall be
designed and sized such that forced ventilation is not required.

Prior to painting, the enclosure shall be cleaned and degreased. The bare metal shall be
etch primed and then given a coat of primer paint to be followed by at least one
undercoat.

The exterior shall be finished in stove enamel paint to the shade specified in the
Particular Specification. The Contractor shall ensure that all sections of the panel are
identical in respect of colour, shade, finish, and so on.

The following minimum total dry film thickness shall be achieved:

• Indoor - 75 microns
• Outdoor - 100 microns
• Enclosure in abrasive atmospheres - 150 microns

The interior mounting plates shall be finished semi-gloss white.

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Special precautions shall be taken to prevent damage to parts of the panel including the
underside during delivery and erection. Any damage caused, shall be corrected to the
satisfaction of the Engineer.

Unless otherwise stated, the means of isolation shall comprise McCabe’s contained
within metal enclosures.

The cover of the enclosure shall be interlocked such that the switch interior is
inaccessible when the switch is closed, and it shall not be possible to close the switch
unless the cover is securely closed.

A device giving a clear positive indication of the position of the switch (that is, ON or OFF)
shall be provided. This indication shall be clearly apparent from the normal operating
position.

Switches shall be capable of being locked in the '


ON'and '
OFF'positions.

Moving contacts shall be removable for maintenance. Fixed contacts shall be fully
shrouded.

3.6.10 Circuit Breakers

Circuit breakers as installed shall be capable of carrying the maximum rated current
continuously.

Circuit breakers shall comply with BS EN 60947: Part 2 Category P2, and be capable of
withstanding the fault level of the system as specified.

All necessary auxiliary contacts shall be fitted, and a minimum of two spare auxiliary
contacts shall be provided on each unit, wired down to terminals.

Circuit breakers shall be fitted with a protection system as specified.

3.6.11 Fuse Switches

Fuse switches shall comply with BS EN 60947: Part 3, and shall be load break, fault
make type.

All necessary auxiliary contacts shall be fitted, and a minimum of two spare auxiliary
contacts shall be provided on each unit, wired down to terminals.

3.6.12 Isolators

Isolating switches shall comply with BS EN 60947: Part 3 and BS EN 62271: Part 102
where applicable. They shall be of the load break, fault make type.

All necessary auxiliary contacts shall be fitted, and a minimum of two spare auxiliary
contacts shall be provided on each unit, wired down to terminals.

3.6.13 Air Circuit Breaker (ACB)

3.6.13.1 General

The Air circuit breakers shall comply with IEC 60947: Part 2 utilization category-B.

The breaking performance shall be such that Service breaking capacity (Ics) should be
equal to the Ultimate breaking capacity (Icu).

The ACB shall have a rated operational voltage of 690V AC (50/60Hz) and rated
insulation voltage 1,000V AC (50 Hz/60 Hz).

Page 95
All ACB shall be draw-out type and of 3 or 4 pole as indicated on the drawing. The draw-
out operation shall be possible through a closed door, while the racking handle shall be
stored on the ACB in such a manner as to be accessible without defeating the door
interlocking. Bus-coupler ACB shall be of the 4 pole type.

Insulated safety shutters shall be provided over the incoming and outgoing main circuits
and over the auxiliary circuits in all draw-out ACB.

The ACB shall be operated via a stored energy mechanism for instantaneous opening
and closing. The mechanism shall be charged electrically. Closing and opening
operations can be initiated from the local push buttons on the circuit breaker front face (or
as remote control).

3.6.13.2 Construction

Circuit breakers shall be designed in such a way that maintenance may be carried out as
a function of their use.

The operating mechanism shall be of the Open/Closed/Open stored-energy type.

The ACB shall have one size from 800 A to 4,000 A and another size from 4,000 A to
6,300 A. The main contacts shall be encased in a reinforced polyester casing and offer
double insulation from the operators on the breaker front face.

3.6.13.3 Main contacts

The main contacts shall be designed such that no maintenance shall be required under
normal conditions of use. The main contacts shall be equipped with a visual wear
indicator that may be accessed by removing the arc chutes, for immediate assessment of
contact wear without requiring measurements or specific tools.

3.6.13.4 Arc chutes

The arc chutes shall be removable on site.

They shall be equipped with metal filters to reduce effects perceptible from the outside
during current interruption.

3.6.13.5 Connection/disconnection mechanism

It shall be possible to disconnect the circuit breaker without having to open the door. The
three possible positions (connected, disconnected and test) shall be indicated.

Before carrying out a disconnection or connection operation, the operator shall be


required to press a release button located on the front of the chassis.

The door shall be equipped with a locking system preventing door opening with circuit
breaker in the connected position. Safety shutters shall be placed over the main incoming
and outgoing circuits. A mismatch-prevention system shall block insertion of a draw-out
circuit breaker with a power rating greater than that of the fixed part.

3.6.13.6 Electrical auxiliaries

The auxiliaries shall be placed in a compartment which, under normal operating


conditions, shall not contain any conducting parts capable of entering into electrical
contact with the circuit-breaker poles. It shall be possible to connect all auxiliary wiring
from the front of the circuit breaker.

3.6.13.7 Mechanical indicators

Mechanical indicators on the front panel of the ACBs shall indicate the following status
conditions:

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1. "ON" (main contacts closed) Spring charged
2. "ON" (main contacts closed) Spring discharged
3. "OFF" (main contacts open) Spring charged – circuit breaker ready to close
4. "OFF" (main contacts open) Spring charged – circuit breaker not ready to close
5. "OFF" (main contacts open) Spring discharged

3.6.14 Protection / Control unit

3.6.14.1 General

The control unit shall be interchangeable on site for adaptation to changes in the
installation.

CT Sensors shall be non-magnetic or of the Rogowsky type for accurate current


measurements.

The control unit shall measure the true rms value of the current.

The control unit shall comprise a thermal memory to store temperature-rise data in the
event of repeated overloads or earth faults. It shall be possible to disable this function if
necessary.

3.6.14.2 Protection

The control unit shall offer the following protection functions as standard:

• Long-time (LT) protection with an adjustable current setting and time delay;
• Short-time (ST) protection with an adjustable pick-up and time delay;
• Instantaneous (INST) protection with an adjustable pick-up and an OFF position.
Current and time-delay settings shall be indicated in amperes and seconds respectively
on a digital display.

Earth-fault protection with an adjustable pick-up and time delay shall be provided for
incoming feeders.

3.6.14.3 Measurements

An ammeter with a digital display shall indicate the true rms values of the currents for
each phase.

A LED bargraph shall simultaneously display the load level on the three phases.

A maximeter shall store in memory and display the maximum current value observed
since the last reset. The data shall continue to be stored and displayed even after
opening of the circuit breaker.

Harmonic measurement/distortion in value and graph.

3.6.14.4 Maintenance

The last ten trips and alarms shall be stored in two registers that may be consulted locally
(date and time, type of fault or alarm).

Maintenance indicators shall be displayable on request on the front panel:

• Percent wear of contacts;

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• Operations counter.

3.6.15 Moulded Case Circuit Breaker (MCCB)

3.6.15.1 General

The moulded-case circuit breakers shall comply with BS EN 60947: Part 1 and BS EN
60947: Part 2 standards.

They shall be of category A with a rated service breaking capacity (Ics) equal to the
ultimate breaking capacity (Icu) on all the operational voltage range for the ratings up to
250 A, and up to 500 V for the greater ratings.

They shall have a rated operational voltage of 690 V AC (50 Hz/60 Hz),

They shall have a rated insulation voltage of 750 V AC (50 Hz/60 Hz).

They shall be suitable for isolation, as defined by IEC 60947-2, ; 7-27.

The moulded-case circuit breakers shall be available in fixed or plug-in/withdrawable


versions as well as in 3-pole and 4-pole versions. For plug-in/withdrawable versions, a
safety trip shall provide advanced opening to prevent connection and disconnection of a
closed circuit breaker.

The moulded-case circuit breakers shall be designed for both vertical and horizontal
mounting, without any adverse effect on electrical performance. It shall be possible to
supply power either from the upstream or downstream side.

The moulded-case circuit breakers shall provide class II insulation (according to IEC 664
standard) between the front and internal power circuits.

3.6.15.2 Construction, operation, environment

For maximum safety, the power contacts shall be insulated in an enclosure made of a
thermosetting material from other functions such as the operating mechanism, the case,
the trip unit and auxiliaries.

The operating mechanism of the moulded-case circuit breakers shall be of the quick-
make, quick-break type with fault tripping overriding manual operation. All poles shall
operate simultaneously for circuit breaker opening, closing and tripping.

The moulded-case circuit breakers shall be actuated by a toggle or handle that clearly
indicates the three positions: ON, OFF and TRIPPED.

In order to ensure suitability for isolation complying with BS EN 60947: Part 2 § 7-27, the
operating mechanism shall be designed such that the toggle or handle can only be in
OFF position (O) if the power contacts are all actually separated; in OFF position, the
toggle or handle shall indicate the isolation position.

Isolation shall be provided by a double break on the main circuit.

The moulded-case circuit breakers shall be able to receive a device for locking in the
"isolated" position, with up to 3 padlocks.

The moulded-case circuit breakers shall be equipped with a "push to trip" button in front
to test operation and the opening of the poles.

The circuit breaker rating, the "push to trip" button, outgoing circuit identification and the
contact position indication must be clearly visible and accessible from the front, through
the front panel or the door of the switchboard.

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3.6.15.3 Current limiting, discrimination, endurance

The moulded-case circuit breakers shall be capable of greatly limiting currents.

The moulded-case circuit breakers shall comprise a device, designed to trip the circuit-
breaker in the event of high-value short-circuit currents. This device shall be independent
of the thermal-magnetic or electronic trip unit.

The moulded-case circuit breakers, the current ratings of which are identical with the
ratings of their trip units, shall ensure discrimination for any fault current up to at least
35 kA rms, with any downstream circuit-breaker having a current rating less or equal to
0.4 times that of the upstream circuit-breaker.

The electrical endurance of the moulded-case circuit breakers, as defined by


BS EN 60947: Part 2 standard, shall be at least equal to 3 times the minimum required by
the standard.

3.6.15.4 Auxiliaries and accessories

It shall be possible to equip the moulded-case circuit breakers with a motor mechanism
for electrically controlled operation. An "auto/manual" switch in front shall, when set to the
"manual" position, lock out electrical control; remote indication of "manual" or "auto" mode
shall be possible.

• Closing shall take place in less than 80 m.


• Following tripping due to electrical faults (overload, short-circuit, earth fault),
remote reset shall be inhibited.
• It shall however be possible if opening was initiated by a voltage release.
The operating mechanism shall be of the stored-energy type only.

The addition of a motor mechanism or a rotary handle shall in no way affect circuit
breaker characteristics:

• Only three stable tripping mechanism positions (ON, OFF and TRIPPED) shall
be possible with the motor mechanism,
• Suitability for isolation shall be provided by positive contact indication (ON and
OFF) in front of the motor mechanism module.
The moulded-case circuit breakers shall be designed to enable safe on-site installation of
auxiliaries such as voltage releases (shunt and undervoltage releases) and indication
switches as follows:

• They shall be separated from power circuits,


• All electrical auxiliaries shall be of the snap-in type and fitted with terminal
blocks,
• All auxiliaries shall be common for the entire range,
• Auxiliary function and terminals shall be permanently engraved on the case of
the circuit breaker and the auxiliary itself,

The addition of a motor mechanism module or a rotary handle, etc., shall not mask or
block device settings.

It shall be possible to equip the moulded-case circuit breakers with devices indicating
faults without tripping the circuit breaker.

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3.6.15.5 General recommendations

Moulded-case circuit breakers with ratings up to 250 A shall be equipped with trip units of
either of two fully interchangeable types:

• Thermal-magnetic (thermal for overload protection and magnetic for short-circuit


protection)
• Electronic
Moulded-case circuit breakers with ratings over 250 A shall be equipped with electronic
trip units.

The trip units shall not augment overall circuit breaker volume.

Electronic trip units shall comply with Appendix F of BS EN 60947: Part 2 standard
(measurement of rms current values, electromagnetic compatibility and so on.).

All electronic components shall withstand temperatures up to 125°C.

Electronic and thermal-magnetic trip units shall be adjustable and it shall be possible to fit
lead seals to prevent unauthorised access to the settings.

Protection settings shall apply to all circuit breaker poles.

3.6.15.6 Thermal-magnetic trip units (up to 250 A)

Main characteristics:

• Adjustable thermal protection,


• fixed magnetic protection for current ratings up to 200 A
• Adjustable (from 5 to 10 times the current rating) for current ratings greater than
200 A.
It shall be possible to ensure neutral protection. The tripping threshold shall be equal to
that of the phases, or to a reduced value (generally half of that of the phases).

3.6.15.7 Electronic trip units

Characteristics:

• Long time protection (LT): Selectable Ir threshold with forty-eight settings from
40 to 100% of the trip unit rating
• Short time protection (ST): Im threshold shall be adjustable from 2 to 10 times
the thermal setting Ir, the time delay shall be fixed at 40 ms,
• Instantaneous protection: The threshold shall be fixed (between 12 and 19 times
In, depending on the rating)
• Four-pole devices shall be equipped with a 3-position setting for neutral
protection: Neutral not protected – neutral tripping threshold equal to half the
phase value – neutral threshold equal to the phase value.

Load monitoring function: The following monitoring functions shall be an integral part of
electronic trip units:

• LED for load indication, lit above 95% of Ir, flashing above 105 % of Ir
• A test connector shall be installed for checks on electronic and tripping
mechanism operation using an external device.

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3.6.15.8 Universal electronic trip units (above 400 A and greater)

Characteristics

• Long-time protection (LT) :


– selectable Ir threshold with thirty-two settings from 40% to 100% of the trip
unit rating
– adjustable time delay
– the breaking threshold shall be at 1,2 Ir and the no-breaking threshold after
2 H at 1,05 Ir,

• Short time protection (ST)


– Im threshold shall be adjustable from 2 to 10 times the thermal setting Ir,
– the time delay shall be selectable among 3 values, with or without the
constant I2t function.

• Instantaneous protection threshold adjustable from 1.5 to 11 times In.


– four-pole devices shall be equipped with a 3-position setting for neutral
protection (neutral not protected, neutral tripping threshold equal to half the
phase value, neutral threshold equal to the phase value),

• Thermal memory
– in the event of repeated overloads, the electronic trip unit shall optimise
protection of cables and downstream devices by memorising temperature
variations.

Load monitoring function: A load monitoring function shall be an integral part of universal
trip units, indicating four load levels (60%, 75%, 90% and 105%) by LEDs, (flashing LED
for 105%)

• options
It shall be possible to install all options for the electronic trip unit without increasing the
circuit breaker volume; options include:

– High-threshold earth-fault protection,


– Load monitoring with adjustable threshold using a changeover switch,
– LEDs in front to indicate the cause of tripping (long time, short time,
instantaneous, earth fault if requested),
– Data transmission via a BUS, in particular all the trip unit settings, current
measurements for each phase, tripping causes, circuit breaker status.

3.6.16 Miniature Circuit Breakers (MCBs)

Miniature circuit breakers (MCB) as per the current ratings and breaking capacity as shown
on the drawings shall be provided in the distribution board. The MCB shall be suitable for
operating at temperature ranging between - 10ºC to + 60ºC ambient and calibrated at least
at 30ºC ambient. Wherever required and applicable, the MCB shall be suitably de-rated as
per manufacturer recommendations.

Miniature circuit breaker (MCB) shall comply with the applicable IEC standards. The MCB
shall have a rated operational voltage of 240 V/415V AC, 50 Hz as defined by IEC
standards.

The MCB shall be modular, compact and din rail mounted design. The MCB shall be easy
clip on type and shall fit on to the standard din rail or to the purpose made brackets inside
the distribution board. The MCB shall be easily removable from the busbar without
disturbing the adjacent installed MCB in the distribution board.

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The MCB shall be available in 1-pole, 2-pole, 3-pole and 4-pole versions. The physical
dimensions of the MCB (within its own version) shall be same for all MCB rating ranging
from 1 A to 63 A and for all breaking capacities up to 15 KA for interchangeability and
standardization purpose.

The operating mechanism of MCB shall be mechanically trip free from operating toggle so
as to prevent the contacts from being held closed against short circuit conditions. MCB
shall be of automatic resetting type. All poles of the MCB shall operate simultaneously for
closing, opening and tripping. The individual operating mechanism of each pole of a multi
pole MCB shall be directly linked within the MCB casing and not only by the operating
handles.

The MCB shall be actuated by toggle. The isolation function shall be certified by tests
guaranteeing the mechanical reliability of the position indication system, the absence of
leakage currents and over voltage withstand capacity between the upstream and
downstream connections. Isolation shall be with positive break indication. The MCB shall
be able to receive a device for locking in the isolated position. It shall not be possible to
padlock the circuit breaker unless the power contacts are open. The number of operation
cycle (0-C) of the MCB shall be at least equal to 20,000.

The MCB shall be provided with bi-metal thermal and magnetic element on each individual
pole and shall combine the functions of protection of circuits against overload currents and
short circuit currents. The MCB shall also perform the function of isolation. With addition of
certain accessories to the MCB, it shall be possible to perform the functions of control and
protection of persons against indirect contact.

The MCB shall be designed for both vertical and horizontal mounting, without any adverse
effect on electrical performance. It shall be possible to supply power either from upstream
or downstream side. The circuit breaker shall ensure discrimination with the upstream
MCCB in an installation. The MCB shall have a limitation Class 3 as per IEC standards.

Wherever the fault level at the distribution board is less than 6KA the minimum ultimate
breaking capacity of the MCB shall be 6 KA as per BS EN 60898 or 10 KA as per BS EN
60947: Part 2.

The operating range of magnetic release of the MCB shall be classified as C tripping curve
as defined in IEC standards. Unless specified otherwise, the MCB shall be suitable for
protecting the cables feeding the conventional loads. The magnetic release operating
range of the MCB shall be between 5 In to 10 In and shall be of Type: C curve as per IEC
standards.

The MCB shall be designed to enable safe on-site installation of various auxiliaries such as
shunt release, under voltage release and fault trip/on–Off indication switches where ever
required. It shall be possible to fit all the auxiliaries on to a MCB. All the auxiliaries shall be
of the snap-in type and fitted with terminal blocks matching the MCB design and finish. All
the auxiliaries shall be common for the entire range.

Front face of the MCB shall clearly print marked with manufacturer name, model/type,
current rating, tripping curve type, voltage rating, breaking capacity and the standard to
which the MCB complies with. The standard symbol/circuit diagram of the MCB shall be
also be print marked on the front face.

MCB shall be provided with a permanent label to indicate the on/off positions, which shall
be print marked on each MCB toggle.

The MCB terminals shall be designed to fit directly on to the manufacturer’s distribution
board busbars on one end and to facilitate easy termination of power cables on the other
end. The MCB terminals shall be of tunnel terminals and shall easily accept up to 16 mm²
flexible cables up to 25 A MCB rating and up to 25 mm² flexible cables for 32 A to 63 A
MCB ratings.

Page 102
3.6.17 Earth Leakage Circuit Breaker (ELCB)

Earth leakage circuit breakers (ELCB) as per the current ratings and sensitivity as shown
on the drawings shall be provided in the distribution board. The ELCB shall be suitable for
operating at temperature ranging between - 10ºc to + 60ºC ambient and calibrated at least
at 40ºC ambient. Wherever required and applicable, the upstream protection device of the
ELCB shall be selected taking in to account the manufacturer de-rating factors as per the
ambient temperature.

The earth leakage circuit breaker (ELCB) shall comply with the applicable IEC standards.
The ELCB shall have a rated operational voltage of 240 V/415V AC, 50 Hz as defined by
IEC standards.

The ELCB shall be modular, compact and din-rail mount design. The ELCB shall be easy
clip on type and shall fit on to the standard din rail or to the purpose made brackets inside
the distribution board. The ELCB shall be of matching design with the manufacturer MCB.
The ELCB shall be easily removable from the busbar without disturbing the adjacent
installed switching devices in the distribution board.

The ELCB shall be available in 2-pole and 4-pole versions. The physical dimensions of the
ELCB (within its own version) shall be same for all ELCB rating ranging from 25 A to 125 A
for interchangeability and standardization purpose.

There shall be a test button on the front face of the ELCB to test the earth leakage trip
function. The test trip circuit shall be electrically operated.

Residual current release of the ELCB shall be an electromagnetic device operating without
any auxiliary source of supply. ELCB shall be of automatic resetting type. All poles of the
ELCB shall operate simultaneously for closing, opening and tripping. The ELCB shall be
protected against nuisance tripping due to transient over voltages.

The ELCB shall be actuated by toggle. The operating toggle shall be on the first pole of the
ELCB for both 2-pole and 4-pole version. The isolation function shall be certified by tests
guaranteeing the mechanical reliability of the position indication system, the absence of
leakage currents and over voltage withstand capacity between the upstream and
downstream connections. Isolation shall be with positive break indication. The number of
operation cycle (0-C) of the ELCB shall be at least equal to 20,000.

The ELCB shall be provided with an electromagnetic device for residual current release
and shall combine the functions of control and automatic breaking of a circuit against an
insulation fault that occurs between the phase & earth. The ELCB shall also perform the
function of isolation. With addition of certain accessories to the ELCB, it shall be possible
to perform the functions of control.

The ELCB shall be designed for both vertical and horizontal mounting, without any adverse
effect on electrical performance. It shall be possible to supply power either from upstream
or downstream side.

The ELCB shall be available in ratings from 16 A to 125 A and the sensitivity range from
30 mA to 300 mA without any change in dimension or appearance. The ELCB sensitivity
shall be of fixed type. Unless specified otherwise, the ELCB at the main incoming circuit of
the distribution board shall be 100 mA sensitivity. Unless specified otherwise, the ELCB
shall be instantaneous release type. Wherever discrimination with a downstream ELCB is
required, the ELCB shall be with selective release.

The ELCB shall be designed to enable safe on-site installation of various auxiliaries such
as shunt release, under voltage release and fault trip/on–off indication switches where ever
required. It shall be possible to fit all the auxiliaries on to an ELCB. All the auxiliaries shall
be of the snap-in type and fitted with terminal blocks matching the ELCB design and finish.
All the auxiliaries shall be common for the entire range.

Page 103
Front face of the ELCB shall clearly print marked with the manufacturer name, model/type,
current rating, sensitivity rating, voltage rating and the standard to which the ELCB
complies with. The circuit diagram of the ELCB shall be also print marked on the front face.
The ELCB shall be provided with a permanent label to indicate the on/off positions, which
shall be print marked on the ELCB toggle There shall also be mechanical indicator on the
front face of the ELCB to indicate the residual current fault trip.

The ELCB terminals shall be designed to fit directly on to the manufacturer’s distribution
board busbars on one end and to facilitate easy termination of power cables on the other
end. The ELCB terminals shall be of tunnel terminals and shall easily accept up to 35mm²
flexible cables.

3.6.18 Motor Starters

Each starter shall comply with BS EN 60947 and unless otherwise specified shall be class
12 utilisation category AC3.

The type and special requirements of each starter is detailed in the Particular Specification.

The arrangement of components, terminals etc., shall be identical in each type of starter.

The minimum size of mounting plate for direct on line starters shall be 0.225 m2 if
terminations are not included within the back plate area. If termination is included on the
2
back plate the size shall be 0.25 m .

The minimum size of mounting plate for star/delta starters shall be 0.27 m2 if terminals are
2
not included within the back plate area, or 0.3 m for other designs.

Motor starting contactors for reversing, star/delta, auto transformer, etc., shall be
mechanically and electrically interlocked.

A timer system shall be provided in the control section of the MCC to ensure that no two
motors start simultaneously under all operating conditions and particularly following a
power failure. The timer system shall allow the duty motors to start or be started in the
relevant duty sequence, prior to all other motors becoming available for start. Time period
between motor starting or becoming available for starting shall take into account the
method of starting of the motor.

All components, i.e. relays, contactors, timers, controllers, etc., shall be identified within the
panel by indelible labels relating them to the schematic diagrams.

Starter sections shall be separate from the control sections where possible.

Motor starters shall include the following items, in the quantities indicated:

1 no. Suitably rated lockable MCCB and bolted neutral link, with magnetic and thermal
overload, interlocked with the section door closed in both the ON and the
padlocked OFF positions.

1 no. Suitably rated direct on line or assisted starting system.

1 no. Set of power factor correction capacitors and protection fuses, if required. See the
Particular Specification for details of the operational requirements.

1 no. Anti-condensation heater, thermostat, fuse and link, through auxiliary contacts of
the main contactor.

1 no. Overload protection.

1 no. Thermistor protection unit are required for all motor-pump sets..

Page 104
1 no. Set of main and auxiliary terminals and a 15% spare capacity.

1 no. Suitably rated 72 mm by 72 mm 90° scale door mounted ammeter with upper scale
compressed for motor starting.

1 no. Door mounted hours run meter, non re-settable type, to 99,999.9 hours.

3 no. Door mounted indicating lamps for Running, Stopped and Tripped.

4 no. Door mounted push buttons to read Start, Stop, Reset and Lamp Test.

1 no. Door mounted control selector switch, see Particular Specification for details of
requirements.

1 no. Motor heater fuses and links.

1 no. Facility in starter for automatically switching heater OFF when motor starts and ON
when motor stops.

1 no. Control supply isolating fuse and links.

3.6.18.1 Types of ac Starters (up to and including 1,000 V AC)

For motors up to 3.75 kW

Direct on Line:

Direct on line starters shall be used complying with BS EN 60947: Part 4, and unless
otherwise specified shall be intermittent duty class 12. The utilisation category shall be
AC3

For motors with a rating of 4 kW and up to 55 kW either:

• Star Delta Starters:

Star delta starters shall be used complying with BS EN 60947: Part 4, and unless
otherwise specified shall be intermittent duty Class 12. The utilisation category shall be
AC3.

The starter shall be complete with sufficient steps to meet the required minimum
starting/pull-out torque of the drive, and any restrictions imposed by the Electricity
Distribution Directorate.

The duty unless otherwise specified shall be intermittent Class 0.1, and utilization
category AC3.

For motor ratings of 55 kW and above the type of starter shall be subject to the approval
of the Engineer. For most applications either soft starts or variable speed drives shall be
used. For loads with a high starting torque, for example, blowers, alternative methods of
starting will be considered for approval by the Engineer subject to the agreement of the
Electricity Distribution Directorate.

• Soft Starters (Thyristor Controlled)

The starter shall be suitable for the intermittent duty, detailed in the Particular
Specification, and to meet the minimum starting/pull-out torque of the drive, together with
any restrictions imposed by the Electricity Distribution Directorate.

The starter shall provide both soft start and soft stop features from auto or hand controls
as specified. Emergency stops shall stop the drive immediately.

Page 105
The ramp time (time required for controller to reach full volts) shall be adjustable.

Thyristors shall have a minimum of 1,200 VRRM, and for starters up to 30 kW thermal
motor overload protection shall be fitted as a minimum. Starters 30 kW and above shall
be fitted with semi-conductor type fuses and electronic overloads suitable for use with
thyristor controlled circuits.

The thyristor stack shall be fitted on a suitable heat sink. The heat sinks shall be
designed to provide sufficient cooling at the maximum ambient temperature without the
use of forced ventilation.

Where specified, the starter shall be fitted with an energy saving feature. This system
shall provide energy optimisation when the motor is operating at no load or part load, by
automatically reducing the applied voltage and hence losses, without reduction in
performance. This system shall be provided with a manual by-pass switch, which will
revert control to a standard soft start/stop system. The thyristor stack heat sink on this
type of starter shall be fitted with a temperature sensor, which shall automatically shut
down the unit in the event of a pre-determined temperature being exceeded. This sensor
shall also light the failed lamp on the face of the starter.

Starters shall incorporate a by-pass contactor for the thyristor stack, this shall
automatically by-pass the thyristor stack when the drive has ramped up to full speed.

• Variable Speed Drives

Variable speed drives shall be of the AC inverter type based on the pulse width
modulation principle of operation, capable of controlling the speed, torque and current of
standard AC squirrel cage motors.

Inverters shall be selected to ensure that the harmonics generated within the system are
within the limits allowed for the system and do not cause interference with plant or
equipment connected to the system. Generally, drives rated at 100 kW and over shall, as
a minimum, be twelve pulse type. However, priority of the number of pulses shall be as
per project specification. The installation and equipment shall be designed to limit or
avoid harmonics as opposed to employing harmonic filtering.

The compartment housing the variable speed control equipment shall also include an
inverter fault lamp and frequency meter.

Each variable speed drive shall be equipped with an independent air conditioning unit.
The unit shall take in air from the sub station housing the starter and the exhaust air shall
be discharged outside of the building.

3.6.18.2 Isolation of Starters

Each starter shall be provided with a moulded case circuit breaker which shall be
interlocked with the door or cover of the starter. The MCCB shall be complete with
auxiliary contacts to isolate all incoming electrical supplies to the starter.

The control circuit supply shall be wired through a pushbutton unit inside each starter, to
enable this supply to be energised with the access door open, for test purposes by
releasing the pushbutton. Closure of the starter door shall automatically reset the
pushbutton. This pushbutton shall be operable in all modes of control.

Where starters are supplied from separate fuses or MCBs within a distribution board the
means of isolation within the starter shall comprise a fully shrouded isolator. If MCBs are
used they shall be complete with an auxiliary contact to isolate the control circuit supply.
If separate fuses are used, the control circuit supply shall be from independent
transformers in each section.

Page 106
3.6.18.3 Contactors

Contactors shall be triple pole, air break with inherent no volt release to BS EN 60947
class 12, utilisation category AC3, and be complete with a minimum of one set of spare
auxiliary changeover contacts.

Motor starting contactors for reversing, star/delta, auto transformer, and so on, shall be
mechanically and electrically interlocked.

3.6.18.4 Protection

The combination of fuse, contactor and overload relay used shall be demonstrated to be
compatible to the approval of the Engineer.

Motor starter circuits shall incorporate as a minimum a thermal overload protection relay
with inherent single phasing protection. The relay shall be adjustable and shall bear
calibration in terms of motor full load current.

The motor protection shall be generally as detailed below, any variation to this will be
detailed in the Particular Specification.

Motors below 30 kW - Thermal overload


Motors 30 kW and above - Electronic type overload units suitable for use with
soft start units where applicable.

Auxiliary contacts shall be used to provide indication, and a minimum of one set of spare
volt free changeover contacts shall be included.

Overload relays shall be manually reset by means of an over current reset button,
coloured black in accordance with BS EN 60073, mounted on the face of the starter
section. This reset button shall electrically reset the overload relay.

3.6.18.5 Control Selection Switch

Selection switches shall be as detailed in the Particular Specification. The following


terminology shall apply:-

LOCAL - Local to selection switch


MANUAL - Manual controls adjacent to the drive
AUTO - Control from automatic controls
OFF

Manual operation shall override all automatic controls except those provided for the
protection of the drive.

Stop/Start push buttons shall be provided to operate Plant in Local mode. Stop/lock push
button shall be provided to stop the plant at remote locations/local to equipment.

Control selector switch shall be key-operated type.

3.6.18.6 Hours Run Counters

Hours run indicators shall be non re-settable flush mounted, six digit, synchronous type.

3.6.18.7 Pushbuttons

Start pushbuttons shall be coloured green and shall only be effective in selected circuits,
primarily hand control circuits.

Stop pushbuttons shall be coloured red and shall only be effective in selected circuits,
primarily hand control circuits.

Page 107
Emergency stop buttons shall be mushroom head, lock stop type, coloured red and shall
be effective at all times irrespective of the position of the selection switch associated with
that drive.

Overload re-set buttons shall be coloured black and lamp test push buttons are to be
coloured yellow.

3.6.18.8 Telemetry

Unless specified in the Particular Specification, each starter shall provide the following
telemetry signals as volt free contacts:

Motor Run/Stop/Start
Motor Failed/Normal
Motor Auto available/Auto not available

The signals from all starters shall be wired to a terminal strip in the telemetry section.

3.6.19 Outgoing Feeders

Feeder sections shall be provided with door interlocked moulded case circuit breakers.

The circuit breakers shall be complete with electronic over current and earth fault
protection. Under voltage relays shall not be provided with these circuit breakers.

A single phase ammeter and CTs shall be provided on the dead side of each circuit
breaker.

3.6.20 Fuses

Switchgear and fuse boards shall be fitted with fuse carriers designed to accept HRC
cartridge type fuses to BS 88 Class Q1, and shall be of the bolted type.

Fuses for motor circuit protection shall be to category of duty 415 AC 80.

Fully isolated fuse holders and neutral links shall be fitted inside enclosures where
required, and sufficient space for easy withdrawal shall be provided. Holders containing
links shall be coloured white, whilst those containing fuses shall be coloured black.

Labels shall be provided giving the circuit identification and the fuse rating.

Three fuses of each rating used within the installation shall be provided as spares. These
fuses shall be securely clipped on the inside of the door of the distribution board
enclosure.

3.6.21 Indicating Instruments

3.6.21.1 General Requirements

Indicating instruments (other than motor ammeters) installed on MCC’s shall be of square
form (96 mm square bezel 150 mm scale length) to comply with DIN 43802 and other
DIN based international standards, with voltmeters and ammeters having full scale
deflections of approximately one and a half times normal working indication.

The performance shall comply with BS 89 with a minimum accuracy class of 2.5.

3.6.21.2 Motor Ammeters

Motor ammeters shall be of square form to comply with DIN 43802 and other DIN based
International standards.

Page 108
The meter shall read true motor current independent of power factor correction.

The instrument shall be suitably scaled in amps such that full load running current is
approximately three-quarter scale, with 6 times overload figured for motor starting.

The following sizes of ammeter shall be fitted:

The ammeter shall be 72 mm square bezel, 65 mm scale - starter compartments of up to


1 m high.

3.6.22 Current Transformers

Current transformers shall be ring type air insulated having short-circuit ratings not less
than those of the associated circuit and shall comply with BS EN 60044: Part 1,
IEC 60044: Part 1.

The secondary windings of the current transformers shall be earthed.

3.6.23 Power Factor Correction

Where specified in the Particular Specification, multistage capacitor bank Power Factor
correction for the total of the panel shall be incorporated. This shall be provided within a
separate cubicle to improve the Power Factor within the limits specified. Capacitors shall
comply with BS 1650, and suitably rated fuses shall also be included.

PCB dielectrics shall not be used. Capacitors shall be of dry type, with very low losses
and to be of long life self heating type.

Capacitors shall be equipped with discharge resistors and shall be of fire protection
material.

Any power factor correction shall be disconnected automatically on connection of any


Standby Generation as a supply.

3.6.24 Labels

Items of equipment, that is, isolators, starters, distribution boards, junction boxes, timers,
fuses, and so on, shall be clearly labelled to correspond with the appropriate schematic or
wiring diagram.

Labels shall be fixed to equipment prior to any testing being carried out.

Labels shall be manufactured from the following materials:

• 3 mm thick black/white/black laminate with engraved 5 mm high lettering.

Internal labels must be visible at all times and must not be obscured by panel wiring, and
so on.

Warning labels shall be engraved to give black letters on a yellow background, and be
preceded by the lightning flash symbol in accordance with BS 5499.

Internal Labels shall be fixed with round or cheese head stainless steel screws. Self-
adhesive labels will not be accepted. External control panel labels shall be fitted with
black plastic rivets.

Internal labels designating components shall be fixed to non-removable equipment.

3.6.25 Indicating Lamps

3.6.25.1 Types of Indication Lamps

Panel indicators shall be transformer type, having lamps rated at least 6 V 1 W, or

Page 109
alternatively powered from a voltage of not greater than 48 V. The lamps shall be
adequately ventilated and arranged for easy removal of the lamp from the front of the
panel without the use of special tools.

The lenses shall be toughened plastic.

Lamps shall be provided with a testing facility.

3.6.25.2 Indication Lamp Colours

The colours of lamps shall normally comply with the requirements of BS EN 60073 thus:

WHITE - Ready or Power Supply Available (that is, the plant is capable of being
run; interlocks, and so on, are made, for example, Supply on, Ready to
Run, Stopped, Closed).

GREEN - System Stopped/Off/Normal Condition

AMBER - Abnormal Plant Condition (that is, action may be required by the
operator. May be used as a first stage alarm when Red used as second
stage alarm).

RED - System Running/On/Normal Condition

BLUE - Other Functions - as specified.

3.6.26 Stop-lock Off/Isolation

A stop-lock off pushbutton switch or fault make/load break switch shall be provided
adjacent to each electric motor for isolation.

The plant shall not restart until the stop-lock off pushbutton has been released and the
system reset at a remote position.

3.6.27 kWhr Meters

3.6.27.1 General

Where Specified in the Particular Specification, incoming circuit breaker compartments


shall be fitted with a kWhr power consumption meter complete with all ancillary
components and wiring.

kWh meters shall operate from a 415 V/240 V, 3-phase, 4-wire, 50 Hz supply via suitably
rated CTs with a 5 A-rated secondary. Meters shall comply with BS EN 62053: Part 11 or
equivalent international standard. KWh meter shall also record the maximum demand.

The meters shall be dust and vermin proof.

The meters shall be compensated for ambient temperatures up to 50ºC.

No creeping shall take place due to variations to the extent of ± 10% of the rated voltage.

The voltage coils shall be of insulated windings contained in a pot type housing made of
plastic material filled with epoxy resin. The voltage coils shall be designed for 415 V
±10%.

Current coils shall be high quality insulated copper wire accommodated in a thermoplastic
housing. The coils shall not be damaged if 1.8 times the rated load is applied.

The meter dial shall be digital with roller type registers. The dial shall have six digits for
direct reading of power consumption up to six figures. Calibration adjustments shall be

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simple and fully detailed in the Operation and Maintenance Manuals to be provided by
the Contractor.

The meters shall be of the totally insulated pattern, with facilities for sealing the terminals
of the wire and lead seals. All terminals shall be tinned brass, rotor and spindle shall be
anodised aluminium. The rotor shall be magnetically or double jewel suspended.

3.6.27.2 Rating and Accuracy

The meters shall be mounted such that they can be viewed without opening the panel
compartment door. All digits shall be clearly visible when viewed from outside of the
panel.

The meters shall be capable of carrying 400% of the rated current without damage or loss
of accuracy.

The meters shall be suitable for unbalanced loads, the minimum starting current shall be
less than 5% of the rated current.

The accuracy of the meters shall be in the range as below:

Table 3 – Accuracy of Meters


Load Current Power Factor Accuracy

25% – 125% of rated current Unity ± 1%


10% – 25% of rated current Unity ± 2%
25% –e 125% of rated current 0.5 ± 2%

Outside of these ranges the errors shall not exceed ± 3 %. Calibration adjustments shall
give a span of ± 3%.

3.6.27.3 Nameplates

The following information (in English) shall be clearly shown on the nameplates of each
meter.

Voltage Rating
Current Rating
Type and Make of Meter
Country of Origin
Frequency
Meter Serial Number
Meter Constant
Year of Manufacture

3.6.28 Current Transformers (CTs)

CTs shall conform to BS EN 60044: Part 1, IEC 60044: Part 1 or equivalent international
standard. The accuracy shall be 0.5 and rated burden shall be such that 150 % of the
burden of all connected loads can be carried indefinitely without damage. The minimum
rated burden shall not be less than 5 VA.

CTs shall be of the ring type resin insulated, and shall be suitably rated for the duty. The
CTs shall not be damaged due to through fault conditions.

CTs are to be located on the load side of each incoming mains power circuit breaker.

3.6.28.1 Type and Routine Tests

Type and routine tests shall be carried out as required by the relevant British Standard or
international equivalent standard, and a test certificate issued with each meter.

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Meters and CTs shall be recalibrated after installation of the MCCs, and calibration
certificates shall be provided in accordance with the specification.

4. PART 4 CONTROL AND INSTRUMENTATION

4.1 Control Circuits and Equipment

4.1.1 Control Voltage and Power Supplies

Control circuit voltages shall be 110 V AC for use within the control panel. For control
circuits external to the control panel 24 V/110 V AC according to the service shall be
used, suitable interfaces shall be provided between the two systems.

Suitably rated step down transformers, conforming to BS EN 61558: Part 2-23,


IEC 61558: Part 2-23, shall be used to provide the 24 V AC control supply.

The control supply shall be rated for the starters specified, with a 20% excess capacity.
Both primary and secondary circuits of the control transformers shall be protected by
suitable HRC fuses or Mob’s.

Isolation of a control circuit supply to one or a group of starters shall not interrupt supplies
to other starters.

Suitably rated HRC fuses or Mob’s and neutral links shall be fitted in each starter/control
section.

4.1.2 Type of Control

Electrical control functions shall be achieved using a programmable controller system.

PLCs

Programmable controllers shall be complete with input/output modules, interface


modules, sequencer units, power supply, etc. All PLCs supplied shall be from one
manufacturer and shall have interchangeable input/output and interface modules. They
shall all use the same programming language and programming tools.

The Contractor shall supply one off hand held programmer complete with leads and
accessories and one off software package for programming via a PC compatible
computer. The software shall be fully licensed for use by the Employer.

Any RAM memory shall be protected by suitable batteries to provide a minimum of


24 hours’ back up in the event of power failure. A "Battery Low" indication lamp and
telemetry alarm signal shall also be provided.

Indication of status of I/O shall be provided by LEDs on the face of the module, which
shall be visible from outside the panel.

A printed schedule on a non-combustible or plastic encapsulated sheet showing details of


each I/O, shall be permanently fixed adjacent to the system, or within the panel.

A minimum of one spare input and one spare output unit of each type used shall be
provided.

DIN rail mounted hinge link terminal strips for input and output signals, including spares,
shall be provided down both sides of the programmable controller. Where output relays
are required, these shall be incorporated with the terminals in one DIN rail mounted unit.

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The programmable controller shall be used to control the plant in the auto mode only.
Manual circuits shall be hard wired to ensure effective operation of the plant if the PC
fails.

Emergency signals shall be hard wired with repeat signals to the PC.

The motor failed output shall be initiated from the motor overload and from a call to run
and not running signal. This shall be reset by a pushbutton mounted on the face of the
starter.

4.1.3 Electromagnetic Equipment

Relays and timers shall be identified in accordance with Clause 3.21.1.

Where AC and DC voltages are present, it shall not be possible to insert AC relays into
DC sockets or DC relays into AC sockets.

Plug in units shall be retained by a spring clip.

Relays shall be provided with a means of visually determining their state.

Timers shall have linearly calibrated scales marked in units of time, with each scale
division being a maximum of 5% of full scale. Alternatively the positions may be labelled
A, B, C, and so on, and a label designating the time scale fitted under the timer.

Timers mounted on the front of the panel shall be flush pattern.

4.1.4 Telemetry Requirements

Space shall be made available within control panels, cubicles, and so on, for installation
of telemetry equipment as detailed in the Particular Specification.

Signals, for which details will be provided in the Particular Specification, shall be wired
from independent voltage free changeover contacts, that is, no shared common
connections, in respective relays to a set of hinged link terminals within the telemetry
section. These terminals shall be fitted adjacent to but not within the space detailed for
the telemetry equipment. Ten (number) or 10% (whichever is the greater) spare terminals
shall be provided.

The sense of telemetry signals shall be as follows:-

Running – contact closes when drive is running.


Stopped – contact opens when drive stops.
Alarm or fault – contact opens when a fault or alarm condition occurs.
Duty – contact closes when required duty is selected.

Analogue signals shall be fully isolated using loop isolators.

4.1.5 Power Supply Failure, Automatic Restart

Control circuits shall be arranged so that on the restoration of power after a disruption of
the supply, equipment under automatic control and equipment operating under manual
control that is required to run continuously and has been running will re-start
automatically. The restarting of plant items shall be phased to ensure that the maximum
electrical demand does not exceed the value stated in the Particular Specification or
Schedule.

4.1.6 Lightning Protection

Lightning protection shall be provided for control and instrumentation equipment where
light current circuits and components would be damaged by electrical surges in either
signal or power circuits.

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Lightning protection units shall be mounted external to the main panel unless a special
boxed section is provided containing a separate earthing busbar which is in turn
connected to the separate lightning protection earth.

4.2 Instruments General

The process P&I drawings will indicate the requirements and locations of instrumentation
necessary to control and monitor the plant. Further detail will be found in the Particular
ICA Specification.

4.2.1 Accuracy

The intended use of a measured value will determine the accuracy requirement. Those
instruments whose measured values are used directly by an automated control system
will demand accuracy (± 0.5% of span). Instruments that measure values used by
operators to monitor the process but do not directly control the process may be of
accuracy (± 1.0% of span). Where instruments are provided purely for display, these may
be low accuracy (± 5.0% of span). Accuracy for particular instrument types will be
specified in the relevant sections below.

The method or location of installation can have a major effect on the accuracy of the
measurement generated by any instrument. All instruments shall be installed in
accordance with the instrument manufacturers’ installation requirements.

4.2.2 Repeatability

Repeatability is defined as the ability of the system to reproduce output readings when
the same measurement is made under the same conditions and in the same direction. It
is thus a measure of consistency of measurement.

A highly accurate instrument will give highly repeatable measurements, however an


instrument which gives highly repeatable measurements may not give accurate
measurements. All instruments, regardless of accuracy, shall be required to give
repeatable measurements.

Repeatability for all instruments provided shall be ±1.0%.

4.3 Level Instruments

4.3.1 Ultrasonic Level Detectors

Ultrasonic level detectors shall be used for most situations where a continuous level
measurement is required. The ultrasonic level detector system shall comprise a
transducer, a separate transmitter unit and an interconnecting cable, operating on the
time-of-flight principle.

The transducer shall be a non contact type suitable for continuous measurement of level.
The transducer shall be weather resistant and safe against submersion (IP 68), and shall
incorporate an integral temperature sensor to allow for temperature compensation of the
measured level. The transducer shall not be affected by the measured liquid and shall be
insensitive to dirt build-up. The transmitter shall support fixed target suppression (removal
of false echoes) and first echo recognition (for correct indication in spite of double
echoes).

The transmitter shall be microprocessor based with an integral operator interface housed
within a corrosion resistant enclosure. The operator interface shall have a numeric
display, bar graph display, and a simple push button interface. All error codes, process
variables, configuration data and other internal values shall be accessible and displayable
on the integral operator interface. It shall be possible to limit access to configuration data
parameters by means of a configuration password.

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The transmitter will be powered from a 110 V AC or 18 V to 30 V DC supply. Output shall
be by 4 mA to 20 mA current loop and shall be proportional to the measured value. A
digital output shall also be provided which shall be configured to generate an alarm in the
event that the level detection system fails.

The transducer shall have a blocking distance no more than 10% of the measurement
range and a 3 dB beam angle no wider than 10°. The system shall give a measurement
of ± 0.5% of the measurement span.

Units furnished shall be suitable for temperatures of - 3ºC to ± 60ºC.

The design and application of ultrasonic level meters shall take into account the vessel or
channel construction, the material, size, shape, environment, process fluid or material,
the presence of foam, granules, size, and so on.

4.3.2 Hydrostatic Level Detectors

There are situations where an ultrasonic level detection system may not be appropriate
due to the shape of a tank or a likelihood of foam or scum collecting on the surface. In
such situations, or where defined in the Particular ICA Specification, an hydrostatic level
detection system shall be used when a continuous level measurement is required. The
hydrostatic level detection systems shall comprise a transducer, a separate transmitter
unit and an interconnecting cable.

The transducer shall be a compact unit incorporating a resistive measuring element


suitable for continuous measurement of level. The transducer shall be suitable for
constant submersion, being hermetically sealed from outside influences such as
moisture, dirt, and so on. A cable of minimum length 10 m shall be provided pre-attached
to the transducer to support the transducer and provide a connection to the transmitter
which shall be mounted nearby. If a transmitter is located such that the cable length is
insufficient, a junction box may be used to extend the cabling in line with the
manufacturers’ documentation. Moisture filters shall be incorporated to prevent
condensation from forming in the atmospheric reference tube. The filter mechanism shall
not require use of any desiccant devices which need to be routinely replaced.

The transmitter shall be microprocessor based with an integral operator interface housed
within a corrosion resistant enclosure. The operator interface shall include a numeric
display showing the digital value and a bar graph showing a 0-100% representation and a
pushbutton interface. All error codes, process variables, configuration data and other
internal values shall be accessible and displayable on the integral operator interface. It
shall be possible to limit access to configuration data parameters by means of a
configuration password.

The transmitter will be powered from a 110 V AC or 18 V to 30 V DC supply. Output shall


be provided as a 4 mA to 20 mA signal proportional to the measured value. A digital
output shall also be provided which shall be configured to generate an alarm in the event
that the level detection system fails.

The sensor accuracy shall be ± 0.5% of measurement span, including the effects of
linearity, hysteresis, and repeatability. The sensor shall incorporate temperature
compensation directly at the sensor to reduce the inherent effects of temperature
changes on the sensor output. The sensor shall also be capable of withstanding an
overload pressure of up to ten times the measuring range without performance
degradation.

4.3.3 Sludge Blanket Monitor

Sludge blanket monitors shall be used to detect the depth of sludge within a settlement
tank, allowing operators to take remedial action before sludge levels become problematic.
The sludge blanket monitoring system shall comprise a transducer, a separate transmitter
unit and an interconnecting cable. Where the transmitter is located on a travelling bridge
assembly, a wireless connection to a fixed remote unit will also be required.

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The transducer assembly shall comprise the sensor and any mounting hardware required
to allow the sensor to operate correctly. The transducer shall be either:

• A submerged ultrasonic sensor operating on the sonar principle. The sensor shall be
fixed on a settlement tank bridge (travelling or fixed bridge assembly). Ultrasonic
pulses will be emitted by the sensor and reflected by the sludge blanket to the
sensor. The sensor shall incorporate a temperature sensor to compensate for
differences in speed of sound transmission. An air purge cleaning system shall be
provided.
• An optical suspended solid concentration sensor, suspended from a cable which
may be raised or lowered using a stepping motor and cable drum assembly. The
suspended solids concentration sensor should use a double beam pulsed light
technique. The system should automatically raise or lower the sensor until the
measured solids concentration matches a user define set point. The calculated
depth will then define the sludge blanket level.

The transmitter shall be microprocessor based with an integral operator interface housed
within a corrosion resistant enclosure. The operator interface shall have a numeric
display, bar graph display, and a simple push button interface. All error codes, process
variables, configuration data and other internal values shall be accessible and displayable
on the integral operator interface. It shall be possible to limit access to configuration data
parameters by means of a configuration password. In addition, the different sensing
mechanisms described above shall require certain specific transmitter features, as
described below:

• Transmitters for use with submerged ultrasonic sensors shall incorporate an air
compressor to provide compressed air to serve the sensor air purge cleaning
system.
• Transmitters for use with optical suspended solid concentration sensors shall
incorporate the control of the sensor raising/lowering mechanism.

In each case, the transmitter shall be bridge mounted. Where the bridge is a travelling
assembly, measurements shall be transmitted to a remote fixed location. Rotating bridge
slip rings shall not be used for the transmission of signals.

In either case, the transmitter will be powered from a 110 V AC or 18 V to 30 V DC supply


(which may be provided via rotating bridge slip rings). Output shall be by 4 mA to 20 mA
current loop and shall be proportional to the measured value. A digital output shall also
be provided which shall be configured to generate an alarm in the event that the level
detection system fails.

The system shall give a measurement of ± 1.0% of the measurement span.

4.3.4 Conductivity Probes

Conductivity probes shall be used to give point level measurements in vessels. These
may be used for control of simple applications, as backup control devices for a
continuous level instrument or to generate alarms.

A minimum of two electrodes are required, a metallic earth electrode which extends to the
lowest point in the vessel, and a level electrode. The metallic level electrode is set at the
desired switching point. When the liquid covers the tip of the electrode, an electrical
circuit is completed between the level electrode and earth electrode.

The electrodes and their fixings shall be manufactured of non corrodible metal, suitable
for intermittent submersion.

The control/switching unit shall be suitable for mounting within a control panel on DIN rail.
Output shall be volts free contact or open collector. Sensitivity shall be easily adjustable
to allow fine-tuning of the switching threshold.

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4.3.5 Float Switch

Float switches shall be used to give point level measurements in vessels. These may be
used for control of simple applications, as backup control devices for a continuous level
instrument or to generate alarms.

The float switch shall comprise a tilt switch housed within a sealed plastic bulb. When no
liquid is present, the bulb shall hang upright, supported by the instrument cable. The bulb
shall be buoyant and float on the surface of the liquid in the vessel, so that when the
liquid level rises, the bulb floats on the surface. As the bulb makes the transition from
hanging to floating on the liquid surface, the tilt switch inside shall operate.

The cabling shall provide cores for normally open and normally closed switching contacts,
allowing the float switch to be used to detect a rising level or a falling level.

4.4 Flow Instruments

The provision of flow meters shall require the instrument to be fitted in accordance with
the manufacturer’s recommendations and must include for: any reduction tapers
necessary to obtain suitable flow velocities past the detector heads; the detection of full
pipe where this may affect the reading; the requirement to provide minimum straight
lengths of pipe work up and down stream of the meter.

4.4.1 Electromagnetic Flow Meter

Electromagnetic flow meters shall be used for situations where a continuous volumetric
flow measurement of a conductive liquid in a closed pipe is required for control purposes.
The electromagnetic flow meter shall consist of a transducer and transmitter. The
transducer and transmitter may be a single integrated unit or separate units with an
interconnecting cable.

Operation shall be based upon Faraday’s law of induction which states that a voltage is
induced in a conductor moving in a magnetic field. The flowing liquid is the conductor,
and a constant magnetic field is generated by the sensor. The induced voltage is
measured by two electrodes in the transducer and is proportional to flow rate. Volumetric
flow is then calculated by the transmitter, based upon the diameter of the pipe in which
the transducer is installed.

The transducer body shall be provided with flanged connectors suitable to allow
connection to adjacent pipe work, and capable of withstanding temporary submersion for
up to 48 hours. Liner and electrodes shall be chosen to be compatible with the process
fluid. The meter body shall include grounding and empty pipe electrodes of the same
material as the measuring electrodes. The transducer shall incorporate a high impedance
amplifier, eliminating the need for electrode cleaning systems. Generation of the
magnetic field shall be by bipolar pulsed DC coil excitation. Power consumption shall be
no more than 15 VA, independent of transducer size.

The transmitter shall be microprocessor based and shall include an integral alphanumeric
display and a simple push button user interface. The display shall indicate flow rate
and/or total flow, and shall be capable of displaying messages indicating an instrument
failure, an empty pipe condition or flow below the acceptable minimum to give an
accurate measurement. The totalised value will be held in non-volatile memory such that
the totalised flow is not lost in the event of a power failure.

Input power required will be from a 110 V AC or 18 V to 30 V DC supply. Analogue and


pulse outputs shall be provided along with a digital output to indicate fault status. The
analogue output shall be by 4 mA to 20 mA current loop and shall be proportional to the
measured value. The pulse output shall be an open collector output. Fault status shall be
indicated by an open collector output, indicating system or process error, flow direction or
low flow (if enabled).

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The instrument shall give measurements at an accuracy of ± 0.5% of the measured
value.

All flow meters shall be calibrated and calibration certificates submit for each flow meter.

4.4.2 Ultrasonic Doppler Flow Meter

Ultrasonic Doppler flow meters shall be used for situations where a continuous volumetric
flow measurement of a liquid containing solids in a closed pipe is required for monitoring
purposes. The ultrasonic Doppler flow meter shall consist of a transducer and transmitter.
The transducer and transmitter will be separate units with an interconnecting cable.

The transducer shall be an inline unit, supplied with a wetted sensor installed in a flanged
section of pipe. The transducer shall emit ultrasonic signals into the pipe which will strike
solids carried by the liquid flow, deflecting the ultrasonic signals back to the transducer.
The deflection will cause the received signals to be frequency shifted, the frequency shift
being proportional to the flow rate.

The transmitter shall be a microprocessor based unit with an integral operator interface
housed within a corrosion resistant enclosure. The operator interface shall have a
numeric display, bar graph display and a simple push button interface. All error codes,
process variables, configuration data or other internal values shall be accessible and
capable of being displayed on the integral operator interface. It shall be possible to limit
access to configuration data parameters by means of a configuration password.

The transmitter will be powered from a 110 V AC or 18 V to 30 V DC supply. Output shall


be by 4 mA to 20 mA current loop which shall be proportional to the measured value. A
digital output shall also be provided, configured to generate an alarm in the event of a
system failure, and a total flow pulse output.

The measurement system shall give a measurement accurate to ± 1% of the measured


value.

4.4.3 Ultrasonic Transit Time Flow Meter

Ultrasonic transit time flow meters shall be used for situations where a continuous
volumetric flow measurement of a liquid containing no solids is required for monitoring
purposes. The ultrasonic transit time flow meter shall consist of a transducer and a
transmitter unit with interconnecting cabling.

The transducer shall be an inline unit, supplied with a pair of wetted sensors installed in a
flanged section of pipe. The sensors shall be located such that the signal path is diagonal
across the pipe, passing through the central axis of the pipe. Each sensor shall emit
ultrasonic signals across the pipe which will be received by the opposing sensor. Due to
the sensor location, the two signal paths shall differ. In one direction, the ultrasonic
signals shall be travelling in the direction of liquid flow, whilst in the other direction, the
ultrasonic signals will be travelling against the direction of liquid flow. The flow rate shall
be calculated from the difference in transit time between the two signal paths.

The transmitter shall be a microprocessor based unit with an integral operator interface
housed within a corrosion resistant enclosure. The operator interface shall have a
numeric display, bar graph display and a simple push button interface. All error codes,
process variables, configuration data or other internal values shall be accessible and
capable of being displayed on the integral operator interface. It shall be possible to limit
access to configuration data parameters by means of a configuration password.

The transmitter will be powered from a 110 V AC or 18 V to 30 V DC supply. Output shall


be by 4 mA to 20 mA current loop which shall be proportional to the measured value. A
digital output shall also be provided, configured to generate an alarm in the event of a
system failure, and a total flow pulse output.

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Accuracy of the measurement system shall be ± 1% of the measured value. This may be
achieved by the use of additional sensor pairs in the transducer unit giving multiple
measurement paths.

4.4.4 Thermal Flow Meter

Thermal flow meters shall be used where there is a requirement for continuous mass flow
measurement. As such, these meters are particularly suited to gas measurements where
density may vary significantly due to other factors.

Flow is measured by monitoring the cooling effect of the fluid as it passes over a heated
transducer. As the fluid passes through the instrument, it passes over two temperature
sensors. One temperature sensor is used conventionally, while the other is used as a
heater. The temperature transducer monitors the fluid temperature, while the self heated
transducer is maintained at a constant differential temperature above the measured fluid
temperature by varying the current passing through it. Higher flow will increase the
cooling effect and hence higher current will be required to maintain the temperature
differential.

The thermal flow meter shall consist of a transducer and a transmitter unit. The
transducer may be either a flanged pipe section or a boss mounted insertion type.
Insertion types may have an integrated transmitter unit or remote transmitter with
interconnecting cabling. Flanged pipe section transducers shall use a remote transmitter
with interconnecting cabling.

Flanged pipe section transducers shall be used for installations in small diameter pipe
work (up to 150 mm diameter). The transducer shall be an inline type with two PT 100
resistance temperature detector sensors fitted.

Insertion transducers shall be suitable for mounting in larger diameter pipe work (greater
than 150 mm diameter) and shall be of suitable length for the size of pipe they are to be
inserted into. The transducer shall be fitted with two PT 100 resistance temperature
detector sensors.

The transmitter shall be a microprocessor based unit, with an integral operator interface,
and shall be housed within a corrosion resistant enclosure. The operator interface shall
have an alphanumeric display, bar graph and simple to use push button interface. Error
codes, variables, configuration data or other internal values shall be accessible and
capable of being displayed on the integral operator interface. It shall be possible to limit
access to configuration data parameters by means of a configuration password.

The transmitter shall be powered from a 110 V AC or 18 V to 30 V DC supply of sufficient


current rating to power the heater. Output shall be by 4 mA to 20 mA current loop which
shall be proportional to the measured flow. A digital output shall also be provided,
configured to generate an alarm in the event of an instrument fault.

The instrument shall give measurements at an accuracy of ± 5% of the measured value.

4.4.5 Orifice Plate Flow Meter

Orifice plate flow meters shall be used for continuous volumetric flow measurement of
liquids with low solids content in closed pipes where high head losses can be tolerated. In
simple terms, an orifice plate is installed within the pipe work causing a constriction,
resulting in a pressure differential across the orifice plate. The pressure drop will be
proportional to the square of the flow rate. The flow rate is obtained by measuring the
pressure differential and extracting the square root. The flow meter shall comprise a
transducer, a separate transmitter unit and an interconnecting cable.

The transducer shall take the form of a section of pipe with the orifice plate installed
within the section. Pressure sensors shall be preinstalled upstream and downstream of

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the orifice plate in tappings to allow the pressure differential to be measured. Liner and
pressure sensors shall be chosen to be compatible with the process fluid. The section of
pipe shall be provided with flanged connections to allow connection to the adjacent pipe
work.

The transmitter shall be a microprocessor based unit with an integral operator interface,
and shall be housed within a corrosion resistant enclosure. The operator interface shall
have an alphanumeric display and a simple push button user interface. The display shall
indicate flow rate and/or total flow, and shall be capable of displaying messages
indicating an instrument fault or flow below the acceptable minimum to give an accurate
measurement. The totalised value will be held in non-volatile memory such that the
totalised flow is not lost in the event of a power failure.

The instrument shall be powered from a 110 V AC or 18 V to 30 V DC supply. An


analogue output shall be provided along with a digital output to indicate fault status, and a
total flow pulse output. The analogue output shall be by 4 mA to 20 mA current loop and
shall be proportional to the measured value. Fault status shall be indicated by an open
collector output, indicating system error or low flow (if enabled).

The orifice area ratio will be selected to allow accurate measurements to be made without
introducing excessive head loss. The system shall give a measurement of ± 5% of the
measured value.

4.4.6 Turbine Flow Meter

Turbine meters shall be used to provide accurate liquid measurement applications where
other flow meter types are unsuitable. Examples include measurement of a corrosive
medium (particularly corrosive gas such as chlorine). The measurement system shall
comprise a transducer, transmitter and interconnecting cable.

The transducer shall consist of a multiple-bladed rotor mounted perpendicular to the fluid
flow within a flanged section of pipe. The rotor shall spin as the fluid passes through the
blades, with rotational speed being a direct function of flow rate. Each rotation of the
sensor shall be detected by an externally mounted magnetic pick-up and converted to a
flow rate by the transmitter.

The transmitter shall be a microprocessor based unit with an integral operator interface,
and shall be housed within a corrosion resistant enclosure. The operator interface shall
have an alphanumeric display and a simple push button user interface. The display shall
indicate flow rate and/or total flow, and shall be capable of displaying messages
indicating an instrument fault or flow below the acceptable minimum to give an accurate
measurement. The totalised value will be held in non-volatile memory such that the
totalised flow is not lost in the event of a power failure.

The instrument shall be powered from a 110 V AC or 18 V to 30 V DC supply. An


analogue output shall be provided along with a digital output to indicate fault status, and a
total flow pulse output. The analogue output shall be by 4 mA to 20 mA current loop and
shall be proportional to the measured value. Fault status shall be indicated by an open
collector output, indicating system error or low flow (if enabled).

The system shall be accurate to ± 1% of the measured value.

4.4.7 Open Channel Ultrasonic Flow meter

All of the flow meters above require that the flow to be measured occurs in a closed pipe
which is fully filled. It is not always convenient to generate such conditions, and hence
there is a need for a method to measure the volumetric flow in an open channel. This will
be achieved by installing a flume or weir in a channel with a free discharge and
measuring the liquid level upstream of the flume or weir. The level measurement shall be
taken by an ultrasonic system using the time of flight principle.

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The transducer shall be a non contact type suitable for continuous measurement of level.
The transducer shall be weather resistant and safe against submersion (IP 68), and shall
incorporate an integral temperature sensor to allow for temperature compensation of the
measured level. The transducer shall not be affected by the measured liquid and shall be
insensitive to dirt build-up.

The transmitter shall be microprocessor based with an integral operator interface housed
within a corrosion resistant enclosure. The transmitter shall be pre-configured with
common flow/height characteristic curves for measuring flow rates with flumes and weirs.
Other flow/height curves may be entered, measured values being obtained by
interpolation between entered data. The operator interface shall have a numeric display,
bar graph display, and a simple push button interface. All error codes, process variables,
configuration data and other internal values shall be accessible and displayable on the
integral operator interface. It shall be possible to limit access to configuration data
parameters by means of a configuration password.

Input power required will be from a 110 V AC or 18 V to 30 V DC supply. Two analogue


outputs shall be provided, corresponding to measured level and calculated flow, and a
pulse output shall be provided along with a digital output to indicate fault status and total
flow. The analogue outputs shall be by 4 mA to 20 mA current loop and shall be
proportional to the measured values. The pulse output shall be an open collector output.
Fault status shall be indicated by an open collector output, indicating system or process
error, flow direction or low flow (if enabled).

The transducer shall have a blocking distance not more than 10% of the measurement
range and a 3 dB beam angle not wider than 10°. The system shall measure the level
with accuracy of ± 0.5% of the measurement span.

4.5 Pressure Instruments

4.5.1 Ceramic Diaphragm Instruments

A pressure instrument utilising a dry cell ceramic diaphragm design shall be used where
a continuous pressure measurement is required for a gas, vapour or liquid at pressures
up to 30 bar. The pressure monitoring system shall comprise an integral
transmitter/transducer unit.

The unit shall be selected from a range to suit the range of pressures which may occur in
a given application (including abnormal operation situations). Maximum deflection of the
ceramic diaphragm shall not exceed 0.025 mm full scale movement to minimize
diaphragm fatigue and the effects of build-up. The unit shall not be damaged by vacuum
conditions, and shall be capable of withstanding at least 200% maximum rated
measurement pressure without damage.

The unit shall be loop powered by a 12 V to 30 V DC supply. A 4 mA to 20 mA current


loop output shall be superimposed on the power supply lines, giving an output
proportional to the measured pressure. The sensor shall have a zero point adjustment
with no on site calibration required.

The system shall be accurate to ± 1% of the measured value.

4.5.2 Pressure Switches

Often a continuous measurement of pressure is not required, but a warning that pressure
is outside of prescribed high or low limits. In such cases, pressure switches shall be used.
Pressure switches may also be used to provide backup to a continuous pressure
measurement instrument.

The pressure switch shall be of the ceramic sensor diaphragm type. The capacitance of
the ceramic sensor changes with pressure and is monitored by a microprocessor, which

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evaluates the signal and switches the output as necessary. The ceramic sensor is a dry
sensor with no fill fluid for pressure transmission, allowing the sensor to withstand
vacuum conditions without failure.

The pressure switch and all fixings shall be manufactured of non corrodible metal,
suitable for permanent submersion.

The control/switching unit shall be suitable for mounting within a control panel on DIN rail.
Sensitivity shall be easily adjustable to allow fine-tuning of the switching threshold.

4.6 Temperature Instruments

Temperature measurement systems shall comprise a temperature sensor and a


transmitter unit. The transmitter unit shall be head mounted. Where the temperature of a
fluid within a pipe is to be measured, the sensor shall be installed within a thermo well.

The temperature sensor shall be a Resistance Temperature Detector (RTD). The sensor
shall consist of an RTD with a resistance of 100 Ω at 0°C, known as PT100. The
resistance shall increase at higher temperatures according to a coefficient characteristic
of the resistor material.

The transmitter shall be a head mounted unit directly attached to the sensor assembly.
The transmitter shall be housed within a corrosion resistant enclosure. No user interface
will be provided on the transmitter unit. The transmitter unit shall provide a means to
connect a personal computer to allow programming of the transmitter.

The instrument shall be powered from a 110 V AC or 18 V to 30 V DC supply. An


analogue output shall be provided along with a digital output to indicate fault status. The
analogue output shall be by 4 mA to 20 mA current loop and shall be proportional to the
measured value. Fault status shall be indicated by an open collector output, indicating
system error.

Thermo wells shall be constructed of drilled stainless steel bar stock. Length of the
thermo well shall be determined to suit the specific requirements of the application.

4.7 Analytical/ Quality Instruments

4.7.1 Dissolved Oxygen

Measurement of dissolved oxygen is essential for correct control of activated sludge


treatment processes in wastewater treatment. Dissolved oxygen monitoring systems shall
comprise a transducer, transmitter and interconnecting cable.

The transducer assembly shall comprise the sensor and mounting hardware. Mounting
hardware shall be provided for either rigid wall mounting, freely swinging suspended wall
mounting or a floating installation with the float suitably anchored to a fixed location, as
required by the application. The sensor shall be either:

• a membrane covered amperometric type suitable for constant immersion, giving high
O2 selectivity and minimal maintenance requirements. The sensor shall also
incorporate an integral temperature sensor. Cabling between the sensor and
transmitter shall be easily disconnected from the sensor using a plug-in connector to
allow quick and easy substitution of sensors in the event of a sensor failure.
• an optical sensor working on the fluorescence quenching principle suitable for
constant immersion giving minimum maintenance and maximum availability. The
sensor shall compensate for fluid temperature and air pressure. Cabling between the
sensor and transmitter shall be easily disconnected from the sensor using a plug-in
connector to allow quick and easy substitution of sensors in the event of a sensor
failure.

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The transmitter shall be microprocessor based and shall include an integral display and a
simple push button user interface. The display shall indicate oxygen content and provide
the option of displaying temperature if desired. The display shall be capable of displaying
all error codes, process variables, configuration data and other internal values.
Calibration shall be a simple procedure, requiring minimal operator input.

Input power required will be from a 110 V AC or 18 V to 30 V DC supply. An analogue


output shall be provided along with a digital output to indicate fault status. The analogue
output shall be by 4 mA to 20 mA current loop and shall be configurable to be
proportional to the measured value or follow a user specified curve. Fault status shall be
indicated by an open collector output, indicating system or sensor error.

The instrument shall give measurements at an accuracy of ± 0.5% of the measured value
and have quick response time. Drift shall be no greater than 1% of full scale per month,
such that sensor recalibration shall not be a frequent requirement.

4.7.2 pH

The pH monitoring systems shall comprise a transducer, transmitter and interconnecting


cable.

The transducer assembly shall comprise the sensor and any mounting hardware
required. The sensor shall use a glass membrane electrode, the outer layer of which shall
give high H+ ion selectivity, to supply an electrochemical potential dependent upon the
pH value of the process fluid. The sensor shall be suitable for constant immersion, with
minimal maintenance requirements. The sensor shall also incorporate an integral
temperature sensor. Cabling between the sensor and transmitter shall be easily
disconnected from the sensor using a plug-in connector to allow quick and easy
substitution of sensors in the event of a sensor failure.

The transmitter shall be microprocessor based and shall include an integral display and a
simple push button user interface. The display shall indicate pH and provide the option of
displaying temperature if desired. The display shall be capable of displaying all error
codes, process variables, configuration data and other internal values. Calibration shall
be a simple procedure, requiring minimal operator input.

Input power required will be from a 110 V AC or 18 V to 30 V DC supply. An analogue


output shall be provided along with a digital output to indicate fault status. The analogue
output shall be by 4 mA to 20 mA current loop and shall be configurable to be
proportional to the measured value or follow a user specified curve. Fault status shall be
indicated by an open collector output, indicating system or sensor error.

The instrument shall give measurements at an accuracy of ± 0.5% of the measured value
and have quick response time. Drift shall be no greater than 1% of full scale per month,
such that sensor recalibration shall not be a frequent requirement.

4.7.3 Conductivity

Conductivity monitoring systems shall comprise a transducer, transmitter and


interconnecting cable.

The transducer assembly shall comprise the sensor and any mounting hardware
required. The sensor shall comprise two coaxial graphite electrodes arranged similarly to
a capacitor. The electrical resistance (and hence its reciprocal, conductivity) is measured
according to Ohm’s Law. Specific conductivity is determined using a cell constant that is
particular to the sensor geometry. The sensor shall be suitable for constant immersion,
with minimal maintenance requirements. The sensor shall also incorporate an integral
temperature sensor. Cabling between the sensor and transmitter shall be easily
disconnected from the sensor using a plug-in connector to allow quick and easy
substitution of sensors in the event of a sensor failure.

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The transmitter shall be microprocessor based and shall include an integral display and a
simple push button user interface. The display shall indicate conductivity and provide the
option of displaying temperature if desired. The display shall be capable of displaying all
error codes, process variables, configuration data and other internal values. Calibration
shall be a simple procedure, requiring minimal operator input.

Input power required will be from a 110 V AC or 18 V to 30 V DC supply. An analogue


output shall be provided along with a digital output to indicate fault status. The analogue
output shall be by 4 mA to 20 mA current loop and shall be configurable to be
proportional to the measured value or follow a user specified curve. Fault status shall be
indicated by an open collector output, indicating system or sensor error.

The instrument shall give measurements at an accuracy of ± 0.5% of the measured


value.

4.7.4 Turbidity

Measurement of turbidity/suspended solids concentration is important to allow the solids


content to be assessed at various points in the treatment process. Turbidity/suspended
solids monitoring systems shall comprise a transducer, transmitter and interconnecting
cable.

The transducer assembly shall comprise the sensor and any mounting hardware
required. The sensor shall function by the 90° scattered light principle. Light in the near-
infrared range shall be emitted by an LED at a defined angle. Particles in the process
liquid will scatter incident light and a photodiode shall measure light reflected back
towards the sensor. The LED and photodiode shall be sealed within the sensor behind
scratch resistant windows. The sensor shall be suitable for constant immersion, shall
incorporate a wiper to ensure that the LED light source and photodiodes remain clean at
all times with minimal maintenance requirements. The sensor shall also incorporate an
integral temperature sensor. Cabling between the sensor and transmitter shall be easily
disconnected from the sensor using a plug-in connector to allow quick and easy
substitution of sensors in the event of a sensor failure.

The transmitter shall be microprocessor based and shall include an integral display and a
simple push button user interface. The display shall indicate turbidity and provide the
option of displaying temperature if desired. The display shall be capable of displaying all
error codes, process variables, configuration data and other internal values. Calibration
shall be a simple procedure, requiring minimal operator input.

Input power required will be from a 110 V AC or 18 V to 30 V DC supply. An analogue


output shall be provided along with a digital output to indicate fault status. The analogue
output shall be by 4 mA to 20 mA current loop and shall be configurable to be
proportional to the measured value or follow a user specified curve. Fault status shall be
indicated by an open collector output, indicating system or sensor error.

The instrument shall give measurements at an accuracy of ± 0.5% of the measured


value.

4.7.5 Chlorine

Measurement of free chlorine residual is important to allow chlorine dosing to be


controlled to ensure that effluent is adequately dosed to ensure satisfactory disinfection
but not excessively dosed which is wasteful of chemicals. Free chlorine monitoring
systems shall comprise a transducer, transmitter and interconnecting cable.

The transducer assembly shall comprise the sensor and any mounting hardware
required. The system shall not require chemical reagents to make measurements. The
sensor shall measure the concentration of free chlorine by amperometric principles. Free
chlorine shall be in the form of hypochlorous acid contained in the medium, which shall

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diffuse through the sensor membrane. Once inside the sensor, the hypochlorous acid is
reduced to chloride ions (Cl–) at the cathode, whilst at the anode, silver is oxidised to
silver chloride. A current flow results from the electron release at the cathode and
electron acceptance at the anode. The current flow is proportional to the free chlorine
concentration in the medium under constant conditions. The concentration of
hypochlorous acid in the medium depends on the pH value. Accordingly, the sensor shall
incorporate a pH sensor and the transmitter shall adjust the free chlorine measurement to
compensate for pH. Cabling between the sensor and transmitter shall be easily
disconnected from the sensor using a plug-in connector to allow quick and easy
substitution of sensors in the event of a sensor failure.

The transmitter shall be microprocessor based and shall include an integral display and a
simple push button user interface. The display shall indicate free chlorine residual and
provide the option of displaying pH if desired. The display shall be capable of displaying
all error codes, process variables, configuration data and other internal values.
Calibration shall be a simple procedure, requiring minimal operator input.

Input power required will be from a 110 V AC or 18 V to 30 V DC supply. An analogue


output shall be provided along with a digital output to indicate fault status. The analogue
output shall be by 4 mA to 20 mA current loop and shall be configurable to be
proportional to the measured value or follow a user specified curve. Fault status shall be
indicated by an open collector output, indicating system or sensor error.

The instrument shall give measurements at an accuracy of ± 0.5% of the measured value
and have quick response time. Drift shall be no greater than 1% of full scale per month,
such that sensor recalibration shall not be a frequent requirement.

5. PART 5 METHODOLOGY AND WORKMANSHIP

5.1 Workmanship

The Plant design, workmanship and general finish shall be of sound quality in accordance
with good engineering practice. Design shall be robust and rated for continuous service at
the specified duties under the prevailing operational site conditions.

Preference is to be given to equipment manufactured to the quality control standards of


BS EN ISO 9004.

No welding, filling or plugging of defective work will be permitted without the written
permission of the Engineer. Welding spatter shall be removed prior to the application of
any protective treatment.

5.2 Equipment Access and Maintainability

The Works shall be designed and installed for ease of maintenance and to allow access
or removal without disturbing adjacent equipment, pipe work, and so on. The Contractor
shall ensure that all working areas have adequate access, lifting arrangements, lighting,
heating and ventilation. All equipment, materials housings, etc., that may be manually
handled during the course of normal operations or maintenance shall be provided with
lifting arrangements according to the following:

• Above 10 kg – Provision of two man lifting arrangement


• Above 20 kg – Provision of suitably rated lifting arrangement
• Above 500 kg – Provision of lifting beam with manual chain block
• Above 1 t – Provision of overhead crane with manual chain block

Lifting arrangements and equipment shall be load tested on site after installation. Load
test certificates shall be supplied for all lifting equipment.

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5.3 Fixing of Machinery

5.3.1 Fixing of Machinery

5.3.1.1 Fixing of Structures

Where any Plant included in the Works is attached to building structures, the magnitude
of the applied loadings must be stated by the Contractor on his drawings. Cutting of
steelwork will not be allowed. Drilling, welding or stud firing into tension flanges or other
steelwork subjected to tensile loads will not be permitted on plate girders or any principal
steelwork member. Where attachments are allowed, proper clamps or straps will be
required. The proposed attachment shall require the approval of the Engineer.

5.3.1.2 Foundations and Building Works

The Contractor shall satisfy himself, before installing the Plant, that the foundation levels,
dimensions and alignment are correct and shall level and adjust the Plant on its
foundations preparatory to suitable bedding of bases.

Where fixings are used by the Contractor he shall drill the holes, providing and fixing
parts, to the approval of the Engineer.

The drilling through steel reinforcement shall not be permitted without the prior approval
of the Engineer.

The Contractor shall supply foundation bolts, packers, frames and grillages necessary for
the Works. Where these items are required to be built in, the Contractor shall ensure that
both details and materials are available in accordance with the Schedule.

The Contractor shall make good any damage to concrete, brickwork or other finishes
caused when undertaking his work. This shall be done to the satisfaction of the Engineer.

Grouting of machinery bedplates and supports shall be undertaken by the Contractor.

5.3.1.3 Shims and Packing

Packing/Shims shall be positioned close to and on each side of holding down bolts.

Packings/shims shall be of flat stainless steel and so positioned as to be fully covered to


a thickness of 60 mm after ‘grouting in’. Alternatively, mild steel packs with zinc rich
protective coating are to be provided.

5.3.1.4 Anchor Bolts

Expansion bolts or self drill anchor bolts shall be to the approval of the Engineer, and
shall not be used within 100 mm distance of concrete edges. Epoxy resin anchors can be
used under such circumstances.

Where expansion bolts are used they shall normally be of the type having a loose metal
shell for at least 80% of the embedded length which is expanded parallel to the bolt by
means of a wedge at each end, the wedge at the lower end being part of or attached to
the bolt.

Proprietary fixing bolts shall be fitted in strict accordance with the manufacturer' s
instructions and the Contractor shall be responsible for the provision of necessary
equipment to drill and clean holes and for the actual drilling, cleaning and fixing.

Anchor bolts shall be stainless steel.

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5.3.1.5 Machinery Guards

Machinery shall be effectively guarded to prevent injury to persons, and meet current
safety regulations.

Guards to parts of machinery which require regular inspection or maintenance shall be


constructed of galvanised steel mesh or other corrosion resistant material which enables
the parts to be examined and shall be attached in such a way as to permit easy removal
and replacement. Guards shall be attached by means of set bolts or studs in tapped
holes. Self tapping screws shall not be used.

Where hinged access covers or doors are provided in covers or guards, they shall be
interlocked with the electricity supply so as to prevent the operation of the machinery
except when covers are in position and fixed.

Warning notices labelled '


Danger - This equipment may start automatically'
, shall be fitted
where appropriate.

5.3.2 Alignment, Lifting, Dismantling, Noise and Vibration

5.3.2.1 Alignment

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 regrout.

Bedplates shall incorporate fine adjustment of the vertical and horizontal alignment
between driver and driven members.

5.3.2.2 Lifting

Machinery shall be fitted with permanent lifting facilities. Large structures shall be
provided with jacking points.

Tapped holes or other provision must be made in 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 setscrews.

5.4 Electrical

5.4.1 Layout of Equipment

Individual items of control equipment which are not incorporated into control panels shall
be positioned and installed to provide a neat and tidy installation. Where wall mounted
equipment is grouped together, wiring between the items shall be installed in trunking.

5.4.2 Mounting of Equipment

Field mounted items shall be mounted on purpose made brackets, welded, bolted or
clamped to the equipment structural steelwork or building fabric/steelwork. No cutting
away of structural steelwork or building fabric/steelwork shall be carried out without the
written consent of the Project Manager. Equipment shall not impede the removal of items
of equipment for maintenance.

Brackets shall be fabricated from galvanised mild steel, 6mm minimum thickness.

All fixing lugs shall be used. Where it is necessary to drill holes in any enclosure for fixing
purposes, washers are to be fitted to maintain the original enclosure IP rating.

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Bolts in brackets or supports that are subject to vibration shall have spring washers fitted.
All fixing nuts, bolts and washers shall be 6 mm minimum and galvanised.

Individual items of control equipment that are not incorporated into control panels shall be
positioned and installed to provide a neat and tidy installation. Where wall mounted
equipment is grouped together with wiring between the items the wiring shall be installed
in trunking.

5.4.3 Protection and Finishes

Materials or equipment in the installation shall be adequately protected against corrosion.


Except in the cases of proprietary equipment for which galvanising would not be
appropriate, all steelwork shall be hot dip galvanised. Damage to galvanised surfaces
shall be made good using a method approved by the Engineer. Nuts, bolts, washers or
other such fasteners shall be manufactured from non corrodible materials.

Painted equipment in a particular area shall be finished in a common texture and shade,
approved by the Engineer.

6. PART 6 TESTING AND APPROVAL

6.1 Testing

Performance tests and such other tests shall be carried out to determine that the Works
comply with the Specification under test conditions, in the manufacturer'
s works, and on
Site.

The Contractor shall provide any labour, equipment/apparatus required for testing
purposes. Test instrumentation shall have current '
Calibration Certificates'and shall be
suitable for the degree of measurement accuracy necessary for the parameters being
checked.

No inspection or passing by the Engineer of the Works, equipment or materials included


in this Contract, whether carried out or supplied by the Contractor shall release the
Contractor from any of his obligations under the Contract.

6.1.1 Works Tests

Before dispatch from a manufacturer' s works each item of equipment shall be tested in
accordance with the relevant Standards, Specifications or Code of Practice. In the
absence of such Standards, Specifications or Code of Practice the tests shall be
performed in a manner subject to the approval of the Engineer. The Engineer shall be
given the opportunity to inspect any equipment he deems necessary.

The Contractor shall give the Engineer at least three weeks’ notice of the tests being
carried out. No tests or inspections shall be carried out before the Contract drawings are
approved.

Costs incurred by the Engineer on repeat tests or inspections of failed equipment shall be
met by the Contractor.

6.1.2 Site Tests and Commissioning

The Contractor shall be responsible for the safe and efficient testing and setting to work
of the whole of the plant and equipment. The methods adopted shall be to the satisfaction
of the Engineer, and shall be in accordance with the safety and permit regulations in force
on the site.

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Before testing is undertaken, the Contractor shall submit for approval, at an agreed
time/date, his Test Procedure and Acceptance Testing Documentation so that all parties
may be fully conversant with the methods to be adopted in demonstration and proving of
the equipment.

The Contractor shall carry out tests as per the equipment manufacturer’s
recommendation in an approved sequence on all equipments.

The Test plan shall include a programme for all inspection/testing clearly identifying the
critical path.

Only following successful completion of pre-commissioning and commissioning tests in


their entirety shall the Contractor commence with the trial operation of the Works.

6.2 Submittals

6.2.1 Certificates of Conformity

Documentation submitted to the Engineer shall include test certificates of all materials
confirming compliance with the Specification

6.2.2 Test Certificate

Test Certificates shall be submitted to the Engineer, upon completion of the site tests.
The original test certificates shall be incorporated in to the operation and maintenance
manual.

The Test Certificates shall be in a format that records all data from the site tests. The
Contractor shall submit a pro-forma of each type of test certificate for the Engineer for
approval.

All test certificates shall be signed by the Contractor and issued to the Engineer within 3
working days of the test being completed.

6.2.3 Documentation

Work test certificates shall be provided for each pump at the time of delivery.

A fully comprehensive set of relevant pump curves shall be provided, if requested by the
Engineer for all pumps supplied.

Delivery documentation as determined by the Conditions of Contract shall be provided at


the time of delivery of the pumps.

Lubricant data sheets shall be provided with the pump delivery documentation.

Every pump delivered to site shall be accompanied by the following documents for the
inclusion into the operation and maintenance manuals and control panel:

• A fully detailed comprehensive maintenance manual for all sections of the pump
and motor.
• List of manufacturer’s recommended spare parts for the pump and motor.
• A spare nameplate fixed permanently on the pump. This nameplate shall be fixed to
the control panel starter section door.

If required by the Engineer the Contractor shall issue type test certificates for the control
and assemblies. Type Test certificates shall be presented for the following tests as
defined in BS EN 60439: Part 1.

• Verification of temperature rise limits.

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• Verification of dielectric properties.
• Verification of short-circuit capacity.
• Verification of continuity of protective circuits.
• Verification of distances.
• Verification of mechanical operations.
• Verification of degree of protection.

Lifting chains and locking devices test certificates shall be provided prior to
commissioning of the pumps and associated equipment. Copies shall be included as part
of the operation and maintenance manual.

6.3 Mechanical

The following tests shall be carried out at the manufacturer’s works or Site, as indicated.

Motors from manufacturer' s standard range will be accepted with a type test certificate.
Motors without a type test certificate shall be tested under load test including an 8-hour
"temperature rise test".

6.3.1 Precautions Prior to Testing

The Contractor shall verify that all testing parameters of each item of plant and
associated material to be tested are within manufacturer’s specification limits.

6.3.2 Testing Method and Notification

The Contractor shall submit to the Engineer a method statement for each item of plant to
be tested.

The Contractor shall notify the Engineer 7 days before carrying out the testing.

6.3.3 Lifting Equipment Load Test

Cranes and other lifting devices shall be load tested in accordance with statutory
requirements and a test certificate issued.

6.3.4 Pumps

The Contractor shall carry out works tests in accordance with BS EN ISO 9906: Class C
on one of each type pump being supplied. Only results in the positive tolerance output
area will be acceptable.

The tests shall be conducted over the full head/flow range of the pump curve from closed
valve to run out, and one of the test points shall be at the duty point, or duty points,
specified in this specification.

The pumps shall be tested with their Contract motors (Motors to be installed by the
contractor with pump). Guaranteed efficiency is required at the duty point. The combined
pump and motor efficiencies quoted by the Contractor in the Schedules shall be
achieved.

A test report including the items detailed below shall be submitted to the Engineer at the
conclusion of each test.

a) Place and date of the acceptance test

b) Manufacturer’s name, type of pump, serial number

c) Specification of the pumps drive

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d) Duty point(s) specified in this document

e) Description of the test procedure and the measuring apparatus used including
calibration data

• Observed readings presented in tabular and graph format


• Evaluation and analysis of test results conclusions

Pumps compliance with the Specification shall be based upon their performance during
the works witness test. The Contractor shall undertake on site further testing on pumps
as detailed in the Particular Specification. These tests shall be to demonstrate the
material integrity of the pump, and the ability of the system to deliver the required flow.

6.3.5 Pressure Vessels

Pressure vessels shall be pressure tested in accordance with statutory requirements and
a test certificate issued.

6.3.6 Valves and Pipe work

Valves and pipe work shall be pressure tested in accordance with the specified
Standards.

6.4 Electrical

The tests shall include but not be limited to the following:

6.4.1 Factory Built Assemblies (FBAs) Test

The following works tests defined in BS EN 60439: Part 1, IEC 60439: Part 1 shall be
carried out:

• Inspection of the FBA including inspection of wiring and electrical operation tests.
• Dielectric test.
• Checking of protective measures including primary or secondary injection testing
and checking the continuity of the protective circuit.
• Loop testing of instruments.
• Functionally testing of control, indication and supervision circuits.
• Variable speed drives shall be load tested with the Contract motor.

6.5 Commissioning

6.5.1 Site Tests and Commissioning

Site tests shall include but not be limited to the following: -

• Insulation resistance tests.


• Dielectric tests.
• Continuity tests.
• Earth loop impedances.
• Earth electrode systems
• Phase rotation.
• Lighting levels.
• Functional tests of protective devices, control systems, telemetry, SCADA and
instrument loops.

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7. PART 7 REFERENCE STANDARDS

7.1 Mechanical

In cases where there is a British Standard, International Standard or Code of Practice


which is appropriate to any item of Plant supplied, any component incorporated in the
Plant, the testing of the Plant or the installation of the Plant, then that British Standard or
Code of Practice or International Standard shall apply.

A (non exhaustive) list of applicable standards follows.

Reference Title

AGMA 6013-A06 Standard for industrial enclosed gear drivers


ASTM A53/A53M Standard Specification for Pipe, Steel, Black and Hot-
Dipped, Zinc-Coated, Welded and Seamless
ASTM A126 Standard Specification for Gray Iron Castings for Valves,
Flanges, and Pipe Fittings
ASTM D4161 Standard Specification for "Fiberglass" (Glass-Fiber-
Reinforced Thermosetting-Resin) Pipe Joints Using
Flexible Elastomeric Seals
BS 21 Specification for pipe threads for tubes and fittings where
pressure-tight joints are made on the threads (metric
dimensions)
BS 466 Specification for power driven overhead travelling cranes,
semi-goliath and goliath cranes for general use
BS 848 Fans for general purposes
BS 476 Fire tests on building materials and structures.
BS 1133 Packaging code. Protection of metal surfaces against
corrosion during transport and storage
BS 1212: Part 1 Float operated valves. Specification for piston type float
operated valves (copper alloy body) (excluding floats)
BS 1615 Methods of specifying anodic oxidation coatings on
aluminium and its alloys
BS 1710 Specification for identification of pipelines and services
BS 1968 Specification for floats for ballvalves (copper)
BS 2456 Specification for floats (plastics) for float operated valves
for cold water services
BS 2831 Methods of test for air filters used in air conditioning and
general ventilation
BS 3037 Specification for tyres for crane rail wheels
BS 3120 Specification for performance requirements of flameproof
materials for clothing and other purposes
BS 3505 Specification for unplasticized polyvinyl chloride (PVC-U)
pressure pipes for cold potable water
BS 3643: Part 1 ISO metric screw threads. Principles and basic data
BS 3643: Part 2 ISO metric screw threads. Specification for selected limits
of size
BS 4190 ISO metric black hexagon bolts, screws and nuts.
Specification
BS 4235: Part 1 Specification for metric keys and keyways. Parallel and
taper keys
BS 4346 Joints and fittings for use with unplasticized PVC
pressure pipes
BS 4506 Specification for shaft ends
BS 4660 Thermoplastics ancillary fittings of nominal sizes 110 and
160 for below ground gravity drainage and sewerage
BS 4884: Part 1 Technical manuals. Specification for presentation of
essential information
BS 4884: Part 2 Technical manuals. Guide to content

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BS 4884: Part 3 Technical manuals. Guide to presentation
BS 4999 General requirements for rotating electrical machines (All
relevant parts)
BS 5000 Rotating electrical machines of particular types or for
particular applications (All relevant parts)
BS 5163 Valves for waterworks purposes. Predominantly key-
operated cast iron gate valves
BS 5391: Part 1 Acrylonitrile-butadiene-styrene (ABS) pressure pipe.
Specification
BS 5392: Part 1 Acrylonitrile-butadiene-styrene (ABS) fittings for use with
ABS pressure pipe. Specification
BS 5400: Part 10C Steel, concrete and composite bridges. Charts for
classification of details for fatigue
BS 5493 Code of practice for protection of iron and steel structures
against corrosion
BS 7773 Code of practice for cleaning and preparation of metal
surfaces
BS 10255 Non-alloy steel tubes suitable for welding and threading.
Technical delivery conditions
BS 13001 Crane safety. General design.
BS EN 124 Gully tops and manhole tops for vehicular and pedestrian
areas. Design requirements, type testing, marking, quality
control
BS EN 593 Industrial valves. Metallic butterfly valves
BS EN 598 Ductile iron pipes, fittings, accessories and their joints for
sewerage applications. Requirements and test methods
BS EN 681 Elastomeric seals. Material requirements for pipe joint
seals used in water and drainage applications
BS EN 1092; Part 2 Flanges and their joints. Circular flanges for pipes,
valves, fittings and accessories, PN designated. Cast iron
flanges
BS EN 1092; Part 3 Flanges and their joints. Circular flanges for pipes,
valves, fittings and accessories, PN designated. Copper
alloy flanges
BS EN 1401: Part 1 Plastics piping systems for non-pressure underground
drainage and sewerage. Unplasticized poly(vinylchloride)
(PVC-U). Specifications for pipes, fittings and the system
BS EN 1561 Founding. Grey cast irons
BS EN 1982 Copper and copper alloys. Ingots and castings
BS EN 10250: Part 4 Open steel die forgings for general engineering purposes.
Stainless steels
BS EN 12373 Aluminium and aluminium alloys. Anodizing
BS EN 12385 Steel wire ropes. Safety
BS EN 60034: Part 14 Rotating electrical machines. Mechanical vibration of
certain machines with shaft heights 56 mm and higher.
Measurement, evaluation and limits of vibration severity
BS EN ISO 9906 Rot dynamic pumps. Hydraulic performance acceptance
tests. Grades 1 and 2
BS ISO 281 Rolling bearings. Dynamic load ratings and rating life
BS ISO 1217 Displacement compressors. Acceptance tests
DIN 1229 Masses per unit area for gully tops and manhole tops for
vehicular and pedestrian areas
DW 144 Specification for sheet metal ductwork low medium & high
pressure velocity air systems
DW 154 Specification for plastics ductwork
IEC 60034-1 Rotating electrical machines. Rating and performance
MSS SP58 Pipe hangers and supports. Materials, design and
manufacture

Page 133
7.2 Instrumentation, Control and Automation

In cases where there is a British Standard, International Standard or Code of Practice


which is appropriate to any item of equipment supplied, any component incorporated in
the Works, the testing of the Works or the installation of the equipment, then the British
Standard or Code of Practice or International Standard shall apply.
A (non exhaustive) list of applicable standards follows.
Reference Title
`
BS 756 Specification for Dean and Stark apparatus

BS 1646: Part 1 Symbolic representation for process measurement control


functions and instrumentation. Basic requirements
BS 1646: Part 2 Symbolic representation for process measurement control
functions and instrumentation. Specification for additional
basic requirements
BS 1646: Part 3 Symbolic representation for process measurement control
functions and instrumentation. Specification for detailed
symbols for instrument interconnection diagrams
BS 1646: Part 4 Symbolic representation for process measurement control
functions and instrumentation. Specification for basic
symbols for process computer, interface and shared
display/control functions
BS 4568: Part 1 Specification for steel conduit and fittings with metric
threads of ISO form for electrical installations. Steel
conduit, bends and couplers
BS 4675: Part 2 Mechanical vibration in rotating machinery. Requirements
for instruments for measuring vibration severity
BS 5308: Part 1 Instrumentation cables. Specification for polyethylene
insulated cables
BS 5308: Part 2 Instrumentation cables. Specification for PVC insulated
cables
BS 5378: Part 2 Safety signs and colours. Specification for colorimetric
and photometric properties of materials
BS 5499: Part 5 Graphical symbols and signs. Safety signs, including fire
safety signs. Signs with specific safety meanings
BS 5750: Part 8 Quality systems. Guide to quality management and
quality systems elements for services
BS 5839: Part 1 Fire detection and fire alarm systems for buildings. Code
of practice for system design, installation, commissioning
and maintenance
BS 5839: Part 3 Fire detection and alarm systems for buildings.
Specification for automatic release mechanisms for
certain fire protection equipment
BS 7405 Guide to selection and application of flow meters for the
measurement of fluid flow in closed conduits
BS 7430 Code of practice for earthing
BS 7671 Requirements for electrical installations. IEE wiring
regulations
BS 60073 Basic and safety principles for man-machine interface,
marking and identification – Coding principles for
indicators and actuators
BS 60529 Degrees of protection provided by enclosures (IP code)
BS EN 50015 Electrical apparatus for potentially explosive atmospheres
– Oil immersion ' o'
BS EN 50020 Electrical apparatus for potentially explosive atmospheres
– Intrinsic safety 'i'

Page 134
BS EN 50073 Guide for the selection, installation, use and maintenance
of apparatus for the detection and measurement of
combustible gases or oxygen
BS EN 60044: Part 1 Instrument transformers. Current transformers
BS EN 60079: Part 0 Electrical apparatus for explosive gas atmospheres.
General Requirements
BS EN 60079: Part 1 Electrical apparatus for explosive gas atmospheres.
Flameproof enclosures ' d'
BS EN 60079: Part 7 Electrical apparatus for explosive gas atmospheres.
Increased safety "e"
BS EN 60079: Part 10 Explosive atmospheres. Classification of areas. Explosive
gas atmospheres
BS EN 60079: Part 14 Explosive atmospheres. Electrical installations design,
selection and erection
BS EN 60079: Part 17 Explosive atmospheres. Electrical installations inspection
and maintenance
BS EN 60079: Part 18 Electrical apparatus for explosive gas atmospheres.
Construction, test and marking of type of protection
encapsulation "m" electrical apparatus
BS EN 60079: Part 25 Electrical apparatus for explosive gas atmospheres.
Intrinsically safe systems
BS EN 60439: Part 1 Low-voltage switchgear and control gear assemblies.
Type-tested and partially type-tested assemblies
BS EN 60446 Basic and safety principles for man-machine interface,
marking and identification. Identification of conductors by
colours or alphanumerics
BS EN 61386: Part 1 Conduit systems for cable management. General
requirements
BS EN 61386: Part 21 Conduit systems for cable management. Particular
requirements. Rigid conduit systems
BS EN 61508: Part 1 Functional safety of electrical/electronic/programmable
electronic safety-related systems. General requirements
BS EN 61508: Part 2 Functional safety of electrical/electronic/programmable
electronic safety-related systems. Requirements for
electrical/electronic/programmable electronic safety-
related systems
BS EN 61508: Part 3 Functional safety of electrical/electronic/programmable
electronic safety-related systems. Software requirements
BS EN 61508: Part 4 Functional safety of electrical/electronic/programmable
electronic safety-related systems. Definitions and
abbreviations
BS EN 61508: Part 5 Functional safety of electrical/electronic/programmable
electronic safety-related systems. Examples of methods
for the determination of safety integrity levels
BS EN 61508: Part 6 Functional safety of electrical/electronic/programmable
electronic safety-related systems. Guidelines on the
application of IEC 61508: Part 2 and IEC 61508: Part 3
BS EN 61508: Part 7 Functional safety of electrical/electronic/programmable
electronic safety-related systems. Overview of techniques
and measures
BS EN 61511: Part 1 Functional safety – Safety instrumented systems for the
process industry sector. Framework, definitions, system,
hardware and software requirements
BS EN 61511: Part 2 Functional safety – Safety instrumented systems for the
process industry sector. Guidelines for the application of
IEC 61511: Part 1
BS EN 61511: Part 3 Functional safety – Safety instrumented systems for the
process industry sector. Guidance for the determination of
the required safety integrity levels

Page 135
BS EN 61558 Part 2-23 Safety of power transformers, power supply units and
similar. Particular requirements for transformers for
construction sites
BS EN 61672: Part 2 Electroacoustics. Sound level meters. Pattern evaluation
tests
BS EN ISO 5167: Part 1 Measurement of fluid flow by means of pressure
differential devices inserted in circular cross-section
conduits running full. General principles and requirements
BS EN ISO 5167: Part 2 Measurement of fluid flow by means of pressure
differential devices inserted in circular cross-section
conduits running full. Orifice plates
BS EN ISO 5167: Part 3 Measurement of fluid flow by means of pressure
differential devices inserted in circular cross-section
conduits running full. Nozzles and Venturi nozzles
BS EN ISO 5167: Part 4 Measurement of fluid flow by means of pressure
differential devices inserted in circular cross-section
conduits running full. Venturi tubes
BS EN ISO 9004 Quality management systems. Guidelines for
performance improvements
BS EN ISO 9906 Rotodynamic pumps. Hydraulic performance acceptance
tests. Grades 1 and 2
IEC 61131: Part 1 Programmable controllers. General information
IEC 61131: Part 2 Programmable controllers. Equipment requirements and
tests
IEC 61131: Part 3 Programmable controllers. Programming languages
IEC 61131: Part 5 Programmable controllers. Communications
IEC 61131: Part 7 Programmable controllers. Fuzzy control programming
IEC/TR 61131: Part 4 Programmable controllers. User guidelines
IEC/TR 61131: Part 8 Guidelines for the application and implementation of
programming languages
ISO 2954 Mechanical vibration of rotating and reciprocating
machinery. Requirements for instruments for measuring
vibration severity
PD ISO/TR 12767 Measurement of fluid flow by means of pressure
differential devices. Guidelines on the effect of departure
from the specifications and operating conditions given in
ISO 5167

7.3 Electrical

General Requirements

The equipments shall conform to all relevant Bahrain, British or equivalent International
Standards, in particular those detailed below. Where a standard or reference has been
updated or superseded the Contractor shall comply with the latest edition or equivalent
standard. The electrical installation shall comply with latest edition of the Regulations for
Electrical Installations published by the Kingdom of Bahrain, Ministry of Electricity and
Water, Electricity Distribution Directorate (Document Ref EDD/R-1).

Bahrain, British and International Standards

Reference Title

BS 88 Low-voltage fuses
BS 89 Direct acting indicating analogue electrical measuring
instruments and their accessories
BS 90 Specification for direct-acting electrical recording
instruments and their accessories

Page 136
BS 159 Specification for high-voltage busbars and busbar
connections
BS 799: Part 5 Oil burning equipment. Specification for oil storage tanks
BS 1362 Specification for general-purpose fuse links for domestic
and similar purposes (primarily for use in plugs)
BS 1363 Specification for 13 A fused plugs and switched and
unswitched socket outlets (Relevant parts)
BS 1650 Specification for capacitors for connection to power-
frequency systems
BS 3939 Graphical symbols for electrical power,
telecommunications and electronics diagrams
BS 3506 Specification for unplasticised PVC pipe for industrial uses
BS 4293 Specification for residual current-operated circuit-breakers
BS 4533 Luminaries. (Relevant parts)
BS 4568: Part 1 Specification for steel conduit and fittings with metric
threads of ISO form for electrical installations. Steel
conduit, bends and couplers
BS 4607 Non-metallic conduits and fittings for electrical installations.
(Relevant parts)
BS 4678 Cable Trunking. (Relevant parts)
BS 5164 Specification for indirect-acting electrical indicating and
recording instruments and their accessories
BS 5308: Part 1 Instrumentation cables. Specification for polyethylene
insulated cables
BS 5308: Part 2 Instrumentation cables. Specification for PVC insulated
cables
BS 5467 Specification of cables with thermosetting insulation for
electricity supply for rated voltages of up to and including
600 V/1,000 V and up to and including 1,900 V/3,300 V
BS 5499 Graphical symbols and signs. Safety signs, including fire
safety signs
BS 6004 Electric cables. PVC insulated, non-armoured cables for
voltages up to and including 450 V/750 V, for electric
power, lighting and internal wiring
BS 6007 Specification for rubber insulated cables for electric power
and lighting
BS 6121: Part 1 Mechanical cable glands. Armour glands. Requirements
and test methods
BS 6121: Part 5 Mechanical cable glands. Code of practice for selection,
installation and inspection of cable glands and armour
glands
BS 6231 Electric cables. Single core PVC insulated flexible cables
of rated voltage 600 V/1000 V for switchgear and
controlgear wiring
BS 6423 Code of practice for maintenance of electrical switchgear
and control gear for voltages up to and including 1 kV
BS 6469 Insulating and sheathing materials of electric cables
BS 6500 Electric cables. Flexible cords rated up to 300 V/500 V, for
use with appliances and equipment intended for domestic,
office and similar environments
BS 7671 Requirements for electrical installations. IEE Wiring
Regulations
BS 7430 Code of practice for earthing
BS EN 50085: Part 1 Cable trunking systems and cable ducting systems for
electrical installations. General requirements
BS EN 50085: Part 2-1 Cable trunking systems and cable ducting systems for
electrical installations. Cable trunking systems and cable
ducting systems intended for mounting on walls and
ceilings
BS EN 50262 Cable glands for electrical installations

Page 137
BS EN 50347 General purpose three-phase induction motors having
standard dimensions and outputs. Frame numbers 56 to
315 and flange numbers 65 to 740
BS EN 50396 Non electrical test methods for low voltage electric cables
BS EN 55014: Part 1 Electromagnetic compatibility. Requirements for household
appliances, electric tools and similar apparatus. Emission
BS EN 60034: Part 5 Rotating electrical machines. Degrees of protection
provided by the integral design of rotating electrical
machines (IP code). Classification
BS EN 60044; Part 1 Instrument transformers. Current transformers
BS EN 60073 Basic and safety principles for man-machine interface,
marking and identification. Coding principles for indicators
and actuators
BS EN 60309: Part 2 Plugs, socket-outlets and couplers for industrial purposes.
Dimensional interchangeability requirements for pin and
contact-tube accessories
BS EN 60439 Low voltage switchgear and controlgear assemblies
BS EN 60439: Part 2 Low voltage switchgear and controlgear assemblies.
Particular requirements for busbar trunking systems
(busways)
BS EN 60445 Basic and safety principles for man-machine interface,
marking and identification. Identification of equipment
terminals and conductor terminations
BS EN 60447 Basic and safety principles for man-machine interface,
marking and identification. Actuating principles
BS EN 60529 Specification for degrees of protection provided by
enclosures (IP code)
BS EN 60664 Insulation coordination for equipment within low-voltage
systems
BS EN 60898 Electrical accessories. Circuit breakers for overcurrent
protection for household and similar installations
BS EN 60947: Part 1 Low-voltage switchgear and controlgear. General rules
BS EN 60947: Part 2 Low-voltage switchgear and control gear. Circuit-breakers
BS EN 60947: Part 3 Low voltage switchgear and controlgear. Switches,
disconnectors, switch-disconnectors and fuse-combination
units
BS EN 60947: Part 4-1 Low-voltage switchgear and controlgear. Contactors and
motor-starters. Electromechanical contactors and motor-
starters
BS EN 60947: Part 4-2 Low-voltage switchgear and controlgear. Contactors and
motor-starters. AC semiconductor motor controllers and
starters
Bs EN 60947: Part 4-3 Low-voltage switchgear and controlgear. Contactors and
motor-starters. AC semiconductor controllers and
contactors for non-motor loads
BS EN 61061: Part 1 Non-impregnated densified laminated wood for electrical
purposes. Definitions, designation and general
requirements
BS EN 61386: Part 1 Conduit systems for cable management. General
requirements
BS EN 62053; Part 11 Electricity metering equipment (a.c.). Particular
requirements. Electromechanical meters for active energy
(Classes 0,5, 1 and 2)
BS EN 62271: Part 102 High-voltage switchgear and controlgear. Alternating
current disconnectors and earthing switches
BS ISO 1461 Hot dip galvanized coatings on fabricated iron and steel
articles. Specifications and test methods
BS ISO 3046: Part 1 Reciprocating internal combustion engines. Performance.
Declarations of power, fuel and lubricating oil
consumptions, and test methods. Additional requirements
for engines for general use

Page 138
DIN 43802 Line scales and pointers for indicating electrical measuring
instruments
EDD/R-1 Regulations for Electrical Installations published by the
State of Bahrain, Ministry of Electricity and Water,
Electricity Distribution Directorate

Page 139
Abbreviations
ACB Air Circuit Breakers EMC Electromagnetic Compatibility
ACOP Approved Code of Practice EPDM Ethylene-propylene-diene-monomer
ACRIB Air Conditioning and Refrigeration Industry copolymer
Board FA Fresh Air
ADCM Acoustic Doppler Current Meters FBA Factory Built Assembly
AFMA Australian Fisheries Management Authority FRP Fibre Reinforced Polymer
AGMA American Gear Manufacturers’ Association FSC Forest Stewardship Council
AISI American Iron and Steel Institute GANA Glass Association of North America
AS Acceptance Strength GGBS Ground Granulated Blast-furnace Slag
ASTA Association of Short-circuit Testing GMS Galvanized Mild Steel
Authorities GRC Glass Reinforced Cement/Glass Reinforced
ASTM American Society for Testing Materials Concrete
ATS Automatic Transfer Switch GRP Glass Reinforced Plastics
AWS American Welding Society HCFC Hydrofluorocarbons
BASEC British Approval Service for Electric Cables HDPE High Density Polyethylene
BOCA Building Officials and Code Administrators HEPA High Efficiency Particulate Air
BRE Building Research Establishment Ltd. HFC HydroFluoroCarbon
BS British Standards HPL High Pressure Laminate
BSRIA Building Service Research and Information HPPE Higher Performance Polyethylene
Association HRC High Rupturing Capacity
CBR California Bearing Ratio HSE Health and Safety Executive
CCTV Close Circuit Television HSFG High Strength Friction Grip
CECOMAF Comité Européen des Constructeurs de HV High Voltage
Matériel Frigorifique HVCA Heating and Ventilating Contractors’
CENELEC Comité Européen de Normalisation Association
Electrotechnique ICBO International Conference of Building Officials
CFC Chlorofluorocarbons IGCC Insulating Glass Certification Council
CIBSE Chartered Institution of Building Services IGE/UP Institution of Gas Engineers – Utilization
Engineers Procedures
CHW Chilled Water IP Ingress Protection
CI Cast Iron ISAT Initial Surface Absorption Test
CLW Cooling Water ISO International Standard Organization
CM Current Margin / Communication cable ITP Inspection Testing Plan
CMP Communication cable (Plenum) KD Kiln Dried
CP Code of Practice kVA Kilovolt Ampere
CPC Circuit Protection Conductor LCD Liquid Crystal Display
CPT Cone Penetration Testing LED Light Emitting Diode
CRS Categorised Required Strength LPG Liquid Petroleum Gas
CRT Cathode Ray Tube LS0H Low Smoke Zero Halogen
CRZ Capillary Rise Zone LSF Low Smoke and Fume
CT Current Transformer LV Low Voltage
c(UL) Underwriters Laboratories Incorporated MCB Miniature Circuit Breaker
(Canada) MCC Motor Control Centre
DEO Defence Estate Organisation MCCB Moulded Case Circuit Breakers
DFT Dry Film Thickness MDF Medium Density Fireboard
DI Ductile Iron MDD Maximum Dry Density
DIN Deutsches Institut für Normung MDPE Medium Density Polyethylene
DPC Damp Proof Course MEP Mechanical Electrical Plumbing
DPDT Differential Pressure, Differential MICC Mineral Insulated Copper Covered Cable
Temperature MIO Micaceous Iron Oxide
DS Durability Strength MMI Man Machine Interface
DVR Digital Video Recorder MOD Ministry of Defence
DW Ductwork Specification MS Micro-silica
EA Exhaust Air MSDS Material Safety Data Sheet
ECMA European Computer Manufacturers MSRPC Moderate Sulphate Resistance Portland
Association Cement
EA Exhaust Air N Nitrogen
ECMA European Computer Manufacturers NDFT Nominal Dry Film Thickness
Association NEMA National Electrical Manufacturers’ Association
ECR Extra Chemical Resistant NFPA National Fire Protection Association
EIA Environmental Impact Assessment/ NRC Noise Reduction Coefficient
Electronic Industries Alliance NS Norwegian Standard

Page 140
O/D Outside Diameter
ODP Ozone Depletion Potential
OFS Oil Fired (Appliance/Equipment) Standard
OFTEC Oil Firing Technical Association
O&M Operation and Maintenance
OPC Ordinary Portland Cement
PD Published Documents
PE Polyethylene
PFA Pulverised Fuel Ash
PFC Power Factor Correction
PM Project Manager
PTFE Polytetrafluoroethylene
PVC Polyvinylchloride
PVC-u Unplasticised Polyvinylchloride
PWTAG Pool Water Treatment Advisory Group
QA/QC Quality Assurance/Quality Control
RA Return/Recycled Air
RCCD Residual Current Circuit Breaker
RCD Residual Current Device
R&D Research and Development
REFCOM Register of Companies Competent to handle
refrigerants
RPM Reinforced Plastic Mortar
RPZ Reduced Pressure Zone
RTD Resistant Temperature Detector
RTR Reinforced Thermosetting Resin
SA Supply Air
SBCCI Southern Building Code Congress
International (Incorporated)
SDR Standard Dimension Ratio
SIS Swedish Institute of Standards
SP Super-plasticizing
SPDT Single Pole Double Throw
SRPC Sulphate Resistance Portland Cement
SS Structural Strength
SSPC Steel Structures Painting Council
TIA Telecommunication Industry Association
TRA Trussed Rafter Association
UL Underwriters Laboratories Incorporated
ULPA Ultra Low Penetration Air
UP Unsaturated Polyester Resin
UPS Uninterruptible Power Supply
UTP Unshielded Twisted Pair
UV Ultra Violet
VC Vitrified Clay
VR Video Recorder
WBP Weather and Boil Proof
W/C Water Cement Ratio
WIS Water Industry Specification
WP Water Proofing
WRAS Water Regulations Advisory Scheme
XLPE Cross Linked Polyethylene

Page 141

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