Specifications

REPUBLIC OF IRAQ

GENERAL DIRECTORATE FOR WATER

BAGHDAD - IRAQ

VOLUME 1 GENERAL SPECIFICATION FOR ELECTRO – MECHANICAL AND CIVIL WORKS

Volume 1 General Specification Electro-Mechanical & Civil Works Index to Clauses - Technical and Civil Works Specification Clauses Clause No. Title Page One Standard specifications 4 Two Clarifying tanks 7 Three Sludge pit and main sludge pipes 11 Four Alumina dosing apparatus 12 Five Chemical disinfection equipment 13 Six Filters 15 Seven Ground filtered water storage tanks 21 Eight Pumping s e t s 23 Nine Switch board and control panels 28 Ten Sub-stations 35 Eleven Power house 39 Twelve Cables 49 Thirteen Lighting 50 Fourteen Building works 53 Fifteen Environmental services 75 Sixteen Water services 85 Seventeen Steel E. T. S. With foundations 88 Eighteen Structures: Suction well, Suction and Intake 91 Nineteen Pipe work and fittings 95 Twenty Workshop building 115 Twenty – One Overhead travelling cranes 116 Twenty - Two Water meters 117 Twenty - Three Sewage disposal system 118 Twenty- Four Corrosion protection and Painting 121 Twenty - Five Safety rules and regulations 12 Packing and protection during Transports Twenty- Six 129 shipping and storage Twenty -Seven Engineers house 131 Twenty –Eight Operators house 132 Twenty - Nine Fencing with guard room 133 Thirty Roads and foot paths 134 Thirty - one General site development works 135 Thirty - two Surveillance and security system 136 Thirty - Three Spare parts 137 Thirty- four Tools 142 Thirty - Five Furnishings 144 Thirty -Six Water sample testing equipment 146 Thirty - Seven Operation and maintenance instruction 151 Thirty -Eight Plant operation and training of operators 152

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Volume 1 General Specification Electro-Mechanical & Civil Works Note:

The general conditions of tender, general conditions of contract, general and civil works specification, technical specification with bill of quantities and form of summary of tender shall form part of the tender documents. Technical and Civil Works Specification To be observed in the execution of work comprised in the construction of certain water work the subject of the contract.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE ONE STANDARD SPECIFICATIONS 1. A. Except when otherwise stated in the relevant clauses of specification all materials and equipment used in the Plant shall in case be inferior to those specified in British Standard Specification (BSS), when no IOS (Iraqi Organization of Standards) or ISO (International Standard Organization) specification is applicable (for all standard the last edition). They shall pass the test mentioned in the relevant standard. All welded steel elevated service tanks shall conform in general to the requirements of the A.W.W.A.D-100. All electrical equipment shall be in accordance with the latest IEC. All switchboards must be IP56. Any material or equipment found to be inferior to that specified in the above mentioned standard will be rejected. All water retaining structures (clarifiers, ground storage tanks, filters) should be designed without expansion joints in walls and foundations Reinforced concrete should be designed according to CP 8110 or ACI 2002. Retaining structures should be designed according to BS 8007. All valves and gates inside the treatment plant shall be electrically actuated with manual override except clarifiers and ground storage tanks. The GDW (General Department of Water) shall have the right to appoint an inspector to inspect and test the goods before shipment. The Inspector is required to indicate in each of his certificates: • To which standard the inspected material and equipment comply giving the name and number of the Standard. • That material and equipment inspected is in no way inferior to that specified in the above mentioned standard

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Volume 1 General Specification Electro-Mechanical & Civil Works B - Standard design for treatment plants as shown below

Capacity of H.L pumps

Capacity of L.L pumps

No of filters and area

m3/hr

m3/hr

m2

1.

400

420

2.

600

3.

No of clarifiers

inside dia. of flocculation tank (m)

inside dia. of sedimentation Tank (m)

4x20

2

7

20

630

6x20

2

7

20

800

840

8x20

2

10

26

4.

1000

1050

10x20

2

10

26

5.

1500

1575

8x40

2

12

34

6.

2000

2100

10x40

3

12

34

7.

3000

3150

16x40

3

14

38

8.

4000

4200

20x40

4

14

38

9.

6000

6300

30x40

6

14

38

10.

8000

8400

40x40

8

14

38

11.

10000

10500

40x50

10

14

38

12.

20000

21000

80x50

20

14

38

Note: The effective side depth of water in sedimentation tank shall be 4.0m 2.

Materials and Workmanship

All plant and materials employed in the finished construction of the works shall conform to the individual IOS or British Standard Specification or approved equal of such plant and materials and of the current issue where such Specification is in force. Where no IOS or British Standard Specification is available, the best water supply practice should be selected. Provided that in the use of all materials of local production they shall be of the best quality. All materials which in the judgment of the Engineer are of an inferior quality or improper to be used in the works shall be removed by and at the expense of the Contractor and likewise all inferior workmanship and finish shall be amended to the satisfaction of the Engineer. 5

Volume 1 General Specification Electro-Mechanical & Civil Works

3.

Drawings to be Supplied

Drawings showing clearly the plant and appurtenances for the complete installation included in t h e Contract shall be submitted by the Contractor. The drawings shall give all necessary leading dimensions including the clearance between the pumps and th e walls. On notice of the acceptance of the Tender the Contractor shall submit, within six months complete signed working drawing of the general arrangement of all details of the complete plant apparatus and appurtenances and elevated service tank for the full information and approval of opinion on the part of the Engineer as; to the efficiency or strength of any part of the plant and appurtenances or in any way reliving the Contractor from his responsibilities and obligations under the Contract. Within two weeks after notification of approval of the drawing the Contractor shall supply a further four sets of complete drawing linen backed for use by the representative of the Engineer on sites of works and for office record. Literature, pamphlets of machineries with names and numbers of different parts as well as chlorinators etc, and operation instruction complete with linen backed drawings are to be supplied in triplicate by the Contractor before starting the work. The price of supplying the drawings shall be included in the total price of the Scheme. During the period of maintenance, the Contractor shall supply to the Engineer, record drawing to a scale approved by the Engineer showing layout of the complete treatment plant and all details of the equipment, writing, cables, pipelines etc. The record drawings shall furthermore show all branches and connections left for future extensions. One ink tracing and five paper prints are to be supplied for each such drawing with 2 (CD) for final drawing. Note: All mechanical & electrical drawing must be submitted before civil drawings.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE TWO CLARIFYING TANKS A- Circular Type The clarification of the raw water shall primarily be undertaken in single stage comprising flocculation and settlement. The tanks employed in those operations shall be of Nos. indicated in Basic Data and shall be constructed in vibrated reinforced concrete of 1:1½:3 mixtures. All inside surfaces shall be smoothly finished and the tanks must be watertight. They shall be equipped with electrically driven (peripheral drive) revolving sludge scrapers and provided with scum collecting channels with discharge common with overflow. The drive shall be equipped with an overload device to stop the drive meter when the overload becomes excessive. The sludge shall be scraped into a central hopper from which it shall be discharged to the river under the hydraulic head to be obtained in the tanks through a common sludge main with tidal flap out falling 50m downstream of the intake work when the highest water level in the source permits that and with bypass arrangement to sludge pit if the highest water level does not permit that the slope of the floor on which the sludge is scraped shall not be less than 8%. The rim of the tank which forms the track for the outer end of the scraper bridge shall be made to correct level throughout and shall be plastered with wood polished concrete plaster. However the scraper mechanism should be able to tolerate 0.1% inaccuracy in the track level. Each scraper shall be provided with a single rubber wheel. The wheels shall have high quality polyurethane or Duthene tiers suitable for humid and hot climate and shall be set radially true. The scraper bridge shall extend from the wall of the tank to a point beyond the center pier to provide convenient access to the flocculators drive. The bridge shall not be less than 0.7m in width and shall be surfaced with chequer plate flooring of not less than 6mm in thickness. The bridge shall have double rail hand railing to both sides, the rail being tubular 30mm minimum outside diameter. Stanchions shall be of cast steel at not greater than 1.6m centers and the finished height of the hand railing shall not be less than 0.7m above the walkway. All steelwork shall be painted in accordance with the specification (clause 24). The tanks shall be additionally provided with a special arrangement for continuous sludge bleeding. This shall be in the form of adjustable overflow permitting continuous sludge withdrawal at a slow rate under minimum hydrostatic head. The diameter of the sludge outlet pipe from each clarifying tank shall be as indicated in Basic Data and that of the common sludge main shall be as indicated in Basic Data. There shall be an inspection chamber at the outlet of the sludge pipe for each tank and shall be located in such a way that the operator could inspect the sludge while operating the 7

Volume 1 General Specification Electro-Mechanical & Civil Works sludge valve. The direction of discharge shall be parallel to the line of motion of the river. An arrangement for flushing the sludge pipes from the pumping main of the high lift shall be provided. The diameter of the flushing pipe shall not be less than 200mm. The main sludge pipe for the scheme shall be extended from clarifying tanks and filters to sludge pit then to river. The inside diameter of each clarifier shall be as indicated in Basic Data and inside diameter of each flocculator also as indicated in Basic Data. The minimum side effective depth of water in the clarifying tanks shall be 4m. The tanks will normally be operated in parallel but shall be made capable of being independently operated for the purpose of overhaul and maintenance of the mechanical equipment and when the degree of turbidity of the raw water so permits. The sludge pipes should be located at a depth capable to empty each clarifier completely. Consideration should be given to the manner of draw-off as locality is subject to intense dust storms which will deposit a layer of impalpable dust on the surface of the water and all care shall be taken to insure that the settled water will be collected at equal rate from all the sides of the tanks. The clarified water shall be collected at adjustable weir along the periphery of the basin. The settled water from each clarifier shall be connected with control chamber by ductile pipes with sluice valve. The flash mixer(s) shall be constructed in a separate concrete chamber each having a retention period of one minute pumping capacity with shaft driven by electric motor. The shafts of the flocculation tanks also shall be driven by electric motors. The motors driving the mechanical equipment shall be of the totally enclosed weather proof squirrel cage type and be suitable for operation at 400V, 3-phase, 50Hz with output for continuous rating and shall conform to BSS 2613 with windings of Class F tropical proof insulation and with limits of temperature rise of 10°C less than those permitted under the BSS. The motor shall be fully equipped in accordance with the Regulations for the Electrical Equipment of Buildings of the Institution of Electrical Engineers, England and shall be housed in an approved manner in protection against inclement weather and the effect of the direct rays of the sun. Where the power of the motors exceeds 7.5KW Star / delta type starters shall be provided. The flash mixers and the flocculators shall be of approved efficiency in their respective performance of thorough pervasion of the chemical and agglomeration of the flocculators. There should be a distribution chamber of a volume as indicated in Basic Data to which the raw water pipes will be connected. Then from this well the raw water will be distributed to each flash mixer. The overflow of clarifying system should be constructed at this structure a control chamber of a volume as indicated in Basic Data to which settled water should be collected before going to the fitters should be provided. The tanks shall be embanked with well compacted good earth to a height of 0.9m below their upper periphery and sown with 8

Volume 1 General Specification Electro-Mechanical & Civil Works suitable grass. The top of the embankment shall be 1.2m wide and the side slope shah be 1:1 level with the top of the embankment, a reinforced concrete 1 meter wide footpath around the tanks and attached to the tank walls shall be provided to allow access for inspection and operation of the tanks. Necessary valves shall be supplied for isolating each clarifier from others during maintenance period. B- Rectangular Type The concrete tacks to be employed in the preliminary treatment of the raw water shall be of the upward flow type, a flocculator shall be incorporated in the tanks. The retention period in the flocculation compartment shall not be less than 20minutes, at a rate of full flow per hour and 1½ - 2 hour in each sedimentation tank. The tank shall be constructed with vibrated reinforced cement concrete 1:1½:3. The sludge shall be discharged to river under the hydraulic head to be obtained in the tanks through a sludge main with tidal flap valve out falling 20m downstream of the point of intake of tile low l i f t pumps direction of the charge shall be parallel to the line of motion of canal. The surface load in the tanks when both in operation shall not be more than 1m3/m2/hr and the water depth in the tanks shall not be less than 3.0m excluding sludge hopper space and the freeboard which shall not be less than 50cm. The bottom of the tanks shall be in a form at a paramedic hopper or hoppers at not less than 45° slopes with a sludge draw-off from the invert of each hopper. The tanks shall be provided with scum collecting channels with discharge common with the overflow and with gangways and with access ladders, the tanks shall be provided with suction tanks for the high lift pumps of capacity not less than 5m3. The dia. of sludge pipe for each tank shall be not less than 100mm, and the common sludge main shall be not less than 150mm. To increase the surface area of these tanks we can use lamella (inclined plate) which shall be rigid self supporting lift table steel from for easy cleaning and maintenance. The plates shall be in st i l le d in the upper half of the tank and arrange 55° degree angle, the plates shall be arrange for easy removal and washing with lifting device. The lamellas plates shall be used for extension the treatment plant only with more filters added for these purposes. The flash mixing shall be done in separate cement concrete chambers having a retention period of two minutes pumping capacity with shaft driven by electrical motor. There shall be an inspection chamber at the outlet of the sludge pipe for each tank shall be located in such a way that the operation can inspect the sludge while operating the sludge valve, the clarified water shall be draw off through perforated collecting pipes or channels spaced 1.0m centers across the tank . 9

Volume 1 General Specification Electro-Mechanical & Civil Works The diameter of the pipe connecting the flocculation tank and each sedimentation tank shall not be less than 200mm. The motors are used in the tanks they shall be of the totally enclosed squirrel cage output for continuous rating and shall conform to BSS 2613 with windings of class F Tropical proof insulation and with limits of temperature rise of equipped in accordance with the (Regulations for the Electrical Equipment of Buildings) of the institution of Electrical Engineers, England and shall be housed in an approved manner in protection against inclement weather and effect of the direct raves of the sun. Where the power of the motor exceeds 18.5KW star / Delta type starters shall be provided. The flocculator shall be of proved efficiency in its performance of through pervasion of the chemical and agglomeration of the flocs. Due consideration shall be given to the effective depth of the tanks the number of inlets and the manner of the draw off of the clarified water in their bearing on the optimum operation of the tanks and moreover to the consequence of the locally experienced intense dust storms which will deposit a layer of impalpable dust on the surface of the water. The Contractor shall include in his Tender for the professional fees for the design of the complete tanks and documents with fully detailed drawing.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE THREE SLUDGE PIT AND MAIN SLUDGE PIPES The wash water overflow and drain from all parts of the plant shall be discharged directly to the river by a common sludge pipe under the hydraulic head to be obtained from the respective units and discharged to the river. A sludge pit with sludge pumps for pumping the sludge to the river shall be provided. A bypass from the sludge main to the pit shall be provided with the necessary control valve for diverting the sludge to the pit whenever it is necessary and vice versa. The pit shall be made of reinforced concrete (1:1½:3) and shall be of capacity as indicated in basic Data the slope of the pit floor shall not be less than 25% towards the suction pipes of the sludge pumps. All inside surface of the pit shall be smoothly finished and the pit shall be provided with hand railing of not less than 0.75m in height above ground level. The sludge shall be pumped to the river by triplicate unshakeable, self-priming pumps (one as stand by). The pumps shall be provided with a level control to stop and start the pumps when the liquid level reaches predetermined maximum and minimum levels in the pit, t h e pumps shall be positive head. The starters shall be fitted with suitable adjustable time relay device so that there is no possibility of more than one motor starting in the station at one time. The pumps control shall be arranged with probe-type metal electrodes, which uses the liquid as an electrolyte to complete the electrical circuit and operate a magnetic relay. The pumps shall be housed in a suitable building which shall be built in accordance with the pumps and filter house building. A monorail should be provided to lift the pumps and accessories from the building for maintenance purposes. Note: Over flow pipe of the GST will be connected to the sludge pit according to hydraulic head and the capacity of the sludge pumps shell be calculated according to this note. General details of the sludge pit and detailed specification of the sludge pumps shall be submitted with the offer.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE FOUR ALUMINA DOSING APPARATUS The raw water will be dosed with a solution of kibbled sulphate of alumina in the process of the precipitation of the suspended matter and for this purpose tanks complete with stirrers driven by electric motor, air ejector, regulators and flow indicators shall be provided. The flow indicators shall be calibrated in both liter/hr of solution and in mg/liter (ppm) for 10% solution in accordance with the pumping rates. The capacity of each tank shall be sufficient for 10% solution to does the water with alum at a rate of 100ppm at a pumping rate of the raw water of the scheme for 8 hours operation. All surfaces of the apparatus and equipment in contact with the sulphate of alumina solution shall be resistant to the corrosive attack by this chemical using acid resistance tiles. The tanks must be ROBUST and if made of concrete (RCC of 1:1½:3 mixtures) provision shall be made in the system of supply for the facility of removing any part for clewing in the event of deposit building up. The solution shall be fed by dosing pumps to each flash mixing chamber. The dosing pumps shall be operated, started up and stopped under control of the raw water pumps. An arrangement for flushing the pipe connecting the dozer to the point of application shall be made from the service pipe iron the plant. There shall be an electrical hoist with runway of 0.25 Ton capacity to lift the kibbled sulphate to the solution tanks a platform not less than one meter wide with handrails shall be provided in front of the tanks to facilitate their operation and inspection. The drain pipe for this apparatus shall be connected to the drain pipe for the Plant. A 0.5 Ton platform weighing scale shall be provided for weighing the alum before charging it in to the solution tanks. Should the Contractor desire to tender for a dosing apparatus other than the aforesaid type, it should be submitted a n d priced as an alternative. General design details of the apparatus must be submitted with the offer.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE FIVE CHEMICAL DISINFECTION EQUIPMENT The filtered water s h a l l be disinfected by chlorine and for this purpose chlorinators shall be provided to dose the effluent of the filters with chlorine. The No. and the dosing of each chlorinator shall be according to Basic Data. All chlorinators shall be of pedestal cabinet form and of the automatic type and suitable for injection feed. The injection units shall be operated by pressure water obtained from the ground storage tanks provided by means of three booster pumps (two as stand by) which shall be for this purpose. An ivorine plate with dose chart consistent with the High Lift pumping rates shall be fitted to the Panel of each apparatus. Automatic devices with indicating lights and gas pressure gauges shall be supplied at site of waterworks for charging the flow of chlorine gas for each set of drum (each set at least two drums) to the other when one set of drum gets empty. The maximum limit of chlorine gas pressure shall not be less than 200psi in addition shut-off valves and pressure gauges shall be provided for manual change over when the automatic device is out of order. The chlorine stores shall be provide with an electric type hoist of 2tons capacity with two 2tons weighing scales with suitable top monorail and cross girders with arms and hooks to lift the chlorine drums and putting them in position. Suitable truncheons seating the chlorine drums shall be provided and fixed to the floor of chlorine store. The general arrangement of drums and the electric hoist in the chlorine store shall be similar to that shown in the typical drawing in the Appendix. One set of chlorine leak detection equipment shall be provided in each of the chlorine room and the chlorine store and they shall be of the type that gives a warning sound when the chlorine concentration in the atmosphere becomes dangerous. The Contractor should submit with the tender all details for these sets. Two 50cm Plastic axial fan ventilators to be located in the chlorine room 1ft (30cm) above floor level under the window shall be provided. They must be suitable for chlorine contact. A similar four fans ventilator shall be provided for chlorine store. Four No. makes suitable for protection against the chlorine gas each packed and a suitable wooden box shall be provided. The walls and floor of chlorine room shall be covered with acid resistance tiles and the same for the store except the floor should have heavy paint of acid resistance. Two rubber suits complete with breathing device and oxygen cylinder and all accessories must be provided and four pairs of glove. A wall mounted chlorine fume detector capable for determining in a i r concentrations to a sensitively of 0.1micro-liter/liter shall be provided and installed one in chlorine store and one in chlorine room. It shall have alarm contact for operator at 13

Volume 1 General Specification Electro-Mechanical & Civil Works 5micro-liter/liter to bring up a warning light within the chemical attendant room with repeat indication on the main water supply control panel. The detector shall have a further set of heavy contact to operate at a level of 15micro-liter/liter. At this level an audible alarm and warning light it in chemical attendant room together with a repeat alarm indicating on the main water supply control panel shall be initiated and operate the exhaust fans automatically. The contractor shall make allowance for all measures necessary to prevent leakage of chlorine gas from pipe work connection between the liquid chlorine gas. These measures shall include: 1- A pictorial representation of the procedure for changing liquid chlorine containers with written instructions where necessary in Arabic and on plastic covered card mounted on a board fixed to the inside wall of the chlorine store. All tools necessary for changing the containers shall also be clipped to this board. 2- All necessary washers and couplings required when changing containers sufficient for five years operation. 3- A water spray bar to provide a water curtain fixed externally over the chlorine store and connected via solenoid operated valve direct to the delivery main from pumping station. The solenoid valve shall operate automatically at chlorine gas concentration within the chlorine store of 15micro-liter/liter. This system must be provided with manual starting from outside the room for emergency The dosing location for the chlorinators shall be: B.

Inlet channel of G.S.T.

C.

Outlet channel of G.S.T.

D.

Each flash mixer.

The system shall be provided with necessary valves to choose the required location. Detailed drawing for the arrangement of the chlorine room, chlorine store and the electric hoist complete with working drawing shall be supplied together with installation instruction and well covered operation and maintenance instruction in accordance with clauses of this specification. A Similar arrangement shall be provided for Boosting Station if required according to Basic Data.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE SIX FILTERS a) Rapid Gravity Filters The filters shall be rapid sand gravity type comprised in a battery of total effective filtering area in comport with a filtering rate of 5m3/m2/hr. The No. of filters and the effective area of each filler shall be as shown in Basic Data. The filters are in the form of rectangular tanks and shall be constructed from vibrated reinforced cement of 1:1½:3 and shall be made perfectly water-tight with fair faced internal surface. The filter under drainage system should consist of a manifold made of reinforced concrete or well protected steel and perforated pipe lateral made of either copper or appropriate plastic material. The lateral end should be supported by a concrete block with 7.5cm in height, allowing the laterals to collect the filtered water from the gravel and also distribute the wash water during the washing process, the cross sectional area of the manifold should preferably be 2-3 times the total area of the laterals in order to minimize friction losses and give the best distribution. The perforations or orifices in the laterals should be directed downward with 150° either clockwise or anticlockwise from the vertical axis of the lateral. The ratio of the final area of the perforations or orifices to the filter bed area should be between 0.2% to 0.5%. Each filter shall be cleaned by an upward wash waters in conjunction with agitation by pressurized air and for this purpose a suitable rotary air blowers complete with an air filter and a silencer, isolation valves, non return valves, pressure gauges and air flow meters shall be provided. An oil interceptor shall also be provided to make sure that no oil goes to the filters. Air blowers shall be provided, to provide the necessary a i r to the filters. The capacity of each blower shall be as indicated in Basic Data. The units shall be containerized to lower the noise level to 20 db. The common delivery pipe supplied with non return valve and relief valve also each delivery pipe from the air blower shall be equipped with a sluice valve. A bypass arrangement shall be provided with necessary valves for emergency use between the sets, The wash water shall be obtained from the storage tank below the pumps the effective size of this tank shall be according to Basic Data or from GST. The wash water pumps shall be mixed flow type, or horizontal split case. The bottom of the wash water troughs must be kept at least 5cm. above of the surface of the expanded sand and the top edge of the 15

Volume 1 General Specification Electro-Mechanical & Civil Works troughs shall not be more than 60cm above the top of the filter bed. The top of the troughs shall be leveled, and the capacity of the troughs shall be such that they will carry the maximum rate of wash water with a minimum freeboard of 5 cm. Lateral travel to the wash water overflowing into the troughs should be between 1.0m to 1.5m (i.e. the clear distance between troughs is hold to be between 2m to 3m), the troughs should discharge into a gullet, the capacity of the gullet be such that it will carry the maximum coming water from the troughs. The filtering material shall be clean silica sand acid washed, there should be no reaction where the sample of the filter medium is placed in diluted hydrochloric acid and when immersed in concentrated hydrochloric acid, the sand shall not lose more than 2% of its weight. The sand shall be compounded pure quartz sand having a depth of not less than 70cm, having an effective size from 0.60mm to 0.650mm and with a uniformity coefficient of not greater than 1.5. A sample of the sand and its size distribution shall be submitted for approval before being used. The gravel supporting the sand should be hard, rounded and durable, be free from flat, thin or long pieces and containing no loam, sand, clay, shells or other foreign materials, grading and layer thickness shall be approximately as follows: Gravel size

Depth

50 to 38 mm

10 cm

38 to 13 mm

10 cm

13 to 9.5 mm

10 cm

9.5 to 6.5 mm

15 cm

6.5 to 2,5 mm

15 cm

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Volume 1 General Specification Electro-Mechanical & Civil Works Testing procedure for filter media 0.6mm to 0.6mm filter sand particle sizing by sieve analysis 1) Sieves: 200mm diameter test sieves to BS 410 sieve size Metric

ASTM

BS

1.4

14

12

1.18

16

14

1.00

18

16

0.85

20

18

0.71

25

22

0.60

30

25

0.50

35

30

0.425

40

36

PAN

PAN

PAN

2) Sample Charge: Obtain a representative sample of the media through suitable sub-division. The sample weight should be minimum 200g maximum 500g. Sample should be dry or free flowing. 3) Sieving: Selected sieve stack should be placed on suitable sieving machine and vibrated for 5min after introducing selected representative sample into top sieve. 4) Results: The particles retained on each sieve should be accurately weighed and tabulated to produce a cumulative weight retained on each sieve. Cumulative percentage retained should then be calculated for each sieve and resultant percentage plotted against sieve sizes to produce a graph curve for the media. The effective size should then be obtained from the plotted graph and uniformity coefficient calculated. 5) Effective Size: Particle size for 90% retained. 6) Uniformity Coefficient: Particle size for 40% retained divided by particle size for 90% retained to conform to contract specification the effective size should lie between 0.6mm and 0.65mm and the uniformity coefficient should be less than 1.5.

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Volume 1 General Specification Electro-Mechanical & Civil Works ACID SOLUBILITY 1) Sample weigh: Obtain a representative sample of the media through suitable sub-division. The sample weight should be minimum 100g after rinsing with distilled water. 2) Testing: The rinsed representative sample should be placed in contact with 10% V/V hydrochloric acid at room temperature for 24 hours. Any initial effervescence and color of the supernatant liquor at the end of the test should be noted. After 24 hours the sample should be washed in distilled water, dried at 105°C maximum and re weighed. 3) Results: Loss in weight of the sample should be calculated and tabulated as a percentage figure to conform to the contract specification the loss in weight should be less than 5% V/V. ORGANIC CONTENT Minimum sample weight 5g loss in weight on ignition at 350°C for 1hr should be less than 5% w/w. The depth of water on the surface of the sand shall be not less than 1.50m. The elevation of water on the filter shall be at least 3.00m higher than the minimum water level in the clear well. The water level in the filter must be below the filter operating floor. Provision must be made for draining the filtered water to waste, the drain valve may be a hand operated valve, and need not be controlled from an operating platform. All other valves shall be electrically operated from a steel controlling desk of attractive appearance to be installed next to each filter. The desk shall comprise: 1) Head -lose gauge with warning light indicator, indicating when the filter ought to be washed. 2) Rate of flow indicator. 3) Control tight indicating the state of filter (filtering, washing, stop). 4) All push buttons to operate the filter valves, with indicating light. 5) Switches to start and stop the air blowers and washing filter pump from G.S.T. with light indicating their position (ON & OFF). 6) Push button for all lamp testing. The waning light shall operate at a predetermined loss of head between 1.2m to 1.8m at which the filter should be washed. The inlet to the filters shall be arranged in such a way as to ensure equal distribution of settled water between the filters. A control of filtered water rate by a weir shall be incorporated in the outlet of each filler to ensure a minimum of 10cm depth of water above the sand bed and a maximum of 1.5m. In this way the filtration rate will only depend on the amount of settled water 18

Volume 1 General Specification Electro-Mechanical & Civil Works coming to the fi l t e r s . When submitting his offer the Contractor shall give full details of the fillers control arrangement to ensure this. The diameter of each pipe connecting the sedimentation tanks and filters should be as indicated in Basic Data and the diameter of common wash water outlet should be connected to the sludge pit. Overflows shall be provided in the inlet channel of the filters. All care shall be taken that the pipe arrangement shall be easy to install, maintain and operate. The entire area of the filters shall be covered by a superstructure, with sufficient headroom not less than 3.5m to permit inspection and operation for filter beds. The minimum depth of a filters bed shall not be less than 3m. A curb must be provided around the filter to prevent floor wash from entering. Filter effluent pipes in the clear well should be trapped to prevent air from entering the bottoms of the filters, the wash water from the filter shall be discharged to sludge pit. Should the Contractor desire to tender for filters arrangement other than the aforesaid arrangement it should be submitted and priced as an alternative. After the maintenance period the loss of depth of the sand must not exceed 3.5cm and the contractor shall supply the required lost quantity. If the loss exceed 15cm all the sand must be replaced be new sand on Contractors account. b) Pressure Filters (for each unit) The settled water shall be pumped from (Intermediate Tank) to ground storage tank pressure filters (Horizontal types), each filter shall be in 20ft (6m) container. Each filter shall have the following requirements: 1. Wall thickness not less than 10 mm 2. Dished ends not less than 12mm 3. Nozzle floor not less than 16mm 4. Number of nozzles shall not be less than 500 No. per filter 5. Rate of filtration when all filters working shall not be more than (68) m3/m2/hr 6. Filter media shall be provided for each filter with spare filter media for complete one filter in suitable sacks 50kg, the sand shall be pure quartz sand having depth less than 60cm, having an effective size of from 0.60 to 0.65 and having a uniformity coefficient of not greater than 1-5 and gravel will be 9.5 - 13 9.5 - 6.5 6.5 - 2.5

10 cm 10 cm 10 cm 19

Volume 1 General Specification Electro-Mechanical & Civil Works 7. Back washing of filters as follows: a) Air for agitation using duplicated air blower (1+1 capacity each 600 m3/hr. b) Water (through other filters and air). c) Water (through other filters only arrangement) for automatic operation and manual operation for back wash sequence. 8. Differential pressure gauge with warning light (sound and light) for filter back wash shall be provided in main control panel. 9. Each filter shall be supplied with two inspection manhole at the top and one at the bottom. 10. Air relief valve of 2 inch reinforced concrete saddles of strip around roofing or other they pass through the walls of

diameter the filter shall be seated on 1:2:4 mixture and surrounded with a suitable semi-plastic material where the filter corridor.

20

Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE SEVEN GROUND FILTER WATER STORAGE TANKS The ground filter water storage tanks shall be constructed in vibrated reinforced cement concrete of 1:1½:3 mixture and the tanks shall be made perfectly water-tight with smooth internal surfaces. The capacity of the tank shall be as indicated in Basic Data excluding freeboard inlet and outlet channels. The water depth in the ta n k shall be as indicated in Basic Data and the tank shall be divided into two or four equal separate cells or compartments according to Basic Data for independent operation. The tank shall be covered with reinforced concrete (1:2:4) roof and shall have over flow washout, manholes ventilators etc. with necessary valves, One 100mm dia. ventilator shall be provided for every 100m2 of roof area or equivalent. The ventilators shall be provided with outer ends fitted with removable weir wool strainers or other suitable device for the purpose of arresting the entry of dust in the normal breathing of the tanks at times of prevailing dust storms. In order to avoid stagnation, horizontal circulation of water (by means of partitions) shall be arranged. Filter water from the rapid gravity filters shall flow into each cell or compartment of the tank and suction pipes of the high lift pumps shall be connected to suction compartment. T h e max water level of the tanks shall be not more than the level of reformed ground level at site of water work. After testing the tanks shall be embanked with good earth of 60cm thickness with side slopes (1:1½) and sown with suitable grass. There shall be indicators in the pump and filter house building to show the water levels in each cell or compartment of the tank. Max water level at the tank shall at least 2.5m lower than Max water level at filters. There shall be movable pumping arrangement to pump out to sludge pit impure water from the tank if the tank cannot be dewatered completely. The invert of the suction such compartments of the tank to which the suction pipes of the high lift pumps shall be connected shall not be less than 1.5m below the invert of the tank. The over flow pipe should be extended to the river. Drain pipe shall be provided for each cell or compartment and the common sludge pipe shall be connected to the overflow pipe or sludge pit. An arrangement shall be provided to prevent any backflow of sludge to the tank. The tank must be separate from pump filter house building. An arrangement for removing any foot valve and strainer without having to empty the tank and stopping the plant shall be provided. One monorail above the suction compartment shall be provided for lifting strainers fitting from the tank. The contractor shall supply and install level transmitter in each compartment of the tank and digital type recorded and indicator shall be installed in instrument panel. 21

Volume 1 General Specification Electro-Mechanical & Civil Works A bypass arrangement shall be provided between the inlet compartment to the tanks and suction compartment of the pumps using a ductile iron pipe with valve to bypass the tank if the tank is four cell or more. Float valve with electrical butterfly valve shall be installed in the inlet pipe of GST of Boosting Station. Overflow system for GSTs in Boosting Station should be according to Basic Data.

22

Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE EIGHT PUMPING SETS A) Horizontal Split Case Pumps The pumps shall be of the single or double entry Horizontal split case type positive suction and of a speed not exceeding 1500rpm when performing their normal duty at maximum efficiency and shall each be driven through a flexible coupling by AC motor. The impellers of the pumps shall be of bronze for High Lift Pump and stainless steel material for Low Lift Pump with passages finished to a perfectly smooth and true surface and shall be keyed to stainless steel shafts and be in static and dynamic balance. They shall be fitted with renewable eye rings neck bushes and shaft sleeves and all internal bushes secured. The glands shall be provided with split bronze lantern rings and filtered water lubricated with sealing device to preclude the admission of air. The pump house floor shall be kept dry by fitting small diameter (not less than 20mm) drain pipes from the gland of each pump to discharge to waste. All ball or roller or grease lubricated bearings shall be arranged for grease gun lubrication and 2 No. suitable grease guns provided. A pressure and pressure vacuum gauge of Bourdon type, priming funnel cock and air cock shall be fitted to each pump. The pressure gauge shall be calibrated in meter head of water and Kg/cm2. Sluice valves with hand wheels shall be non return valves with bypasses. The sluice valves on the suction branches shall be water sealed in preclusion of air being drawn in during pumping operation. The non return valve shall be installed between the pump and the delivery sluice valve so that it can be isolated for cleaning when necessary. The sluice valve should preferably be installed with their spindle vertical. The sluice valves, non return valves and pressure gauges shall be of the best quality and from reputable manufacturer, where tapers are employed in the connections of the pumps to the suction main they shall be of the flat topped type with the flat surface on the upper side. All care shall be taken that the pumping arrangement for the pumps shall be easy to install, maintain and operate. All fitting used in the piping arrangement shall be standard fittings. All pipe work within the building shall be supported on fair faced concrete stools or on wall brackets, maximum spacing for supports is 1.8m on horizontal runs and 3.0m on vertical runs. Each of the high lift pumps shall have a separate suction from the clear water storage tank. The motors driving the pump shall be suitable for operation at 400V, 3-phase 50Hz up to 500KW, 11KV for larger motors with output continuous rating and shall be of the squirrel cage induction protection IP55 minimum type with fan cooling and shall conform to BSS 2613/1971 with windings of 23

Volume 1 General Specification Electro-Mechanical & Civil Works class F tropical insulation and with limits of temperatures rise of 10°C less than those permitted under this specification. They shall be fully equipped in accordance with the Regulations for Electrical Equipment of Buildings of the Institution of Electrical Engineers, England. They shall be able to work under voltage variation of 5% occasionally, under 10% during short periods, without developing damageable heat rating of No for must be operate (55°C). Air break automatic starter with push button ON/OFF with under voltage overload relay (MCCB) molded case circuit breaker shall be provided with each motor. The starting equipment shall be of the star delta starter. The starter shall be located at the side of each pump if the starter located in the upper floor a local ON/OFF must be provided near each pump. A monitoring ammeter shall be installed on the starter such that the operator can watch the rise of motor current while loading. The couplings between the motors and pumps shall be of the flexible rubber bush and steel pin type and shall be turned to ensure perfect balance and bored to the shaft gauge and securely keyed and fitted to the shaft. Each unit shall be mounted on a common base plate of substantial casting with machined surfaces for the feet of the pump and motor and with planed underside and shall be erected on fair faced concrete foundation. The pumps motors, starters and their accessories shall be of the best quality of reputable manufacturer. The characteristics of the pumps shall be stable. The horse power of the motors shall be such as will provide a margin of 10% over and above the required in their stated parallel operation. The overall efficiency of the pumping units shall be guaranteed not less than 70%. Each pumping unit shall be provided with the following protections: •

Protection against uprising and priming and dry running.

•

Protection against mono phase driving.

•

Protection against stator healing.

•

Protection against bearing excess heating.

Three sets of characteristic curves for each set of pumps shall be provided for office record and three sets of complete instruction for operation and maintenance of the plant shall be supplied. A complete set of wiring diagram for all electrical equipment shall be provided on suitable and durable material and fixed to the wall of the motor room for easy reference. The floor shall be sloped (about 1 in 100 minimum) towards a sump from which the drainage should be pumped by twin electric pump which shall be provided for this purpose to waste for alternative operation. The floor of all pumps pits shall be covered with suitable best quality tiles. Walkways shall be provided for all pumps pit in order that all 24

Volume 1 General Specification Electro-Mechanical & Civil Works the windows could be open. b) Mixed Flow Pumps Mixed flow pumps shall be close coupled vertical suspended pumps. The pump and drive unit shall be close coupled and mounted in correct alignment. The casing shall be split at the suction flange to permit withdrawal of impeller after dismantling of suction pipe work. The material of the casing shall be close grained cast iron minimum Grade 260 to BS 1452 free from blowholes and other defects. Lifting rings shall be provided on the pump and drive unit casing to permit lifting of complete pump unit including bed plate. The impellers shall be stainless steel. The shaft shall be manufactured from high tensile steel minimum with renewable phosphor bronze or stainless steel sleeves of large bearing surface where the shaft passes through the seal housing. The shaft bearing and seals should be oil water lubricated type or dry type. The motor specifications shall be according to horizontal split case pumps but vertically mounted. C) Submersible Pumps General Description The pump and electric motor drive shall be directly coupled and shall form a single vertical unit freestanding within the sump on a combined base and suction strainer. Materials of Construction Materials of construction shall be as follows: Pump casing and stator housing close grained cast iron free from blowholes and other defects. Renewable phosphor bronze case wear ring shall be fitted at both suction and delivery. A separate oil filled casing shall be provided between the pump and motor casing to lubricate and tool the seals. A strainer shall be provided at the base of the unit. All connecting bolts and nuts shall be of stainless steel. Impeller stainless steel, non clocking type machined to a smooth and accurate profile to discourage aversion of fibrous matter and provide for passage of solids. The impeller and shaft assembly shall be statically and dynamically balanced as a whole unit. Shaft: Stainless steel renewable sleeves of large bearing surface where the shaft passes through the seal housing. Bearing: A heavy duty tapered roller bearing and a heavy duty ball bearing shall be provided. 25

Volume 1 General Specification Electro-Mechanical & Civil Works Seals: Shaft seals shall be of the mechanical type with tungsten carbide interfaces and of well proven design and backed by a lip seat. A separate oil filling casing shall be provided between the pump and stator casing to lubricate and cool the seals. An oil reservoir level indicator shall be provided at a convenient level above the pumps. The seal housing shall be provided with a plug to enable checking of the oil level and condition to be carried out, motor work at 400V, 3 phase, 50Hz, IP68, class F insulation.

Accessories and Fittings The following accessories and fittings shall be provided: Reflux valve and wedge gate valve on delivery main, level electrodes for stop, start and emergency low level alarm, holder for level electrodes suitable for wall mounting complete with intermediate supports. Cables for power required (Dol or Y/D) with control cables for float switch. D) Sludge Pumps End suction centrifugal pumps with non-clocking stainless steel impeller, rpm not exceeding 1000rpm, the pump and motor must be designed to handle heavy slurry suspended materials. Other specifications are as for horizontal split casing. E) GENERAL 1- Cooling of Motors The cooling of all motors exceeding 500KW shall be either by means of pipe ventilation with dueled discharge of warm air to the exterior of the building and with efficient air fillers on the inlet apparatus to prevent airborne dust entering the enclosure, or alternatively by a closed air circuit and water cooled system including all necessary external ventilating and ducting. A thermometer shall be fitted to indicate the bearings temperature and a visual indicator shall be fitted in the cooling circuit to show that the fluid is flowing. A temperature sensor shall be fitted to operate an alarm on the station alarm panel if bearing should get over heated. Temperature sensors embedded in the motor windings shall also be indicated to stop motor and to give alarm indication if the windings are too hot (for all motors). All valves inside the plant shall be electrically operated with indicator.

26

Volume 1 General Specification Electro-Mechanical & Civil Works 2- Characteristic Curves and Performances Characteristic curve of the pumps shall be submitted with the Tender including curves of total head capacities BHP at coupling and overall efficiencies. The efficiencies of the low lift pump units should cover the range of static lift or head between the lowest low water, and highest high water at the source of supply. The performance of the pumping units as specified when operating at the imposed head comprised in their sequence of operation shall be submitted in the following form: PERFORMANCE OF PUMPS AT WORKS PUMPING STATION 1 Static head in m.

2

3

4

5

Total Discharge in Water Horse W.H.P. as imposed m3 per Power as calculated head in m. minute calculated from columns on pump from columns 2&3 1&3

6

7

B.H.P. at pump coupling

% Pump efficiency W.H.P X 100 B.H.P.

A further triplicate copies of the characteristics curves of all pumps included in the plant should be submitted for record before handling over the plant.

27

Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE NINE SWITCHBOARD AND CONTROL PANELS The main switchboard to be mounted in special room next to the pump house building shall be of cubical type and shall comprehend the required No. of panels. An electric clock with 300mm diameter suitable for operation at 1.5VDC (dry battery) shall be mounted in the center panel. The equipment of the panel shall comprise: Main Switchboard Two incoming supply main each contains: 1. One No. air circuit breaker motorized type draw out type with thermal overload, magnetic short circuit and earth leakage protection and single phasing protection for incoming power and adjustable for ±25% each rated 1.25 full load of the plant with capacity (1.5) times of rated current and breaking capacity 70KA and above. 2. Three No. Ampere meter for - ditto- 144mm diameter 3. One No. Voltmeter 0-500V with six position selector switch and protection fuse. KWH meter with 3 current transformers suitable for unbalanced load. 4. One No. CB on each side parallel to each incomer for supply from the diesel generator with mechanical find electrical interlocking system. 5. One No. 3-phase auto CB with full protection for lighting supply connected before the main CB. 6. Phase sequence meter and 3 No. indicating lamps (one per phase). 7. Lamps testing push button. BUS - Coupler 1. One No. automatic air circuit breaker draw out type with thermal and magnetic protection as bus - coupler. 2. Bus coupler indicator ON/OFF defect (Red/Green/Amber) neon lamps.

28

Volume 1 General Specification Electro-Mechanical & Civil Works Motor - Distribution Section 1. One No. Ammeter for each motor 144mm diameter 2. One No. Working hour meter for each motor 3. One No. automatic air circuit breaker with full protection feature with draw able type for each motor 4. Read/Green/Amber pilot lamps to indicate On/Off/Defect positions of each motor circuit. Auxiliaries 1. One No. ammeter for each auxiliary unit including filter load center flocculators load centers, chemical building, workshop, administration building, houses load center other small distribution boards. 2. One No. air circuit breaker with full protection features for each unit as per item (1) above with indicating lamps. 3. Two No. air circuit breaker each rated 100A, 3 phase, fixed on the side of the panel. The panels shall be of attractive appearance and complete in every respect. The frame shall be efficiently earthed and rubber mats provided there to with 10 pairs of rubber gloves for each station. The Board shall be protected according to IP56. The inside of the panel shall be supplied with anti-condensation heater as well as 24 VDC lighting fitting with the required battery and battery charge. NOTES 1. If the L.L. is separate site a separate board should be provided as above with a power building. 2. Similar board should be provided for each Boosting Station (if any). 3. Standby supply for schemes with more than 2 Transformers will be connected on the 11KV side. Chemical Load Center The Contractor shall supply, install and test a complete load center in the chemical building to feed a l l the mixers, dosing pumps, lighting, hoist and crane comprising of:

29

Volume 1 General Specification Electro-Mechanical & Civil Works Panel No .1 1. One No. 3-phase automatic air circuit breaker with overload earth fault and single phase protection. 2. Three No. ammeters 144mm dia. 3. One No. voltmeter 144mm with selector switch. PANEL No. 2 and No. 3 1. One No. automatic Star/Delta (for motors larger than 18.5 KW) or direct on line start (for motors less than 18.5 KW) swing out type backed up overload contractor and fuses, with ON/OFF switch interlocked with the cover. The front cover contain (Name and Number) of the motor (in Arabic) indicating lights for ON/OFF/FALLT state of each motor. One No. ammeter 75mm with START/STOP/REST push buttons. 2. One No. automatic c i r c u i t breaker 3 phase for lighting. 3. One No. A.C.B, 3 phase 30A spare. 4. Two Nos. earthing point connected to the a.m. center load with the required cabling. 5. One No. A.C.B. 3 phase for laboratory. Administration & Filter Centers Same as (above) to cover the supply to all control valves as well as lighting and heating and cooling of the administration and filter centers, air blower, wash water pumps, houses, guard room, workshop will be fed from administration building center. In case the filters building is separated from the administration building, each building will have its own load center and the filter building load center will be similar to the main switchboard in general features. Control Panel Instrument Panel This panel will be floor mounted and contain the following instruments: 1. Red warning light for each filter. 2. Water level indicator for each compartment of G.S.T with audio warning for low depth and over flow in the treatment plant. 3. Digital recorder with indicator and integrator to water meter specified in clause (22) Water Meter. 4. Filter wash water recorder and indicator with integrator to water 30

Volume 1 General Specification Electro-Mechanical & Civil Works meter. 5. Water pressure indicator and chlorine residual indicator for each rising main. 6. Direct reading pH meters for raw and filtered water. No display instrument or light shall be installed less than one meter above floor level. Control Desk The control desk s h a l l be constructed of 2.5mm thick sheet steel, with structural frame primed and suitably indicated and fully accessible and finished in suitable color, all control compartments installed in the cabinet shall be factory prewired. Terminal blocks shall be provided for simple connection to remotely located equipment and sensors. All switches, push buttons, control lights, recorders, totalizer and meters, gauges and indicators shall be located on the desk face, mounted flush with the surface. The operation and malfunction indicating lights diode shall be incorporated into the complete flow diagram or ounliti color plastic on the desk. The desk layout and flow diagram shall be subject to approval prior to construction (2x3m). The following components shall be included in the cabinet: 1) Alarm System a. The system No. 1 shall be powered by AC supply and initiated by failure of equipment with AC powered control system high and low level etc. as follows : -

Pressure vessels - High water level - low water level.

-

Duty main pump failure.

-

Standby main pump running.

-

Duty low demand pumps failure.

-

Standby low demand pumps running.

-

Duty air compressors failure.

-

Standby air compressor running.

-

Pump well flooded.

-

Pump reflux valves jammed.

-

Reservoir high water level.

-

Reservoir low water level.

-

Chlorine residual high. 31

Volume 1 General Specification Electro-Mechanical & Civil Works -

Chlorine residual low.

-

Duty chlorinator failure.

-

Standby chlorinator operating.

-

Duty booster pumps failure.

-

Standby booster pumps running.

-

Chlorine lock alarm.

-

Chlorine leak alarm.

-

ph high.

-

ph low. b. Alarm system No. 2 shall be powered by DC supplied from heavy duty batteries and shall be initiated by failure associated with diesel driven standby generator and maim supply. The Contractor shall detail the alarm indication considered necessary for diesel engine and the associated alternator, but they shall include:

-

Alternator protection trip.

-

Alternator air temperature high.

-

Diesel lubricating oil pressure low,

-

Diesel generator running.

-

Diesel generator trip.

The audible alarm shall sound for five minutes and provision shall be included for automatic re-setting. The visual alarms shall operate continuously until canceled manually. 2) Ammeter for each low lift, high lift, back wash water and air blowers. 3) Any additional operating information that may be necessary for plant operation and maintenance which is characteristic of the pumping and water treatment plant. 4) 300 mm dia. quartz clock operated from 1.5 volts DC supply. 5) Call system with the required desk type microphone and suitably distributed loud speakers in the low lift, clarifier, high lift, filters, administration building, chemical building, guard room, engineers house, operators houses and workshop. 6) Digital camera for each building as well as the purification system with monitor in control room

32

Volume 1 General Specification Electro-Mechanical & Civil Works NOTE: 1A and 1B may be combined in one control panel, and this panel must be located in control room, in high lift pump, the contractor will be responsible for furnishing the control room, and supply it with air condition unit. The Contractor shall supply and install wireless system with UPS power supply units (DC & AC) in the control panel for transmitting speech signals between Treatment Plant & all ESTs and the Directorate of water. Water level indicators for each G.S.T. outside the treatment plant with full scale deflection with min and max audio alarm must be transmitted by means of multi core armored c a b l e laid in suitable PVC conduits along the pumping mains, also for the use for communication plus 3-spare pairs. Spare parts for five years and all necessary test a n d maintenance tools, fault location equipments, 500m of cable and different types of joint boxes and compounds should be supplied with the offer. Telephone System The telephone installation shall be the type generally known as the "Private Automatic Branch Exchange" (PABX) with facilities for initiating the receiving external as well as internal calls at all instruments. All internal calls shall capable of being dialed directly and shall be independent of the operator. The switch board shall be capable of accommodating all extension mentioned below, it shall be possible to restrict outside access to any selected extension. The telephone system shall consist of an automatic switchboard of 30 internal and two external lines and shall be installed in the control room. The switchboard shall be complete with 220V, 50Hz supply unit and emergency battery supply (12hr) and to board the following telephone apparatus shall be connected and it will be provided with special desk. a. One No. desk telephone in each of the following rooms: •

Chief Engineers room.

•

Engineers rooms.

•

Laboratories.

•

Operator’s rooms.

•

Control rooms.

•

Engineers houses.

•

Operator’s houses.

•

Lecture rooms. 33

Volume 1 General Specification Electro-Mechanical & Civil Works •

Meeting rooms.

•

Workshop.

•

Booster Station or Low Lift site: in each operator houses and guard room and pumping station.

NOTE: For booster station, there, must be special arrangement to connect all line with one external line coming from Treatment Plant also Low Lift site. b. One No. wall mounted with 100mm bell in: •

Raw water pumps area.

•

Treated water pump area.

•

Workshop.

•

Guard room.

•

Chemical building.

•

Filter control gallery.

•

Filter operator room.

•

Power houses (Low Tension switch board room).

•

Guard Posts.

c. One No. weather proof (cabinet and door made of aluminum alloy) with 100mm bell in: •

Suction Structure.

•

Flash mixers.

The contractor shall make all the required study for the required area for installing the above mentioned control and instrument panel. BOOSTER STATIONS Same as above a. Water level in each •

EST s

•

Ground Storage Tanks.

b. Pressure gauges of 150mm dia. on each pumping main with rate of flow. c. Working hour meter for each pump. d. Telephone connection between each E.S.T. for item (a) above. 34

Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE TEN SUB – STATIONS The supply voltage will be either 33KV or 11KV. The breaking capacity shall be 1500MVA and 750MVA respectively. If the power required is more than 4MVA or there is no 11KV supply from the national network a 33KV to 11KV or 33KV to 400V station should be supplied and erected according to the state organization of electricity requirements and specifications and the contractor is responsible to get their approval for that. 1) 11/0.400 KV Sub Stations The Contractor shall supply, install and test the following equipment for each sub – station, The Contractor may separate the power supply for the low lift pump house as well as the L.T. switchboard (with a typical sub-station) and build a suitable building for the transformer and switchgear (if required). The same shall be applicable for Boosting Stations. a) Take - off Points Consist of 2 x 10m tubular steel poles, brackets, pin insulators, lightning arrestors, hand operated three pole H.T. link switch, H.T. link fuses of the suitable rating, cable boxes and H.T. cables (XLPE). The take - off points will be fixed near the guard room. In case of 33KV sub-station this will be eliminated and it will be connected directly from sub-station to H.T. switchboard. b) H.T. Switchboard The switchboard shall comprise five No. panels each housing an automatic CB of the draw out type with skeleton compartment for future extension. The circuit breaker shall be according to BS 116 latest Edition having breaking capacity 750MVA at 11KV and impulse level of 75KA and CB will be vacuum or SF6 type. The 11KV system is un earthed but all allowances must be taken and required equipment should be supplied for converting the system to an earthed systems. In case there is more than two transformers within the site the required panel should be supplied within this switchboard. Panels No. 1 for incoming supply • •

The CB shall be rated 630A 3 No. 144mm ammeter 35

Volume 1 General Specification Electro-Mechanical & Civil Works • • • • • • • • • • • • • •

No. 144mm voltmeter and selector switch No. Current transformers for operating t h e protection and instrumentation 1 No. T.P. isolating voltage transformers. 1 No. 1 DTH over current and earth fault relay with over current and earth fault settings. 1 No. 1 DMT under voltage relay for supply failed alarm. 1 No. test terminal block. 1 No. healthy trip lamp and push button. 1 No. 110 DC shut trip and auxiliary switch. 1 No. Set of spare auxiliary switches 3 normally open and 3 normally closed. 1 No. unit cable sealing for box for 3 -core incoming cable. 1 No. pilot cables terminating box. 1 No. alarm disconnecting relay with indicating lamp and reset button. 1 No. alarm bell remotely mounted (operated from battery system). 1 No. discrepancy switch, incorporating indicating lamps.

Panel No. 2 -Transformer No. 1 - FEEDER -

Same as Panel No. 1 except that:

-

CB rate 400A.

- 1 No. Bochloz relay with 2 elements for "surge trip" and gas "alarm". - 1 No. excess oil temperature trip relay with the elements for "alarm" and "trip" stages. Panel No. 3 Transformer No. 2 - Feeder -

Same as Panel 2

Panel No. 4, Panel No. 5 for automatic power factor correction c) DCs Supply Complete set of DC supply consist of nickel alkaline type with required electrolyte and distilled water, crater, stands, stand insulator, inter-cell and inter raw connection, battery charger, panel for battery ,panel for DC feeders, accessories and spares (2 hydrometers, 2 thermometers to read 0°C - 70°C, 2 large containers for mixing the electrolyte, 2 moving voltmeters 3-0-3 volts, complete set of maintenance equipment, one complete of spare part. 36

Volume 1 General Specification Electro-Mechanical & Civil Works d) Two No. oil immersed transformers each rated 1.25 of full load of the plant 11/0.4KV Vector Group DY 11 with L.T. neutral brought out and solidly earthed, ONAN type, off load tape charger +4.5% +5% - on the 11KV side, rating plate bi-directional mending temperature indicator with centigrade pointer and indicating maximum pointers each indicating pointer having two sets of adjustable contacts, oil temperature indicator same as above, thermometers pocket with captive cap, explosion vent of double diaphragm type with portholes type sight bath type, gas, actuated relay, double float, drain valve complete with sampling cock, vacuum valve, filter valve, conservator, terminal boxes on H.T. and L.T. sides. e) The 0.4KV side of each transformer shall connected by means of bus bars inside suitable conduit to CBs in the main distribution switchboard all the H.T. cables from the take off point to the transformers shall be (XLPE) type. f) At least 4 earthing points are required to earth the neutral point of the transformers with all the necessary cables and electrodes. The Contractor shall supply the low lift pump house and filter building with separate transformers if required and build suitable rooms if it is necessary. H.T. switchgear should be in the same H.T. board for main pump house. NOTES: Iraqi standard transformers (11/0.4KV) are: 1000KVA, 630KVA, 400KVA, 250KVA & 100KVA. 2) H .T. LINES The Contractor shall include in his price to supply and erect an over head H.T. or ground cable between treatment plant and low lift pump house if required. The poles will be tuber steel 10m high and conductors of copper. All technical specification will be according SOE requirements. The contractor is required to survey the rout along the raw water delivery pipe. In case that the low lift station or other stations are within the site, a ring system by means of cables should be provided. 3) 33/11KV or 33/0.400KV step Down Sub Station The Contractor shall supply a complete step down intermediate sub-station 33/11KV or 33/0.400KV complete from take off points to 11KV or 400V. Feeders out door type CBs will have vacuum or S.F.6 type. Breaking capacity of the system will be 1500MVA and all the 37

Volume 1 General Specification Electro-Mechanical & Civil Works system equipment shall be in accordance to SOE requirement and there approvals. Each station will be equipped with 33KV, 11KV CB as spare. The Contractor is responsible for civil works for the control room, and fence of 50x50 meters, will all required cables near the fence up to each 11KV or 400V transformer site and feeding point for low lift, filters building and workshop transformers.

38

Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE ELEVEN POWER HOUSE Stand by generator sets site of Treatment Plant or any site 1) Scope of Supply The object of this tender is to supply and install diesel generating sets of stationary design in quantities and capacities as in Basic Data. These generation sets shall be used to operate these water treatment plants at 100% of pumping capacity plus 100% services during periods of complete electricity mains shut down. These sets shall be erected and connected parallel to the mains system. All sets shall be designed for manual and automatic start and shall incorporate all necessary equipment like with automatic change over switches for emergency to permit feeding the consumer either from the mains or from the emergency diesel sets at any time. All water treatment plants are connected to the electricity mains national grid. 2) Capacity of Generating Sets All generating sets shall be designed to have continuous net site rating output under the following site conditions: Ambient temperature

55°C in the shade

Altitude above sea level

1000 meters

Relative humidity

80%

Every generating set shall be able to run at 10% overload for a period of one hour after working on full load for 12 continuous hours. The results shall be within the normal limits of the working conditions of the set. All generating sets shall be designed for 50Hz 3-phase, 0.8 P.f. generated voltage shall be 11KV or 400V with step-up transformers to 11KV. All sets shall be equipped with synchronizing devices allowing the operated in parallel of two or more sets. All generating sets shall be skid mounted installed in suitable building. 3) Description of Engine & Auxiliaries 3.1) General 3.1.1)

Medium

speed,

vertical

or

V-type

4-stroke,

water

cooled, 39

Volume 1 General Specification Electro-Mechanical & Civil Works compression ignition, diesel engine directly coupled to the alternator on a common base and provided with anti vibration dampers. The engine and the alternator must have been coupled together and run as unit during work tests. A test certificate to this effect shall be submitted with the generating set. The rpm of all generating sets shall be 1500rpm at the maximum. 3.1.2) The engine shall be fitted with a tachometer and suitable speed regulating gear to provide a 5% up or down speed variation together with an electrical drive for remote speed control from the switchboard, as well as a counter of running hours of the generating set. 3.1.3) A suitably designed governor as required for each engine which controls speed throughout output range from no-load to 10% overload within the required limits and prevent excessive over-speeding when up to 10% overload is thrown on and off suddenly. The governor must also incorporate suitable over speed trip both mechanical and electrical. 3.1.4) Each engine shall be fitted with a suitable heavy duty oil bath air filter suitable for use in dusty atmospheres and tropical climates. If the design put forward brings the a i r inlet near the engine exhaust system, the exhaust system must be heavily lagged or cooled to ensure that the engine aspirates air at normal ambient room temperature. 3.1.5) The exhausted system shall be wrapped with asbestos and legged to avoid appreciable rise in ambient air temperature. The outlet of the exhaust silencer shall be situated on top of the container and directed upward. They shall have a suitable arrangement to prevent rain water getting inside the container and suitable means for draining such water. 3.1.6)

Every engine shall be fitted with following meters:

3.1.6.1.

Lubricating oil pressure meter.

3.1.6.2.

Water temperature meter.

3.1.6.3.

Exhaust gas temperature meter.

3.1.6.4.

Charging battery ammeter.

3.1.7) Each engine shall be of site rating in accordance with the latest Edition of British Standard Specifications 649 or German VDE Specification. 3.1.8) Every engine shall be suitable to work efficiently and produce the quoted power operating on the available fuel produced in Iraq by the government Oil Refineries Administration. 3.1.9)

Anti freeze must be supplied. 3.2) Cooling System

a) Every engine shall be radiator water cooled. The radiator shall be 40

Volume 1 General Specification Electro-Mechanical & Civil Works designed for tropical climate at an ambient temperature of 55°C in the shade. b) The radiators shall be installed at front of the engine in a separate compartment of the container in such a way that it shall not be affected by the engine vibration absolutely. The cooling fan shall be driven either by an electrical motor or belt driven by the engine. In both cases the power required for driving any cooling fan shall not be considered in the total output of the generating set. Tenderers shall state clearly the actual power required for driving the cooling fan in KW and for each kind of generating sets offered. Suitable circulating water pump shall be provided for every engine with thermostatic control. Full details of the cooling system for every generating set shall be stated in the offer. Scale forming inhibitor enough in quantity for three radiator filling charges shall be supplied with every generating set. 3.3) Lubricating Oil System 3.3.1) The lubricating oil system shall be closed system with the case of the engine acting as an oil reservoir or with an external reservoir of the totally closed type. 3.3.2) The lubricating oil for the engine shall be pumped into the system by the gear or the chain driven pump coupled to the engine drive. 3.3.3) The engine is to be fitted with a lubricating oil heat exchanger suitable for climate conditions at site and of such size and type that it is capable of maintaining the engine oil temperature within the limits recommended by the engine manufactures throughout the ambient air temperature range at site and under any load condition. 3.3.4) Heavy duty lube filter shall be provided for every engine. The Tenderer shall state clearly whether the filters offered are suitable for use with detergent lubricating oil. 3.3.5) Manually operated lubricating oil priming pump is to be fitted to the engine for raising the oil pressure and circulating the lubricating oil before starting. This pump is to be fitted with an additional connection and stop cock so that it can be used to drain the engine oil when an oil change is carried out, this feature may be omitted if pumping out of used engine oil is covered by some other standard fitting on the engine put forward. 3.3.6) The lubricating oil used in Iraq is a product of the Government Oil Refineries Administration and the engine put forward should be able to use these oils. Detailed technical information could be obtained from the department concerned. 3.3.7) Pressure gauge and thermometers of round dial type shall be installed in the lubricating oil circuit as follows: 41

Volume 1 General Specification Electro-Mechanical & Civil Works 3.3.7)c.1. 3.3.7)c.2.

Two thermometers to measure the inlet and outlet oil temperature to the heat exchange. Two pressure gauges to measure the pressure before and after the main oil filters.

3.4) Fuel Oil System The fuel system for every engine shall consist of fuel transfer pump. Fuel service tank which shall be of such capacity sufficient f o r 8 hours operation on full load fuel injection pump or pumps and atomizer with all inter connecting piping and filters. A hand operated semi-rotary pump with necessary piping for filling the service tank of every generating set from the bulk storage tanks shall be included. Bulk storage tanks for fuel shall be supplied and erected and shall have capacities sufficient for 48 hours full load operation. The tender shall state clearly the design of the said fuel tank and for every capacity of generating set at each site shall be properly connected to their fuel bulk storage tank. Also the tender state clearly the design of erection of the tanks at sites. Filling of every electrical driven fuel pump via a proper pipe connection or a hose 65mm dia. from a road tanker, every storage tank shall have a level indicator meter and from meter registering in liters. Provision shall also be made for a breather and an inspection. 3.5) Starting System All generating sets shall be designed for manual / auto starting and it is preferred to be electrical by electric starter and set of alkaline batteries with charger charging of the batteries shall be as follows a) When the generating is in operation, charging the batteries shall be effected by a charging alternator driven by the engine with charging alternator control board relay. b) When the generating set is not in operation, charging the batteries shall be effected by a separate automatic battery charger operating on 220VAC supply All inter - connections and erection of the above mentioned equipment shall be carried out by the Contractor. The set will be equipped with manual, automatic and test starting switches. 42

Volume 1 General Specification Electro-Mechanical & Civil Works

3.6) Control & Warning System Each engine shall have protections against faulty operating and abnormal conditions by means of system of relays, pressure and thermal sensors. Visual and audio able signals are to be provided for each engine against oil pressure too low and cooling water temperature too high and over speeding and low fuel. The circuit breaker shall be arranged to trip first and the engine is then brought to standstill, if faulty conditions persist for a certain predetermined time after alarm signal has been given. Then the system shall be complete with reset knobs and other attachments necessary for proper operation. The warning system shall also give indication of low fuel level in the daily tank. All warning and shut down indicators shall be located in the low tension switchboard. 4) Alternators 4.1) The generated voltage of the alternators will be 0.4KV and 11KV as mentioned in item (2) of these specifications taking into consideration that all the electrical power required to drive auxiliaries and cooling fan shall be excluded from the net output of the generating set, the outputs of the alternators shall be continuous in accordance with B.S.S.2613 (latest edition) or any other international Equivalent Standard. 4.2) The windings shall be impregnated Class “H” and finished for use in a tropical climate and t h e machine should be designed for use in an ambient temperature of 55°C in the shade and continuously site rated to B.S.S. 2613 (latest edition). 4.3) The temperature rise of the insulted winding measured by a thermometer or other approved method after a continuous run on full load is not to exceed tine limits laid down in B.S.S. 2613 and amendments, due regard being paid to Clause 17. The machine shall be able to with stand the overload allowed by Clause 21 of B.S.S. and amendments. 4.4) Excitation shall be by means of brushless alternators with rotating rectifier. 4.5) All alternators shall be damped and suitable for parallel operation. Important Note The alternator shall be of totally enclosed type, fan cooled with IP23 degree of protection for alternator and IP43 for terminal box. All protective measures should be taken to ensure the safety of the operators 43

Volume 1 General Specification Electro-Mechanical & Civil Works from electrical shock due to contact with metallic parts of the generating set and auxiliaries. 5) LOW Tension Switchboard The switchboard shall be sheet steel clad, totally enclosed, dust and vermit proof of clean and modern appearance and flush mount instruments and switchgear. The switchboards shall be manufactured from thick gauge zinc coated sheet steel primed and finished in high class light grey paint. The switch gear shall be designed to withstand a fault level of 40MVA at 400V. Every generating set shall have an alternator panel and a changeover switch which shall include the following: 1. Triple pole main circuit breaker suitably rated with magnetic reverse power and overload releases manually operated through push buttons with mechanical “ON”, “OFF” and "TRIP" indicators. Overload releases must contain time lag adjustments. 2. Metering for voltage current, power factor, frequency KW, etc. 3. Automatic voltage regulation and trimming. 4. Indicating lamps. 5. All necessary fittings and attachments required for proper operation and as mentioned previously in these specifications. 6. Speed remote control switch. 7. Feeder air circuit breaker for 60A capacity with same protection characteristics like the main breaker with suitable terminal connection for cable to supply power to equipment not included in the consumers network. Besides 3 single phase 10A socket plug connections fire to be provided. 8. A Manually and automatic operated change-over (transfer) switch shall be included with the switchgear for the purpose of supplying electricity either from the mains or from the generating set and to safely prevent the two systems operating together. This shall be achieved through suitable mechanical and electrical interlocking with indication of correct and complete engagement and disengagement of contact blades. Easy access and ample space should be provided to connect the mains and consumers cables. The rating of this switch should be double that of the generating set. The emergency or generating set side of the switch should have facilities for connecting two generating sets running in parallel and having the same capacity. 9. Synchronizing device which include a synchro-scope double frequency meter, double voltmeter and a synchronizing switch. 6) High Tension Switchboards for All Generating Sets with 11KV 6.1) They shall be sheet steel clad free standing, floor mounting, totally 44

Volume 1 General Specification Electro-Mechanical & Civil Works enclosed dust and vermin proof of clean and modern appearance and flush mounted instruments and switchgear. The switchboards shall be manufactured from thick gauge, zinc coaled sheet steel primed and finished in high class light grey paint. The switchgear shall be designed to withstand a fault level of 500MVA at 11000 6.1.1) Alternator Panel Each shall include the following: 6.1.1.1) Sets of 3 air insulated copper bus bars 400A. 6.1.1.2) Main output circuit breaker suitably rated draw out type, manually operated through push-buttons with overload, short circuit and reveres power protection, overload releases must contain time lag adjustments. 6.1.1.3) Complete synchronizing equipment. 6.1.1.4) Manual automatic voltage regulation and trimming . 6.1.1.5) Remote speed control switch. 6.1.1.6) Metering for voltage, current, power factor, frequency KW etc. 6.1.1.7) Indicating lamps, 6.1.1.8) All necessary fitting and attachment required for proper operation and as mentioned previously in specification. 6.1.1.9) Earth leaking protection. 6.1.1.10) Complete sets of current and potential transformers. 6.1.1.11) Small power transformers 25KVA 11KV/0.4KV shall be included in the switchgear with suitable protection, on both sides. This transformer shall be used to supply electricity to diesel set auxiliaries and other equipment not included the consumers network. 6.1.1.12) A manually operated 11KV changeover (transformer) switch shall be incorporated within the container serving the same purpose as the one envisaged for the low tension generators item 5.8. 7) Wiring and Cabling 7.1) All low tension power cables copper type (600/1000) shall be 4-core PCV insulated suitable for underground use. 7.2) All high tension power cables (11000 volts) shall be 3-core copper steel tape armored and PVC sheathed XLPE insulated suitable for 3phase, 11KV unearthed system. 7.3) All sizes and qualities of the cables shall be stated clearly in the offer. 7.4) Where necessary, all low tension cable shall run inside trenches covered with chequer plates within buildings where switchgear of water treatment plant is located. Fixing of cables inside trenches shall be on trench side walls or laid of tray 20cm above the bottom of the trench and in according with 14th Edition of IEE Regulations 45

Volume 1 General Specification Electro-Mechanical & Civil Works or the relevant BSS Outside the building, cables shall be laid in trenches covered with concrete slabs. The Contractor shall be responsible for the complete electrical connection between the alternator panels, feeder panels, isolating switches and the point of load application in the plants, with all necessary fitting cable and boxes, lug etc. 7.5) Cable sizes shall be calculated for earning capacity at rated current of set at 55°C ambient temperature in the shade, it is preferable that one size of low tension and one for high tension cables shall be delivered and a single or double run of cable shall be used with each generating set according to its capacity. 8) Foundations The Contractor shall be responsible for supplying materials and making suitable foundations for the generating sets and auxiliaries with their containers and fuel tanks. The foundations shall be executed in accordance with the recommendations and design of the manufactures. The dimensions of the foundation and anti-vibration installations shall be suitable for the sites conditions considering a ground bearing capacity of the plant. The concrete foundation shall be cast in one operation using vibrators and concrete mixers. Concrete mix shall be 1:2:4 of sulphate resisting, cement, sand and gravel. The sand shall have less than 0.25% salts. Laboratory tests of sand and gravel shall be submitted prior to mixing for approval. The results of the tests shall comply with the relevant BSS and CP. The tests shall be carried out in one of the official laboratories no excuse whatsoever shall be accepted for any crack or vibration in the foundations. 9) Erection The erection of the generating sets and all their associate equipment shall be carried out under the direct supervision of a fully qualified engineer appointed by the Contractor. Due care shall be given to equipment and materials handled so that no damage shall be incurred. The contractor is responsible for repairing any damage sit no extra cost or period. The work shall be carried out in the neatest clean and proper manner complying with the appropriate British Code Practice.

46

Volume 1 General Specification Electro-Mechanical & Civil Works 10)

Operation & Maintenance

The generating sets shall be operated and tested prior to acceptance and handover test at the beginning of handover tests the daily fuel oil tanks, bulk storage tanks shall be filled to their full capacity and the engine oil changed with new, best quality lubricating oil. Cost of the above items shall be deemed as included in the total cost of the Contract. The generating sets shall be tested for six hours on full load and one hour on 10 % over load. The temperature of the exhaust and cooling water shall then remain within the limits specified by the engine manufactures. All other auxiliary equipment shall be tested to the satisfaction of the Acceptance Committee. The Contractor shall be responsible for training our operators on all kind of maintenance and operation procedures for a period of two months and a certificate shall be issued certifying that this task had been fulfilled by the Contractor completely. Also the Contractor shall be responsible for supervising the maintenance of these generating sets for a period of one year during which he will be responsible to repair and replace any damaged part of any of these generating sets and to supply the spare required and labor works on his own account. The Contractors shall supply fire fighting extinguishers with the generating sets. They shall be of suitable type and size to cope with fires in the electrical and fuel system. 11)

Deviation from the Specification

All tenders are required to adhere to the specifications and in case of any deviation, these should be clearly stated on a separate page item by item given the clause and item number and the reasons for such deviations, if such a deviation page shall not be submitted with the offer it shall be considered that the offer is complying fully with our specifications. 12)

Spare Parts and tools

Every generating set shall be supplied with all spare parts necessary for 15000 working hours as recommended by the manufacturers. These spare parts shall be priced separately. They shall cover all the requirements of the diesel engines, alternators, switchboards and auxiliaries detailed list shall be submited, where every item shall be priced separately. As a guidance to the manufactures the spare far every 47

Volume 1 General Specification Electro-Mechanical & Civil Works generating set shall include full quantities of all kinds of filters for fuel oil, lubricating oil, complete set of inlet and outlet valves, turbo charger repair kit, fuel pump elements, injectors solenoid valves, governor, set of piston rings, 50% of sets for pistons cylinder heads, main and big end bearing, 2 sets of top and major overhaul kits, few sets of V-belts etc. Alternator spares shall include set of bearings, revolving rectifiers and diodes, automatic voltage regulator etc. For alternator panel and switch gear a full recommended spares for indication lamps circuit breaker, relay, fuses, meters, etc. shall be submitted. For all 11KV generating sets a total number of 10 spare cable outdoor end boxes and same number indoor end boxes together with 20 sets of 11KV fuse elements shall be delivered. A complete set of standard tools shall be included in the supply with each generating set. One set of special major overhaul tools, for each type of diesel engines shall be supplied. This set shall include the following: 12.1) Two AVO meters 12.2) Two Muggers (10-2500V) 12.3) One tachometer (mechanical) 12.4) Soldering kit 12.5) Injector and nozzle tester. 12.6) Cable Jointing Kit 12.7) Two workshop manuals There will be a similar power plant in the Booster Stations and in the Low Lift in case it is in different site as included in Basic Data.

48

Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE TWELVE CABLES All inter connecting power cables to the motors and other appurtenances with the necessary cable boxes shall be provided and fixed by the Contractor. The cables shall be copper, strand type of the PVC insulated and sheathed type suitable for use in humid atmosphere similar to NYY-VDE Q 271 and of a type and size in accordance with the carrying capacity of cables given in the tables accompanying the "Regulations for the Electrical Equipment of Buildings of the Institution of Engineers, England", and in accordance with the requirement of the manufacturers of the plant take in consideration ambient temp (55°C) and condition of laying. These cables buried in trenches direct in the ground shall be installed in an enclosed trench 600mm wide by 760mm, deep minimum including 10mm cover. Single core cables arranged in groups of two or three in flat formation with the surface separated by a distance equal to one diameter or in trefoil formation with cable touching. Groups separated by a minimum (larger spacing to be used where practicable) distance of 50mm either horizontally or vertically multi core cables installed singly separated by a minimum (large spacing to be used where practicable) distance of 75mm either horizontally or vertically. All cables spaced at least 25mm from the trench wall and supported rather by trays or 500mm distance supports. Cables buried in the ground outside the building shall be wire / tape armored and bedded in two layers of 100mm of sand at a depth of 900mm.

49

Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE THIRTEEN LIGHTING The level of illumination throughout the building shall be uniform and of value 150 lumen/m2 for corridor, stair 400 lumen/m2 in pumping station and control room 300 lumen/m2 for other rooms. This level is to be attained by means of fluorescent lighting fittings (2x40W) of the totally enclosed type, moisture proof with power factor correcting capacitors. The Contractor is also to provide suitable No. of single and 3-phase 13A, 25A socket outlets suitably distributed inside the building. All switches sockets and other electrical necessaries used inside the building shall be moisture proof. Ceiling fixed mercury 160W fitting of water proof type are to be used for lighting the area around the building from the outside at a spacing of no more than 6m. The switches for these fitting are to be situated inside the buildings near the entrance lighting another subcircuits shall be properly protected by means of sub-distribution (MCB) boards. The Contractor shall make arrangement for lighting the area around the plant along the fence in spacing not more than 20m using 8m tubular steel poles and 250W mercury bulb and 250W projector one for each clarifier on an 8m pole to be fixed near the flash mixers and directed to each flocculator center 160W mercury fittings mounted on 3m.long steel poles of 75mm dia. and spaced every 10m along all the inside roads and foot paths of the plant. The main switches operating the whole system shall be situated in the guard room. The whole of the external lighting system shall be controlled by photo cell each filter will be illuminated by means of flood lights mercury or sodium not less than 400W situated on the beam above the control console each with its own switch. The filter gallery and pipe gallery, walk way will be illuminated by means of fluorescent lights. Six safety hand lamps operating on 24V and transformers are to be provided complete with guard and 10m of 3-core flexible trailing cable, one wire acting as earth continuity. At least ten earthing points are to be provided and installed complete having maximum resistance of 2 ohms. Effective connection to earth of all the electrical equipment, sockets outlets etc. is to be made with insulated wire of ample cross sectional area and in accordance with the latest edition of the "Regulations for the Electrical Equipment for Buildings of the institution of Electrics Engineers, England" The installation within the substation shall be carried out in 600/1000V grade PVC. Insulated cable drawn into heavy gauge screwed welded conduits unless otherwise specified. Conduits shall comply with BS 31 or equivalent and of approved manufacture. So conduit of less than 19mm diameter will be permitted. All conduits and fittings for surface installations shall be heavily 50

Volume 1 General Specification Electro-Mechanical & Civil Works galvanized and where external to buildings be of the watertight pattern. Where multiple conduit runs occur or the discretion of the Engineer the Contractor shall supply and install heavy gauge galvanized trunking of adequate size to confirm with IEE Regulations 223G or equivalent and fixed direct to the surface or supported by HS galvanized brackets at a maximum of 1.2m centers. Bends and tees and other accessories shall be prefabricated and of the same manufacture as the trunking. Cable retaining bridges shall be provided and suitable spaced to ensure that cables remain in the trunking when covers are removed. All draw boxes and junction boxes shall be of ample size to permit the cable being drawn in and out. They shall comply with BS31 or equivalent and be of malleable iron and of approved manufacture. At all lighting and switch points the conduit shall terminate in a suitable box provided with internal lugs to permit the back plates of the fitting or switches being attached to them by screws. All circular boxes shall be provided with long spouts internally threaded incorporating a shoulder for proper butting of the conduit. The ends of all conduits shall be carefully rearmed to remove all burrs or sharp edges on the inside after the thread has been cut. All dirt, paint or oil on the threads shall be removed immediately prior to erection. The ends of the conduit shall butt solidly in all couplings. Where they terminate in switch fuses, fuse boards adaptable boxes non spouted switch boxes etc. they shall be connected there to by means of smooth bore male brass bushes compression washers and sockets. All exposed threads and all bends shall be painted with aluminum spirit paint immediately after erection. All bends are to be made on side to suit conditions and not more than two right angels will be permitted without the interposition of a draw box. No tees, elbows, sleeves either of the inspection or solid type will be permitted. All conduits shall be swabbed through before wiring is commenced and cables shall not be draw into any section of the system until all conduit and draw boxes for that particular section have been fixed in position. Provision shall be made in all conduit rum for the removal of moisture due to condensation. Conduits where run on the surface shall be fixed by means of distance saddles, the conduit boxes being of the raised back pattern or approved packing piece used to avoid "Setting" the conduit. They shall be run in a symmetrical manner and follow the building lines at all times. The Contractor shall ensure that conduit is not allowed to become rusty and shall include in his Tender wire brushing and protective aluminum painting as necessary. The Contractor shall prepare conduit and trunking run drawing if called upon to do so and no work shall be carried out until approval of the 51

Volume 1 General Specification Electro-Mechanical & Civil Works drawings has been given. Switches shall be of the surface watertight pattern galvanized and gauged where necessary. Switches shall be operated by knurled wheel in brass, working through a gland, with heavy machine cast Iron cover plated secured by three brass screws to the conduit box. The wiring arrangement for the office rooms, Resident Engineers house and operator house shall be in conduit buried in the ceiling and titling. The same apply for the lighting of the Booster Stations. The Contractor shall supply and install the required distribution centers for 3 phase lighting system which is supplied from the CB in the incoming panel as load center. The Contractor s h a l l install the following emergency lighting fitting 20W with the required DC and AC supply and cabling: -8 No. in Chemical Building -2 No. in each Transformer Room in TP & LL and BS -2 No. in Control Room -8 No. in high lift pump house -8 No. in Workshop -2 No. in each chief Engineers Room -6 No. in low lift building -1 No. in guard Room -8 No. in each power house (in diesel roam and LT & HT and DC Room) -4 No. Booster Station, pump house and 2 no in chemical room -8 No. Booster Station power building -6 No. in administration building

52

Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE FOURTEEN BUILDING WORKS The general arrangement of the buildings the general layout shall be as shown in Drawing in the Appendix. If the Contractor wishes to make any changes in this arrangement he shall indicate it in his offer and price it as an alternative. The thickness of external walls shall be 36cm and internal walls 24cm. The building shall be constructed in brickwork or masonry framed in reinforced concrete members of 1:2:4 mixture. The roof of the buildings shall be of reinforced concrete of 1:2:4 mixtures. The upper surface of the concrete roof shall be laid to cross falls for rain water drainage for disposal to down pipes of 10cm dia. and shall be covered with 1cm thickness of bitumen which shall be carried up against the parapet walls. The roof shall be covered with 10cm of clean and fine sandy soil. The roof shall be faced with concrete block and mastic joints. The brickwork or masonry shall be jointed throughout in 1:3 cement mortars. The ground floors of several rooms shall be founded on 25cm of consolidated hard core of which 15cm shall be formed in 1:2½:5 concrete laid to true planes and shall be faced with best quality floor tiles of terrazzo or mosaic and of an approved color and pattern and extended one course in the formation of a skirting to the walls. The walls of the buildings shall be plastered in 1:3 cement mortar of 1cm thickness. The plastering to the walls and ceiling shall be finished to a smooth surface. The adhesion of the plastering and tilling to the respective under surface shall be throughout through and the face truly line able in character expect administration building which shall be JUSS plastering. The windows to the buildings shall be steel framed dust proof type and the sashes glazed with first quality 4mm sheet glass well fitted bedded and lack putting with full height ornamental iron grills. The windows of the building shall be protected with fly proof wire mesh fixed with iron framing. The windows of operator rooms and office laboratory shall be provided with curtain frame and curtain rings well fixed to the walls. The main entrance doors shall be of the double French teak wood type with side and overhead lights and shall be ornamental in appearance and shall be not less than 2.4x2.4m high. The doors to the other rooms shall be wooden doors where of an external nature apart from the operator room which shall be of the double French type and of well seasoned wood framing with facing of 4 plywood where of an internal nature. All windows and doors shall be of best quality and shall be as shown in the drawings in Appendix. The lintels and sub shades over doors and windows shall be formed in 1:2:4 reinforced concrete. The butts and locks of internal doors shall be of brass. The footing of the building shall be constructed in reinforced 53

Volume 1 General Specification Electro-Mechanical & Civil Works concrete 1:2:4 coated with not less than two layers of suitable asphalt coating and shall be spread in accordance with the imposed loading. The thresholds and steps shall be formed in 1:2½:5 concrete with outward fall of 1/100 external to the doors. The lavatories and bath rooms shall be furnished with 62.5x45cm porcelain wash hand basin with two chromium plated pillar taps, load waste pipe etc. towel racks with a shower with copper rose and tap white glared porcelain water closet of the Asiatic type (the internal clearance of the pan shall not be less than 50cm) complete with trap and three gallons mosquito proof elevated flushing tank with butter valve and shall respectively connected to the station water service system as hereinafter specified. The bottom of the flushing tank shall be at least 2m above the floor of the room. The drain of the wash hand basin, shower and closet shall be connected to the sewage disposal system as specified in these specifications. No manhole or inspection pit should be made inside the bath room and lavatory. The tracks of the overhead travailing crane specified in the relative clause shall be carried on cantilevers or corbels from the wall columns. All internal faces of the walls and ceilings shall be given two coats of appropriate washable emulsion paint and the external face of the walls shall be given two coats of appropriate cement paint. The internal faces of the walls and ceiling of the (WC) and bath room shall be given two coats of an appropriate oil paint. The paint shall be of approved quality and color. The internal faces of the walls of the (WC), kitchen, bathrooms, shall be faced with porcelain tiles from the floor to the ceiling. The Contractor shall provide and install a complete electrical fire alarm system in accordance with the recommendations of CP 1019 and BS 3116 Part 1 and part IV (last edition). A fire alarm and warning system shall be provided throughout various buildings the system shall be generally be a manually operated one and shall include smoke detectors break-glass contacts local alarm bells and alarm indicator panel and a general alarm siren mounted externally at high level in a prominent position. Break-glass contacts shall generally be placed at exits from building but in the case of large areas they shall be spaced at not more than 50m apart. The indicator panel shall give visual indication of the following: (a) (b) (c) (d)

Power failure Low battery voltage Open circuit Fault to earth

Operations of any alarm shall give visible and audible sound in the office and general alarm shall be given throughout the area by means of bells. Bells shall be 200mm dia. They shall be obtained from the fire alarm equipment manufacturers and the Contractor shall provide and installed 54

Volume 1 General Specification Electro-Mechanical & Civil Works 24V nickel cadmium battery and charging unit complete in ventilated steel case. Fire extinguishers shall be supplied and distributed in the buildings of the following types: •

Powder type

•

C02 type.

•

Fire blanket

The required No. of each type shall be as indicated in Basic Data. Arrangements to be made for disposing the water collected by means of the two Nos. submersible pumps with float valves in the following: a. Filter galleries b. In each pump house (T.P., B.S, and L.L.) c. Sludge pump house The Contractor shall make provision of the construction of a separate building to install the transformers. Necessary detailed drawings are to be submitted to the S.O.W.S. for its approval. Also drinking water cooler of best quality in accordance with the resident Engineers approval for treated water building, filter building, administration building low lift, Booster Station, Chemical Building, workshop. The cost of this item shall be included in the total price of the Tender. Concrete and Concrete Work a) General All materials used for plain or reinforced concrete work shall best quality and free from defects likely to undermine the strength and life service of the work. The materials furnished must sit least comply with Iraqi Organization Standards (IOS) and the latest BS Specification wherever these are applicable or their approved equal, Concrete made from sulphate resistant comment is abbreviated S.R. concrete and concrete made from normal Portland cement is abbreviated N.P.C. concrete. b) Cement Cement shall be of the Portland cement and complying in every way with the requirements of IOS 5 for Normal Portland Cement and with IOS 6/1968 for sulphate resisting cement. Sulphate resisting cement must be used for all concrete works below ground level or in contact with soil. The cement shall be transported in sealed bags, unless otherwise approved by the Engineer, and shall be stored at the site in perfectly 55

Volume 1 General Specification Electro-Mechanical & Civil Works weather dried stores with the damp proof clear of all possibilities of flooding. The Contractor shall make provisions for providing these stores at his expense and to the Engineers satisfaction. Cement shall be dry and free from lumps and caking. Any cement which has fully or partially set or which in the opinion of the Engineer fails to comply with the specifications or has become damaged in the works through dampness, storage or otherwise shall be rejected. It shall be the responsibility of the Contractor to remove forth with all such cement from the site and no time is such cement to be used in the works. Great care shall be taken that various types and brands of cement shall not come into contact with each other and should such an event all such contaminated cement shall be removed from the site. c) Aggregates Coarse aggregate shall consist of thoroughly washed river gravel, crushed gravel, crushed stone or a combination thereof. It shall be cleaned, hard, durable, uncoated particles free from injurious amounts of soft, pliable, laminated or elongated pieces, alkaline, gypsum, organic or other deleterious matter which may reduce the strength of a durability of the concrete or attach steel reinforcement. Should any pre washed aggregate be founded to be dirty after transit to the site, the Contractor shall adopt such measure as the Engineer may direct to wash and clean it before incorporation in the permanent work. Coarse aggregate of porous nature or containing clay lumps exceeding 1% by dry weight shall not be used. Dust or other fine materials passing BS sieve No. 100 or equivalent and exceeding 3% (by volume) shall be removed from the coarse aggregate by screening, washing or other adequate methods. Coarse aggregate shall be well graded in the max size and shall not be greater than specified for the particular variety of concrete. Grading of coarse aggregate as delivered to the mixer shall conform to the requirements as per the annexed Table 1 and Table 13. Table 1 Percentage by weight passing through BS Sieves normal size of graded aggregate Sieve Inch 3 1½ ¾ ½ ⅜ 3/16

size 1½-3/16” ¾-3/16” ½-3/16” mm 38.1-4.8mm 19.4-4.8 mm 12.7 - 4.8mm 76.2 100 38.1 95-100 100 100 19.1 30-7 95-100 100 12.7 90-100 9.5 10-35 25-55 40-85 4.8 0-5 0-10 0-10 56

Volume 1 General Specification Electro-Mechanical & Civil Works

Thus, the maximum nominal size of coarse aggregate for heavy wall footings shall be taken as 38mm. For beam, girders, columns and slabs the maximum aggregate size to be used shall be 19mm. For slabs 10cm thick, the maximum common layers size shall be 12.7mm. For cases not defined above, the Contractor shall submit a grading of coarse aggregate with maximum nominal size for the Engineers approval. Prior to the delivery samples shall be submitted to the Engineer together with sieve analysis showing the proportions by weight passing the sieves. The Contractor shall carry out sieve analysis when required by the Engineer to do so, and adjust the grading according to above. TABLE II Percentage by weight passing BS Sieves BS

Grading

Grading

Grading

Sieve

Zone I

Zone II

Zone III

3/8"

100

100

100

3/16 "

90-100

90-100

90-100

No. 7

60-95

75-100

85-100

No. 14

30-70

55-90

75-100

No. 25

1.5-34

35-59

60-79

No. 52

5-20

10-30

15-30

No. 100

0-10

0-10

0-10

The total amount of deleterious materials (loam, clay, silts or organic matter) shall not exceed 3% of tile total weight of the fine aggregates. The fine aggregate shall not contain more than 0.45% by weight of soluble sulphate. d) Fine Aggregates Fine aggregates shall comprise approved sand free from injurious amount of soft, alkaline, organic or other deleterious matter. The aggregate shall range in size and proportion in accordance with the Table described below: 57

Volume 1 General Specification Electro-Mechanical & Civil Works

e) Water Water used in mixing concrete shall be fresh, clean and free from injurious amounts of acids, alkaline, oil, sewage, salts and organic matter. f) Batching & Mixing of Concrete The mixing of concrete shall be done in a mixer of an approved type which will ensure a uniform distribution of materials throughout the mass, so that mixture is uniform in color and homogeneous. The arrangements made for handling, gauging, transporting and mixing the materials and for adding the cement and water shall be such that the operations can easily be checked and inspected. The mixer s h a l l be equipped with a device approved by the Engineer for hand controlling the quantity of water in each batch so as to give the slump or water cement ratio required by the Engineer. The mixer shall not be charged in excess of the rated capacity nor be operated in excess of the rated speed. Each time the work stops, the mixer should be cleaned out and when next commencing mixing an additional 10% cement over that specified should be added to the first batch. Excessive mixing and addition of water to preserve required consistency will not be permitted. The mixing time for each batch, after all materials including water are in the mixer drum, shall be at least at follows: Capacity of mixer

Mixing Time

½ cubic meter or smaller

2 minutes

¾ to ½ cubic meter

3 minutes

The mixing time may be increased when the charging and mixing operations fail to result in the required uniformity of composition and consistency of the concrete. During windy weather efficient precautions shall be taken to prevent cement from being blown away during the process of apportioning and mixing. The total water content for each batch of concrete shall be minimum amount necessary to produce a plastic mixture of the strength specified and the desired density, uniformity and workability and the concrete shall have a ratio of water to Portland cement of not more than 0.6 by weight. In calculating the total water content in any mix, the amount of moisture on the surface of the aggregate particles shall be included.

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Volume 1 General Specification Electro-Mechanical & Civil Works g) Steel Reinforcement All steel reinforcement shall be clean and free loose flaky rust and scale, and free from oil, grease or other coatings which destroy or reduce its bond with the concrete. All steel reinforcement shall be fabricated to the forms and dimensions required and secured in place by use of metal or concrete supports, spacers or ties, such supports shall be of sufficient strength to maintain the reinforcement in place throughout the concreting operation. The supports shall be used in such a way that will neither be exposed nor contribute in any way to the discoloration or deterioration of the concrete. Before concreting, all reinforcement shall be carefully cleaned of all set or partially set concrete which may have been deposited there on during the placing of previous lift of concrete. Cutting & Bending Steel reinforcement may be mill or field bent. All bending shall be in accordance with the Standard approved practice. All bars shall be bent cold. Splicing In slabs, beams and girders, splices of reinforcements at points of maximum stress shall be avoided whenever possible, such splices where used shall be welded, lapped or otherwise fully developed, but in any case shall transfer the entire stress from bar to bar without exceeding the allowable bend and allowable shear stresses. The minimum overlap for a lapped splice for bars shall be 24 bar diameters, but not less than 30cm. h) Conveying of Concrete Concrete shall be conveyed from the mixer to the place of final deposit as rapidly as practicable, by methods which prevent segregation, or loss of ingredients. There shall be no vertical drop greater than 1m except where suitable equipment is provided to prevent segregation and where specifically authorized. i) Depositing of Concrete Approval of the Engineer shall be obtained before starting any concrete pour. Concrete shall be deposited as nearly as practicable in its final position to avoid segregation due to re-handling or flowing. The concreting shall be carried on at such a rate that the concrete is at all times plastic and flows readily into the spaces between the bars. No concrete that has partially hardened or been contaminated by foreign 59

Volume 1 General Specification Electro-Mechanical & Civil Works materials shall be deposited on the work, nor shall re-tempered concrete be used. Once concreting is started, it shall be carried on as continuous operation until the placing of the panel or section is completed. The top surface shall be generally level. When construction joints are necessary, they shall be made in accordance with the requirements of these specifications. j) Compacting Deposited Concrete Concrete shall be compacted by approved tools and in such a manner as to ensure that it forms a dense mass, free from honeycombs or segregation, filling the forms and the spaces between reinforcement compactly and without voids. Vibrators when used shall have a frequency of not less than 5000 cycles/minute. In no circumstances shall vibrators be attached to or allowed to touch reinforcement. Vibrators shall be used only to compact concrete in the position in which it is deposited. Where conditions make compacting difficult, or where the reinforcement is congested, batches of mortar containing the same proportions of cement to sand as used in the concrete, shall first be deposited in the forms to a depth of at least 2.5cm. k) Curing & Protection of Concrete All concrete shall be maintained in moist conditions for at least the first fourteen days after placing. Concrete shall be protected during the first stage of hardening from the harmful effects of sun shine, drying winds, cold and frost, and also from surface water shocks. No concrete shall be deposited during weather conditions which are considered to be unsuitable by the Engineer in cold weather such precautions as necessary shall be taken that the temperature of the concrete shall not be less than 15°C during the first stage of hardening. All possible precautions in curing concrete must be carried out. L) Construction Joints Joints shall be so made and located as to least impair the strength of the structure. The position and number of the joints shall be subject to the approval of the Engineer before concreting is commenced. Where a joint is to be made the surface of the concrete shall be thoroughly cleaned and laitance removed. In addition joints shall be thoroughly wetted, and sloshed with coat of neat cement grout immediately before placing of new concrete. Where called for, water stops of a type approved by the Engineer shall be concreted into the concrete previously placed and left protruding and undamaged to marry with concrete cast later. 60

Volume 1 General Specification Electro-Mechanical & Civil Works All least two hours elapse after depositing concrete in the columns or walls before depositing in beams, girders or slabs supported thereon. Beams, girders, brackets, column capitals and haunches shall be considered as part of the floor system and shall be placed monolithically therewith. Construction joints in floors shall be located near the middle of the spans of slabs, beams or girders. Unless a beam intersect a girder at this point, in which case the joints in the girders shall be offset a distance equal to twice the width of the beam. In this last case provision shall be made carry the shear forced by making use of inclined reinforcement. The Contractor shall take all the necessary steps by means of timber edgings, etc. to ensure an exact horizontal straight finish to the outside edge of any lift of concrete. This shall apply also to all vertical joints or to any stoppage joints which may arise during the construction of the work, the lines of which shall be straight and regular. m) Concrete Face work All exposed surface of concrete to water shall be made true to line, fair and smooth without after rendering. Every care shall be taken to ensure perfect appearance of the finished surface. Particular care must be taken on all exposed work that no irregularity or roughness occurs between the successive sections of the forms, and that the finished face be perfectly smooth and to such shapes, as required, free of board or from marks, and of uniform color. All concreter work for all water retaining structures and pumps pit shall have three layers of suitable asphalt coating. The surface of the concrete shall be gone over immediately the forms are removed and all uneven edges, fins, projections made good and any minor holes or pitting shall be filled up after the approval of the site Engineer. All finished work shall be made to the satisfaction of the Engineer. FRAMEWORK A) General Forms shall be constructed either of approved wood or steel to conform to the shape, line and grade required. Forms shall have sufficient strength to withstand the pressure resulting from placement and vibration and the concrete, and shall be used, wherever necessary, to confine the concrete, and shape it to the required lines or to ensure against contamination of the concrete with material caving in or sloughing from adjacent excavated surfaces.

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Volume 1 General Specification Electro-Mechanical & Civil Works B) Design of Forms Design of forms shall be so designed and constructed that can be properly placed and thoroughly compacted without loss of water. Formwork shall be adequately strutted, braced or tied. It shall be capable of withstanding the pressure resulting from the placing of the concrete, whatever method of compaction is employed, without undue deflection or loss of alignment. Lumber, once used in forms shall have tails withdrawn and surface in contact with concrete shall be carefully cleaned before pre use. C) Deflection of Formwork Location

Permissible Deflection

Between adjacent framing members

+1.5mm

Between adjacent ties on a framing member

+0.8mm

Over the full depth of a vertical face

+3mm

Over 10 ft length horizontally

+3mm

The Contractor shall make allowance in the form work for any camber specified by the Engineer. IF required the Contractor shall supply to the Engineer designs or calculation for form work he proposed to use. d) Support Formwork shall be so designed that the sides of the beams and slabs can be removed without disturbing the soft forms or their supports. Props and supports shall allow accurate adjustment of the formwork to line and level and be capable of being removed in an approved sequence without injury to any portion of the structure. Provision shall be made for removal of formwork without disturbing props required for supporting hardened concrete. e) Clean and Oiling of Forms At the time concrete is placed in the forms, the surface of the forms shall be free from encrustations of mortar, grout or interfere with the fulfillment of the specification requirements relative to the finish of formed surfaces before concrete is placed, the surfaces of the forms shall be oiled with a commercial form oil that will effectively prevent sticking and will not stain the concrete surface. 62

Volume 1 General Specification Electro-Mechanical & Civil Works

f) Removal of Forms The formwork must be removed slowly, as the sudden removal of wedges is equivalent to suddenly applying load to the partly hardened concrete. Timber, steel, cement, asphalt pots and other materials should not be stacked on any newly constructed floor without the permission of the Engineer. Under average weather conditions (15°C) the following table will give a guide to the minimum periods after casting at which forms and supports can be removed. Forms supporting sides of beams, walls and columns.

2 days

Forms supporting secondary slabs, provided props are left in

6 days

Forms supporting main slabs provided props are left in

12 days

Forms supporting beams, provided props are left in

12 days

Props supporting secondary slabs

24 days

Props supporting main slabs

28 days

Props supporting beams

28 days

For concrete made with rapid hardening Portland cement these times may be reduced according to the approval of the Engineer. g) Form Ties The material and position of any ties passing through the formwork shall be to the Engineers approval. Any holes left after removal of ties shall be filled with concrete of mortar of approved composition. Use of embedded wire ties for holding forms shall not be permitted in concrete walls to be subjected to water pressure or where the surface through which the ties extend will be permanently exposed. Wire ties may be used for holding forms for concrete walls where embankment is to be placed against both sides of the wads. Wire ties shall be cut off flush with the surface of the concrete after the forms are removed.

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Volume 1 General Specification Electro-Mechanical & Civil Works h) Proportions and quality of concrete Four classes of concrete, defined below, shall be used in the various items of work: Class A - Concrete containing not less than 400kg of Portland cement per m3 (normal mix: 1:1½:3). Class B - Concrete containing not less than 300kg .of Portland cement per m3 (Normal mix: 1:2:4). Class C - Concrete containing not less than 200kg .of Portland cement per m3 (Normal mix: 1:3:6). Class D- Concrete containing not less than 150kg of Portland cement per m3 maximum size of aggregate 38mm (Normal mix: 1:4:8). The minimum crushing strength of the various classes of concrete measured on cube sample of 15x15x15cm shall be at least as follows: Class of concrete

At 7 days (kg/cm2)

At 28 days (Kg /cm2)

Concrete Class A

190

280

Concrete Class B

150

210

Concrete Class C

90

140

For each grade of concrete a set of 6 cubes shall be made, three shall be tested at an age of 7 days and three at 28 days. Where sulphate resisting cement is used, the figures for strength given in the Table shall be attained by 42 days. The Engineer may order the prompt removal of any concrete work which upon testing proves to be of inferior strength to the above specifications and the Contractor shall follow the Engineer’s instructions with regard to the above. The Contractor will not be entitled for any payment or extension of time for any such work. i) Placing and Compaction for Exposed Finish Concrete Fair-face concrete shall be placed with special care and fully compacted with immersion vibrators where at all possible. The concrete shad be placed in about 15cm layers and each layer compacted by means of immersion vibrators inserted vertically at point 40cm to 50cm apart. The: rate of concrete placing shall be kept within the capacity of the vibrators rand no more than 10cm of un-vibrated concrete shall exist as a 64

Volume 1 General Specification Electro-Mechanical & Civil Works surcharge over the vibrator at any time. j) Hand Mixing Where small quantities of concrete are required, the approval of the Engineer is necessary to allow mixing by hand. The proportion of cement should in this case always be increased by 1%, Hand mixing should be carried out on a clean hard surface or platform to prevent dust and mud being shoveled up with the concrete. The cement, sand and coarse aggregate should be carefully measured in their correct proportions and thoroughly mixed before water is added. Only sufficient water to make the mix workable should be used, this should be sprayed from a watering can. Mixing should continue until the color of the wet concrete is uniform. TEST ON CONCRETE a) General The Engineer or his authorized representative should have the right to determine the suitability, or otherwise of al l tests. He shall order a reasonable number of tests to be carried out on the concrete from time to time to verify the adequacy of the materials and the methods to produce the required results. The Engineer may in cases of doubt order the "Test under full load" of any portion of a completed structure to determine its adequacy for service. Tests concrete and its materials shall be made in accordance with the latest IOS or British Standard Specifications. Complete records to all tests shall be available for inspection during the progress of the work. The Contractor shall carry out all sampling and testing to the satisfaction of the Engineer, and costs of everything related to the tests shall be done by the Contractor. b) Compression Tests Concrete This test shall be carried out for measuring the strength and determining the quality of the concrete, on test tubes 15x15x15cm the moulds for the test cubes shall be of steel or cast iron with the inner surfaces perfectly square and machine faced. Timber moulds shall not be used. Each mould shall have a metal base-plate with a true surface to support the mould and prevent leakage. Specimens shall be made and cured according to Standard Practice to be approved by the Engineer. The concrete for samples shall be taken at the concrete mixer and shall be either rammed or vibrated under similar conditions as those prevailing during construction.

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Volume 1 General Specification Electro-Mechanical & Civil Works c) Slump Test The concrete shall be of such consistency that it can be readily worked into the corners and angles of the formwork and around reinforcement without segregation of the materials or bleeding of free water at the surface. The workability shall be controlled by direct measurement of the water content, allowance being made for water in the fine and coarse aggregates. On striking the formwork it shall present a face which is free from honeycombing, pitting surface crazing, or excessive dusting and which shall not, in the opinion of the Engineer be inferior to the standard of finish referred to. The consistency of concrete shall be determined by a slump test in accordance with BS 1881 or the ASTM Standards C143/42 or equivalent. The slump shall fall within the following limits, provided the required strength is obtained: Slump in cm General building construction

Min

Max

For vibrated concrete

5

8

Non-vibrated concrete approved by the Engineering

7

15

d) Water - proofing of Concrete Where required, the concrete shall be water proofed with a compound mixture. The type of t h e water proofing compound s h a l l be approved by the Engineer before being used. The compound shall be used in strict accordance with the manufactures instructions. e) Concrete Tolerance Positions members shall be accurate within 6mm but this tolerance must not be cumulative. Size of members shall be accurate to within ±3mm. The displacement of shuttering boards at joint shall not be greater than 0.8mm. The displacement from straightness of members shall be within 10mm in 12m but this tolerance must not be cumulative. The twist in members shall not exceed 10mm in 10m but this tolerance must are not be cumulative. Columns which are not exposed and have a fair-face finish and those which house windows and other frames tight to straightness to within ±1.5mm. Note: All material quality and test to RC work shall be according to clause one of standard specification as well as the above specification or which is better to this office.

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Volume 1 General Specification Electro-Mechanical & Civil Works

PILING General characteristics Piles shall in general be of approved cast in-situ or precast concrete type. The Contractor may however propose a type of pile different from those specified herein which case, full performance and characteristics details shall be submitted by the Contractor with his Tender for consideration. Cast in-situ piles Cast in-situ piles shall in general be of the driven type. The concrete in the pile shall be Class "C" using approved sulphate resisting cement. The pile shall be reinforced with vertical steel reinforcement consisting of not less than five bars spaced uniformly around the perimeters of the pile. The cross sectional area of the vertical reinforcement shall not be less than 1% of the total cross section of the pile. The reinforcement shall be enclosed with spiral reinforcement which shall not be less than 6mm in diameter and with a maximum pitch of 15cm. In addition the top 15 cm of pile, immediately below cut off level, shall have 4 turns of spiral at 3cm pitch. The reinforcement shall be placed at a clear distance of 7cm from the face the pile. The vertical reinforcement shall extend a length of 1m above the finished concrete level of the pile. In forming the pile positive means shall be employed to assure that the concrete shaft shall be continuous and of a minimum diameter greater than the diameter of the forming apparatus. The pile forming apparatus shall be driven to obtain the required working load. The reinforcement cage shall then be lowered and the shaft shall be filled with concrete. At a l l stage of the work every precaution should be taken to prevent wasting and the formation of voids in the concrete. During extraction of the casing observation should be kept on the surface of the concrete to detect any tendency towards lifting of the concrete. PRECAST PILES The size and type of the pile proposed for use as well as the method of making it and description of the equipment for driving it shall be submitted by the Contractor for approval before the award of the Contract. The pile should be designed cast and adequately cured to develop the strength necessary to withstand the transporting, handling and driving stresses without damage. The concrete should be of quality not inferior to Class "B" and the cement used shall be sulphate resisting of an approved type. 67

Volume 1 General Specification Electro-Mechanical & Civil Works No high early strength cement shall be used. When piles are to be driven into or through ground such as rock, coarse gravel clay with cobbles and other soils liable to damage the concrete at the tip of the pile, the pile shall be provided with flat or pointed co-axial shoes. In uniform clay or sands the shoes may be omitted. The head of pile should be protected with packing of resilient material, care being taken to ensure that it is evenly spread and held securely in place. A helmet should be placed over the packing and provided with a dolly of hard wood or other material for driving the pile. The Contractor shall drive enough trail piles to determine the length of pile required for the different conditions on site. These trails shall be made well ahead of pile driving proper to prevent delay in the work and so that the Contractor will have available in good time piles of the proper length to meet any soil conditions. SETTING OUT AND PERFORMANCE The Contractor shall set out and drive all piles as accurately as possible conforming to the numbers, positions and rakes shown on the drawings. The deviation from the axes shown on the drawings shall not exceed 5cm at any cross section of the pile. The sequence of driving the piles should be such as to prevent damage to any recently completed piles where the concrete has not had time to harden sufficiently. Test piles shall be selected by the Engineer and tested by the Contractor to double the required working load. The arrangement of the test shall be approved by the Engineer. Complete records of driving and load test shall be presented to the Engineer. The pile driving record shall show the type of hammer and the number of blows per unit length needed to drive the pile its full length. The test load shall be applied in increments of ¼ the working load and reading of settlement shall be taken after each increment. The load increment shall be maintained for at least 2 hours and until no further settlement is noticeable on a dial gauge with 1/100mm graduations. The total test shall be maintained such that no more than 0.5mm settlement occurs in any 24 hours. The test load shall be removed in decrements of ¼ the test load and rebound recorded after each l o a d decrement. The final rebound shall be recorded 24 hours after the entire test load has been removed. The permanent settlement shall not be greater than 6mm measured at the top of die pile. If result of load tests or of concrete cube tests taken from the concrete used for the pile do not meet the specifications set out here above then the Engineer may order the refusal of the piles concerned and the driving of replacement piles. The Engineer may at his discretion accept the piles concerned on the basis of a lower working capacity. In 68

Volume 1 General Specification Electro-Mechanical & Civil Works both cases the Contractor shall furnish the replacement and/or the extra piles entirely at his expense without the right for a claim for extension of rime. The Contractor shall also bear the cost of the enlargement to the pile cap and other works made necessary by driving the replacement and/or extra piles. Should any pile be damaged by over driving or not conform to the tolerances of the specifications, extra pile or piles shall be driven in its place and pile caps enlarges at the Contractors expense unless in the opinion of the Engineer the pile is out of Plumb or place due to the results of an underground obstruction. Piles rejected after driving may remain in the ground at the discretion of the Engineer and cut off as directed. When rejected piles are withdrawn from their space, if not utilized in driving another pile, shall be filled with gravel or broken stone without payment therefore. CEMENT, MORTAR, PLASTERING AND RENDERING The cement mortar shall consist of cement and sand as specified and shall be gauged in wooden boxes in the following proportions: Proportion of Volume Class of work

Cement

Sand

Brickwork

1

3

Plastering to walls

1

3

Rendering to floors and walls of water containing concrete

1

1

The sand shall be hard, durable, clean and free from adherent coating such as clay and in accordance with the relevant IOS Specification. The cement and sand shall be mixed together dry on a clean wooden or iron stage until the mix is perfectly homogeneous in color, water shall be added through a rose in quantity sufficient to give no more than a stiff workability and the mixture shall then be turned until perfectly even consistence is obtained. The surface of the work to be plastered, rendered or tiled shall be thoroughly prepared before the coat or tiling is applied. The surface of the concrete shall be cleaned of all lose material by a wire brush and shall be thoroughly soaked with water for at least 24 hours prior to laying the tiles and likewise the surface of the brickwork before plastering. The rendering and plastering shall be float finished to true planes and regular curves and 69

Volume 1 General Specification Electro-Mechanical & Civil Works to even and polished surface to achieve an even surface screeds shall first be formed either with mortar or with wooden boards which shall be removed after completion and replaced with mortar. The screeds shall be formed with the aid of a plump bob, spirit level and the necessary rules. Thereafter, the mortar shall be spread with a trowel between the screeds and flattened by means of suitable rules. The finished surface shall be a smooth flat surface free from trowel marks, great care being exercised to avoid over toweling. All arises shall be rounded and line able and a hollow fillet shall be run at all internal angles. The finished plastering shall be watered six times a day and kept thoroughly damped for a period of fourteen days after completion. Any plastering rendering or tiling found to be hollow or in any other way defective shall be removed and made good to the approval of the Engineer at the expense of the Contractor. JUSS Plastering The surface to be plastered shall be prepared as in relevant Clauses. A preparatory coast of 1:1 sand cement slurry shall then be applied to the clean, wet surface by vigorous brushing and immediate stippling with a banister brush in order to form a close textured key. Two coats of JUSS shall be applied. The first coat shall be applied evenly and with sufficient material and pressure to form a good bond with the brick and concrete surface, in order to obtain a flat surface, screeds shall be used as in the case for cement plastering. The surface shall then be rodded and floated to a true even plain, then roughened slightly with a stiff bristled brush. The second coat of smooth white finish shall be applied by trowel as soon as the first coat is firmly set and before it is dry (if the first coat is thoroughly dry, it shall be wetted evenly by brushing or spraying). As the finish coat sets and shrinks, it shall be thoroughly and uniformity packed and compressed by heavy scouring with the trowel. The material shall be allowed to shrink between scouring operations, and additional water shall be brushed on as required. The scouring shall be continued until a smooth dense surface is obtained. Total thickness of plaster should not be less than 2cm. The JUSS used shall be pure calcium sulphate from the mechanical JUSS factory in Baghdad or of equal approved quality and shall be delivered to the site in sealed bags. Upon arrival on site it shall be stored in dry sheds with raised floor and water proof walls and roof. All under burnt or over burnt JUSS shall be rejected and the Contractor shall provide facilities for each batch of material to be checked and tested on the site or where the Engineer may direct to the satisfaction of the Engineer.

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Volume 1 General Specification Electro-Mechanical & Civil Works BRICKS & BRICKWORK The bricks to be employed in the construction of the building shall be local production and factory made. They shall be of dense substance thoroughly burnt free from flaws and salt efflorescence and true to shape. The contractor before placing an order for bricks shall submit a sample for the approval of the Engineer. After approval the Contractor shall hand over the samples to the representative of the Engineer at the site of works. The samples shall be taken in accordance with the provision of the specifications. In the construction of the brickwork all bed and vertical joints shall be filled in solid as the bricks are laid and no flushing up or grouting from the top will be permitted. All bricks shall be submerged in clean water for one hour before being laid. Where the bricks are frogged the frog shall be laid upwards and no four courses shall rise more than 25mm above such four courses laid dry. The joints shall be struck to 12mm rebate as the work proceeds to form a key where the brickwork is subsequently plastered. All unfinished brickwork shall be cleaned and thoroughly wetted before the new work is added. The courses shall be laid parallel in neat close and regular joints and all perpends shall be truly kept and shall be true in the vertical and horizontal alignments throughout. The brick work shall break joint correctly with the underlying course and no broken bricks or bats shall be used, it shall be carried up evenly and uniformly no one portion being raised more than 1m above another at one time and the whole properly bonded together . All brick work below ground level shall be painted with cement mortar made with sulphate resisting cement. MASONRY & MASONRY WORK The masonry to be employed in building construction shall be dense substance and without cracks, free of dust and salt efflorescence. The face of the masonry must be in a regular shape. The Contractor shall submit a sample for the approval of the Engineer. The stones should be in regular equal strata. The outer face joint shall be filled with 1:3 cement mortar, the internal and external faces shall be plain and vertical, all unfinished masonry works shall be clean and thoroughly wetted before the new work is added. Tying stones of length equal to the width of the wall should be laid in its length and the least dimension of it should not be less than 20cm tying stones shall be laid in every 50cm all height and minimum 120cm the horizontal distance between every two stones. Tying stones should be laid in a manner that the vertical joints in the last row should be stopped by the row underneath. All work should be done under the supervision and approval of the Engineer. 71

Volume 1 General Specification Electro-Mechanical & Civil Works

DOORS GENERAL Dimensions and details of doors shall be in accordance with the drawings. Shop drawings of doors, including the method of hanging doors on frames, shall be submitted for the written approval of the Resident Engineer before beginning of fabrication. The hardware shall be of best quality and all will be arranged under a master and sub master system. Steel Doors All steel doors and frames shall be made of mild welded without deposition of metals and properly reinforced. Corners shall be welded construction with all joints face welded and ground smooth. Welds must develop the full strength of the section and all joints in face to occur over reinforcing members. After assembly, all metal shall thoroughly cleaned of rust, oil and grease and given a coat of an approved rust resisting metallic primer with filler as required. Doors and frames shall be painted with two coats of approved oil paint, the colors of which shall be according to the instruction of the Resident Engineer. SLIDING FOLDING STEEL DOORS Doors shall be double or single sliding or sliding folding type, as specified, and shall consist of mild steel plates welded to mild steel angle iron or channels framing and bracing. The leaves of sliding and sliding folding doors shall be hung from wheel ball bearing hangers operating in an overhead corrosion resisting box type track of adequate size fixed by brackets to the lintels. The doors shall also be provided with corrosion resisting floor channel and guides, stops, handles, hasp and staple and bolts for fastenings track brackets and other hardware to walls. All doors under this item shall be fitted with a tower bolt on one side and a locking arrangement on the other, and push and pull handles on both sides. Doors when required shall be equipped with small hinged pass doors for use by pedestrians. Weather proof and dust proof doors where specified shall be fitted with weathering fabric inserted at the sides, top and bottom. Weathering shall be carried around at leading edge to act as wiper.

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Volume 1 General Specification Electro-Mechanical & Civil Works STEEL HINGED DOORS (DOUBLE LEAF) All double leaf hinged doors shall be double plated, consisting of 1.5mm mild steel sheets welded to iron framing and shall be well braced. The frames shall be of a suitable section to provide sufficient rigidity. The hinges shall operate on bush bearing and shall be strong and durable. The door shall be fitted with best quality flush type tower bolts from the inside, door checks (closers) and shall have locking arrangements of the best quality from outside. Lock sets shall be with dead bolt operated from outside by key, inside by thumb turn and shall be provided with fixed knobs or level handles on both sides (as specified). STEEL HINGED DOORS (SINGLE LEAF) The specification of this type of door shall be similar to the double leaf hinged doors above except that no tower bolts, only one door check (closer), and one handle on each side shall be required. STEEL HINGED DOORS (TRIPLE LEAF STEEL & GLASS) The dimensions of the door shall be generally according to the drawings. Specification of steel sheets, framing and hardware shall be similar to the double leaf, hinged doors mentioned above. WOODEN DOORS MATERAILS Timber The kind of timber to be used on each stem will be stated in the Bills of Quantities. Timber shall be well seasoned and free from serious material defect and decay insect attack. Plywood Shall be 3 ply board 5mm thick, the Contractor shall furnish samples of plywood for approval and selection of grain texture of face plies. Hardware All hinges, locks and latches shall be of the best quality and the Contractor shall furnish samples of all hardware for approval. Method of Construction Flush Doors: shall consist of wooden frames of uniform thickness covered on both faces with plywood such that both sides of the door shall be perfectly flush. The finish thickness shall not be less than 5cm hardwood lips shall be provided to the edges. Members of the frame shall be whitewood of no less than 30x15mm finished size, in addition, 73

Volume 1 General Specification Electro-Mechanical & Civil Works intermediate horizontals in rails 20x40mm shall be provided. The number of such, rails shall be such that they cover 50% of the door area. Outer casings or frames shall be hardwood 150x75mm fixed to walls by three steel bags on each side. Exterior doors shall have a suitable wooden sill, interior doors may have the wooden sill omitted and replaced by steel tie-embedded under the floor finish. All doors shall have three pressed steel butt hinges and metric lock of best available quality. STEEL WINDOWS Dimension and details of steel windows shall be in accordance with the Drawings. All steel windows shall be constructed of mild sections of such dimensions as to ensure proper rigidity and welded without deposition of metals and properly reinforced, corners shall be welded construction with all joints face welded and ground smooth, welds must develop the full strength of the section. All open able panels should be supplied with brass fly screen of an approved make and shall be proved with Z section frames. Such screens should be installed in such a manner so as not interfere with the proper operation of the window, but shall nevertheless fully prevent entry of insects. After assembly, all metal shall be thoroughly cleaned of rust, oil and grease then sand prepared and given an adequate coat of rust resisting metaling primer with filler as required, and shall receive two coats of oil paints, the color of which shall be according to the instructions of the Resident Engineer. GLAZING All glass sheets for windows and/or doors shall be 4mm thick unless otherwise stated on Drawing or by the Resident Engineer. The material shall be locally purchased and of the best available material on the market. Any glass chipped, cracked, scratched, broken or permanently stained, itched or damaged in any way prior to the acceptance of the building shall be replaced at no additional cost. Putty shall be of the tropical type specially prepared for use with metal windows and/or doors of a make approved by the Resident Engineer.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE FIFTEEN ENVIRONMENTAL SERVICES General The section includes the design, supply, installation, testing, commissioning and maintenance for the maintenance period of the heating, ventilation and air-conditioning system and the hot and cold water services for the treatment works. Heating, Ventilation and Air Condition Systems The following environmental standards shall be maintained: (i)

Air conditioning, including heating and cooling as required, shall be provided in living quarters and in all areas where operating personnel are required to attend on a permanent basis or for relatively long periods. The basis of the design of the equipment shall be as follows:

Ambient conditions Summer

60°C D.B 20°C W.B

Winter

3°C D.B.

Inside conditions Summer

20°C ID.B. 16°C W.B

Winter

20°C D.B

Windows

Single glazing with metal frames and rectilinear shading device

Plant

As per equipment schedules

Outside

Per person approx. (24cfm).

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Volume 1 General Specification Electro-Mechanical & Civil Works Requirements (ii)

In area where there might be high heat gain from plant (i.e. main pump house generator room, transformer rooms), a high rate of ventilation shall be provided. In these areas provision shall also be made for the employment of selfcontained mobile or portable air conditioning units to provide tolerable working conditions for plant maintenance and checking. It is not anticipated that space heating will be required in any of these areas, except in the generator room, where when on standby duty.

(iii)

In other areas of lesser activity and where small items of plant are located and in storage areas a lower rate of ventilation shall be provided. Space heating may be provided in some of these areas as detailed.

(iv)

The Quantity of air changes per hour for each particular room shall be dependent on room function and shall be in accordance with present day good practice and it must not exceed 10% by volume flow rate of air for each room.

Location Requirement schedule Location

Administration building

Requirement Central or room air conditioning unit with heating and cooling. Plus Ceiling Mounted Fans

Filter control galleries offices Control rooms Workshop office Laboratories Living rooms Bed rooms

Rooms air conditioning units with heating and cooling plus Ceiling Mounted Fans

Guard rooms

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Volume 1 General Specification Electro-Mechanical & Civil Works Toilets Shower rooms Kitchens Observation Rooms

Ventilation

Generation Rooms Alum Rooms and store Chlorine Rooms and store Ventilation Pump Rooms

L.T H.T. Switch board rooms Transformer rooms

plus Prevision for portable Room Air conditioning Units Plus ceiling fans air conditioning units plus ceiling fans Ventilation Ceiling mounting fans

Workshop area stores

plus Ventilation

Electric Motors All electric motors and control equipment supplied under this section shall be suitable for 400/230V three phase four wire system and the starting requirements shall be as set out in the specification. The motors shall be suitable for operation in a tropical climate and insulation standards shall be class B or class F in all cases. Space Heating (i)

The heating medium shall be electricity in all cases. The type of heaters to be used shall be as follows: a. Convector type heaters generally wall mounted with natural convection, having a maximum loading of 2KW. b. Fan assisted convection heaters wall mounted, to a maximum loading of 3KW. c. Convector heaters, both natural convection and fan assisted type, shall have built in thermostats, an ON/OFF switch and 77

Volume 1 General Specification Electro-Mechanical & Civil Works indicator lights. d. Unit heaters shall have excess temperature protection consisting of a bio-metal strip built into the heater casing it shall be wired in the control circuit of the heater so as to intercept the supply on an excess temperature occurring. Re setting of the cut shall be manual. Room Air Conditioning Units Air conditioning units in smaller areas such as rooms in staff houses and small offices shall be the self contained room type conditioners. They shall be complete with quit running centrifugal fan with an air cooled hermetically sealed compressor in a sheet steel enclosure with backed enamel finish. Grilles shall be heavy gauge expanded metal and air filters shall be the throw away type. The units shall be fitted through the external wall at low level and the external section shall be suitably weather proofed. On the inside the internal projection maybe incorporated in a work bench or other fitment and steps shall be taken to ensure that any hot surface are properly insulated from the fitment. Where heating may be required at times in the air conditioned area an electric heater battery of the required capacity shall be built into the air conditioning unit. Thermostatic control shall be provided by rather a room thermostat or thermostat built into the re-circulation air path at the unit. Central Air Conditioning Units Larger areas requiring air conditioning shall be served from a central station air handling unit of adequate capacity, capable of providing heating and cooling in the particular zone which it serves. The A.C. plant may be the split system consisting of an air handling unit located in a plant room adjacent to the area being served with the compressor / condensing unit remotely located on the roof or else it may be a single unit with combination heating and cooling, depending on the particular circumstances. Enclosures shall be in galvanized steel construction of suitable rigidity with welded base assembly. Access panels shall be held in position by quick release fasteners. Enclosures for external location shall be suitably waterproofed and weathered against driving rain and sand storms. Air conditioning supply units shall be of sizes, characteristics and capacities required and equipped with vibration isolators as recommended by the unit manufacturer. A one piece welded drain pan shall be provided 78

Volume 1 General Specification Electro-Mechanical & Civil Works under the complete fan and coil section on horizontal units and under the complete coil section on vertical units. Drain pans shall have a drain connection and shall have a heavy duty galvanized finish. Fans for these units shall be double inlet multi blade centrifugal fans, of the non overloading silent running type, with the wheels mounted on a shaft of ample size. There shall be sufficient number of fans for each unit to give the specified performance. Fans shall be properly connected to the ductwork as specified, with short flexible collars of woven asbestos properly sewed and clamped. All fans shall be given a starting and running balance test and shall be thoroughly tested in each case, shall be of sufficient capacity to continuously deliver the maximum specified quantity of air through the actual resistance of the ductwork, grilles coils, filters, etc. under normal operating conditions. The fan shaft of each unit shall be supported by at least two bearings of self aligning type, each bearing shall be securely attached to the casing of the unit. Insulation shall be 25mm blanket fiber glass securely fastened to all panels with approved adhesive. Drain pans shall be insulated with 12mm cellular expended polystyrene girl board fastened to pan with adhesive. Seams shall be sealed with mastic. Coils shall be continuous aluminum plate or helically wounded aluminum fin and copper tube type bonded by mechanical expansion. Coils shall be designed for a maximum working pressure of 2100KN/m2 (300psi). Chilled water type coils will be provided with connections for convenient drainage and air venting and all connections shall be threaded. Piping connections shall be of the solder type. All connections shall extend through the casing and all shall be at the same side of the unit. Each unit shall be equipped with a constant speed electric motor with a maximum speed not to exceed 1500rpm. Each motor shall be provided with a motor control as specified elsewhere in these Specifications. Each unit shall be equipped with a V-belt drive of standard manufacture. There shall be at least two belts for each unit. All drives shall be so sized as to have sufficient capacity with one belt broken and shall be provided with adjustable ratio sheaves and approved perforated sheet metal belt guards, when the fan drive is outside the unit casing. Fans shall be the backward curved, non overloading silent running, high speed centrifugal type or axial aerofoil type. Fans shall have direction of rotation and direction arrangement to suit space conditions. Fans housing shall be rigidly built and braced. Where fan scroll is 500mm or more in width, an access door shall be provided. The door shall be of the pan type set in a raised frame so that the inner surface is flush with the scroll. The door and frame shall be arranged for insulation where required. The door shall be secured to the frame by hand grip bolts, and shall be provided with lift handles. Bearing shall be self aligning and shall not 79

Volume 1 General Specification Electro-Mechanical & Civil Works cause leakage of oil or grease, cups or oil chambers must be provided in accessible positions outside of the duct connections for easy lubrication. All fans shall be guaranteed to fulfill the specified requirements, without producing any noise that can be heard anywhere in the building outside of the fan rooms and other machine spaces the Contractor and the manufacturer will be held responsible to replace any fans found unsatisfactory in this regard without any added cost to the Employer. Wheels shall have ample strength they shall be statically and dynamically balanced to avoid vibration. Each fan and its motor drive where separately mounted shall be supported on vibration absorbing base on top of 100mm high concrete pad. Each fan motor shall be sized to drive its respective fan when the fan is in operation at a speed (due to pulley adjustment) of 25% in excess of the required to meet fan performance. Mobile air conditioners where specified shall be similar to the fixed units except that they will be fitted with castors. They shall have two adjustable air outlets for the conditioned air near the trap. Axial extract fans used shall be silent running aerofoil type directly coupled to totally enclosed motors. Before being ordered all surely grilles and diffusers shall be checked by the manufacturer for throw, drop and noise. All grilles and diffusers shall be specially selected for their particular application and designed for quite operation. Air grilles and registers shall be fabricated from extruded aluminum metal with rear parts finished mutt black. All supply grilles shall have an opposed blade damper of suitable capacity fitted at the back. The dampers shall be key-operated from the front. All outside air intakes and air handling equipment shall be protected by air filters. Each air handling unit shall be equipped with an air filter of sufficient capacity and dimensions to ensure that all air passing through the unit shall be filtered to a high standard. The filter shall be washable tube type suitable for side withdrawal. They shall be as (Vokes) Univee 2 superfine or equal approved mounted in a purpose built holding frame to provide an overall efficiency of 99.8% to BS 2831 No. 2 test dust. Each fresh air intake point shall be equipped with a bank of filter cells, of sufficient capacity to handle the volume of air. Each cell shall consist of a single pleated sheet of handles and latches. Each filter ban shall be equipped with an inclined draught gauge to measure filter resistance to air flow. This gauge will be mounted in an accessible position to enable resistance to be observed readily by maintenance personnel. Compressors shall be the hermetically sealed reciprocating type with forced feed lubrication and motor winding protection. They shall be designed for air cooled operation and shall be acoustically insulated by means of internal anti-vibration mountings and heavy gauge shell. 80

Volume 1 General Specification Electro-Mechanical & Civil Works Condenser coils shall be seamless copper tubes with aluminum plate fines and galvanized steel and sheets. Tubes shall be mechanically expended into fin collars to ensure maximum heat transfer efficiency. Condenser fans shall be non overloading propeller type having totally enclosed motors with permanently lubricated ball bearings. The refrigerant shall be of an approved type for the particular duty and site conditions and the refrigerant circuits shall have approved expansion valves rather than capillary tubes. The compressor / condenser units shall be suitable for external roof mounting. Sheet Metal Work and Appurtenances The Contractor shall furnish a l l sheet metal work and appurtenances required to connect all heating, ventilating and air conditioning apparatus and ready for regular operation, including: All casing indicated or required, all duck work from registers, diffusers and grilles to suction and discharge sides of fans, flexible connections between ducts and fans, and belt guards for motor drives. The Contractor shall blank or otherwise fill all spaces around his ducts where they pass through floors, walls or partitions, so that no holes are left. The materials used for this purpose shall be equal in fire resistant qualities to the construction through which the ducts pass. Care shall be taken to prevent transmission of floor vibration to ducting. All sheet metal work exposed to the weather or elsewhere if indicated on drawings, shall be built substantially as shown of galvanized iron, one gauge heavier than shown in the table below, and painted with two coats of bitumen or approved rust resisting paint. All work shall be properly braced, supported and secured to the building construction. All other ductwork for conventional system, except where otherwise specified, shall be built of best bloom galvanized iron in accordance with the following schedule:

Larger dimension of duct

Galvanized iron thickness

Up to 1500 mm

1.0mm.

1500mm to 2000mm

1.2mm

Above 2000 mm

1.6mm

81

Volume 1 General Specification Electro-Mechanical & Civil Works Joints in ductwork shall be as follows: (i) (ii) (iii) (iv)

Straight sections of round duct shall be formed by rolling the sheets to the proper radius and grooving of the longitudinal seams. Rectangular ducts shall be constructed by breaking the corners and grooving the longitudinal seam. Elbows and transformation sections may be formed with corner seams but complicated firings shall be constructed with double seams covers. Transverse joint connections, etc. shall conform with the current recommendations of the Chartered Institute of Building Services of England.

Ducts shall be braced as follows: Larger dimensions of duct

Size of bracing angle

Distance between bracing angles

Above 600mm to 1000mm

25mmx25mmx3mm

1.2m

Above 1000mm

40mmx40mmx5mm

0.6m

Angle bracing shall be of galvanized steel or painted with rust resisting paint and shall be carried out on all four sides of ducts. All ductwork which is to be insulated and is over 900mm in the larger dimension, all un insulated ductwork over 1350mm in larger dimension shall have angle iron running along the length of the duct along the center of the wider dimension, which shall be of the same size as the four angles. This shall be used for additional stiffeners and to prevent the sagging of the wide ducts. Galvanized iron ducts up to 900mm in width shall be suspended by means of galvanized iron straps securely fastened to the angle iron bracing or the slip connection. Ducts above 900mm shall be suspended by galvanized angle iron hangers of same size as bracing angles. Hangers shall not be more than 2.5m apart. Ducts shall be built with curves and bends, where necessary to affect an easy flow of air. All duct corves an inside radius smaller than the width of the curve shall be equipped with approved single thickness varies. Vertical ducts shall have full size bends where horizontal branches are taken off unless shown to the contrary. Where square elbows are used in changing direction the Contractor shall furnish and install suitable designed duct turns only approved aerodynamically correct vanes will be considered for approval. A substantially constructed manual volume damper or the butterfly 82

Volume 1 General Specification Electro-Mechanical & Civil Works or multiple blade type (200mm maximum blade width) shall be provided in every branch duct of every conventional duct system. Each damper shall be equipped with a locking quadrant of heavy construction, with approved operating and locking devices, mounted outside the duct in an accessibly position. Registers as hereinafter specified shall be set behind supply air grilles. Install automatic main dampers of louver pattern in air inlet ducts, discharge ducts from return and / or exhaust fans, etc. These dampers shall be generally provided by the manufacturer of the automatic temperature control system and shall be as specified hereinafter. Volume control and modulating dampers shall be of the opposed blade type. The Contractor shall arrange his ductwork to receive automatic dampers and shall set the same in place. The Contractor shall provide and affix a brass tag on each balancing and volume damper, indicating the area to which its duct runs. Where ducts pass through fire break walls fire dampers shall be installed in all ducts where required. Dampers shall be 3.5mm steel plate mounted to turn freely, in steel plate frame inserted in duct, proportioned and weighed to closed at once if released from link and provided with spring catches to hold closed until manually reset. Dampers and frames shall have suitable eyes and standard fusible links rated at 93°C normally holding them open but releasing upon contact. Access doors of ample size for resetting the dampers shall be provided in the ductwork. Suitable flameproof connections shall be furnished and installed on all suction and discharge connections of fans and air conditioning unit, for preventing the transmission of vibration through the ducts to occupied spaces. Flexible connections shall be of suitable weight and composition for the static pressure developed. All air conditioning supply ducts including fresh air intake to units shall be insulated. The insulation shall be rigid fiberglass slab 20mm thick with a suitable finish for painting over. Joints shall be with a suitable adhesive tape. The slabs shall be fixed in position by means of mechanical fasteners at 300mm centers or else by use of an approved and suitable adhesive. Testing The heating, ventilating and air conditioning systems are to be tested for air quantities, capacities and horsepower. Air quantities are to be obtained by anemometer and volume meter reading. Each of the system shall be tested by the Pitot tube method. Two reading shall be made, one at the suction side of the fan and one on the discharge side. The Contractor shall make and record the following tests: 1 2 3

Air volumes at each supply, return and exhaust outlet Total air handled by each supply fan Total return air to each supply fan 83

Volume 1 General Specification Electro-Mechanical & Civil Works 4 5 6 7

Total air handled by each exhaust fan Total static pressure each fan Motor speed, fan speed and input ampere reading each fan Average velocity on intake and discharge sides of each fan

The heating and cooling coils for each system s h a l l be tested and the following data taken and tabulated: 1 2 3 4 5

Average velocity over intake side of each coil face. Entering air conditions to each heating coil (D.B and W.B.). Entering air conditions to each cooling coil (D.B and W.B.). Leaving air conditions from each heating coil (D.B and W.B). Leaving air conditions from each cooling coil (D.B and W.B).

All tests shall be supervised by the Engineers Representative. The Contractor shall provide all required instruments and labor. Should the contractor refuse or neglect to make any tests necessary to satisfy the engineer or his representative that he has carried out the true intent and meanings of the specifications, the employer may make such tests and charge the expense thereof to the contractor. Schedule of Technical Particulars to be supplied by Tenderer. The Tenderer shall supply a full description of the proposed system including: • • • •

Design calculations Technical specifications Manufacturer of equipment Manufacturers type No.

84

Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE SIXTEEN Water Services This section covers the complete service water supply system and includes: (i) (ii)

(iii)

The service water pumps, controls and water pressuring arrangements. The service water distribution pipe work including the ring main around the water works complex with connection mains to the cold water storage tanks in the raw water pump house, filter building, treated water pump house, chemical building, administration building, power building, garage workshop, guard house, observation posts and the engineers and operators houses together with all necessary valves and fittings complete as shown on the drawings. Hot and cold water plumbing including a l l stopcocks, hot and cold water storage tanks, water heaters, drinking water chillers and internal plumbing pipe work to HAVC units and sanitary fittings and all else necessary for the complete plumbing including hot and cold for the treatment works.

External pipe work shall be in Ductile Iron pipe work to comply with BS 4772 complete as shown on the drawings. Internal pipe work within the buildings shall be in galvanized steel tubing to comply with BS 1387 Joints shall be threaded. Water storage shall be provided at high level in buildings as indicated on the drawings. Storage tanks shall be in galvanized mild steel to comply with BS 417 or molded PVC in accordance with BS 4213. The Contractor shall also provide suitable supports, removable tank cover and high pressure ball cock and overflow pipe to each tank. Water heaters shall be electrically operated and shall generally be the self contained cistern type suitable for wall mounting. They shall be complete with a small built in tank with high pressure ball cock and overflow outlet. Water heaters shall have capacities set out in the drawings. The electric loading of the heaters shall be approximately 2KW per 100 liter of water capacity. Heaters serving individual wash basins shall be the under sink type located under the basin. These shall generally have a loading of 2KW per 20 liter of water capacity. Valves shall be gate type with bronze bodies and non rising spindles stop cocks shall be provided at all branches of the ring main. They shall be key operated, of cast iron construction and shall be installed about 400mm below ground surface. A concrete enclosure with a cast iron cover shall be provided over the stopcock.

85

Volume 1 General Specification Electro-Mechanical & Civil Works Any hot water outlet which is further than 10m away from the hot water source shall be served with a circulating pipe work system. The circulation shall be provided by an electrically driven pump which shall be of adequate capacity, to ensure that the temperature drop along the pipe loop shall not exceed 5°C. The pump shall be designed for hot water circulation and have an impeller of bronze or stainless steel. All pipe work shall be suitable for a working pressure of 350KN/m2 (50psi) and shall be tested to double this pressure. It shall maintain this pressure for a period of eight hours without any noticeable drop and any leaks shall be made good at the Contractors expense. Tests shall be witnessed by the purchaser or his representative and due notice shall be given to the purchaser of the tests taking place so as to arrange attendance on site. The treatment plant water serves system shall comprise a supply main of not less than 100mm. In addition to above the following will be supplied: 1 1.5” dia. in supply to the alumina dosing tanks. 2 10 No.¾” dia. external stand pipes in the surroundings of the pumping station. 3 6 No. 1” dia. for each clarifier sprinklers traversing the periphery of the embankment to the clarifying tanks and 10 No. for the ground filtered water storage tank. 4 1” dia. pipe for each operator house, workshop, sludge pit. 5 ¾” dia. for guard house. Note: In case the L.L. is in a separate site a 75mm dia. will feed the L.L. site by using 4m3 pressed steel roof tank with the required high pressure ball valve with overflow and under drain arrangement. The tank will feed the service network as well as shaft lubrication and cooling system, and all buildings and gardens. A similar system as for treatment plant shall be provided for the Booster Stations. Pressed steel tank of a size not less than 4.88x2.44x1.22m deep with thickness of 4.76mm shall be erected at the upper roof of the filter building connected to water. Services for the supply of water to treatment plant during plant shut down hours. The same with a size 3.66x1.22xl.22m for Low Lift site and Booster Station constructed at the roof of pump house building. Also water services to all other buildings are required. At Booster Station as follows: 1) 8 Nos.¾” dia. external stand pipe in the surrounding of pumping station and GST 2) ¾" to operator house 3) 1" to pump house 4) ½" to guard house 5) ½" to power house 86

Volume 1 General Specification Electro-Mechanical & Civil Works

The service shall be connected to the supply main through ferrule cocks and stop cocks and bib cocks fitted to the services in the normal requirements. The bib cocks to the external stand pipe shall be suitable for house connection.

87

Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE SEVENTEEN STEEL TANKS A- STEEL ESTs WITH FOUNDATIONS The elevated services tanks to be erected shall have capacity and height from ground level to low water level, as indicated in Basic Data. The tanks shall be supplied with peripheral walkway and shall be supported on vertical circular stanchions ventilators shall be provided to the tanks with outer ends fitted with removable wire wool strainers or other suitable device for the purpose of arresting the entry of dust in the normal breathing of the tank at times of prevailing storms. The manhole covers shall be hinged and secured in there closed position by butterfly nuts and dust proof in their fitting. The supply pipes shall be fitted at top water level with floating control valves of the streamline type with stilling device and shall be suitable in size for the rate of discharge at low friction head loss. The structure shall be designed to withstand a maximum wind gust of 180km/hr and seismic loads as follows: The total lateral seismic force due to an earth quake is 0.017955 W left Euphrates zone excluding west desert, the area between the two rivers including west desert should be 0.03591 W and 0.04788 W for the rest of Iraq. W is total (dead and life) loads. The RC foundation shall be of 1:2:4 mixture with sulphate resisting cement of superficial area in concord with Clause as specified and shall coated with not less than two layers of best quality asphalt coating. The lower ends of supply, delivery and overflow pipes shall be each fitted with duck foot bend at reformed ground level and invert of the pipes shall be 5m outside the periphery of the tank at a depth 1.2m below ground level using two 90° bends for respectively connecting to the pumping mains and distribution mains to be laid by the Contractor as hereinafter specified and delivery pipe will be connected to the bolted gland flexible jointed cast iron distribution main with the required sluice valve according to dia. Clause. A bypass 1m above ground level across each tank between the supply and delivery mains of same dia. shall be provided with necessary valves for employment when the tank is out of service for repairs and maintenance. Also a non-return valve shall be provided in the delivery pipe before the bypass. The intimate terminal point of the delivery main from the tanks shall be fitted with a bolted gland flexible jointed socket piece suitable for connection to be like dia. distribution mains as aforesaid. The Contractor will be required to submit the followings: a) Signed certificate from the manufacturer confirming the proper 88

Volume 1 General Specification Electro-Mechanical & Civil Works erection of the tanks as required by the manufacturer. b) Test certificate of internal coating of the tanks. c) A detailed calculation for the design of the tanks (shells, columns, type of welding, plate characteristics, etc.) with the offer of the tank. Min Rust thickness shall be 5mm. d) An X-Ray test should be done on welding points and a certificate of proper work should be submitted by the Contractor to DGW representative during the construction of the tanks. e) An automatic alarm for the purpose of warning the guard when the ESTs have been filled and the float valve in the tanks have closed. In principle the alarm shall be based on the increase in head which will build up in the pumping mains to ESTs when the float valves close and the flow in the mains ceases. Bordon type pressure gauges confirming to BSS shall register the pressure increase and be arranged to sound electric horn in the guard room with canceling switch. This system will be in addition to the system mentioned in other clauses. f) There shall be two red airplane warning flushing lights operating on 48V with 50 bulbs spare on top of each tank with miniature circuit breaker in a box situated outside the guard room. The cable feeding the lights will be drawn in a PVC conduit and the fitting at the top of the tank will be fully isolated from the tank structure lightning system and earthed properly arranged. Also the whole structure will be suitably earthed by means of a separated system of not less than 5 earthling points. The overflow pipes with bell mouth shall outfall at a point as indicated in Basic Data. The scour pipe with a dia. not less than 200mm shall be connected to the overflow pipe. Sluice valves with hand wheels shall be fitted to the supply, delivery and scour pipe in the normal control 1m above ground level. The tanks shall be complete with internal and external ladders and with target type water level indicators. The external ladder to the tanks itself shall be of the revolving type for welded tanks and fixed for pressed steel tanks. The external ladder of the tower with guards from the ground shall have three landing platforms with railing suitably placed. Hand railing of 75cm height shall be provided to the tanks platform. The tanks should have 3 coats of oil paint according to civil defense regulations. Valves of dia. larger than 250mm will be gear type. The supply, delivery and overflow pipes should be the same dia. as feeding pumping mains. The length of the overflow line must be as indicated in Basic Data. Area beneath EST shall be formed in concrete slab of not less than 15cm and sloped to the outside. The dimensions of this slab will be 2m more than the foundation of the tank from all sides. 89

Volume 1 General Specification Electro-Mechanical & Civil Works Probe or cap active level measurement with transmitter and wire connection to the treatment plant control board shall be provided and also a telephone in the guard room to connect the tank and Treatment Plant in the same telemetry cable with the required power supply AC and DC arrangement (KW meter, CB, etc.). If the Contractor desires to quote for tanks of different shape, the description and price of alternative tanks shall be given in the forwarding letter of the Tender otherwise his tender will not be considered. B- Welded Steel E S T s The tank shall be formed in welded steel plated with domed top and dished invert and with well rounded shoulders and hips. C- Pressed Steel ESTs The tank shall be formed in pressed steel plates of not less than 6mm thick and mounted on a tower with grillage framed in rolled steel sections and shall be divided into two equal compartments for the purpose of independent operation at times of maintenance and repair. The roof shall be formed in chambered steel sheets not less than 3mm thick supported on steel trusses.

90

Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE EIGHTEEN Suction Well, Suction Mains and Intake Structure A- Suction Mains and Suction Well Each low lift pump shall have a separate suction main which shall be formed in ductile iron pipes of a dia. as indicated in Basic Data with strainer. The suction well shall be made of reinforced concrete 1:1½:3 with sulphate resisting cement and shall be divided into two equal compartments for independent operation. The dimensions of each compartment shall be according to Basic Data excluding inlet and outlet compartment. The well shall be closed at bottom and fed by channel or ductile iron pipes. The inlet to the feed channel or pipes shall be protected by coarse screen bar of spacing not more than 100mm with manual racking arm include at 45° and fixed to concrete head walls with aprons and with concrete step for ease of maintenance. The inlets and outlets to the well shall be fitted with penstocks operated from a platform at the top of the well. The top of the well shall be 75cm above the reformed ground level or the highest water level which is higher, and invert of the well shall be 1.5m below lowest low water level in the river. To facilitate the maintenance of inlets a concrete stair of 1m, wide shall be made on the river bank towards the inlets. The mains between the well and the pump and filter house shall be laid at true rising grade not less than 1/200 and shall be bedded through their lengths in concrete 1:2½:5 mixture of 15cm thick and 1m base width. The base of the well shall be sloped towards one end and a submersible pump with non-clogging impeller with a suitable capacity shall be provided to pump the settled silt when required for each compartment. External and internal steel ladders with extended hand holds and walkway with handrails around the section well shall be provided. The foot valves to the suction pipes shall be free connecting with rubber seating to the doors and fitted with galvanized steel strainers. The contractor shall be responsible for supplying all materials required to carry out the work. An arrangement shall be made to flush the strainers, feeding pipe mains and the well from the delivery mains of the high lift pumps and for this purpose a bypass from the delivery main to the feeding pipes shall be provided. The pipe dia. shall be not less than 150mm. An outlet not less than 75mm with ball valve and flexible hose not less than 10m long shall be provided for cleaning the well. All the above pipes where laid within the ground shall be bolted gland ductile iron pipe. When the pipes are laid above the ground or in the steel structure, they 91

Volume 1 General Specification Electro-Mechanical & Civil Works shall be flanged ductile iron pipes. Pipes with Tyton joints are not acceptable. The Contractor shall make arrangements to direct the water in the river towards the project by making diversions in the current of the water if required, and rip raping the embankment for a distance of 200m along the project area. B- Suction Mains Each low lift pump shall have a separate suction formed in flexible jointed pipes to be used conforming to BSS 4772 and ISO 2531kq. The lining of these pipes shall be the same as specified for the filtered water rising mains. The inlet to the suction mains shall be located at the depth of water in the river at lowest low water permits a depth of not less than 0.6m above the top of the strainer. The mains shall be laid on a true rising grade of not less than 1/200 and shall be bedded throughout their length in 1:2½:5 concrete of 15cm thick and 1.2m width. The excavation of the pipe trench extending from the pump house to a point where the depth of cover has become reduced at 0.9m shall be carried to a depth of 0.3m below the level of the bottom of the pipes. The pipes throughout this section shall be supported in the first instance on brick stools of 0.3m height at the bank of each joint. On completion of the laying and jointing of this section the pipes exclusive of the joints shall be semi-surrounded with concrete of 1:2½:5 mixture extending from the bottom of the trench to the horizontal diameter of the pipes. The pipes shall be central in this semi-surrounded which shall be of a base width of 1.2m for each. The further section of the mains extending from the terminus of the aforementioned suction to and inclusive of the suction head shall be supported and fixed at a suitable intervals not exceeding 2.5m from each other on and to an angle iron cross member to the required No. of rows of 10"x8" RSJ vertically driven hard and firm into the invert of the bed of river by a hydraulic monkey of suitable weight. For the purpose of pricing his tender the Contractor shall assume an embedded depth of the piles of 5m which shall be subject to a plus or minus adjustment in accordance with the rates set out by him in the Schedule of price. The tops of the piles shall be cut off flush with the top of pipes and an arrangement for a walkway leading the end of the suction mains shall be provided at a level 300mm above the highest high water level with handrails and galvanized open mesh grills from the embankment along the structure and around the bulkhead below. A substantial bulwark shall be provided to the suction head in safeguard against impingement by river craft. The height of this structure shall be 2m above the walkway level complete with a monorail and chain block for lifting the suction pipe and strainer. To preclude the sibling of the mains during periods of high silt content of the river provision shall be made for 92

Volume 1 General Specification Electro-Mechanical & Civil Works backwashing of the mains from the pumping main to the spring loaded relief valve fitted to the other end of each main. The discharge iron and valves shall be directed on the strainers at an angle. The foot valves shall be free acting with rubber seating to the doors and fitted with galvanized steel strainers. A conspicuous beacon cage and mask with suitable electrical intermittent red flushing lights shall be erected on the bank of the river at the point of the intersection of the suction mains for the precautionary purpose of warning the river craft of the location of the suction main extending within the river. All the above pipes where laid within the ground shall be bolted gland ductile iron pipes. When the pipes are laid above the ground or on the steel structure they shall be flanged ductile iron pipe. Pipes with Tyton joints are not acceptable. The Contractor shall submit detailed design for the intake structure taking into consideration water velocity and all precautions from floating subjects during high water level and floating season, such as trees, dead animals, etc. The clear distance between suction pipes on the intake structure shall be not less than 1.5m. Puddle flanges shall be manufactured from the same material as the pipe work of which they form part and shall be to the approval of the Engineer. All pipe work shall be color coded in accordance with BS 1710 to facilitate identification. Each valve shall have securely attached to it a large label identifying it by number and designating its function. Standard special pipes and medium bends shall be used wherever possible in the layout. C- INTAKE STRUCTURE The intake structure shall be constructed according to drawing from reinforced concrete. The pump sump (Basement) shall be designed as a water tight structure in two compartments for independent operation during maintenance with bypass arrangement controlled by a 2 Nos. sluice valves. The floor of the (Basement) shall be sloped to one corner with a sump to pump accumulated settled sludge to the river using duplicated submersible pumps. The Basement shall have access ladder and lighting. The channel from river to the intake Basement shall be constructed according to the drawing from reinforced concrete the contractor is responsible to make a full hydraulic study to design the final shape of the channel. Rip raping along the shoulder of the river for a distance of 50m from each side of the channel to protect the structure and to direct the 93

Volume 1 General Specification Electro-Mechanical & Civil Works water to the channels. The Contractor shall make all necessary arrangement to minimize the problem of settling of the suspended maters at the channel bar during high turbidity seasons by using submerged scraping device. Fence along the side of the intake channel shall be provided. Bar screens shall be hand raked type manufactured from rectangular section mild steel. Fixing lugs and bolts shall be manufactured from stainless steel provision for conversion to mechanical rack in the future is required. The head loss across the screen shall be monitored by means of an (air purge) system. The equipment to be provided shall include dip tubes on both the upstream and downstream side of the screen, air compressor, mercury manometer, electrical probes, switches, contacts oelags and amplifiers, etc. required. The general design of the building shall be in accordance to clauses as specified.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE NINETEEN PIPE WORK AND FITTINGS General The types of pipe work to be supplied and laid are as indicated in Basic Data. When pipe work passes through an external wall of a building below ground level, the Contractor shall supply puddle flanges cast on the pipe or formed by bolting two flanges back to back for building in (Bolton) puddle flanges will not be acceptable. Pipe work, Fittings, Valves, etc 1- Ductile Iron Pipes, Fittings, Valves etc. a) Pipes and fittings Ductile iron pipes and fitting shall be manufactured, tested etc. in accordance with international Standard Organization ISO 2531. In addition to the requirements of ISO 2531, each pipe and Fitting shall have legibly cast, stamped, or indelibly painted on it the following marks as appropriate: (i) (ii) (iii)

The class designation of pipes The angle of bends in degrees The length in mm

Pipes shall be Class K9 and lined internally with a sulphate resisting cement mortar to ISO 4179. Pipes shall be protected externally by a sprayed zinc coating followed by the specified bituminous coatings. Tees shall be Class K14. All other fitting shall be Class K12 flanges should be drilled minimum MPIO fittings shall be lined internally and externally by dipping in non toxic epoxy type coating material followed on the exterior only by the specified bituminous coating. Spigot and socket joints shall be of an approved (push in) type incorporating an anchored rubber joints ring. The joints shall be leak tight and sufficiently flexible to allow up to 2° deflection. Bolted gland joints shall be of an approved (mechanical) type incorporating 1 No. gland with bolts and a rubber joint ring. The joints shall be leak tight and sufficiently flexible to allow for angular deflection. 95

Volume 1 General Specification Electro-Mechanical & Civil Works Anchored joints shall be of the mechanical spigot and socket type incorporating a locking ring around the spigot end of the pipe. The anchored joints shall prevent the joints pulling out and resist the longitudinal thrust forces on any fitting in the pipeline at the site test pressure. The anchored joints shall retain the facility for some deflection and shall be suitable in all other respects for use in pressure pipelines. The joint rings shall be natural or synthetic rubber. Flanged joints shall be machine faced and drilled. Flanged and gland bolts for installation within buildings shall be stainless steel bolts. Flange bolts for buried flanges shall be cadmium plated to BS Class A. Flange gaskets shall be either corrugated molded rubber conforming to BS 2494. Flange gaskets shall cover the full face of the flange and hence be located in position by the flange bolts. B) Wedge Gate Valves (i) For water supply systems Wedge gate valves shall be manufactured, tested etc. in accordance with British Standard BS 5163 Wedge gate valves shall be (waterworks pattern) clockwise closing complete with gunmetal faces and inside screw, non rising forged manganese bronze spindles. The valves shall be suitable for installation in buried pipelines and for operating in a terminal position. Flanges shall be machine faced and drilled according to the required test pressure plus 3 bars. Stem seals shall be of the stuffing box and gland type. Wedge gate valves shall be suitable for operation by removable tee key and all necessary reduction gearing suitable for buried valves is to be provided to limit operating torque to mot more than 70KN-m. A squared valve cap shall be provided for each valve or extension valve spindle and shall be secured by a non ferrous hex ago in headed set screw. Extension valve spindles shall be stainless steel. Spindle guide brackets shall be cast iron with a bronze bush and shall be supplied with 12mm diameter non ferrous expanding bolts insulating washers and sleeves. Surface boxes for tee key operated wedge gate valves shall be of cast iron with a chained lid with bayonet joint and spindle guide suitable for installation inroads.

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Volume 1 General Specification Electro-Mechanical & Civil Works ii) For Compressed Air System Isolating valves shall be cast iron wedge and double disc valves manufactured, tested etc. in accordance with BS 5150. C) Butterfly Valves Butterfly valves shall be clockwise closing of the U-section water or double flanged (tight shut off) type, manufactured and tested in accordance with BS 5155. Valves are to be complete with resilient sealing faces and suitable for installation in horizontal buried pipelines. Flanges shall be machine faced and drilled according to the required test pressure plus 3 bars. Butterfly valve flanges shall be supplied for individual or through bolting for valves up to and including 600mm and individual bolting for valves 700mm diameter and above. Butterfly valves are not to be supplied with flanges tapped for individual bolting using stud bolts except where the shaft housing prohibits through bolting. The disc axis shall be horizontal and by an arrangement of gears the valve shall be operated by means of a vertical spindle. Butterfly valves shall be suitable for operation by removable tee key and all necessary reduction gearing suitable for buried valves shall be provided to limit operating torque to not more than 70KN-m. A squared valve cap shall be provided for each valve or extension valve spindle and shall be secured by a non ferrous, hexagon headed set screw. Extension valve spindles shall be stainless steel. Spindle guide brackets shall be cast iron with a bronze bush and shall be supplied with 12mm diameter non-ferrous expanding bolts insulating washers and sleeves. Surface boxes for tee key operated butterfly valves shall be cast iron with a chained lid with bayonet j o i n t and spindle suitable for installation in roads. D) Penstocks Penstocks shall be manufactured to standard patterns as specified on the drawings and from the following materials:

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Volume 1 General Specification Electro-Mechanical & Civil Works

Frames and doors

Close grained cast iron minimum Grade 14 to BS 1452 free from Blowholes and other defects

Spindles (to be non rising)

forged manganese bronze

Operating Nuts.

Gunmetal Grade LG 2 to BS 1400

Circular Seating Faces up to 600 mm dia.

Gunmetal Grade LG 2 to BS 1400

Circular seating faces greater than 600mm and all rectangular seating faces

Phosphor Bronze

Wedges shall be adequate in number to support the door and shall be of large bearing area with phosphor bronze facings. Guide rails shall receive the door once it has started to open. Clearance within the guides shall be a minimum to prevent vibration of the door under flow conditions. A taper roller bearing shall be provided to take thrust from the spindle. E) Ball Valves Regulating valves for compressed air systems shall be ball valves manufactured, tested, etc. in accordance with BS 5159. Strainers shall be provided before control valves. F) Check (Non return or Reflux) Valves Check valves shall be of the (free acting) swing type, doors shall be of solid gunmetal with integral face, and gunmetal seating. The door hinges shall be formed from stainless steel bar through integral lugs on the door with low friction water lubricated bearings of thermo-setting plastic material in gunmetal housing. All parts shall be accessible for maintenance. Valves up to 450mm diameter shall have a bolted cover. Large diameter valves shall be formed in two valves. Lifting ring(s) shall be provided on the casing. Horizontal check valves up and including 450mm diameter shall be single door, up to 900mm double door, up to 1200mm triple door and up to 1500mm the middle door shall be divided into two making four doors in 98

Volume 1 General Specification Electro-Mechanical & Civil Works all. Vertical check valves up to and including 450mm diameter shall be single door, larger diameter valves shall be triple door. G) Air Valves Air valves shall be double orifice type to suit a maximum working pressure as required. Valves shall have a cast iron small orifice plate with gunmetal seat, the other having a cast iron large orifice plate with rubber seat. The valves shall be supplied with rubber gaskets and cast iron splash covers. Surface boxes for air valves shall be of cast iron and suitable for installation in roads and of the following size: i) ii) iii)

For 150mm diameter double air valves, 900mm by 900mm clear opening with two piece chained lid For 150mm diameter single air valves, 900mm by 600mm clear opening with two piece chained lid For 100mm diameter air valves, 700mm by 400mm clear opening with one piece chained lid

H) Hydrostatic Sludge Draw off Valves Hydrostatic sludge draw off valves shall be of the direct lift type. They shall include a cast iron pillar (head stock) and rising forged manganese bronze spindle attached to a stainless steel bridge across the bell mouth. APVC tube shall connect the bell mouth to the lower cast iron cylinder and slide inside it through inland bronze guide rods shall be used. I) Pipeline Strainers for Water Systems Pipeline strainers shall be Y type single strainers fitted where shown on the drawings. The casing shall be cast iron with flanged connections and the screens shall be stainless steel with perforations to suit the water being handled. 2) Steel Pipes, Fittings, Valves, etc. a) Pipes and Fittings Steel pipes shall be fabricated, tested etc. in accordance with BS 3601 and 534. The minimum tensile strength of the steel shall be 360N/mm2. The required grade and thickness of steel together with type and 99

Volume 1 General Specification Electro-Mechanical & Civil Works strength of pipe shall be as required. Steel pipes and fittings for installation within structures shall be lined internally dipping in non toxic-epoxy type coating material and externally together with fiberglass cathodic protection required and the Contractor shall carry a full soil test for all pipelines. Welded places should be re-coated after welding. Stainless steel tubes shall be manufactured tested, etc. in accordance with BS 3014 or BS 3605 as appropriate. Galvanized steel tubing shall be heavy weight BS 1387 with screwed ends connections screwed and socketed or flanged. Union joints or flanged joints shall be made on connections to valves, branches, plant and equipment and where necessary for ease of erection and where shown on the drawings. Unions shall be Navy pattern with two bronze seats and screwed BS 21 taper thread. Flanges shall be galvanized screwed on pattern to BS10 Table E machined across face and screwed and expanded on to the pipe. Joints shall be made with 3mm thick approved compressed asbestos joint rings. Bolts nuts and washer shall be galvanized mild steel. Screwed pipe fittings shall be galvanized malleable iron banded fittings to BS 21 screwed BS pipe thread. Screwed joints shall be made with best quality hemp and boss white or PTFE tape or equal and approved jointing compound. Black mild steel tubing shall be heavy weight to BS 1387. Pipes of diameter exceeding 175mm and diesel fuel pipes shall be seamless to BS 3610 or 806. Slip on flanges shall be neck and bore welded and shall be machined across the face. Pipe work shall be screwed and socketed or butt welded throughout with union joints or flanged joints on connections to valves branches, plant and equipment where necessary for ease of erection and where shown on the drawings. Welded fittings shall be to BS 1965:1953 or BS 1640:1953 and long radius welding elbows shall be used. Unions shall be malleable iron Navy-pattern with two bronze seats with ends screwed to a BS 21. Screwed fittings for diesel oil pipe lines shall be black malleable iron with ends screwed to BS 21. Screwed fittings for compressed air pipelines shall be wrought iron to BS 1740 or steel tubular to BS.1387. Flanges shall be welded to the pipes and shall be to BS 10 Table (E) machined across face. Joints shall be made with 3mm compressed asbestos joints rings or other approved jointing material. Bolts shall be black mild steel of sufficient length and diameter to suit the flange application. Long screw connectors and bushes shall not be used. Branches off mains shall be made with purpose made welding branch fittings where position and shall be easy sweep pattern except where required for draining and venting. Where the size of the branch is outside the range of branch fittings available the branch shall be formed 100

Volume 1 General Specification Electro-Mechanical & Civil Works from piping carefully formed and shaped for connection. Branches of equal size to the main pipe shall be made with an approved from of reinforcement. Holes cut into the main for branches shall be carefully shaped so that there is no restriction to the flow. Valves and plug for chlorine gas pipe work shall be to BS 341 with thread to BS 919. The Tenderer shall allow for supply pipe work and fittings to match the standard in use by the Employer. Spiral welded steel pipe shall be manufactured according to API-5 Ls standard. The grading shall be closed according to pressure required. B) Flange Adaptors Flange adaptors shall be manufactured in steel or malleable cast and shall comprise 1 No. flange with sleeves spigot, 1 No. gland with bolts and 1 No. wedge shaped rubber joint ring. All steel components including bolts, shall be (hot dip) galvanized after fabrication. The flange adaptors shall be suitable for a maximum sustained operating pressure of at least 20bar. The flange shall be machine faced and drilled according to the required test pressure plus 3bars. C) Flexible Couplings Flexible couplings for jointing spigots shall be manufactured in steel or malleable cast iron and shall comprise 2 No. glands with bolts, 1 No. sleeves without a central register and 2 No. wedge rubber joint rings. All steel components including bolts shall be (hot dip) galvanized after fabrication. Flexible couplings shall be of the long sleeves type supplied without central registers. The couplings shall be suitable for a maximum sustained operating pressure of at least 20bar. D) Hydro Pneumatic Accumulators for Alum Dosing System Hydro pneumatic accumulators shall have nitrite rubber separator bladder and seals, terminating in a stainless steel grid assembly. The accumulators shall have PN type lithcoted shells and shall be suitable in all other respects for use with 70% concentrated solutions of aluminum sulphate and working pressures up to 12bar. E) Stop Gates Stop gates and frames shall be fabricated from mild steel plate 101

Volume 1 General Specification Electro-Mechanical & Civil Works rolled steel sections and individual gates shall be suitable for (off seating), (on seating) or (off and on seating) pressures. Each gate shall be designed to withstand the full unbalanced pressure of the total depth from channel invert level to the top of the topmost gate with a factor of safety of at least 3. The gate shall be sealed against the guides and sill by PVC sealing strip damped to all four sides and on both faces of the gate. Rubber materials shall not be used. seal.

Leakage rate shall not exceed 0.2 liters/second/meter length of

The guides and sill shall be manufactured from mild steel section with stainless steel sealing faces. The guides shall be supplied in suitable lengths for either grouting into the walls and floor channels or bolting to the face of walls. (On seating) or (off seating) gates shall have integral equalizing penstocks of valves. The initial lifting action shall open the penstock allowing the level to equalize on each side of the gate. The penstocks shall close automatically. Lifting beams with integral chain sling shall be provided for raising and lowering the gates. The beam shall fit into and be positioned by the guides and shall be adjustable to cater for different width of gate. The beam shall automatically engage for lifting disengagement shall be achieved by subsidiary control ropes. Sufficient stands shall be supplied to accommodate all stop gates to supply stacked in a vertical position. The design of the stand shall be such that no pressure bears on the sealing strips. Tenderers shall include in their prices for the supply of a jig for the assistance in locating the guides prior to concreting. Where specified all necessary structural frames required to support motorized hoists for raising and lowering the gates shall also be supplied. 3) Un-plasticized PVC Pipes, Fittings, Valves, etc. a) Pipes and fitting Un-plasticized PVC pressure pipes shall comply with the relevant requirements of BS 3505 Joints and fittings for pressure pipes in accordance with DIN 8061/8062 shall comply with the relevant requirements of DIN 19532 solvent welded not acceptable and should be mechanical joints. Un-plasticized PVC Pipes, joints and fitting for gravity sewers shall comply with the relevant requirements of the Iraqi Organization of standards IOS. 102

Volume 1 General Specification Electro-Mechanical & Civil Works

4) Polyethylene Pipes, Fittings, Valves, etc. a) Pipes and Fittings Low density polyethylene pipes shall be manufactured, tested etc. in accordance with BS. Height density polyethylene pipes shall be manufactured tested etc., in accordance with BS 3284 and BS 3796. Small diameters pipes shall be laid in the longest possible lengths without joints. Where joints are required these shall be butt welded using the heat fusion technique. Pressure gauges shall be fixed on each main outside the pump house for reading the pressure in each main. Isolation sluice valves shall be inserted in all the pumping mains just outside the pump house immediately on the downstream side of the pumping mains. Also recoil valves shall be fitted to the mains isolation sluice valves shall be provided each at one kilometer for all the mains, the diameter of all the valves are the same as that of the mains mentioned above. The diameter of washout valves shall be 100mm the washout shall be valved at their inner ends a small weep hole shall be drilled in the inverts of the washout pipes and their lower ends for drainage and the pipes nearest surrounded with one foot thickness of coarse gravel. The isolation valves shall be ½” tapped and drilled at each side of the wedge and fitted with ½” gunmetal ground plug ferrule cocks and extended to withstand the short distance of the ground surface with ½” galvanized iron pipes terminative with stop-cocks of ferrule ends for the purpose of taking pressure gauge readings. Conventional type cast iron surface box with locking lid shall be provided to the stop cocks and also to the isolation sluice valves air valves and washout valves together with a 100mm dia. pipe sleeve extending from the gland of the valves to within the surface box, the surface box shall be founded on concrete footings. Necessary air valves shall be fitted to the mains, the first of which shall be located immediately downstream of the recoil valves hereinafter specified and thereafter at all ridges and other places as shown in drawings in the Appendix. The air valves shall be of 100mm dia. and be of the {double} kinetic type with isolating sluice valve or similar and shall be housed in water tight chambers formers formed in cement concrete work and which shall be fitted with suitable cast iron surface boxes with locking arrangement. Recoil valves as manufactured by Messrs. Glenfield. Kennedy Ltd. or similar shall be fitted to the mains. The recoil valves shall be housed in a chamber formed in concrete which shall be suitably floored and provided with manholes cover of adequate clear opening and shall be supported on a concrete stool. All valves shall be provided with tail pieces with anchoring to be built in the manhole thrust when the valve will be 103

Volume 1 General Specification Electro-Mechanical & Civil Works closed under test pressure. Where the mains cross rivers or barrage, steel structures required on the existing weirs for this purpose and the contractor shall include in the Tender for the professional fees for the design and construction of such structures. Where the mains cross canals and small distributor cannels meet within their alignments they shall be laid at such depth of cover as will provide a minimum of 15cm below the inverts of the distributaries and shall be graded to preclude any point where air may be trapped. The mains shall be square boxed with a minimum of thickness of 50cm of concrete of 1:2½:5 mixture at the distributor crossings and which shall be extended at a distance of 0.9m into each bank and likewise so at all road crossings. Necessary washout valves and air valves shall be fitted to the mains as shown on the drawings and other places where necessary with chambers. Where the mains cross big streams (more than 3.0m) steel structures required for this purpose and the contractor shall include in his tender the professional fees for the design and construction of such structure. The contractor shall submit a design for approval before execution of the work. Where the mains cross roads and rail ways box culvert shall be required and shall include all cost in the total sum offender. The work shall be executed according to the Regulations of state Organization of Roads and Bridges. Where the mains cross Main River two No. of pipes used to be laid in the bed of the river. Thrust resisting joint type should be used to the crossing pipes. The distance between each pipe should be not less than 5m the contractor should supply all necessary valves and air valves and fittings. Where to mains cross the canals and small distributory canals meet within their alignments they shall be laid at such a depth of cover as will provide a minimum of 15cm below the inverts of the distributaries and shall be graded to preclude any point where air may be trapped the means square boxed with a minimum thickness of 50cm of concrete of 1:2½:5 mixture at the distributory crossings and which shall be extended at a distance of 0.90m into each bank and likewise so at all road crossings. Necessary washout valves and air valves shall be fitted to the mains as shown on the drawings and other places where necessary with concrete chambers. Where the mains cross the main highway a box culvert required for each crossing and executed according to regulations of roads and bridges. As the target type water level indicator to all the elevated storage tanks will not be legible from the pump house, the Contractor shall supply and install an automatic alarm to each tank for the purpose of warning the operator when the tanks are full and the gloat valve in the tanks are closed. As the target water level indicator to all elevated storage tanks and 104

Volume 1 General Specification Electro-Mechanical & Civil Works ground storage tanks at site of waterworks will not be legible from the pump house, the Contractor shall supply and install an automatic alarm to each tank for the purpose of warning the operator when the tanks are full and the float valve in the tanks are closed. In principle the alarm shall be based on the increase in head which will build up in the pumping main to the storage tanks when the float valve closes, and flow in the main has ceased. A Bourdon type pressure gauge or gauges conforming to BSS 1780/1951 shall register the pressure increase and be arranged to sound an electric bell so that operator may stop the pumps. Water hammer protection of required for the pumping mains shall be ensured by cylindrical reservoir under pressure, vertically mounted, fed by electrical air compressor. The Contractor shall give with his offer full details of these protections, supported by calculations. The Contractor should make arrangements for laying and supplying of all pipes, specials bends, air valves, washouts, fittings, etc. whatsoever required to complete the work in accordance with the Technical Specification. Valve and penstock Actuators - Electrically Driven 1) General Valve actuators shall be suitable for use on the nominal 3 phase power supply specified and shall incorporate motor integral reversing contractor starter, local control facilities and terminal for remote control and indication connections. 2) Actuator Sizing The actuator shall be sized to guarantee valve closure at 1.05 times the maximum differential pressure that may develop under standard or start up pressure. Maximum differential pressure shall be assumed to be the Maximum upstream pressure with the control valve fully closed and its outlet vented to atmosphere. The safely margin of motor power available for seating and unseating the valve shall be sufficient to insure torque switch trip at maximum valve torque with the supply voltage 10% below nominal. The operating speed shall be such as to give valve closing and opening at approximately 10-12 in/min unless otherwise stated. 3) Motor The electric motor shall be 3 phase squirrel cage as detailed with a time rating of 15min maximum ambient temperature or twice the valve stroking time, whichever is the longer, at an average load of at least 33% of maximum valve torque. Overload protection shall be provided by direct sensing of motor temperature by a thermostat embedded in die motor 105

Volume 1 General Specification Electro-Mechanical & Civil Works winding. 4) Gearing The actuator gearbox shall be of the totally enclosed oil lubricated type, suitable for operation at any angle and provided with the appropriate filling and drain plugs. The drive shall incorporate a lost motion hammer below feature. The output shaft shall be hollow to accept a rising stem, and incorporate thrust bearings of the roller type. The design shall be such as to permit the gear case to be opened for inspection or disassembled without releasing the stem thrust or taking valve out of service. 5) Hand Operation A hand wheel shall be provided for emergency operation, engaged when the motor is declutched by a lever or similar means, the drive being restored to power automatically by starting the motor. The hand wheel drive shall be mechanically independent of the motor drive and any gearing shall be such as to permit emergency manual operation in a reasonable time. Clockwise operation of the hand wheel shall give closing movement of the valve. 6) Drive Bushing The valve actuator shall be furnished with a drive bushing to suit the valve stem or gearbox input shaft. The drive bushing shall be easily removable for renewal. The drive bushing shall preferably be positioned to enable standard length valve stem to be used. 7) Torque and Position Limit Switches and Position Indicators Open and close torque and for position limit switches shall be provided as required by the type of valve, plus two additional limit switches of each end of travel for remote indication and interlocking. Means shall also be provided to prevent the open torque switch tripping while the initial unseating hammer blow effect is applied. Provision shall be made for two extra sets of limit switches to be available to order, comprising at least two switches per set, each set independently adjustable to any valve position. Switch contact rating on inductive circuits shall be 5A AC up to 4000V, 50W DC up to 250V. A mechanical dial indicator shall be provided to indicate whether the valve is fully open, fully closed or in an intermediate position. Provision shall be made for the addition of a sealed potentiometer of 106

Volume 1 General Specification Electro-Mechanical & Civil Works at least three watts rating for continuous remote position transmission. The mechanical dial indicator should also show continuous valve movement. 8) Integral Starter and Controls The reversing contactor starter and local controls shall be integral with the valve actuator, suitably housed to prevent breathing and condensation build up. The starter shall be suitable for 60 starts per hour and shall comprise mechanically and electrically interlocked reversing contactors appropriate rating to the motor size with coils fed from a 120V control transformer of 40VA minimum rating. The common connection of the contactor coils at the transformer shall be grounded so that the contactor drops out in the event of leakage to ground. The primary winding shall be separated from the secondary by a grounded screen. The secondary output shall be protected by a fuse of an easily replaceable cartridge type. Local controls shall comprise pushbutton switches for open, close and stop, and a local L remote selector switch pad-lockable in any one of three positions: a. b. c.

Local Control only. Off-on electrical operation. Remote Control plus local stop only.

Provision shall be made for the following: a. b. c.

Phase discriminator, to prevent starting with incorrect phase rotation or one phase dead. Interposing relays for open / stop / close control from specified remote DC supply (minimum voltage 24). Monitor relay with normally open contact, coil energized from control transformer only when local /off/ Remote switch is un Remote position, to show actuator is electrically operable by remote control.

9) Wiring and Terminals Internal wiring shall be of tropical grade PVC insulated standard cable of 5A minimum rating for control circuits and of appropriate size for the motor 3 phase power. Each wire shall be clearly number identified at each end. The terminals shall be of the stud type, the 3 phase power terminals being segregated by a separate insulating cover. The terminal compartment shall be designed so that actuator electrical components are protected from moisture ingress while the terminal cover is off for wiring on job site.

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Volume 1 General Specification Electro-Mechanical & Civil Works 10) Enclosure The actuator enclosure shall be IP68 to BS 5420 Group D Division 1 Explosion proof actuators which do not have 0 ring sealed cover joints shall be provided with silica gel-desiccant sufficient to absorb all condensation caused by breathing for a minimum period of six months without renewing. 11) Heat Exchangers Heat exchanger shall be water to water manufactured from stainless steel on shell and tubes. The coil shall be spun in spiral from copper or stainless steel and the shell shall be mild steel or stainless steel. The heat exchangers shall be sized for the duty required and suitable for the pressures applying to the system. The heat exchangers and system shall be complete with pressure and temperature gauges indicating the conditions on primary and secondary flow and return connections. pipe work installation. The Contractor shall install unions or pairs of flanges at the following locations: a. At interval not greater than 15m, unless otherwise approved by the Engineer. b. At all items of major plant and equipment to permit disconnection and removal for maintenance. c. Where indicated on the Drawings to assist dismantling of sections of pipe work without disturbing other pipe work and equipment. Pipe work shall be run neatly parallel to walls or grid lines on the site plan and shall, where necessary, be set around projections. All vertical pipe runs shall be plumb. Direction changes in groups of piping shall be set out from a common center point. The layout of piping shall take into account expansion and contraction, particularly at ends of runs where changes of direction occur. Expansion and contraction shall be taken up in changes of direction as far as is practical but if expansion loops or bellows expansion fittings are used, adequate pipe guides and anchors are to be fitted on the line. To avoid the transmission of noise and vibration, it shall be the responsibility of the Contractor to ensure that no pipe work is rigidly attached to plant or equipment. Pipe Supports All pipe work shall be adequately supported on purpose made 108

Volume 1 General Specification Electro-Mechanical & Civil Works brackets hangers or clips. The maximum spacing for pipe supports or hangers shall be as follows: Maximum Center/Centre of Supports of Pipes (m) Diameter Cast Iron, steel, heavy gauge copper. (mm) 15 20 25 32 40 50 65 80 100 100 +

1.8 2.5 2.75 2.75 3.0 3.0 3.6 3.6 4.5 As BS 3974 Part 1

Stainless steel, light gauge copper, plastic for water 1.2 1.5 1.8 2.2 2.5 2.7 2.7 2.7 3.0

Stress in any part mild steel hangers, brackets or clips shall not exceed 60N/mm2. Pipe work shall be supported generally as indicated on the drawings and in particular on both sides of all the changes of direction. No loads are to be transmitted to any plant machinery. All supports for steel pipes shall be manufactured in accordance with BS 3974 part 1. Pipes shall have sufficient clearance for insulation to be fitted where required. Testing of Pressure Pipelines Pipelines (together with all specials and valves incorporated in the mains) shall after lying and before being covered in, be tested with water as specified below. The test pressure which shall not be exceeded under any circumstances shall be either: a. b. c.

The test pressure stated on the Drawing, or A pressure of 20 meters head or 50% in excess of the maximum working, or Such pressure as directed by the Engineer for the class of pipe concerned.

After filling is completed and full absorption, if any, has taken place the required test pressure on the site shall be applied for duration of 60 minutes. During site tests the pressure must not fall by more than 0.1kg/cm2 over a 60 minute period and no further pumping will be permitted during this period. The Contractor shall note that in order to prevent movement of the pipeline during the course of the test, it may be 109

Volume 1 General Specification Electro-Mechanical & Civil Works necessary to anchor the pipeline by partially backfilling the trench. Should this operation be necessary the backfilling shall not be permitted to cover any joint. The pipe at any lower end of each length to be tested shall be temporarily blanked off and adequately strutted. The pipe length shall then be filled with water and the upper end temporarily blanked off and adequately strutted and additional water shall then be pumped into the pipe by means of a force pump fitted with an open dial pressure gauge until the required pressure has been reached. Should leakage of water occur at the joints, the joints shall be reassembled to eliminate such leakage, or should this prove not possible, the Contractor shall supply and assemble new joints. Should any pipe or joint burst or should water leak or weep through the body of any pipe or joint the Contractor shall forthwith remove the faulty pipe or joint and replace it with a further pipe or joint. In all the above cases the length under test shall be retested as above described and the process repeated, if necessary, until the pipeline satisfactorily withstands the prescribed test. The costs incurred in remedying or replacing and retesting the pipeline (including the removal of the damaged and adjacent pipes and joints where necessary, and incidental coast) shall be entirely at the Contractors expense. The Contractor shall provide, fix and work the force pump, pressure gauge, air tap and all other apparatus required to the approval of the Engineer and shall fill the pipes with water and subsequently empty them after the test. Groundwater may not be used for testing pipes. Water drained from the pipes shall be discharged so as not to affect the stability of the works or adjacent structures. All water shall be provided and disposed of at the Contractors expense. The pipeline shall be tested in lengths as directed by the Engineer. Where pipeline are for the transfer of chlorine gas under vacuum then they shall be tested under vacuum. The pipelines must be absolutely air tight and the pipeline will be deemed to have passed the test if there is no rise in pressure within the pipeline under test over a 24 hour period. All costs incurred for testing the pipelines as above described shall be included in the Contractors rates for respective pipelines. All pipes shall be coated from outside with bitumen. The bitumen shall comply with the requirements of BS 3416 cement lining with minimum thickness of 6mm shall be given for inside. Anchorage Thrust blocks to transmit the maximum unbalanced resultant pressure arising at horizontal bends to the soil forming the side of the trench at points of deviation for straight pipes shall be constructed in concrete of 1:4:8 mixtures. Each block shall butt against the pipe throughout the internal area extended between the tangent points of 110

Volume 1 General Specification Electro-Mechanical & Civil Works curve and to the full depth of the pipe and shall be extended in the direction of the resultant thrust and the width between the extended radii through the tangent points and for such a distance as will provide a bearing area against the side of the trench compatible with the safe loading pressure of the soil. The price of this item shall be included in the total price of the chem the maximum unbalanced pressure shall be assessed from that arising from a surge pressure. The face of the trench on which the thrust block shuts shall be truly vertical. The thrust arising on the isolation sluice valves on the testing of the mains shall be taken by securely fixed temporary struts bearing on footing cut in the side of the trench of undisturbed soil and wedge up tight. Where the pipes are to be carried along or under the bridges or culverts anchorage shall be done with suitable MS clamps fixed with the bridges or culverts. Testing the Water Main The pumping main shall be subject to water test pressure on the completion of the laying and jointing of the main and at such time as sit can conveniently be filled. The sections shall be tested to a pressure head equal to 1½ time the shut off head of the pumping units. The leakage in any section of the main under test shall not exceed the rate of one liter per centimeter diameter of pipe per kilometer per 24 hours for each 35 meter head of water. The suction main of the pumping units shall similarly be tested to a pressure of 40 meter head of water. The duration of any test should not be less than four hours. The price of this item shall be included in the total price of the scheme. If any length of maims be found defective in the aforesaid test the same shall be forthwith made good to the satisfaction of the Engineer. By and at the expanse of the Contractor and the Contractor shall thereupon at his own expense make a second water test of that section of the main and so on until the main has been proved perfectly watertight within the limits specified. The Contractor shall make his own arrangement for testing machines. If so desired the Contractor can alternately affect the aforesaid tests by compressed air at pressure half of the respective hydraulic pressure. Disinfection of Pipe Lines The Contractor shall carry out washing out and chlorination of all water pipe work in the works. He shall provide all necessary equipment, operators and labor required. The pipes shall be charged with chlorinated water for 24 hours during which time all sluice valves shall be operated throughout their full travel and returned to their original position. The drain cocks on all the air valves shall be opened fully and allowed to run for such time as the Engineer directs and washouts flushed to introduce 111

Volume 1 General Specification Electro-Mechanical & Civil Works chlorinated water into the branches. At the end of the 24 hours the pipes shall be flushed with clean water until all traces of chlorine have been removed. Pipe and Cable Channels All pipes and cables within the internal confines of the pump and filter house building shall be laid in rectangular channels formed in 1:2:4 reinforced concrete in the floors of the building where such pipes and cables are below the floor level. The pipes shall be supported on concrete stools and the cables on suitable racks at intervals of about 1.2m apart. The channels shall be covered with steel chequer plates not less than 9mm thick with lifting holes and bear on mild steel curbs bedded and pointed in cement mortar. The sides and bottom of the rectangular channels for all pipes and cables should be fair faced. Building in Pipes Unless otherwise shown on the drawings, all iron pipes passing through concrete walls of water tight structures, shall incorporate a puddle flange. Such flanges shall be of the same dimensions as flanges for the size and class of pipe to which they are attached, and shall be solidly built in, and a screwed -gland collar with screwed gland joints shall be fitted to the pipes on the internal side. Where pipes pass through other walls above floor level they shall be covered with a strip of "Ruberoid Roofing" or other suitable approved semi -plastic material, Sleeves shall be provided to the pipes where they pass through walls below floor level and shall be of a size slightly greater than the maximum diameter of any part of the pipes. The intervening space between the pipe and the sleeve shall be blocked in with hot bitumen. All pipes passing through walls shall be provided with a flexible joint at a suitable point outside the building to take up any contraction, expansion and settlement that may arise. Demarcation Beacons The pumping mains shall be demarcated by concrete beacons at the point of the change in the horizontal alignment and at each air valve, isolation sluice valve, washout valve and at such further points not exceeding ½km between consecutive beacons. The beacons shall be formed in concrete of 1:2½:5 mixture and shall be reinforced with 4 Nos. round steel bars of 63mm. wired in position and be of a size measuring 75cm long by 30cm square base by 15cm pyramidal top. They shall be firmly set 50cm deep at a distance of 150cm from the main. All beacons shall have the identification of the plant set in at their top. 112

Volume 1 General Specification Electro-Mechanical & Civil Works One MS plate 40x30cmx6.3mm thick Melded with 3.8x3.8cm angle or the iron bracket shall be fixed with bolts and nuts at the back of each concrete beacon. The top of the plate shall remain about 50cm, above the top of the beacons. The plate with bracket shall be painted yellow. In the plate shall be written (I.S.V.) for isolation sluice valve (A.V.) for a i r valve as the case may be in red at the top part of the plate and distance such as 0.5km etc. as measured from the pump and filter house and low lift pit shall be written at the bottom part of the plate. Letters and numbers shall be about 4” high. Excavation for Foundations, Trenches etc The contractor shall perform excavations of every description regardless of the character of the material encountered, to the lines, grades and dimensions indicated on the drawings or as directed by the Engineer, All excavations must be cleared of all mud, loose material, dirt and debris. From time to time during the progress of excavation the Engineer will examine the levels. All operations of the excavations which are carried out lower or wider than specific levels and also of excavations that had been cleared of mud, loose material, dirt, etc. shall be filled with mass concrete at the Contractors expense. The Contractor shall control the grading in the vicinity of the buildings and other structures so that the surface of the ground will be sloped to prevent water from running into the excavated area. Any water which accumulates in the excavation shall be removed promptly. All arrangements for pumping out water and keeping excavation free from sub soil water shall be made by the Contractor. All timbering and shoring as may be required during excavation shall be installed by the Contractor to protect the banks, adjacent paving, structures and utilities. The ground surface shall be excavated for the pipe trenches to such a depth as will allow a minimum of 0.9m of cover to the pipes and to such further depths as shall be required in order that proper inclinations curves and shapes may be obtained or as may be necessary to avoid airlocks in the line of the main or to avoid underground obstructions that may be encountered. The trenches shall be bottomed up to the exact gradient and shall be such width as are necessary and proper for laying the lines of pipes and for laying and fixing all bends, valves and other adjuncts connected with the lines of pipes and shall be suitable for proper setting of the whole job. Back-Filling, Embankments & Reinstatement of Trenches After completion of foundations, footings and walls and other construction below the elevation of the ground and prior to back-filling all faults shall be cleaned of all trash and debris. Materials for filling shall consist of excavation or borrow or other material approved by the 113

Volume 1 General Specification Electro-Mechanical & Civil Works Engineer and shall be free of trash, lumber and other debris. All materials required for back-filling shall be placed in horizontal layers not exceeding 15cm in thickness after compaction and shall have moisture content such that the required degree of compaction may be obtained. Each layer shall be compacted by suitable equipment to not less than 90% of the maximum density obtained at optimum moisture content. Care shall be taken when placing backfilling against surface which have received water proofing and / or damp proofing treatment to prevent damage to the coating. No earth filling against wall and foundations slab shall be carried out without the permission of the Engineer. Embankments including those required in the forming roads and tanks and other structure shall consist of approved excavated and borrow material free from deleterious and organic materials and shall be capable of producing homogeneous and stable material, when moistened and compacted. The fill material shall be placed in horizontal layers no more than 15cm thick after compaction and shall be compacted in the manner herein specified. After the mains are laid and joints formed they shall be surrounded apart from the joints with selected materials which shall be carefully packed in place so as to avoid injury to the pipes but no reinstatement of the trenches shall be undertaken by the Contractor before the permission of the Engineer. The soil around and for 30cm over the top of the pipes shall be free from stone, and where required by the Engineer it shall be screened to exclude the material which would damage the pipes. The remainder of the trench shall be filled with the best and most suitable portions of the excavated material which shall be thoroughly rammed as the work proceeds. The special materials forming the surface and foundations of streets, roads and footpaths shall in every case be carefully stripped and set aside and shall be replaced in original position as before the excavation was made. When the joints have been satisfactorily tested they shall be surrounded with selected materials and the section of the trench filled in a like manner to the remainder or the trench as specified. All surfaces which have been disturbed during the course of contract whether within the site or on any other land shall be reinstated to a condition at least equal to that existing before its disturbance as a result of the Contract.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE TWENTY WORK SHOP BUILDING The contractor shall construct the building according to the General layout. The walls and general finishing shall be in accordance to main building.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE TWENTY ONE OVERHEAD TRAVELLING CRANES An electrically operated overhead gantry crane of a capacity suitable for lifting the heaviest of t h e pumping units with a margin of 25% and three motions shall be installed in the machinery room of the pump house building the capacity of the crane should be at least 5 tons. A similar crane shall be provided for low lift pump house workshop, power buildings, Booster Station. A mass rail hand operated crane s h a l l also be provided in the filter gallery of same capacity to lift the heaviest valves. Note: for power building in L.L of craves, to be in vol.2 of contract.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE TWENTY TWO WATER METER The contractor shall provide and install complete in all respect the following water meters. a) Main Water Meters 1. Ultra sonic Transducers with precision machined throat sections operating on the frequency difference technique. The measuring equipment shall be provided with a flow transmitter and indicating recorder system operated by the linear output from the transducer and totalizer. The flow indicators and records shall be installed in the main panel in the main flow recorder shall be of inkless roll chart type and shall be graduated in metric units, with 5 years supply of charts. There shall be one meter for each pumping main treatment plant and Booster Station and raw water pumping mains. 2. Standard Ventura tubes with roll type chart recorders and with indicators and integrator and totalizer. The lubes shall be installed in the pumping main at a point outside the pump and filter house building and the recorders and indicator and integrator mounted on the telemetry panel in the pump and filter house buildings. The tubes shall be constructed of cast iron with parabolic from of throat piece of bronze which shall be accurately machine to size. The differential pressure head shall not exceed 1.5m and the accuracy of registration shall be within 1% at half rate of flow and within 2% over the full range. The meter shall be housed in chamber formed in concrete of 1:2½:5 mixtures which shall be provided with cover formed in steel chequer plates with lifting holes and bearing on cast iron curbs and pointed in cement mortar. 3. Electro-magnetic flow meters with its accessories as Ultra-Sonic Venturi meters. b) Filter Wash Water Meters Provisions shall be made for measurements of air flows. Note: All meters should have the same diameter of the main in which it is installed. 117

Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE TWENTY THREE SEWAGE DISPOSAL SYSTEM The sewage disposal system shall comprise a. sewage digestion tank (septic tank) and oxidizing bed and the necessary inter connecting drains and inspection chambers as depicted in the Drawings. The walls and floor of the digestion tank shall be formed in reinforced 1:2:4 concrete and shall be rendered internally to 1:1 cement mortar of 1cm thickness. The roof-slab shall be formed in 1:2:4 reinforced concrete. The oxidizing bed shall be formed in broken bricks of approximately 7.5cm in their maximum dimensions and 5cm in their minimum dimensions. The inspection chambers shall be formed with floor invert and benching shall be accurately formed and shall be rendered to 1:1 cement mortar of 1cm thickness. The roof of the inspection chambers shall be provided with a light weight cast iron inspection cover with frame. The roof slabs to the digestion tank shall be bedded and jointed in weak cement mortar in facility of removal as and when required. The pipes and specials entailed in the drain shall be of 100mm diameter minimum and formed in spun cast iron pipes. The drains shall be trapped and ventilated immediately outside the bathroom and lavatory, with 4" diameter H.C.I pipe with 100mm cowl on top. The sewage disposal system shall be constructed at least 100m away from the ground filter water storage tank. There shall be one sewage disposal system for each building, one for the Resident Engineers building and one for operator building guard house etc.

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Volume 1 General Specification Electro-Mechanical & Civil Works Specified Protective Systems for Water Treatment Works Equipment (Minimum Film Thickness) Equipment

Applied Prior to Delivery and Installation 1st Coat

2nd Coat

3rd Coat

(T) Wash

Zinc Phosphate Epoxy Primer (0.025mm)

Thixotropic Chlorinated Rubber Primer (0.075mm)

Thixotropic Chlorinated Rubber (0.075mm)

Walkways Ladders Chlorinated Rubber To be approved Steps Handrail1ng Gloss (0.025mm) by Engineer

Zinc Phosphate Epoxy Blast primer (0.025mm)

Zinc Phosphate Epoxy Primer High Build (0.075mm)

Thixotropic Chlorinated Rubber High Build (0.075mm)

Thixotropic Chlorinated Rubber High Build (0.075mm)

Chlorinated Rubber To be approved Gloss build by Engineer (0.025mm)

Steel (Blast

Zinc Phosphate

cleaned)

(0.025mm)

Zinc Phosphate Epoxy Primer High Build (0.075mm)

Pitch Epoxy High build (0.100mm)

Pitch Epoxy High Build (0.100mm)

alkyd Based

miraculous Iron Ore Paint

Steel (Galvanize d) Steel (Blast cleaned)

Steel (Blast Cleaned) Steel of machine or equipment to manufacturers standard finish

Aluminum Alloy cast iron

Primer

Lead Free Metal Primer (0.05mm)

Undercoat

4th Coat

Remarks

Pre-treatment

Substrate

Steel Work

Applied FOLLOWING Installation Finsh1ng Coat

Pitch Epoxy high Build (0.100mm)

Color Finish

Black Self Color

Alkyd Based Gloss To be approved Enamel (0.025mm) by engineer

Structural steel work

Archimedean Screws

Diesel Oil Storage tanks

(to be compatible with chlorinated rubber finishing coat)

Dry Well Pumps, Chlorinated Rubber To be approved motors, Gearboxes, Gloss (0.025mm) by the engineer Valves

manufacturers standard finish

To be

Manufacturers Standard Finish

Chlorinated Rubber Where pipes are coated with bitumen, 2 coats of an approved aluminum sealer must Gloss (0.025mm) be applied.

Approved by the Engineer

Dry Well Pipes

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Volume 1 General Specification Electro-Mechanical & Civil Works Specified protective systems for "water treatment works equipment (minimum film thickness) Equipment Substrate

Pre-Treatment 1st coat

2nd Coat

3rd Coat

Following Installation 4th Coat

Finishing Coat

Color Finish

To be Approved by engineer

Zinc Phosphate (Blast Cleaned) Epoxy Blast or Aluminum Primer Alloy (0.025mm)

Zinc Phosphate Epoxy Primer High Build (0.075mm)

Thixotropic Thixotropic Chlorinated Chlorinated Rubber High Rubber High Build Build (0.075mm) (0.075mm)

Thixotropic chlorinated rubber gloss

Zinc Phosphate Epoxy Blast (Blast Cleaned) Primer (0.025mm)

Zinc Phosphate Epoxy Primer High Build (0.075mm)

Thixotropic Thixotropic Chlorinated Chlorinated Rubber High Rubber High Build Build (0.075mm) (0.075mm)

Thixotropic chlorinated To be Approved rubber gloss build by Engineer

Zinc Phosphate Epoxy Primer High build (0.075mm)

Pitch Epoxy Pitch Epoxy High High Build Build (0.100mm) (0.100mm)

Pitch Epoxy High Build (0.100mm)

Black Self color

Zinc Phosphor Epoxy primer (0.25mm )

Pitch Epoxy Pitch Epoxy Build High Build (0.100mm) (0.100)mm

Pitch Epoxy High Build (0.100mm)

Black self color

Solvent Free Epoxy Paint (0.125mm)

Solvent Free Epoxy Paint (0.125mm)

Solvent free epoxy paint

Solvent Free Epoxy Paint (0.125mm)

Solvent Free Epoxy Paint (0.125mm)

Solvent free epoxy paint

Cast Iron

Steel

Zinc Phosphate Machinery Cast Iron Epoxy blast Below Water (Blast Cleaned) Primer Level. (0.025mm) In Contact With Sewage Steel of Sludge "T" Wash (Galvanized) Cast Iron

Machines of Steel Work in (Blast Cleaned) Contact with Potable Steel Water Etch Primer (Galvanized)

Remarks

(0.025 mm)

(0.025 mm)

Including Submersible pumps

Machinery Above Water Level and not in Contact With Sewage, Sludge or Potable Water

Applied

Applied prior to delivery and installation

(0.125 mm)

(0.125 mm)

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE TWENTY FOUR CORROSION PROTECTION AND PATINTING OF EQUIPMENT General 1. The Contractors attention is drawn to the schedules of protective system as given in the Table. All paint materials shall be obtained from a supplier approved by the Engineer before any manufacturing commences. All paint materials shall be applied strictly in accordance with supplier’s instructions. 2. All steelwork to be installed below top water level or within the splash zone shall wherever possible be hot dip galvanized after manufacture to BS 729 Part 1. Sampling and testing shall be carried out in accordance with BS 729 Part 1. The coating shall contain not less than 600g/m2 of zinc. All drilling, stamping, welding, cutting and bending shall be carried out prior to galvanizing and all erection markings shall be clearly legible after galvanizing. Sections which will buckle or distort the galvanizing process shall be zinc sprayed. Zinc sprayed metal coatings shall comply with the requirements of BS 2569 Part 1. The nominal thickness of the coating shall be not less than 0.1mm and the surface shall be of uniform texture free from lumps, coarse areas and loosely adherent particles. 3. The Contractor will inspect the surface preparation and make daily visits during the application of all paint systems, on behalf of the Engineer. The Contractor shall give seven days notice to the Engineer of the date of commencement. No application of paint shall be carried out until the surface preparation has been inspected and approved by the Contractor. 4. The Contractors attention is directed to BS in respect of the protection of iron and steel structures from corrosion all other paint shall also be constructed so as to reduce the danger of corrosion to a minimum and allow ready access for maintenance 5. Unless otherwise agreed by Engineer, the contractor shall apply the protective systems listed in the Tables. However, before any alternative protective system w i l l be approved by the engineer it must be compatible with Employers on the protective system. Details of all such requests shall be submitted in writing to the Engineer 28 days before manufacturing commences. 6. Unless otherwise agreed by the Engineer, a l l material forming part of any single protective system shall be supplied in sealed containers of not more than 5.0 liters capacity and shall be used in strict rotation. Unless otherwise agreed by the Engineer, samples of 121

Volume 1 General Specification Electro-Mechanical & Civil Works material of not less than 2.5 liters capacity shall be submitted for testing to the Engineer. 7. Lead based paints shall not be used. 8. Where surfaces will be in permanent contact they shall, after being thoroughly prepared and immediately before being assembled and fixed, receive the primer and one coat of paint. 9. Where painting or protective finishing is damaged during erection or deteriorates during the maintenance period, the Contractor will be required to make good at his own cost. 10. All machinery bolts, nuts, washers, etc. are to be electroplated galvanized, unless otherwise approved by the Engineer. Electroplate galvanized coatings shall comply with the requirements of BS 3382. 11. All bright parts or machined surface shall be treated with an anti-rusting composition or wrapped with anti-rusting composition impregnated paper. After erection all such parts shall be thoroughly cleaned and polished. Preparation of Iron and Steel Surfaces to Receive Paint 1. Except where galvanizing is specified, all iron and steel work to be painted shall be blast cleaned in accordance with CP 2008 to a quality as defined in Swedish Standard S.I.S 055900:1962 SA 2½ to achieve a surface profile with minimum amplitude of 0.025mm and a maximum of 0.075mm. All surface must be free of moisture before blasting and painting and all welds shall be ground to a smooth contour must be free of blowholes and imperfections. Weld spatter shall be removed from surrounding areas. 2. The maximum grade of abrasive permitted shall be as specified in Table 2 of the BS 4243 Metallic abrasives shall used exclusively where recovery is possible, e.g. in airless blasting, in blasting chambers or where vacuum recovery equipment can be used. The abrasive used for blasting shall be free from contamination and any recovered material shall be cleaned to the satisfaction of the Engineer before re-use. Where recovery is impracticable, e.g. on site, non- metallic abrasives of approved quality may be used. These should consist of slag or mineral matter in which silica is present only in a combined harmless form. 3. All blast cleaning must be carried out under cover. 4. Following blast cleaning, surface must be protected within 4 hours with a Zinc phosphate epoxy blast primer. 5. Galvanized steel shall be degreased, abraded and again degreased before the application of any coating. The surface shall be pretreated with a brush application of T" wash etching solution. Should further degreasing be indicated this must be carried out before a further application of "T" wash is given to the affected areas. The first coat of the specified system shall be applied within 4 122

Volume 1 General Specification Electro-Mechanical & Civil Works hours. 6. The use sherardised coatings will not be permitted. Welds and surface which have been affected by welding shall be prepared for painting by the same process as described in the Contract for the adjoining metal. Weld spatter shall be removed. 7. Painted surface shall be cleaned of all dust immediately prior to the application of further paint. Any loose paint and rust shall be removed. Areas contaminated by oil and grease shall be cleaned with white spirit, Where required by the Engineer, the whole surface shall then be cleaned by washing down with a solution of an approved liquid detergent followed by rinsing with clean fresh water and allowed to dry thoroughly before paint is applied. Materials 1. Chilled iron shot and grit shall comply with the requirements of BS 2451 2. "T" Wash shall consist of a single pack phosphoric acid copper carbonate solution. 3. Zinc Phosphate primers shall consist of a two pack polyamide cured epoxy, pigmented with zinc phosphate. 4. Chlorinated rubber paints shall consist of chemically resistant Pigments dispersed in a plasticized rubber base. High build chlorinated rubber paints shall contain a thixotropic agent. 5. Pitch epoxy paints shall consist of a 2 pack polyamide cured coal tar pitch epoxy. 6. Black bituminous coating solution for cold application shall comply with the requirements of BS 3415 Part 1. 7. Water rinse-able and solvent rinse-able paint removers shall comply with BS 3761. Electrical Panels and Fittings All electrical panels shall be protected in accordance with the system listed in the table in a color to be selected by the Engineer externally and white internally. Bolts, thumbscrews hinges, etc. on the outside of panels shall be chromium plated after copper and nickel plating followed by polishing. Other ferrous metal fittings used shall be rust proofed by PVC coating, plating or other approved method and / or the use of stainless steel where appropriate. Aluminum Structures Aluminum structures and fitting shall be protected as indicated on the Tables. Whenever dissimilar metals (e.g. steel / aluminum) are in contact, the Subcontractor thickness to prevent electro-chemical corrosion, the Neoprene, which should be within 50 and 60 on the shore 123

Volume 1 General Specification Electro-Mechanical & Civil Works "A" and F.R.H.D. scales and have a resistivity of approximately 108 ohm m must not protrude outside the surface to be clamped. However, stainless steel bolts, nuts and washers may come into direct contact with aluminum but when used to clamp aluminum to another metal, each bolt must be fully insulated from one of the metal by the use of a tubular sleeve washer of reinforced phenolic resin bonded plastic. Pipe Work All exposed pipe work shall be color coded generally in accordance with BS 1710 to facilitate identification. Paint Storage 1. Paint shall be stored in sealed containers in a lock-up store where it is not exposed to extreme temperatures. The temperature of the store shall be kept between 7C° and 27°C (45°F and 81°F). Any special storage conditions recommended by the manufacturer shall be observed. 2. Paint which has not been used within the "self life" period specified on the containers or within 12 months of the date of manufacture, whichever is the lesser, shall be replaced. 3. Paint from painters, kettles shall be returned to store at the end of each working period where it shall be kept in a sealed container. Before it is reissued for use it shall be thoroughly mixed and no fresh paint or thinners shall be added. Application of Paint 1. All paints shall be supplied from the store to the painters ready for application and the addition of thinners or of any other material shall be thereafter prohibited. Any instructions given by the paint manufacturer shall be strictly followed , 2. Paint shall be applied to dry surface which have been prepared and cleaned. The interval between preparation of the metal surface and the application of the first priming coat of paint shall be in accordance with the relevant requirements. 3. Paint shall not be applied under the following conditions : a. When the ambient temperature falls below 4°C (40°F) or the relative humidity rises above 90 percent. b. Maximum temperatures above which painting shall not be carried out shall be as recommended by the manufacturer. c. During rain, snow, fog, mist or dust storm. d. When condensation has occurred. 4. Two pack paints shall not be applied at a lower temperature than that recommended by the paint manufacturer. They shall not be applied, when the temperature is likely to fall below the specified 124

Volume 1 General Specification Electro-Mechanical & Civil Works minimum during the period. 5. The only method of spray painting permitted shall be airless spray and shall be subject to the following restrictions : a. Priming paints shall only be applied by spray if specified by the nominated supplier and shall be subject to the approval of the Engineer. b. Airless spraying shall be confined to application in works and shall only be allowed on site with the approval of the Engineer. c. Spraying will not be permitted where soiling of adjacent surface cannot be prevented. 6. Each coat of paint shall be applied either by brush or airless spraying to produce a continuous film of paint of uniform and even thickness .As soon as the first priming coat has dried an extra strl.jp coat of paint shall be applied to edges, corners, crevices, bolt heads, rivet heads and welds, using paint of a similar composition to the priming coat, but in a contrasting shade. Successive coats shall have different shades for identification and each coat shall be thoroughly dry before the application of a further coat. 7. No manufacturer’s name or identification palate shall be painted over. All such plates shall be unasked before any painting operation starts. TAT type of grease adaptors shall be treated similarly. Vented filler plugs in gearboxes shall not be painted over. 8. The total dry paint film thickness of the paint system on bare steel surface and on metal coated surfaces shall be as tabulated in the schedule. The dry paint film thickness shall be measured by Elecometer or other instruments approved by the Engineer. 9. In order to obtain the dry film thickness specified the Contractor shall ensure that the coverage rate given by the paint manufacturer will enable this thickness to be attained. 10. Wet film thickness gauges may be used for checking but shall not be permitted as a means of predicting the dry film thickness. 11. Unless otherwise agreed by the Engineer the paint system shall be applied under cover in controlled conditions at the fabricators work except for chlorinated rubber gloss finishing coats which shall be applied on site. 12. No paint shall be used after the expiration of the pot-life stimulated by the manufacturer shall not be mixed with fresh paint or have thinners added to them. 13. Single pack paints in the process of "skinning" on which a skin has formed during storage shall be immediately disposed of. Storage of Painted Steelwork 1. Painted fabricated steelwork which is to be stored prior to erection shall be kept clear of the ground and shall be laid out or stacked in an orderly manner that will ensure that no pools of water or dirt can 125

Volume 1 General Specification Electro-Mechanical & Civil Works accumulate on the surface. Suitable packing shall be laid between the layers of stacked materials. Where cover is provided it shall be ventilated. 2. Primer painted steelwork which is to be stored outdoors or transported prior to fabrication or erection shall not be exposed before being over coated for periods longer than the following: Outdoors a. "T" Wash on galvanized surface b. Zinc Phosphate primers 0.01-0.025mm thick c. zinc phosphate primers 0.025-0.075mm thick

Nil 4 weeks 6 weeks

Repairs to Damaged Surfaces 1. Areas of protective finish which have been damaged during handling, storing, loading and off-loading, transportation, erection and construction shall be cleaned to bare metal, or metal coating where this has been applied, and the edges of the undamaged protective coating with sandpaper. 2. Where a metal coating has been damaged the affected area shall be thoroughly wire brushed to remove any loose rust, rubbed down, cleaned and a coat of Zinc Phosphate epoxy primer applied. 3. The specified complete protective system shall then be re-applied and shall overlap the existing by at least 75mm all round the affected part.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE TWENTY FIVE SAFETY RULES AND REGULATIONS General The installation must comply in every detail with local safety laws, rules and regulations and fire regulations and with the regulations of the local Electricity Authority the Regulations for the Electrical Equipment of Buildings issued by the institution of Electrical Engineers. All exposed re-belt drives, rotating and couplings and other moving parts shall be provided with adequate guards constructed so as to eliminate danger of contact with any rotating part. Warning notices shall be provided. Position requiring access (such as oil inspection points) shall be safe from moving parts and outside the guards. The guards shall be fixed securely but be designed so that they can be removed without disturbing the plant. All guarded enclosures shall be so constructed as to eliminate danger of contact with any rotating parts. Opening giving access to rotating parts shall be such that the standard test finger as illustrated in BS 2817 when inserted through any opening does not touch any moving part. Guards for V-Belt Drives V-belt drive guards shall be constructed from woven wire steel mesh. The mesh of the guard shall not exceed 10mm with a strand diameter of not less than 0.2mm. The guards shall be split on the driving and standby motor and the fan shaft vertical center lines to facilitate removal. The edge of each section of the guard shall be provided with rolled steel angle frames drilled for bolting them together. The whole guards’ assembly shall be galvanized after manufacture. The guard sections shall be bolted together using black steel bolts and washers with brass nuts, having a flat washer under the bolts head and a spring washer under the nut. The bolt shall project through the nut by not more than two threads or less than one thread. The guard shall be constructed to provide a minimum clearance all round the drive of not less than 100mm. To provide the belt adjustment, the guard shall be sized to the full 127

Volume 1 General Specification Electro-Mechanical & Civil Works extent of the drive adjustment as provided by the motor slide rails. The guard shall be rigidly secured to the base frame of the fan motor sets and, where necessary, to the fan frame. No guard fixing may penetrate the fan casing. Guards for Exposed Shafts and Direct Drive Couplings The guards shall be constructed from woven wire mesh or steel sheet. Woven wire mesh guards shall he split horizontally at the drive center. The mesh size of the guard shall not exceed 10mm with a strand diameter of not less than 2mm. The two halves of the drive guard shall be provided with rolled steel angle frames drilled for bolting the two halves together. The guard shall be galvanized after manufacture. The guard sections shall be bolted together using black steel bolts and washers with brass nuts, having a flat washer under the bolt head and a spring washer under the nut. The bolt shall project through the nut by not more than two threads or less than one thread. The drive guard shall be securely mounted upon the base of the pump set. Drive guard constructed from steel sheet shall be welded construction. They shall comply with the arrangement and other details stated above. Ventilation holes in the guards shall not be larger than 5.0mm diameter or in the case of slots or louvers not wider than 5.0mm. High Voltage Switchgear Where high voltage switchgear is to be supplied then all necessary safely equipment including man retrieval hooks shall also be supplied.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE TWENTY SIX PACKAGING AND PROTECTION DURING TRANSPORT, SHIPPING AND STORAGE All plant equipment and materials particular prefabricated or preerected items and spares shall be properly packed and protected against damage during transport, shipping, storage and installation. The Contractor shall be responsible for the packing and delivery to site of all equipment, off loading and transportation from place of storage to point of erection. He shall also be responsible for the storage of all materials prior to erection whether at his own risk. Each item shall be packed properly or protected for shipment and transport from the place of manufacture to the site. Transformers may be transported dry, filled with dry air or nitrogen. Under these conditions the air or gas shall be under pressure. A lockable and protected valve shall be fitted so that a pressure gauge can be fitted to demonstrate to the Engineer the pressure involved. The core earth link shall be disconnected during transport and a temporary connection be brought cut of the tank via an insulator so that the core can be tested before each stage of the journey to site and before site erection takes place. For transformer delivery dry the first filling shall be undertaken by vacuum, and the oil snail be preterit and tested by a mobile plant. The Engineer shall be invited to witness the complete oil filing. Pipe ends and other similar open ends shall be protected from both external damage an ingress of dirt and moisture during transit and while awaiting erection at site. Flanged pipes shall have their open ends protected by a wooden blank flange secured service bolts. Spigot and sockets shall be protected by padding and wrapping. Pipes shall not be transported or stacked with one pipe inside another. Precautions shall be taken to protect shafts and journals of sufficient strength to resist chaffing and indentation due to movement in transit shall be suitable for a period of twelve months. In case of ball or roller bearing s installed in any item of plant, the Contractor shall state, prior to dispatch, what precautions have been taken to avoid indentation of the bearing faces. If the method proposed is not approved, or if no special precautions are taken, then the Contractor must be prepared to have replacement bearings available at site. Lids and internal cross battens of all packing cases shall be fixed by screws and not nails. Hoop metal bindings of cases shall be sealed where ends meet and if not of stainless material shall be painted.

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Volume 1 General Specification Electro-Mechanical & Civil Works Contents of boxes shall be bolted securely or fastened in position with struts or cross battens and not with wood chocks wedged in place, unless they be fastened firmly in place. All struts or cross battens shall be supported by cleats fixed to the above and below to form ledges on which the battens may rest. Boxes shall be up ended after packing to prove that there is no movement of contents. Where parts are required to be bolted to the sides of the case, large washers are to be used to distribute the pressure and the timber shall be strengthened by means of pads. All marks on the outside of boxes shall be either of a water proof material or protected by shellac or varnish to prevent obliteration in transit. Wood wool shall be avoided as far as possible for packing purposes. Waterproof paper and felt linings are to overlap at seams at least 10mm and the seams shall be securely fixed together. The enclosure shall be provided with screened openings to allow for ventilation. Where practicable all indoor items such as electric motors, switch and control gear, instruments and panels, machine components, etc. are to be completely wrapped in polyethylene sheeting sealed at the joints and the enclosure provided internally with an approved desiccator. Each crate shall contain a packing list in a waterproof envelope and copies in triplicate shall be forwarded to the Engineer prior to dispatch. All items of material shall be clearly marked for easy identification against the packing list. All cases, packing, etc. shall be clearly marked on the outside indicating the total weight, showing where the weight is bearing and the correct position of the slings and shall bear an identification mark in relation to the appropriate shipping documents. The Engineer may require to inspect and approve the packing before the items are dispatched but the Contractor is entirely responsible for ensuring that the packing is suitable for transit and such inspection will not exonerate the contractor from any loss or damage due to faulty packing. Particular attention shall be given to the design of packing in recognition of the fact materials may be subject to storage on an open site for a time and may be subjected to harsh treatment. Wherever particular the packing shall be so designed that the plant or equipment may be installed and fitted without the necessary for completely position until put into service. The Tenderers attention is drawn to the painting specification and the minimum number of coats that shall be applied before delivery to site.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE TWENTY SEVEN ENGINEERS HOUSE The Contractor shall before commencing the waterworks, construct an office building for the exclusive use of the Representative of the G.D.W attached to this Tender Paper. The building shall be constructed in cemented brick without any framed structure. The inside and outside walls shall be in 24cm thickness, all other respect shall be according Clause 14, and the internal surface of walls and ceilings shall be plastered with JUSS except those of the kitchen, bath room and W.C. where the walls shall be faced from floor to ceiling with best quality white porcelain tiles and the ceiling shall be constructed according to the specification of the pump house and filter house building and other clauses. The bath and lavatory room fitting with sewage disposal system shall be similar to that of the pumping station. In addition porcelain shower basin and Oriental W.C. shall be installed in the bath room. All windows shall be fitted with curtain rails , wooden pelmets and good quality curtains. Where shall be electric fans in office room and one in living room and one in each of the two bed rooms with necessary lighting arrangements for all rooms, stairs, corridor, gate, etc. with one electric meter. The furnishing shall be: 1. One electric Geyser of 50 gallons capacity complete with pipe fittings necessary to provide hot water for kitchen and bath room. One washing machine and one 2000W iron, with iron table. 2. Window type 2 tons air conditioner for each room. All furnishings shall be of the best and approved quality. So long as the electricity is not available the Contractor shall make temporary arrangements for heating and lighting. The building shall be placed in position near Waterworks site to suit the convenience of the Representative of the G.D.W.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE TWENTY EIGHT OPERATORS HOUSE The Contractor shall before commencing the waterworks, construct buildings which will be used in the beginning by the representatives of the G.D.W. and afterwards by the operators to be appointed by the local Authority. The buildings shall be as shown on the drawings. The walls and the buildings shall be constructed in cemented brick without any frame structure, the inside and outside walls shall be in 24cm thickness all other respect shall be constructed in accordance with clause 14. The clear height of each room shall not be less than 3m. The internal surfaces of the walls and ceiling shall be plastered with JUSS of the best available Quality except the bath room W.C. and kitchen where the walls shall be faced from floor to ceiling with best quality white porcelain tiles and the ceiling plastered with cement. In all other respects the building shall be constructed according to the specification. The bath room shall be fitted with porcelain shower basin. In all respects the bath room and WC room fittings and sewage disposal systems of the building shall be similar to the pumping station. The water services shall be connected to the water services system of pumping station. There shall be two electric fans in the sitting room and one in each bed room with necessary lighting arrangement for all room, corridor, gate etc. with one electric meter. The furnishing for each operator house shall be as follows: 1. One electric Geyser of 50 gallons capacity complete with pipe fittings necessary to provide hot water for kitchen wash basin and bath room. 2. Air condition 2 ton.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE TWENTY NINE FENCING WITH GUARD ROOM a. The whole site of the proposed water work and for future water works shall be fenced by brick as shown on drawings. b. Site of low lift it is in a separate site. c. Fences between the houses at site of water works, low lift site and all boosting stations made of bricks or masonry 2.5m high from R.G.L. d. Fence for each EST 200 meter and G.S.T. as required. e. Site of Booster stations f. Guard room and gates, etc. shall be included for each fenced site. Guard room or guard house shall be constructed in cemented brick without any framed structure. The thickness of all walls shall be 24cm.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE THIRTY ROADS AND FOOTPATH A. Roads and foot path shall be according to general layout starting from the gate. The road will extend up to the main entrance of all buildings and also up to the doors of the alum store room. Chlorine store room and to clarifies as shown in Drawing. The road shall be from 5cm after compaction in 2-layers asphalt concrete and 15cm thick reinforced cement concrete (1:2:4) with hard core underneath with not less than 19cm thickness, there shall be a car park to accommodate at least two cars. There shall be a footpath from the road to the clarifying tanks and ground filters water storage tank. The footpath shall be made with 3” thick cement concrete 1:2½:5 over 10cm thick hard core. The arrangement of the road and footpath shall be as shown in the drawings. The road and footpath for boosting station shall be according to the same specification as above. B. Road and footpath for Booster Station as A above. C. Road between treatment plant and site low lift if it is an a separate site of 5m in width constructed on a compacted sub-base of 0.3m thickness and finished with asphaltic concrete in two layers each 57mm thick. The bitumen macadam base course shall be evenly spread on the foundations, laid and rolled in accordance to BSS 1621.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE THIRTY ONE GENERAL SITE DIVELOPMENT WORKS A. The work shall be carried out only after clearing of all crops, shrubs, and other vegetation including roots and after the structures are executed leveling of the site shall be carried out to the final elevation indicated in basic data. B. Gravel surfacing shall be placed on the shoulders of the roads, around tanks, clarifiers, etc. the material of gravel surfacing shall consist of clean gravel or crushed stone free from dirt and soft pieces the maximum size not exceeding 38mm. The gravel shall be placed on the prepared and compacted soil compaction shall be secured by the rolling equipment until required thickness of 8cm is obtained. This will be for Treatment Site, Booster Station, Low Lift, Elevated Service Tanks, GST, etc. C. Grassing and Planting: Grassing shall be done for all site area and embankment, including top soil supply, the seeding and type of grass shall be appropriable to the local climate also the planting of trees, and flowers bed. The Contractor shall be responsible for the good condition of the planting and Grassing during maintenance period. D. Ornamental Sculpture: The contractor shall include the design and construction of water fountain with ornamental sculpture representing the idea of water treatment with relation to Iraq history, the material of the sculpture shall be made of Bronze the idea and design shall be submitted for approval. E. Two Models (3 dimension) shall provide for following: -Treatment plant only: The whole scheme from the riser to all Elevated Storage Tanks (limit of the contract). This shall be of best quality covered by transparent cover, one of them shall be located at administration building, the other at the Establishment in Baghdad.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE THIRTY TWO SURVEILLANCE AND SECURITY SYSTEM A surveillance and security system shall be provided to prevent entry of unauthorized persons to the site to be detected. The equipment shall consist of the following: a. b. c. d. e. f. g.

Microwave Devices. Infra Red Detectors. Alarm Bells. Alarm Panels. Closed circuit television. Viewing monitors. Guard post in each corner 8m height in each corner shade and necessary ladder, projector light, etc.

The microwave shall have a radiation not exceeding 50W/m2 when measure data distance of 0.5m from the radiating source and shall be position at a height of a not less than 2.5m vertically above the ground and shall have a beam pattern of at least 90°. The system shall be complete with all necessary control and test equipment cameras shall be mounted at height above ground level varying from 3.5-7m and the monitors shall be black and white type having a min screen size of 30cm. This system required for Treatment Plant only and the monitoring devices shall be located at the monitoring room in the control room. The Contractor shall submit full details of his proposal during the tendering stage. Spare parts for minimum 2 years operation including repair tools and test tools.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE THIRTY THREE SPARE PARTS All spare parts shall be suitably wrapped and boxed for long term storage and be identified clearly on the outside of the package. The Tenderer shall also include in his prices for the preparation of a card index system and plans setting out the most efficient method of storage of all the spare parts to be supplied. The contractor shall provide the following spare parts whenever it is applicable. SPARE PARTS LIST For each pump the Contractor should supply the scheme with under mentioned parts and all spare shall be suitably wrapped and / or boxed for long term storage and be identified clearly on the outside of the package. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Sealing rings. Stage bushes. Discharge bushes. Flooding bushes. Stuffing box rings. Stuffing box glands. Packing. Oil rings. Impeller keys. Bearing brass. Bushes (set). Set of ball bearing for motor. Set of bearing (ball or roller) for pump. Impeller for each pump. Shaft for each pump. Shaft sleeves for each pump. Casing joints (gasket). Set of coupling rubber bushes and spindles. Set of brushes. Pressure and vacuum gauge. Water seal eager. Suction half casing joints. Delivery half casing joints. Shaft sleeve joints. Complete pump and motor and starter for each set of Identical pumps (L.L., H.L., B.S., W.W.)

4 4 4 4 4 4 2 Kgs 4 2 2 4 4 4 1 1 4 4 4 4 Nos. 1 set for each type 4 4 4 4 1

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Volume 1 General Specification Electro-Mechanical & Civil Works STARTERS For each starter: -

Set of contractors and springs Push button. MCCB. Indicating Lamps. Ammeter. Over load relay with coil. Timer.

2 1 of each size 1 of each rating 3 No. 1 3 set 2

SPARE PARTS FOR ALUM & CHLORINE APPARATUSE For each type chlorinator -

Flexible connection. Cylinders manifold complete with valves Gas pressure gauges. Water pressure gauges. Auxiliary cylinder valves . Injector diaphragms. Injector nozzles. Washers. Gaskets. 1 ton drum. Chlorine strainer. Springs. Flow meter tubes. Regulating valves. Change over device. Gland wool. Injector balls. Copper arrestor washers. Tub Graphic Grease. O Ring. Solenoid Valves complete.

2 2 1 1 1 1 1 3 set 3 sets 2 1 1 2 1 1 ½kg 1 50 1 4 sets 1

Alum dosing Pumps & Mixer • • • • • • • • • • • • • •

Plungers, diaphragm cylinders, liners Bearing and valves. Gear box. Seals, packing and washers. Suction and delivery main anti acid valves Metering unit complete with its tubes. Spare stirrer motor. Sets of motor bearings Complete stirrer motor starters. Sets of contacts for motor starter. Strainer for dosing pump. Shaft and impeller. Diaphragm for P.V.C Valves. Pump starter.

1 set 1 set 2 1 set 4 2 2 2 4 4 2 4

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Volume 1 General Specification Electro-Mechanical & Civil Works Spares for each Electric hoist and crane for each rating Limit switch complete Load chain wheel Axle Bottom guide (push button) Trip frame Spare motor complete Pair of brake bars with linings and studs Rectifiers Primary fuses Control transformer

2 pairs 1 1 1 sets 1 1 1 2 2 1

Switch board: Complete set spare parts for 33KV and 11KV substations, Transformers, circuit breakers, relay current transformers, voltage transformers, and for each type of units and individual units. • • • • • • • • • • • •

ACB 33KV, 11KV circuit breakers MCCB Mini circuit breakers Fuses Relay of each type Current transformer Ammeter Voltage selector switch Lamps Push buttons Contactor

25% for each rating 1 of each type 25% spare for each size 10% spare 25% 25% 5 for each rating 5 each size 2 No. 50% spares 5% of each size 25% spare for each rating

Flash Mixer • • • • •

Spare motor (complete) Set of bearing (roller or ball) Stainless steel shaft and impeller. Grease nipples Spare starter complete

2 6 2 2 2

Bridge Drive and Flocculators • • • • • • • • • • • • • •

Polyurethane typed wheels (set) Brushes for slip-ring unit (set) Slip ring (set) Starters (for drive) Motor bearing for drive Complete motor for drive (spare) Starter (for flocculator) Complete motor for flocculator Motor bearing for flocculator Grease nipples Scraper rubber (set) Flocculator shaft bearing Drive and axial bearings PVC supporting wheel for scraper blades (set)

4 1 1 4 1 2 1 8 2 1 2 4 4 1

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Volume 1 General Specification Electro-Mechanical & Civil Works Standby Generators Recommended spare parts from the manufacturer for 15000 hrs operation: Valves Actuators A. B.

1 No complete valve actuator for each type of filter valve. 2 Nos. electric motors tor each type actuator of filter controls and valve control on pumps with starter. Lose of head gauges, 4 Nos.

C.

Spare for Air Blowers • • • • • • • • • • • • • • • •

Bearing (exhauster inlet) Bearing (exhauster outlet) Washable element for air inlet filter Complete starter Carbon steel lubricant disk Cast iron sealing chambers Steel gear spacers Cast iron oil spash Set of carbon steel rings Nut and key Carbon steel bearing Rubber seal ring Cast iron flexible rings Set of gasket Oil level plug Set of rubber blocks for joint

4 sets 4 sets 2 1 1 1 1 1 1 1 1 1 1 1 1 1

River Installation • •

Relief valve (complete) Foot valve with strainer

1 1 for each size

Pipes and Valves • •

Set of gasket for each dia. Set of valve gland packing for each type of valve

40 4

The Contractor shall supply the followings equipment very well protected A. 2 Nos. flange joint sets complete for each size of flanged joint to be incorporated in the works. B. 1 No. valve for every type of diameter of valves incorporated in the works.

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Volume 1 General Specification Electro-Mechanical & Civil Works Another Electrical Spare I. complete sets of spare parts recommended by manufacturer a. Telephone system b. Wireless system c. Surveillance system d. Fire alarm system e. Call system f. Digital camera II. III.

for

the

following

for

1

year

25 % of fluorescent and vapor mercury or sodium bulbs. 2% complete fitting of indoor and outdoor lighting and emergency lighting.

IV. 10% cable drum for each size.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE THIRTY FOUR TOOLS A. 2 Sets of polished steel spanners of superior quality one to fit every nut on the pumps , motors and other apparatus including holding down bolts and complete with lockable trolley Larger Dimensions. On which each spanner shall be hung on ft strong brass hook or clip. Open ended combination spanners, ring spanners, curved ring spanners, swivel socket spanners, hexagon socket screw wrenches, box spanners, ratchet spanner, torque, wrenches and adjustable spanners. All the above will be heavy duty type. B. 2 Box, of comprehensive litters tools with a complete set of universal tools C. 1 electrically operated hand boring machine suitable for holes in steel up to 25mm and running on two speeds, equipped with steel brackets to secure the machine for vertical use, two sets of steel drills (3-25mm 23 pieces) and accessories in modern box. D. One set of stocks and dies complete with raps grade from % to 1 " without threads. E. One set of the nuts graded from ½" to 1” with whit worth threads. F. One 150mm bench vice with revolving head. G. One (250x32)mm double-edge electric grinder pedestal type suitable for operation at 230V equipped with two fine grinder wheel, two coarse grinding wheel and two wire wheel. 2 Nos. of each of the following: a. A.V.O. meter with 150mm dia. pocket type Tong Test 0-5000 - 1000A/0 -500V. b. Megger 10/1000/1500/12000V c. Water leak detector meter. d. Vibro-meter. e. Phase sequence meter. f. Cable test detector. g. Pipe detector H. Acetylene welding set portable type with oxygen bottles mounted on trolley adapting head, reducing valve with union, pressure gauge, four cutting nozzles with spacing grinder, four welding nozzles, four armored flexible hoses each 10m long complete with union, two pairs of glasses, one set of necessary spanner and tools. I. One portable welding set with accessories for connection to a power plug contact (rectifier with silicon dioxide) and the welding current shall be continuously adjustable ranging to 200A and equipped with 20cm of supply cable, 20m of welding cable with durcible tongs, 2 pairs of welding gloves 2 head shields, one clipping hammer, 2 spare heavy duty ground clamp. Five wire brusher, 50kg of different diameter of welding electrodes, 3 No. power plugs distributed 142

Volume 1 General Specification Electro-Mechanical & Civil Works between the workshop, machinery room, and near the clarifier to operate the welding machine. The machine will be fixed on 4-wheel trolley and a suitable lockable hard wood or steel box to contain all the mentioned fittings. J. Tools and instrument a. 1 No. hydraulic press machine for cable shoes fixing complete with dies for fixing (10-630)mm cable. b. 1 No. draw-off tackler for coupling and bearing in pumps and another one motor bearings. c. 1 No. Venire (1 set) and micrometer d. 1 Nos. steel rulers. e. 2 Universal test indicator set with Knuckle joint holder and magnetic base. 2 Set of files, 2 sets of Allen Keys, 3 set of pliers, set of curved and half round bearing scraper, 4 sets of heavy duty screw driver, 4 set of Adjustable spanners. f. 2 Nos. 1 ton chain block g. 1 Electric pipe cutter with 24 spanners wheel. h. 1 lifting trolley hydraulic type i. 2 No. hydraulic jack for vehicles up to 2 tons weight j. 2 No. elect driven flushing pumps on trolley capacity 1000m3/hr at 20m head, complete with 5m suction hose and 50m, delivery hose (5m pieces) with 20m power cable. k. 4 Nos. complete set of chlorine handling suit with head cover and breather hinge with small air bottle. l. 2 Nos. battery operated frock lifting capacity of 2 Tons complete with Battery charges. m. 5 Nos. small submersible pumps with floating switches. n. Portable compressor to be used for cleaning switch gear and for painting with spray gun and 5m long flexible rubber tube. o. The Contractor shall supply a complete service set tools in each Boosting Station, contained in a lockable trolley also for L.L a separate site.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE THIRTY FIVE Furnishings Operators Room A. 2 No. steel tables with drawers measuring 1800x1800x750mm for each operator room in the plant. B. 2 No. strong tubular chairs with rest revolving type and 2 armless types for each operator room in the plant. C. Wooden furniture, for the chief Engineer and Engineers room to be agreed on the type and hand color with the Resident Engineer it shall be of best quality. D. 1 No. steel wardrobe (1x2x0.7m) for each operator Room. E. Wooden book cabinet with shelves and complete with glass doors 2mx2mx0.4m for each Engineer room. F. 2 No. computers with complete accessories and printers, scanners. G. Furniture for lecture room consisting of 20 wooden students, chairs, 1 lecture stand 1 vinyl covered blackboard, white screen roller type overhead projector. General Store Shelves portioned rack of general proportions and storage cabinets with drawers for small items enough for the whole spare parts suitably labeled. Work Shop A. Plumber tool chest. B. Electrician tool case. C. First aid kit (5 No.). D. 2 Nos. fitters (Trestles with loose 1m l o n g platform). Office Cum Laboratory a. b. c. d.

2 Nos. wooden office tables with drawers. 4 Nos. straight backed teakwood office chair 1 No. wall cupboard with 2000mm long x 600mm high 1 No. acid resistance bench along 3 walls porcelain sink of 90cm height and 60cm depth e. 1 No. small refrigerator (14 ft3) Lavatories and Bath Rooms a.

1 No. two point coat hanger each door

b.

1 No. 60x45cm, mirror over each wash hand basin.

The furnishing shall be an approved quality and finish.

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Volume 1 General Specification Electro-Mechanical & Civil Works Restaurant a. b. c. d.

1 No. refrigerator (14 ft3) 4 Nos. wooden tables 1000x1000x900mm 16 Nos. wooden chairs 1 No. gas cooker of good quality five point and oven and aluminum cupboard (1000x500x2000mm)

All windows in the Management building and Laboratory shall be furnished with curtains and folders.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE THIRTY SIX WATER SAMPLING TESTING EQUIPMENTS: The manufacturers of the filtration plant shall furnish a sampling apparatus complete in all respects, which shall be established by the Contractor in the office cum laboratory room of the pump and filter house building or chemical building. The apparatus shall comprise a marble or stainless table on which are mounted three clarity jars for the visual examination of the raw water clarified water and filtered water respectively. Provision shall be made for the draw off of samples through faucets for chemical and bacteriological analysis. The laboratory equipments shall be either type A or type B according to Basic Data. WATER TESTING EQUIPMENT Type A I) Chemical Lab 1- Laboratory turbidity meter, HACH model 2100A or high equivalent, with all necessary accessories. 2- pH meter, 0-14, with electrode stand & holder, meter display preferable, accuracy ±0.05 on normal range, with 2 spare electrodes. 3- Laboratory Floc-Tester, with six stirring units, rpm regulator, 0-200 rpm with necessary spare parts including drive belts & motor. 4- Conductivity-meter measuring ranges 0-20ms/cm complete with electrode stand, holder and 2 spare electrodes. 5- Oven drying, capacity 40-60 liter, temperature range 5°C above ambient to 250°C, ±2°C. 6- Furnace muffle, temperature up to 1100°C ± 5°C capacity 3-5 liter. 7- Spectrophotometer, UV/VIS, 195-1000nm, bandwidth 8nm, Analogue, with deuterium lamp, built-in power supply, with necessary cells. 8- Balance, analytical, capacity 160g, precession ±0.05mg, readability 0.1mg. 9- Water Bath, 6 openings of 90mm. 10- Hot plate, rectangular, acid resistance, temperature up to 350°C with 3 more step switch, size ~ 35x25cm Qty 2. 11- Magnetic stirrer, variable speed, with necessary magnetic followers Qty 2 12- Water distilling apparatus all glass, 2-4 liter/hr distillate conductivity 1ms/cm. 13- Water Sampler standard model for sampling from river, streams 146

Volume 1 General Specification Electro-Mechanical & Civil Works .etc. 14- Nessler, lovibond BDH, with necessary discs for determination Cl2, Fe, Mn, N- compounds in water. II) BACTERIOLOGICAL LAB 1- Auto clave, electrically heated, ~ 30 liters capacity, with all necessary accessories. 2- Hot air sterilizer 40-250°C, ~ 12 liters working volume, with time switch up to 2 hrs. 3- Incubator, temperature range 5°C above ambient to 70°C working volume ~ 35 liters. 4- Water bath with cover, for bacteriological purpose, temperature controller, ~ 15 liters capacity, with necessary test tube racks. 5- Balance - top loading, capacity 2000g, precession ±0.1g. 6- Refrigerator. 7- Magnetic stirrer hot plate variable speed, thermostat control, with necessary magnetic followers. II MISCELLANEOUS ITEM 1234567891011-

Filter pump - wafer jet air type Bunsen Burner for bottled LPG Tripod stand Wire gauze Stop watch Burette stands including assorted clamps boss heads & rods Pipette rack, 20-30 opening Pipette filler Tongs, general purpose Spatula, scoop Rubber stopper solid & centre hole assorted

12- Filter paper Whatman grade GFLC 7cm cp 13- Filter paper Whatman 40, 15 cm dia. 1415161718-

2 2 4 6 2 4 3 12 6 6 50 24 pks of 100 24 pks (of 100) 24 6 pairs 4 1 1

Cleaning Brushes general purpose beakers test tubes Gloves medium size Goggles protective First aid cabinet wall mounted up to 25 persons Eye-wash station wall mounted Funnel supports for 6- funnels height adjustable by thumb Screw wood 194 or plastic.

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Volume 1 General Specification Electro-Mechanical & Civil Works IV GLASSWARE 12345678-

Hartley Funnel, 7cm dia. Filter flask, Pyrex 500ml Burette straight stopcock, 25 ml and 50 ml, class B, borosilicate Ditto- but amber Beakers Pyrex with spout & graduation, capacity 50, 100, 250, 500 ml Pipettes graduated full delivery, class B capacity 1.5 & 10 ml. Pipettes volumetric class B capacity 25, 50 & 100 ml Measuring cylinders, tall form with spout, heavy hexagonal base, capacity 100, 250, & 500 ml. 9- Conical flask wide neck, Pyrex, capacity 100, 250, 500 ml 10- Volumetric flask Class B with stopper ,capacity 100, 250, 500 & 1000 ml 11- Funnel, conical, glass, 55 ,70 , & 100 mm 12- Weighing funnel glass dia. 20 mm 13- Evaporating dish porcelain low form 100 ml capacity. 14- Crucible silica low form with lid capacity ~ 30 ml 15- Watch glass 50, 70 &100 mm dia. 16- Desiccators 25cm dia. with knob cover perforated disc & silica gel 17- Reagent Bottle clear glass narrow neck capacity 250 & 500ml 18- Ditto - but amber 19- Storage bottle plastic with tap & handle screw cap ~ 25 Liters capacity 20- Wash bottle plastic, round, 500ml capacity. 21- Reagent Bottle plastic, natural color, screw cap narrow & wide neck capacity 50, 100, 250, 500 & liter assorted 22- Separating funnels conical shape, with stopper, 250 & 500 capacity 23- Thermometer mercury in glass -10 to 150°C 24- Petri dishes Pyrex Ø90mm 25- Test tubes soda lime glass 20x130mm 26- Durham tube rimless

6 6 6 each 2 each 12 each 12 each 12 each 12 each 24 12 12 6 30 30 10 2 24 12 2 12

each each each

each each each

100 12 each 4 30 200 200

V Chemicals 1. Ammonium acetate 6 kg 2. Ammonium chloride 1kg 3. Ammonium hydroxide 12 L 4. Acetic acid , glacial 6L 5. Barium chloride 1kg 6. Calcium chloride 1kg 7. Calcium carbonate I kg 8. Ethyl alcohol, absolute 12 L 9. Ferrochrome black T 25 g 10.Ethylene diamine tetra acetic acid di sodium salt 500 g 11.Ferrous , ammonium sulphate 1kg 12. Hydrixyl amine hydrochloride 1kg 13. Hydrochloric acid, cone 12 L 14. Methyl red 50 g 15.Methyl orange 100 g 16.Murexide 25 g 17.Methyl alcohol 6L 18.Magnesium sulphate heptahydrate 500 g 19.Mackonky Broth 12 kg 20.Nutrient Agar 6 kg 21.Nitric acid, cone 3L 22.Potassium permanganate 500 g 23.potassium chromate 100 g 24.Potassium hydroxide 1kg 148

Volume 1 General Specification Electro-Mechanical & Civil Works 25.Potassium iodide 26.Phenolphthalein 27. Phenanthroline, monohydrate 28.Sodium chloride 29.Sodium hydroxide 30.Sodium thiosulphate 31.Starch 32.Silver nitrate 33.Sulphuric acid, cone 34.Laboratory First Aid chart 35.Element Periodic Table

100 g 100 g 10 g 6 kg 6 kg 500 g 500 g 250 g 2L 1 1

VI FURNITURE Work Benches plinth mounting and wall fixing drawers and cupboards, as necessary according to laboratory plan. Rinsing Basin Unit stainless steel sink with all necessary water / waste fittings for cold / hot water. Fume cupboard with exhaust fan and all necessary water/ gas fittings, to be installed in chemical lab. Collection cupboard with two sliding doors suitable also for reagent storage Office desk with paneled kneehole. Rotating spindle type stool. Swivel type chairs with arm rests Titration Bench. Balance Table Poisons cupboard Wardrobe waste basins Metal window curtains as necessary Electric water heater, wall mounted, ~ 35 liters capacity Laboratory clock

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Qty. 2 Qty. 1 Qty 2 Qty 2 Qty 4 Qty 4 Qty 1 Qty 2 Qty 1 Qty 1 Qty 2 Qty 2

Materials, melamine plastics on face and reverse side red acid resistant tile for bench tops. TYPE B The Contractor shall include in his tender for the supply of the following water testing equipments required complete with 2 years necessary glass ware and chemicals. I. EQUIPMENT 1. 2. 3.

Laboratory turbidity meter HACH mode 2100 A or high equivalent with all necessary accessories. pH-meter 0-14 complete with electrodes stand & holder with 2 spare electrode. Laboratory Floc-tester worth six stirring units, rpm regulator, 0-200 rpm with necessary spare parts including drive belts 7 MOTOR. 149

Volume 1 General Specification Electro-Mechanical & Civil Works 4. 5. 6.

Conductivity-meter, measuring range 0-20 ms/cm complete with electrode stand holder and 2 spare electrodes. Water distilling apparatus Nessler lovibond with necessary discs & reagents for determination Cl2, Fe & Mn in water.

II FURNITURE 1. 2. 3. 4. 5. 6. 7. 8. 9.

Work Benches as necessary Rinsing Basin Collection cupboard Office desk Rotating spindle type stool Swivel type chair with arm rests Electric heater wall mounted Metal window curtains. Laboratory clock.

Qty 1 Qty 1 Qty 1 Qty 2 Qty 2 Qty 1

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE THIRTY SEVEN OPERATION & MAINTENANCE INSTRUCTIONS When general arrangements and details of the treatment plant have been approved and at least four months before erection the Contractor shall submit to the Engineer two metal covered sets of detailed operation and maintenance instructions in Arabic and in English. The instructions shall cover the main plant and all associated ancillary equipment as supplied under this part of the work. It will not be sufficient to incorporate manufacturer’s standard brochures as part of the instructions unless they refer particularly to the equipment supplied and are free extraneous matter. The information provided shall include essential flow and circuit diagrams, pipe work, general arrangement and detailed drawings of the installation, manufacturer of special materials where used and shall furthermore include schedules of lubricants and all ball and roller races employed on the plant. The drawings and diagram which may be approved shall be reduced to convenient size and bound. If the complete instructions are unduly be appropriately sub-divided and produced approved ten copies are to be handed to the the site and these are to be provided at least

bulky, then the manual is to in multi-volume form. Then Engineers for distribution on one month before erection.

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Volume 1 General Specification Electro-Mechanical & Civil Works CLAUSE THIRTY EIGHT PLANT OPERATION AND TRAINING OF OPERATORS The Contractor shall provide the required no. of skilled men for plant operation for 1 year continuous 24 hrs per day operation starting from PAC. For the second year the contractors shall be responsible for maintenance and supervision of the whole plant. During this second year period the Contractor is responsible for training the local staff. All spare parts used in the first year must be borne by the Contractor.

152