Specification - Pump Station

Exhibit II – Specifications and Contract Drawings
SPECIFICATION FOR PUMP STATION
SECTION 1
1.1 CODES, STANDARDS AND REGULATIONS
Unless otherwise specified, the work performed under this Contract shall comply in all
aspects with the current requirements of:
(a) Indah Water Konsortium.
(b) Occupational Safety and Health Act 1994.
(c) Factory and Machinery Act 1967 and Factory and Machinery (Safety, Health and
Welfare) Regulations 1970.
(d) The Regulations of Jabatan Keselamatan dan Kesihatan Pekerjaan.
(e) The Uniform Building By-Law 1984.
(f) Rules, regulations and requirements of Jabatan Bomba dan Penyelamat Malaysia.
(g) Building Operations and Engineering Construction (Safety) Regulation 1986.
(h) Electricity Supply Act 1990.
(i) The Regulations for the Electrical Equipment of Buildings (16th Edition) as issued
by the I.E.E., London.
(j) Tenaga Nasional Berhad.
(k) Syarikat Bekalan Air Selangor (SYABAS).
(l) Energy Commission.
(m) The relevant British Standards, Codes of Practice where applicable
(n) SPAN Guidelines For Developer.
1.2 SCOPE OF WORKS
The scope of works shall be as detailed in the Specification, Drawings and Bill of Quantities or
Schedule of Prices including
(a) Specified Mechanical and Electrical Works
(b) Submissions
(c) Testing and Commissioning
(d) Operation and Maintenance Training Program
(e) Warranty of Equipment and Systems
(f) Service and Maintenance during Warranty Period (defect liability period)
1.3 GENERAL REQUIREMENT ON PLANT AND INSTALLATION
In complying with the requirements of this Specification, the design and workmanship shall
conform to the best current Engineering practice. Each of the several parts of the Plant shall
be of the manufacturer's standard design while meeting the requirements of this Specification.
All similar parts of the Works shall be interchangeable.
The essence of design shall be simplicity and reliability to give long continuous and efficient
service with low maintenance cost. Particular attention shall be paid to internal and external
access in order to facilitate inspection, cleaning and maintenance.
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The design, dimensions and materials of all parts of the Works shall be such that they will not
suffer damage as a result of stresses under the most severe service conditions.
Fully detailed specification of the parts of the Plant shall be submitted with the factory working
drawings and erection drawings describing particularly the materials to be used.
The materials used in the construction of the Plant shall be of the highest quality and selected
particularly to meet the duties required of them. Materials which may be liable to attack by
termites or other insects shall not be used. Detachable parts shall be constructed to avoid
adhesion due to any cause.
The Plant shall operate without undue vibration and with the least possible amount of noise
such that nuisance is not created.
The Plant shall be designed to minimise the risk of fire and any damage which may be
caused in the event of fire.
The Plant shall be designed to prevent ingress of all vermin, accidental contact with live parts
and to minimise the ingress of dust and dirt.
Detailed planning and co-ordination by Contractor will be necessary to achieve a fully co-
ordinated and efficient installation particularly with regard to sequence of erection. Precise
positioning and handling of all items forming the total system having due regard to proper
access for ease of maintenance and replacement shall be undertaken.
1.4 SUBMISSIONS
The following submissions shall be forwarded to the CR for approval before the scheduled
dates indicated.
Item Submissions Submission Date Nos. of Copy

1. Builders’ Work and Drawings 4 Weeks After Award 4
2. Method Statements 2 Weeks After Award and 4

Progressively
3. Technical Data and Samples 2 Weeks After Award and 2

Progressively
4. Shop Drawings 8 Weeks Before 4

Commencement of each
Section of Work
5. Site Inspection and Test 6 Weeks Before 4

Procedures and Forms Commencement of Testing
and Commissioning
6. Factory Test Report for Major Before Shipment of 4

Equipment Equipment
7. Final Draft As Built Drawings 4 Weeks Before Testing 2

and Commissioning
8. Final As Built Drawings 2 Weeks After Completion Refer to Section

of Testing and 1.5.9
Commissioning
9. Testing and Commissioning 6 Weeks Before Testing 4

Procedures and Forms and Commissioning
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Item Submissions Submission Date Nos. of Copy

10. Testing and Commissioning 2 Weeks After Completion 4
Report of Testing and
Commissioning
11. Final Draft of O&M Manual 4 Weeks Before Testing 2

and Commissioning
12. Final O&M Manual 3 Weeks After Testing and 6

Commissioning
1.5 REQUIREMENTS AND CONTENTS OF SUBMISSIONS
1.5.1 General
The submissions shall contain no less than the information listed below. Additional
information may be included if deemed necessary.
1.5.2 Builder’s Work and Drawing
Within four weeks of acceptance of Tender, the Contractor shall submit four copies of fully
detailed and dimensioned drawings showing any necessary Builder’s Works required in
connection with the equipment together with full technical information to enable the
associated mechanical and electrical installation work to be checked or re-designed. Failure
to provide the correct information will result in the corrective work being carried out at the
expense of the Contractor.
1.5.3 Method Statements
List of Method Statements to be submitted:

a. Pump installation
b. Ventilation system (i.e. ducting and fan) installation
Each method statement shall include:
• Scope of works
• Reference to specification, code of practice and recognized Malaysian and
international standard.
• Step by step procedure in carrying out the works, and illustrate with sketches where
applicable.
• List of site inspection and test to be carried out and make reference to site inspection
and test procedures.
• Precautions in executing the works.
• List of tool and special equipment requirement in carrying out the work.
1.5.4 Technical Data and Samples
The Contractor shall submit complete information including fabrication, assembly, foundation
and installation data with detailed specifications and performance information covering
materials of construction, parts, devices, wiring diagrams and all other accessories of the
equipment furnished. The submissions shall include, but not limited to the followings:
• Tabulation of specification and technical data of equipment or material proposed with
respect to Contract Specifications.
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• Tabulation of motor rating and electrical data (where applicable)

• Legible English version of technical catalogs, literatures and performance curves to
substantiate the technical data of equipment proposed.
• Letter of approval from Authorities having jurisdiction over the works or equipment
(where applicable).
• Test report from independent laboratories (where applicable).
• Samples fastened or clamped onto a sample board.
• Pump characteristic curves showing:
- Plot flow, total dynamic head, brake horsepower, shutoff head, efficiency and
net positive suction head required for full operating range of pump.
- Recommended limits of continuous operation.
- Reflect operation with the specified fluid (e.g. include the effects of fluid
viscosity).
• Motor data, including:
- Manufacturer
- Minimum guaranteed efficiency
- Power factor at full load, ¾ load and ½ load.
- Locked rotor current
- Motor speed
1.5.5 Schedule of Shop Drawings Submission
The schedule of shop drawings submission for each service shall contain:-
• List of shop drawings to be submitted
• Planned submission date and actual submission date of each drawing
• Records of amendments and revisions to shop drawings
• Approval status of each drawing and date of approval.
The schedule of shop drawings submission shall be updated periodically.
1.5.6 Shop Drawings
The shop drawings shall include the following information:-

• Plan view showing the routing and level of services
• Sections showing the level of services, access to services, clearance for installation
and maintenance, and clearance for other services.
• Coordinated plans and sections indicating all services including clearance for
installation and maintenance.
• Tabulation of brand name, model no. and capacity of major equipment and
components.
• Schematic drawings showing the Mechanical and Electrical Systems and control
systems.
• Details of plinths, mounting brackets, thrust blocks, anchor bolts and supports.
• Non repeated drawing number and revision number
• Approved standard title block.
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1.5.7 Site Inspection and Test Procedures and Forms
The site inspection and test procedures and forms shall contain the following information:-
• Reference to specification, code of practice and Malaysian Standard or internationally
recognized standard.
• Step by step procedure in carrying out the inspections and tests.
• Criteria for passing the site inspections and tests.
• List of calibrated measuring instruments and gauges to be used.
• Site Inspection and Test Forms with the following information.
− Checklist of item of work to be inspected
− Column to enter test results
− Reference to shop drawings and/or construction drawings
− Space for signature by supervisor who conducts the inspection or test, CR who
endorses the inspection and test results and where applicable, owners’
representative who witnesses the tests
− Distribution list
− Date of inspection and test
− Non repeated inspection and test reference number.
1.5.8 Factory Test Report for Major Equipment
Factory test report for the designated equipment shall contain the following information:-
• Reference to specification and internationally recognised standards.
• Extract of relevant section of test standard
• Procedure in carrying out tests
• List of calibrated measuring instruments and gauges
• Calibration report for measuring instruments and gauges from recognised institute or
laboratory.
• A plot of measured performance data against manufacturer’s published performance
curves.
• Signature of manufacturer’s CR who conducted the test.
• Signature of CR and the Owner’s representative who witnessed the tests (if
applicable).
• Sketches, drawings or photographs showing the set-up of measuring instrument,
gauges and equipment under test.
1.5.9 As Built Drawings
The requirement for as built drawings shall be

• Same requirement for shop drawings and to incorporate all amendments made during
construction.
• One true to scale translucent print on ammonia film of 0.03mm thickness.
• Two CD ROMs using Autocad Version 2010 or higher.
• Six paper prints (in A1).
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1.5.10 Testing and Commissioning Procedures and Forms
Testing and Commissioning procedures shall include:-

• Reference to specification, code of practice, Malaysian Standard or internationally
recognised standard.
• Sketches and drawings indicating the set-up of measuring instrument and gauges.
• Step by step procedure in carrying out the tests.
• List of calibrated measuring instruments and gauges.
• List of tests to be carried out for each equipment or sub-system.
• Acceptable tolerance for field measured data.
• Criteria for passing tests.
Testing and Commissioning Forms shall be provided with the following information:-
• Specification performance data for equipment and sub-system
• Checklist for functional test
• Column for entering field measured data and operating parameter.
• Column for remarks and details of deficiency.
• Space for signature by supervisor who conducted the tests, CR who endorsed the
test results and where applicable the owner’s representative who witnessed the tests.
• Distribution list
• Date of test
• Non repeated test reference number.
1.5.11 Testing and Commissioning Reports
The testing and commissioning reports shall include:-

• Directory identifying the organization of the testing and commissioning reports in
systematic and logical order.
• Approved testing and commissioning procedures.
• Calibration reports of measuring instruments and gauges from recognized institution
and laboratory.
• Sketches, schematic, drawings and photograph showing the set-up of measuring
instruments and gauges.
• Endorsed copy of testing and commissioning forms.
• Explanation of variance of final measured data and designed value.
1.5.12 Operation and Maintenance Manuals
The complete O&M Manual shall comprise the following documents:-

• Directory identifying each section of the document.
• Emergency and agency notification procedures.
• Operating Manual containing information on
− Building function
− Building description
− Operating standards and logs
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− System description
− Operating routine and procedures
− Special procedure (if any)
− Basic trouble shooting procedure
• Maintenance Manual Containing
− Equipment data sheet and list of suppliers
− Information on warranty
− Installation, operation and maintenance instructions
− List of spare parts
− Preventive maintenance actions
• Test reports documenting set points and observed performance during start up and
commissioning.
• Manufacturers’ technical literature comprising performance curves, technical catalogs
and technical information.
1.6 TOOLS, APPLIANCES AND TEST EQUIPMENT
Each tool, appliance and test equipment required to be supplied shall be marked clearly
indicating its size and intended purpose and shall not be used in the erection of the Plant.
Factory certificates shall be provided.
Contractor shall demonstrate to CR, the use of the tools, appliances and test equipment and
trouble shooting and maintenance procedures before the tools and appliances are taken over
by the Employer. All tools and appliances shall be placed in appropriately labelled storage
boxes and shall be supplied complete with accessories including probes and power leads.
1.7 OPERATIONS AND MAINTENANCE TRAINING PROGRAM
1.7.1 Objective
The objective of the O&M training program is to provide the staff of building owner with the
knowledge to operate and maintain building system in accordance with design intent,
manufacturers’ recommendations, and procedures contained in the O&M Manual. Lecture
notes shall be supplied for the training.
1.7.2 Scope of Training
The training program shall furnish a thorough understanding of all equipment, components,
systems, and their operation. The training shall include the following topics.
(a) Use of O&M Manual with an emphasis on
• Design intent
• Description, capabilities, and limitation of the systems
• Operation procedures for all modes of operation
• Procedure for dealing with abnormal conditions and emergency situation
• Use of operation manuals
• Use of maintenance manuals
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(b) Recommended procedures for collecting and interpreting specific performance

data.
(c) Specialized manufacturers’ training programs.
1.8 ABBREVIATIONS
The following abbreviations shall have the respective meanings assigned to them:
' - minute
% - percent
RM - Ringgit Malaysia
amp - amperes
AC - alternating current
AISI - American Iron and Steel Institute
AMF - Automatic Mains Failure
ASHRAE - American Society of Heating, Refrigerating and Air-
conditioning Engineers
AVR - Automatic Voltage Regulator
ACB - air circuit breaker
Bomba - Jabatan Bomba dan Penyelamat Malaysia
BS - British Standard
cd - candela
CIE - International Commission of Illumination
CP - Codes of Practice
dB - decibel
DB - distribution board
DC - direct current
DF - distribution frame (Telekom)
DOE - Department of Environment
ELCB - earth leakage circuit breaker
fluo - fluorescent
g - gram
hr - hour
HT - High Tension (11 kV)
Hz - hertz
HPSV - high pressure sodium vapour
HRC - High rupturing capacity
HRCQ - heat resistant cold quenched
ICAO - International Civil Aviation Organisation
IDMT - Inverse Definite Minimum Time
IEC - International Electrochemical Commission
IEE - Institute of Electrical Engineers, UK
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JPP - Jabatan Perkhidmatan Pembetungan

kA - kiloampere
kg - kilogram
kHz - kilohertz
km - kilometer
kPa - kilopascal
kW - kilowatt
kV - kilovolt
kVA - kilovolt ampere
LV - low voltage
TMB - Telekom Malaysia Berhad
TNB - Tenaga Nasional Berhad
l - litre
m - meter
2
m - square meter
m3 - cubic meter
mA - milliampere
mm - millimeter
mm2 - square millimeter
M&E - Mechanical and Electrical
MCB - Miniature circuit breaker
MCCB - moulded case circuit breaker
MSB - main switchboard
MCSC - moving coil with shunt circuit
MHz - megahertz
MICC - mineral insulated copper cladded
No - number
NFPA - National Fire Protection Association
o - degree
o
C - degree Celsius
PA - Public Address Systems
PCB - printed circuit board
PILCSWA - paper insulated lead covered steel wire armour
PVC - polyvinylchloride
Qty - quantity
r.m.s - root mean square
RPM - revolutions per minute
SDF - Subscriber Distribution Frame
SF6 - sulphur hexafluoride gas
SWA - steel wire armoured
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SWG - Standard Wire Gauge

SSB - sub-switchboards
SSO - switch socket outlet
TEFC - totally enclosed fan cooled
V - volt
VCB - vacuum circuit breaker
W - watt
XLPE - Cross link polyethylene
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SECTION 2
2.1 GENERAL
2.1.1 Packing
Each Plant shall be packed properly and protected for transport from the place of manufacture
to the Site. The packing and protection used shall remain good for a period of at least 6
months after delivery to Site.
Ends of tubes and other similar open ends shall be protected from external damage and
ingress of dirt and moisture during transit and before erection. Open ends of flanged pipes
shall be protected by adhesive tape or jointing and covered with a wooden blank flange
secured by service bolts.
Precautions shall be taken to protect shafts and journals resting on supports. At support
points, wrappings impregnated with suitable anti-rust compounds or vapour inhibitors shall be
used to resist chafing and indentation due to movement.
For ball or roller bearings installed in any of the Plant, Contractor shall before such plant is
transported, submit to the Engineer for approval the precautions to be taken to prevent
indenting the bearing faces.
Contents of packings shall be bolted securely or fastened in position with struts or cross
battens. Where wood chocks are used, they shall be fastened firmly in place. Where parts are
required to be bolted to the sides of the packings, large washers shall be used to distribute
the pressure. The struts and battens shall be strengthened by means of a pad. Cases shall be
up-ended after packing to demonstrate that there is no movement of the contents.
Waterproof paper and felt linings shall overlap at seams of at least 12mm width and the
seams shall be secured together in an approved manner. Such paper and felt wrappings shall
have screened openings for ventilation purposes.
Where practicable, all indoor items such as electric motors, switches and control gear,
instruments and panels, machine components and the like shall be "cocooned" or covered in
polyethylene sheeting, sealed at the joints and the enclosure provided with an approved
desiccator.
All packings shall be clearly marked on the external surface to show the total weight, the
points where the weight is bearing, and the correct position where slings are to bear. An
identification mark relating them to the appropriate shipping documents and packing list shall
also be marked. All marks shall be of a waterproof material. Otherwise they shall be
protected by shellac or varnish to prevent obliteration.
Hoop bindings of packings shall be sealed where ends meet and shall be painted if the
material is susceptible to corrosion.
Each packing shall have a packing list in a waterproof envelope and copies in triplicate shall
be forwarded to the Engineer at least 3 weeks before arrival of the respective packing on Site.
Before transportation to Site, each packing shall be treated with an approved fungicide.
Sleeving and fabrics treated with linseed oil or linseed oil varnishes shall not be used.
Engineer shall have the right to inspect and approve the packings before the packings are
transported but such inspection and approval shall not relieve Contractor of his obligations
and liabilities under the Contract.
2.1.2 Erection Marks on Multipart Assemblies
All plant comprising multipart assemblies such as steel frameworks and pipe installation shall
be marked with distinguishing numbers and/or letters corresponding to those shown on the
approved Contractor's Drawings or material lists. These erection marks, if impressed before
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painting or galvanising, shall be clearly legible after painting or galvanizing.
2.1.3 Cleaning, Protection of Surfaces and Painting
All bright metal parts shall be covered before shipment with an approved protective
compound and protected adequately during transportation to Site. After erection, these parts
shall be cleaned with a suitable solvent and the metal parts polished bright.
All metal work to be painted, except where the finish painting or polishing is to be completed
in the factory, shall be well brushed down and given one coat of red lead paint before
transportation to Site.
All parts which will be buried in concrete, shall be cleaned and protected by a cement wash or
other approved method before transportation to Site. Before being built into the concrete,
these parts shall be thoroughly desiccated and cleaned of all rust and adhering matter.
Where two finishing coats of paint are specified, the first coat shall be of a different shade
from the second. Where aluminium paint is specified, the undercoat shall be slightly coloured
by the addition of washing blue.
Interiors of tanks and similar containers shall be thoroughly cleaned by shot blasting or wire
brushing before painting. Fuel tanks shall be corrosion free and left untreated internally.
Tanks to store other oils shall be painted with a suitable oil resisting varnish or enamel.
The interior of outdoor control cubicles, cabinets and the like where condensation is liable to
occur shall be coated with an approved anti condensation compound.
2.1.4 Lubrication
The Works shall include the supply of the oil required for flushing each lubrication system and
the first filling of approved lubricants.
A schedule of the oils and other lubricants recommended by the manufacturer for all
components of the Plant shall be submitted to the Engineer for approval. The types of
lubricants shall be kept to a minimum and must be readily obtainable in Malaysia. A copy
each of this schedule shall be included in each of the draft and final Operation and
Maintenance Manuals. For grease lubricated roller bearings of electric motors, lithium grease
shall be used in preference over other grease if it is one of the grease types recommended by
the manufacturer of the bearing.
Contractor shall supply at least one grease gun for each category of nipple provided. Where
more than one type of grease is required, a grease gun for each grease type shall be supplied
and the gun permanently labelled accordingly.
2.1.5 Rating Plates and Name Plates
Each of the Plant shall have a rating plate permanently attached to it in a conspicuous
position. The rating plate shall be of a durable and corrosion resisting material and shall be
engraved with identifying name, type or serial number together with details of the loading
conditions under which the plant has been designed to operate and such diagram as may be
required by the Engineer.
2.1.6 Locks
Locks shall be of the Yale brand or approved equivalent. Three keys shall be supplied for
each lock and all locks shall not be interchangeable. Where a set of locks is provided under
any particular section of a plant, a group master key shall be supplied as well.
All locks shall be of brass. Where fitted to doors, locks shall be chromium plated.
Locks shall be designed, constructed and located on the Plant so that they remain
serviceable in the climatic conditions specified without operation or maintenance for two
years.
Where a group of locks are supplied with any of the Plant, a rack or cabinet of approved
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design shall be supplied to house the padlocks and/or keys not in use. The locks and keys
shall be engraved with a suitable identifying code and this identifying code shall be displayed
on the racks or cabinets on engraved labels attached thereto.
2.1.7 Protection of Materials Against Weather
In choosing materials and their finishes, due regard shall be given to the humid tropical
environment under which the Plant will work.
(a) Metals
Stainless steel shall be used to the extent possible. Iron and mild steel shall be
painted or galvanized as appropriate in accordance with Sub-Clauses 2.1.3 and
2.2.5 of this Specification. Indoor parts may have chromium or copper-nickel
plating or other approved protective finish. Small iron and steel parts (other than
steel not susceptible to corrosion), the cores of electromagnets and the metal
parts of relays and mechanisms shall be treated in an approved manner to
prevent corrosion. Cores and the like which are built up of laminations or cannot
for any other reason be treated against corrosion, shall have all exposed parts
thoroughly cleaned and heavily enamelled, lacquered or protected.
Where different metals are in contact, they shall be selected so that the potential
difference between them in the electro-chemical series is not greater than 0.5V.
Otherwise, the contact surfaces of one or both of the metals as appropriate shall
be electroplated or finished in such a manner that the potential difference is
reduced to within the required limits. Where practicable, the two metals may be
insulated from each other by an approved insulating material or a coating of
approved varnish compound.
(b) Screws, nuts, springs, pivots, etc.
The use of iron and steel shall not be used in instruments and electrical relays
unless otherwise approved. Steel screws, if approved for use, shall be zinc,
cadmium or chromium plated. If plating is not possible due to tolerance
limitations, the iron or steel shall be corrosion-resistant. All screws in timber shall
be of dull nickel plated brass or of other approved finish. Screws for instruments,
except those forming part of a magnetic circuit, shall be of brass or bronze.
Springs shall be of corrosion resistant material such as phosphor-bronze or nickel
silver.
(c) Adhesives
Adhesives shall be impervious to moisture and resistant to growth of fungus and
ravage by insects.
(d) Rubber
Neoprene and similar synthetic compounds not subjected to deterioration under
the climatic conditions of the Site shall be used for gaskets, sealing rings and
diaphragms.
Variation from the above provisions may be permitted where tropical grade
materials are not available provided the Plant is hermetically sealed.
2.1.8 Labels
Labels shall be provided to identify all items of equipment, circuits, cables and where
applicable, current rating of fuses and setting of relays, Labels on the exterior of equipment
shall be clear perspex, reverse engraved, filled flush with black (or red as suitable) filling and
the back portion painted the same colour as the equipment. Labels shall be attached by
means of machine screws and nuts or machine screws driven into drilled and tapped holes.
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2.2 MECHANICAL
2.2.1 Nuts, Bolts, Studs and Washers
Nuts and bolts for incorporation in the Works shall conform to the requirements of the
appropriate BS. Unless otherwise approved, bolt heads and nuts must be of hexagon head
and bolt heads shall not be welded to the shanks.
Washers, including tape washers, locking devices and anti-vibration provisions, shall be
provided where necessary.
Nuts and bolts for pressure parts shall be of the best quality bright stainless steel, machined
on the shank and under the head and nut.
All bolts, nuts and washers of outdoor plant in contact with non- ferrous parts shall be of
corrosion-resistant material.
Bolts fitted on Site shall have a driving fit in the reamed holes they occupy and the threaded
portion shall have a diameter that will not be damaged during driving and shall be
conspicuously marked to ensure correct assembly at Site.
Stud holes in any Plant which are subjected to heat during operation shall be adequately
vented.
Bolts and studs shall be finished flush with the surface of the nuts.
2.2.2 Forgings
All shaft and rotor forgings in excess of 150mm diameter shall be examined for flaws and
subjected to heat treatment for the relief of residual stresses.
All major forgings, may be examined at the manufacturer's works by the Engineer during
forging and heat treatment. The equipment required for the detection of defects by the latest
methods shall be provided by Contractor.
2.2.3 Castings
All castings shall be free from blowholes, flaws and cracks as is practicable. No welding,
filling or plugging of defective parts is permitted without the approval of the Engineer.
2.2.4 Weldings
Where fabrication welds are liable to be highly stressed, such as in pressure parts or those
subjected to rotational stresses or reversal of stresses in operation, Contractor shall supply
the Engineer with four (4) copies general arrangement drawing of the related work and, at a
later date but at least six (6) weeks before fabrication commences, a detailed drawing of all
proposed welds.
All tests shall be carried out in accordance with the relevant British Standards. Mechanical
tests shall be carried out as required. Non-destructive examination shall be by radiographic
means in accordance with BS EN 1435 1997. The exposed negatives shall be made
available to the Engineer.
2.2.5 Galvanising
Galvanising shall conform to BS EN ISO 1461 : 1999.
2.2.6 Floor Collars, Wall Boxes and Weathering
At all points where pipes pass through floors or walls, suitable cast iron floor collars or wall
boxes shall be provided and fixed. Wall boxes shall be flush with the floor or wall and shall be
of a neat design and approved finish.
All other necessary fittings for the passage of pipes through external walls together with the
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supply and fixing of all necessary components shall also be provided for protection against
weather of such holes in an approved manner.
For flanged pipework, boxes shall be large enough to permit the passage of the flange.
2.2.7 Pipe Supports
All pipework and accessories shall be supported and mounted in an approved manner. All
necessary slings, saddles, structural steelwork, foundation bolts, fixing bolts and all other
required attachments shall be provided.
No point of passage of pipes through floors or walls shall be used as a support.
All valves and the like shall be independently supported.
2.2.8 Chromium Plating
Chromium plating shall comply with BS EN 12540 : 2000.
2.2.9 Heat Insulation
All exposed surfaces which normally exceed 75oC during operation shall be properly guarded
or lagged.
2.3 ELECTRICAL
2.3.1 Earthing
Each of the Plant in or on which is fitted any electrical equipment shall be provided with an
earthing terminal, suitable for connection by means of copper strip or of stranded copper
conductor to the earthing system. The provisions for earthing shall be such that no reliance is
placed on the conductivity of metal to metal joints without the use of special connectors.
2.3.2 Electrical Insulation
All insulating materials shall be suitably finished so as to prevent deterioration of their

qualities under the specified working conditions.
Ebonite, synthetic resin-bonded laminated material and bituminized asbestos cement-bonded
panels shall be of a suitable quality selected from the grades or types specified in the
appropriate BS.
All cut or machined surfaces and edges or resin-bonded laminated materials shall be cleaned
and sealed with an approved varnish as soon as possible after cutting.
Instruments, apparatus and machine coil windings, including wire wound resistors, with the
exception of those immersed in oil or compound, shall be thoroughly dried in a vacuum or by
other approved means and then immediately impregnated through to the core with an
approved insulating varnish. Varnish with a linseed oil base shall not be used. Coils which
cannot be varnish impregnated shall be impregnated with an approved wax compound.
Paraffin wax or compounds containing paraffin wax shall not be used. The coils shall be
covered before and after impregnation with a lapping of cotton or silk, or thread in the case of
coils too narrow for tape, or covered by a sheet of suitable synthetic material. The
impregnated coils shall finally be covered with an impervious enveloping varnish or given a
dip coat of wax depending on whether they are varnish or wax impregnated. Coils
impregnated with compound may be finished with compound sheet or tape.
Paper or other material of a hygroscopic nature shall not be used to cover coils. Where inter-
leaving between windings in coils is necessary, the best thoroughly dried manila paper which
permits penetration by the insulating varnish or wax shall be used.
The insulation of all machine windings, solenoids terminal boards, and the like, other than
those immersed in oil or compound, shall be of BS 2757, Class B materials unless otherwise
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specified.
All windings of machines shall be adequately braced and laid in micanite slot linings suitably
protected by an approved non-hygroscopic material.
2.3.3 Electrical Instruments and Meters
All electrical instruments and meters shall comply with BS EN 60051-1:1999 and, unless
otherwise specified, shall be of industrial grade accuracy. Three-phase power measuring
instruments shall be of the 3-phase unbalanced load pattern wherever the current and voltage
referenced permit.
Unless otherwise specified, all indicating and recording instruments shall be of the flush-
mounting pattern with dust and moisture-proof covers.
Instrument dials shall not be less than 96mm x 96mm and shall be white with black markings
unless otherwise approved.
Scales shall be of such material that no peeling or discolouration will take place with age
under humid tropical conditions.
The movements of all electrically actuated instruments shall be of the dead-beat type.
Wherever necessary, instruments shall be provided with readily accessible zero adjustment.
All integrating watt-hour meters shall be of an approved switchboard pattern coloured black
unless otherwise specified, and selected to give the grade of metering specified. They shall
be single directional and shall be fitted where required with suitable contacts for DC
impulsing.
Meters shall be calibrated to the appropriate grade in BS 5685 and due allowance shall be
made in such calibration for the errors in the instrument transformers to be used in service.
Ammeters shall be fitted with maximum demand indicators.
2.3.4 Small Wiring
All control-panel wiring and secondary wiring in circuit breakers, motor starters, control gear
and the like shall be carried out in a neat and systematic manner with cables supported clear
of the panels and other surfaces at all points to obtain free circulation of air.
In all cases, the sequence of the wiring terminals shall be such that the junction between
multicore cables and the terminals is effected without cross over. Insulating bushes shall be
provided where necessary to prevent the chafing of wiring.
All panel wiring shall conform to Type A or Type B of BS 6231, as appropriate. The
conductors shall have a minimum cross sectional area equivalent to 7 strands of 0.67mm
diameter.
Wire colours shall comply with the following:
Colour of Wire Circuit Particulars
Red Red-phase connections in current and voltage
transformer circuits only.
Yellow Yellow-phase connections in current and voltage
Blue Blue-phase connections in current and voltage
Green and Yellow Connections to earth.
Black AC neutral connections, earthed or unearthed,
connected to the secondary circuit of current and
voltage transformers.
Grey Connections in DC circuits.
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Wiring diagrams must indicate wire colours. For back-wired panels, all diagrams shall be as
viewed from the back of the panel. For front-wired panels, all diagrams shall be as viewed
from the front. Wiring diagrams must state the highest number in any group.
All wires shall be fitted with numbered ferrules at each termination. At points of
interconnection between wiring where change of numbering cannot be avoided, double
ferrules shall be provided. Such points shall be clearly indicated on the wiring diagrams.
The ferrules on all wiring directly connected to circuit-breaker trip coils, tripping switches and
the like shall be of a colour, preferably red, different from that of the remainder and marked
"trip".
Wires shall not be teed or jointed between terminal points.
Bus wiring between control panel and the like shall be provided and shall be fully insulated
and completely segregated from the main panel wiring.
All metallic cases of instruments, control switches relays and the like mounted on control
panels or in cubicles, steel or otherwise, shall be connected by means of bare copper
conductors of not less than 4mm 2 in cross-section to the nearest earth bar.
2.3.5 Fuses and Links
All fuses and links associated with electrical instruments, protection and control circuits shall
be of approved type and grouped as far as possible according to their functions and clearly
labelled, both on the panels and associated wiring diagrams.
Fuses and links shall be connected to enable all or any of the control circuits to be isolated for
maintenance purposes.
Fuses and links associated with tripping circuits shall preferably be mounted on the outside of
the control panels in approved positions, whilst the remainder shall be internally mounted.
All fuses shall be high rupturing capacity (HRC) cartridge type in accordance to BS 88, with
class 'Q' fusing factor. Rewireable fuses shall not be accepted.
Carriers and bases for fuses shall be black.
2.3.6 Control Switches and Pushbuttons
Control switches for electrically operated circuit breakers shall be pistol-grip type arranged to
operate clockwise when closing the circuit breakers and anti-clockwise when opening them.
They shall be designed to prevent accidental operation and interlocked to prevent two
successive operations in the "close" direction.
Switches for the other apparatus shall be operated by shrouded pushbuttons or handles of
the spade type, the pistol-grip type being restricted for circuit breaker operations only. Control,
reversing selector, and test switches shall be mounted, constructed and wired so as to
facilitate maintenance of contacts without the necessity for disconnecting wirings.
Control switches for circuit breakers and for motor-operated setting devices shall be non-
locking type with spring return to the 'neutral' position, and such control switches shall be
controlled by independent springs. Contact springs shall not be used alone.
All pushbuttons shall be non-retaining type made of non-hygroscopic material, non-swelling
and fitted to avoid any possibility of sticking.
The contacts of all switches and pushbuttons shall be strong, silver- plated, self-cleansing
when operated so as to provide a reliable below-resistance path even at low voltage.
All control switches shall be provided with labels complying with Clause 2.1.8 of these
Specifications, in addition to clear indication as to the direction of each operation, for
example, "open", "close", "raise" and "lower".
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2.3.7 Indicating Lamps and Fittings
Indicating lamps fitted to the facias of switch and instrument cubicles or panels shall be
adequately ventilated. Back-indicating lamps shall be easily removed and replaced from the
front of the panel by manual means not requiring the use of extractors.
The bezel of metal or other approved materials holding the lamp glass shall be of an
approved finish and easily removable from the fitting so as to permit access to the lamp and
lamp glass.
The lamps shall be installed in an accepted standard form of lamp holder. The rated lamp
voltage shall be at least 4% in excess of the auxiliary supply voltage, whether AC or DC.
Alternatively low voltage lamps with series resistors shall be acceptable.
The lamps shall be of standard colour of red, green, blue, white and amber and shall be in the
glass and not on applied coating. Transparent synthetic materials may be used instead of
glass.
All lamp colours shall conform to the following:
Red - energised or operative position
Green - unenergised or inoperative position
Amber - fault or abnormal condition
White - healthy or normal condition
Blue - signal used with label
2.3.8 Auxiliary Switches
Each Plant shall be equipped with all necessary auxiliary switches, contactors and
mechanisms for indication, protection, metering, control, interlocking supervisory and other
services. All auxiliary switches shall be wired up to a terminal board on the fixed portion of
the plant, whether they are in use or not.
All auxiliary switches and mechanisms shall be mounted in approved accessible positions
clear of the operating mechanisms and shall be protected in an approved manner. The
contacts of all auxiliary switches shall be strong and shall have a positive wiping action when
closing.
2.3.9 Anti-Condensation Heaters
Any major item of electrical equipment which are liable to suffer from internal condensation
due to atmospheric or load variations shall be fitted with heating devices suitable for electrical
operation at 50Hz single-phase 240V AC of sufficient capacity to raise the internal ambient
temperature by 5oC. The electrical apparatus so protected shall be designed so that the
maximum permitted rise in temperature is not exceeded if the heaters are energised while the
apparatus is in operation. Where heaters are fitted, a suitable terminal box and control
switch, with indicating lamps, shall be provided and mounted in an accessible position. All
such equipment, whether fitted with a heating device or not, shall be provided with suitable
drainage and shall be free from pockets in which moisture can collect.
2.3.10 Cable Boxes and Glands
Electrical equipment shall be fitted with approved cable boxes and brass glands, complete
with all necessary fittings.
Provision shall be made for earthing the body of each cable box.
Where cable boxes are provided for 3-core and 4-core cables, the sweating sockets on the
two outer phases shall be inclined towards the centre to minimise bending of the cable cores.
For XLPE/PVC insulated and sheathed power cables, controlled brass compression glands of
an approved type shall be provided. Where such cables have armouring and an outer
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sheath, the gland shall be of the type which grips each sheath and the armouring separately.
Glands shall be arranged to project at least 25mm above the gland plate to avoid moisture
collecting in the cable circuit.
2.3.11 Contactors
Contactors shall comply with BS EN 60947-4-1 with uninterrupted ratings UR mechanical duty
Class II and making and breaking category AC3, as appropriate.
Both the main and auxiliary contacts shall be renewal type, solid copper, hard silver-faced
shrouded and designed to ensure effective freedom and contact bounce and adhering of the
fixed and moving portions of the magnet assembly. Auxiliary contacts shall be provided for
control and indication. Contactor coils shall be fully tropicalised and wound for continuous
operation at phase voltage with Class ‘E’ insulation as specified in BS 2757.
In cases where contactor-control current may be energised by interlocking connection with
other circuits, conspicuously mounted warning labels or other approved means shall be
provided to ensure that such interlocking connections are isolated by the operation of the
appropriate selector switch to the current position. Pairs of contactors for reversing switches
shall be electrically interlocked.
Changeover contactors shall be interlocked both mechanically and electrically.
The contactor shall be located within the enclosure so that upon making or opening of the
contactor under normal or fault conditions, damage will not be caused to other equipment and
wiring within the enclosure.
Contactors equipped with both local and remote control shall have local/remote changeover
switches capable of being locked in either position.
2.3.12 Protective and Control Relays
All relays shall be of the heavy duty BPO 3000 pattern and fully tropicalised.
Relays which provide different modes of operation and are common to one particular circuit
shall be grouped conveniently in a dust-proof metal cabinet with removable hinged covers
giving access for adjustment and clearing without dismantling the relay.
Each relay shall be provided with clearly inscribed labels describing its application and rating
in addition to the general purpose labels.
Means shall be provided on the relay panels for the testing of protective relays.
2.3.13 Moulded Case Circuit Breakers (MCCB)
All moulded case circuit breakers shall comply with the requirements of BS EN60947-2:1996
and shall be of the current limited type. Unless otherwise stated, the AC rated short-circuit
capacity shall be:
• 10kA for standard rated currents up to and including 30 amp.
• 22kA for standard rated currents up to and including 400 amp.
• 45kA for standard rated currents greater than 400 amp.
The MCCB shall incorporate a time delay device to ensure that it will tolerate harmless
transient overload unless this is well in excess of 25% of its rated value for a sustained
period.
The MCCB shall be able to isolate the fault instantaneously for short circuit current of the
order of six to ten times the normal load current.
MCCB shall employ silver tungsten contacts of the high pressure, butt type, ensuring cool
operation at full load and shall be equipped with de-ionizing arc chutes for the rapid extinction
of arcing occurring during overload operation. The breaker shall be operated by a toggle- type
handle lockable at "Off" position and having a quick-make, quick- break mechanisms and
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shall be mechanically trip free from handle to ensure that the contacts cannot be held closed
against short circuit and abnormal current. Visual indication of the "OFF", "TRIPPED" and
"ON" positions, phase identification colours and appropriate labels shall be provided and shall
be able to incorporate auxiliary switch under-voltage release and shunt-trip unit, if required.
Sample of MCCB shall be submitted to the ENGINEER for approval before fabrication of
switchboards.
Units shall be complete with bolted-type neutral link, links for both supply neutral connection
and earthing, screening shutters actuated automatically with the circuit breaker isolated and
withdrawn and capable of padlocking in such position, SN auxillary switches independently
adjustable for N/O or N/C automatic release coils and manual tripping device.
2.3.14 Miniature Circuit Breakers
Miniature circuit breakers (MCB) shall comply with BS EN60898:1991 and shall have
breaking capacity not less than 6kA (rms) and of B-type with Class 3 energy limiting
characteristics.
The mechanism of the MCB, shall provide positive closing and trip-free action. On the dolly of
the MCB, the words 'ON' and 'OFF' shall be clearly engraved such that only one indication is
visible at any one time.
The MCB shall incorporate a thermal and/or magnetic overload unit which shall be sealed at
the factory.
The contacts shall be of high conductivity copper with silver plated tips.
2.3.15 Air-Circuit Breakers (ACB)
Air-circuit breakers shall be certified by an independent short-circuit testing authority as being

suitable for a rated short-circuit current of 41kA with a short-time rating of 3 seconds at 415V.
The ACB shall be manufactured in accordance with BS EN60947-2.
Units shall be capable of being independently and manually operated and of the horizontal
draw-out isolation type so arranged that they may be completely isolated from the incoming
supply and busbars except that secondary circuits shall not be broken with the circuit breaker
in the isolated position in order to permit test tripping and the like.
Closing mechanisms shall be of the trip-free type and incorporate "ON/OFF" and
"ISOLATED/PLUGGED" indicators and mechanically interlocking to prevent:
(a) Withdrawal or plugging of the circuit breaker in the closed position.
(b) Closure unless either fully plugged or fully isolated.
(c) Opening of cubicle door until breaker is isolated.
(d) Plugging-in until the cubicle door has been closed and locked.
Units shall be complete with bolted-type neutral link, with links for both supply, neutral
connection, and earthing; screening shutters actuated automatically with the circuit breaker
isolated and withdrawn and capable of padlocking in such position; six auxiliary switches
independently adjustable for normally open (N/O) or normally closed (N/C); automatic release
coils; and manual tripping device.
2.3.16 Current and Voltage Transformers
Current and voltage transformers shall comply with BS EN 60044-1:1999 and BS EN 60044-
2:1999 as appropriate. They shall be housed or accommodated to suit their particular duties.
All current and voltage transformers shall be capable of withstanding short circuit current
specified for switchgear assembly.
Secondary windings shall be wired to front-of-panel test terminal boards and earthed at one
point in the circuit, to facilitate secondary injection tests.
All transformers shall be provided with an identifying label giving type, ratio, class, output and
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serial number.
2.3.17 Overcurrent and Earth Fault Inverse Time Protection
Relays shall be of the microprocessor based, inverse time overcurrent type.

Overcurrent elements shall be supplied with adjustable settings for both operating current and
time, the design of the relays being such that the adjustment can be carried out on-load. The
range of current setting adjustment for phase faults shall be 50% to 200% of the rated full
load and time setting multiplier shall be over the range of 0.05 to 1.0. The current/time
characteristics of the relays shall be in accordance with the four inverse time characteristics of
IEC 255.
Inverse time earth fault elements shall comply with the foregoing but shall be continuously
adjustable from 10% to 40%.
Earth leakage relay ELR shall be of the type suitable for use on a 240/415V, 50Hz a.c.
system and up to ambient temperature of 40 C comply with BS EN 61008-1 and 61008-2.
ELR shall be provided with test button for simulation of a fault, earth leakage LED indicator
and protection against nuisance tripping due to transient voltage and d.c. sensitive. For
adjustable sensitivity and time delay type, selectivity range for sensitivity shall be 30mA,
100mA, 300mA, 500mA and 1000mA and the time delay selectivity range of 0 s to 1 s. ELR
shall incorporate with matching balanced core current transformer and shunt trip coil for the
circuit breaker to which it controls the tripping shall also be provided.
The microprocessor based protection rlays shall be rated 240V/415V and operating voltage
shall be in a range from 90V to 250V. The relays shall be housed in robust panel flush
mounting case to IP 54 and shall be fully trolpicalised and suitable to be used up to an
ambient temperature of 50 C and relative humidity of 95%.
2.3.18 Residual Current Operated Circuit Breakers
Residual current operated circuit breakers without integral overcurrent protection (RCCB) and
residual current operated circuit breakers with integral overcurrent protection (RCBO) shall be
current operated functionally independent of line voltage type, suitable for use on a 240/415V,
50Hz. a.c system and up to an ambient temperature of 40 C. RCCB shall comply with BS
EN61008-1 and 61008-2-1 and RCBO shall comply with BS EN 61009-1 and 61009-2-1.
They shall be of either two-pole or four-pole type as indicated in the Drawings. The rated
current and the rated residual operating current of the RCBO shall be as specified in the
Drawing. For RCBO, protection against overcurrent shall be B-type with Class 3 energy
limiting characteristic comply with BS EN 60898, and shall have breaking capacity of not less
than 6 kA.
RCCB and RCBO shall provide resistance against nuisance tripping due to an impulse
voltage or transient overvoltage.
Test push button and visual indication for ‘ON’ and ‘OFF’ or ‘I’ and ‘0’ shall be provided. They
shall be equipped with screw clamping type of cable terminals, which shall be covered by
moulded phonolic plastic with knockouts for cable entry.
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SECTION 3
3.1 GENERAL
3.1.1 Description
These Mechanical Equipment Provisions apply to all mechanical systems and equipments.
3.1.2 Manufacturer's Experience
Unless specifically named in the detailed specifications, a manufacturer shall have

furnished equipment of the type and size specified and the equipment shall have been
successfully operated and be in regular use in similar applications.
3.1.3 Factory Inspection
The Engineer or his representative may inspect fabricated equipment at the factory without
cost to the Contractor. The Engineer or his representative will notify the Contractor in
sufficient time so that the factory inspection can be arranged. Factory inspection will be
made after the manufacturer has performed satisfactory checks, adjustments, tests and
operations. Approval of equipment at the factory only allows the Manufacturer to ship the
equipment to the site, and does not constitute final acceptance by the Engineer.
3.1.4 Standard of Quality
All mechanical equipment furnished shall be new and of current design. Manufacturers
listed as "equal" have been determined by the Engineer to meet or exceed the minimum
acceptable standard for the designated equipment. However, this shall not relieve the
named Manufacturer from the responsibility of meeting all specified requirements.
Equipment which the Contractor can demonstrate to the Engineer is in accordance with the
Specifications and equal or better in quality and performance to those models specifically
named, will be acceptable.
3.1.5 Equipment Guarantee
The Contractor shall guarantee all equipment supplied against defects in workmanship or
materials for a period of one year, unless stipulated otherwise, following acceptance of the
completed project. Under this guarantee the Contractor agrees to correct without delay at
his own expense any failure of such parts due to faulty materials, construction, or
installation or to the failure of any such equipment to successfully perform within the limits
of the Specifications.
The Engineer will give prompt written notice of observed defects.
If the Contractor after notice, fails to proceed promptly to comply with the terms of this
guarantee, the Contractor will be held liable for all expenses incurred.
3.1.6 Submittals
Refer to the General Specifications for basic submittal requirements.

• Certified Test Curves -The Contractor shall submit four (4) copies of certified
performance or certified test curves for all pumps specified herein. The Contractor shall
notify the Engineer three (3) weeks prior to any testing to allow the Engineer to witness
the tests.
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• Shop Drawings – Prior to fabrication, the Contractor shall obtain from the Manufacturer,
shop drawings for all equipment. Shop drawings shall include fabrication, assembly,
foundation drawings, piping diagrams and wiring diagrams together with detailed
specifications and data covering materials used, power drive, assembly, parts, devices
and other accessories forming a part of the equipment to be furnished. After checking
the shop drawings for accuracy and suitability the Contractor shall submit four (4)
copies of the shop drawings and materials lists to the Engineer for approval. Approval of
drawings does not relieve the Contractor from any responsibility under the Contract
terms and conditions.
• Operation and Maintenance Manuals – The Contractor shall deliver to the Engineer not
less than six (6) copies of an Operation and Maintenance Manual for each item of
equipment supplied.
• The manuals shall contain all necessary drawings, three-dimensional schematics of all
piping required, single line diagrams and details required to cover all operational
procedures. The manuals shall also describe the necessary maintenance programme
recommended for maximum equipment life and procedures required for emergency
conditions. The manuals shall include parts lists and spare parts recommendations and
name and address of the nearest spare parts and repair facility. The manuals shall be
written in English.
• Record Drawings and Specifications – The Contractor shall deliver to the Engineer,
tracings on stable material suitable for reproduction purposes together with a record set
specifications of all equipment as installed.
3.1.7 Interpretation of Contract Drawings
Process requirements for piping, valves and fittings are shown on the Drawings and
Specified. Any deviation from these requirements shall be submitted in accordance with the
specified procedures for deviations. The drawings indicate the desired configuration of
piping, valves and fittings (as well as mechanical equipment and certain instrumentation).
The drawings shall not be construed as being complete assembly plans, but rather
guidelines to be followed in order to provide the necessary piping, valves and fittings shown
on the Drawings. In addition, any piping not shown on the Drawings which is required for a
complete and operable system shall be furnished.
3.1.8 Routing of Pipelines
It is the responsibility of the Contractor to route all piping. Piping shall be routed in such a
way so as not to interfere with other piping, equipment, instrumentation, electrical work or
structures. Pipeline routing shall be in accordance with the guidelines presented in the
Drawings. Minor changes due to differences in equipment size or configuration will be
permitted provided that such changes do not interfere with other work. Any major deviations
from the layouts shown on the drawings will require approval. All piping layouts shall be
subject to approval by the Engineer prior to installation.
All exposed piping shall be located against walls, under ceilings, or in floor trenches. If floor
trenches are used, grating shall be installed to cover the trench.
In no case shall piping be located so as to interfere in any way with traffic or access to
equipment. Minimum head room shall be 2.m (7 feet) unless specifically shown otherwise
on the drawings.
All piping running below concrete structures shall be encased in concrete. Two (2)
mechanical joints or flexible couplings spaced 3.1m (10 feet) apart shall be included in the
pipeline for flexibility, the first joint or coupling located 1.2 m (4 feet) beyond the
encasement.
Unless specifically shown on the drawings or approved by the Engineer, no wall
penetrations shall be made underwater.
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3.2 GENERAL MATERIALS AND WORKMANSHIP
3.2.1 All Equipment
All equipment furnished under this Section shall be new and guaranteed free from defects
in materials, design and workmanship. It shall be Contractor's responsibility to determine
the conditions and service under which the equipment will operate and to warrant that
operation under those conditions shall be successful. All parts of the equipment shall be
amply proportioned for all stresses that may occur during fabrication erection and
intermittent or continuous operation.
3.2.2 Design of Equipment
All equipment shall be designed, fabricated and assembled in accordance with the best
modern engineering and shop practice. Individual parts shall be manufactured to standard
size and gages so that repair parts, furnished at any time, can be installed in the field. Like
parts of duplicate units shall be interchangeable. Equipment shall not have been in service
at any time prior to delivery, except as required by tests. Materials shall be suitable for
service conditions.
3.2.3 Except Where Otherwise Specified
Structural and miscellaneous fabricated steel used in items of equipment shall conform to
the Standards of the American Institute of Steel Construction or approved equal. All mild
steels shall be galvanized. All structural members shall be considered as subject to shock
or vibratory loads. Unless otherwise specified, all steel which will be submerged, all or in
part, during normal operation of the equipment shall have a minimum nominal thickness of
6mm (1/4 inch). Iron castings shall be tough, close-grained gray iron free from blow-holes,
flaws, or excessive shrinkage and shall conform to ASTM A-48. Stainless steel have
conform to AISI Specifications, or approved equal.
3.2.4 Location
Location of the fabricator and his shop schedule shall be furnished to the Engineer prior to
the beginning of fabrication so that the Engineer can schedule shop inspection.
3.2.5 Lubrication
The Contractor shall provide lubricants of types recommended by equipment

manufacturers, quantities sufficient for consumption prior to completion, testing, and final
acceptance. A two-year supply of each lubricant shall also be provided. Equipment
lubrication systems that require attention not more than once a week during continuous
operation, do not require attention during start-up or shut down, and do not waste
lubricants, shall be provided.
3.2.6 Structural Steel Fabrications
Shall conform to "Specification for the Design, Fabrication and Erection of Structural Steel
for Buildings" of the AISC unless otherwise indicated or specified. All fabrications shall be
designed for dynamic and vibratory loadings. Structural steel shapes shall conform to
ASTM A36, A440, A500, A501, A570, A618, or equal, as applicable. Welding shall conform
to AWS D2.0 Code. Galvanization of specific items shall be in accordance with ASTM A123
or A386 as applicable; galvanized bolts and fasteners shall be used with galvanized
assemblies.
3.2.7 Equipment Bases and Bed Plates
Equipment assemblies shall be mounted on a single heavy cast iron or welded steel
bedplates unless otherwise shown or specified for bases and bedplates with machined
support pads, tapered dowels for alignment or mating of adjacent items, adequate openings
Page 444 of 486

to facilitate grouting, and openings for electrical conduits shall be provided. Seams and
contact edges between steel plates and shapes shall be continuously welded and the welds
ground smooth.
Bed plates should not be used to support machinery or piping equipment bases and
bedplates to aid in leveling prior to grouting, to be provided. The plates shall have a
minimum thickness of 6mm (1/4 inch).
3.2.8 Jacking Screws and Anchor Bolts
Jacking screws shall be provided in the equipment bases and bedplates to aid in leveling
prior to grouting.
Equipment suppliers shall furnish anchor bolts, nuts, washers, and sleeves of adequate
design as required for proper anchorage of the bases and bedplates to the concrete bases.
Sleeves shall be a minimum of 1-1/2 times the diameter of the anchor bolts. Unless
otherwise shown or specified, anchor bolts for items of equipment mounted on baseplates
shall be long enough to permit 37 mm (1-1/2 inches) of grout beneath the baseplate and to
provide adequate anchorage into structural concrete.
Anchor bolts, together with templates or a setting drawing, shall be delivered sufficiently.
3.2.9 Safety Guards
Belt or chain drives, fan blades, couplings, exposed shafts and other moving or rotating
parts on all sides shall be covered with safety guards to the satisfaction of the ENGINEER
and conforming to all local safety codes and regulations. Guards shall be designed for easy
installation and removal, complete with necessary supports, accessories, and fasteners, all
shall be hot-dip galvanized. Design guards in outdoor locations to shall be designed to
prevent entrance of rain and dripping water. The safety guards shall be fabricated from 16
USS gauge or heavier, galvanised or aluminium-clad sheet or 13 mm (1/2 inch) mesh
galvanized expanded metal.
3.2.10 Drive Units
(a) General - All drive units shall have an AGMA rating and service factor suitable for
twenty-four (24) hours per day operation under the operating load. Drive unit
housing shall be constructed of high grade cast iron, welded steel, or other suitable
material. Thermal rating of each unit shall exceed the design load or proper cooling
devices shall be provided. All drives shall be designed especially for the services for
which they are to operate.
(b) Electric Motors - All Electric Motors to be furnished under this Contract shall meet
the provision of the Specifications and the following requirements:-
1. The rating of the motors shall be such that they will not be overloaded at
any point within the range of the operation of the equipment connected
and shall be of adequate rating and starting characteristic to allow
equipment to be brought up to the rated speed within a reasonable time.
2. Motors shall be provided with adequately designed bases and as indicated
or specified.
3. Motor Shafts shall not allow excessive motor vibration.
4. Bearings shall conform to the requirements of the Specifications.
5. Bolts and Cap Screws shall be high strength zinc-plated and chromated
steel.
6. Enclosures - Motors located in areas designated as hazardous shall be
explosion proof. Motors located outdoors shall have weather-protected
enclosures. Motors submerged in water or sewage shall be watertight. All
other motors shall have splashproof enclosures.
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(c) V- Belt Drives - Where motors are mounted above the driven machine on a
pedestal, the belt tensioning shall be accomplished by four studs which are double
nutted to the motor plate to raise and lower the motor plate. Hinges with a jacking
screw to tension the belts shall not be used.
3.2.11 Gears
Oil-lubricated, totally-enclosed gear reducers and increases shall comply to the following:-
(a) Service Rating - Each gear shall have a nameplate service horsepower rating equal
to or greater than the nameplate rating of the driving motor. Each gear shall have
mechanical and thermal capacity equal to or greater than an equivalent horsepower
determined by multiplying the service horsepower rating by the specified factor
recommended by AGMA for heavy duty service, except each set of worm gears shall
have minimum service factor of 1.20 and all other gears shall have a minimum
service factor of 1.5 unless otherwise specified.
(b) Thermal Rating - Obtain thermal rating for the equivalent horsepower without
auxiliary cooling equipment such as heat exchangers. Design units to operate
continuously for the conditions specified in a location where ambient temperatures
vary from 20 - 400C. If cooling coil is required, provide minimum 25mm (1-inch)
diameter tubing and a 25mm (1-inch) solenoid supply water valve with the gear.
(c) Bearings - Provide antifriction bearings throughout, designed to give 20,000 hours B-
10 life (unless specified otherwise) for the specified horsepower in continuous
operation, of proportions, mountings, and adjustment consistent with acceptable
modern practices for applied radial and thrust loads at speeds involved. Antifriction
bearings as used in these specifications include roller bearings, ball bearings and
other such similar bearings which employ primarily rolling friction and exclude those
bearings such as sleeve bearings, Babbitted bearings and others which employ
primarily sliding friction.
(d) Gear Nameplates - Equip each gear with an AGMA or equal nameplates which
shows service horsepower, actual service factor for actual mechanical or thermal
rating as applicable, and AGMA gear Class I rating.
3.2.12 Contacts
For interlock or failure indicating contacts specified to be supplied as part of equipment,

provide SPDT switches rates for 240 VAC, 50 Hz at 5 amperes resistive or 3 amperes
inductive loading, terminated at screw-type barrier strips in a NEMA 4 enclosure, unless
otherwise shown or specified.
3.2.13 Nameplates and Data Plates
Provide Type 302, 304 or 316 stainless steel nameplates of ample size with embossed or
preprinted lettering, fastened to the equipment in a prominent place with corrosion-resisting
pin. On nameplates, display manufacturer, serial number, date of manufacture, model
number, and essential operating characteristics. Inscribe data plates with specified or
directed information. All information shall be in the English language in metric units.
3.2.14 Equipment Tags
Each item of mechanical equipment shall be tagged with permanent, legible tags, readily
visible after installation. Tags shall conform to the designations shown on the Drawings and
approved in size and design by the Engineer.
3.2.15 Vibration Control
All rotating and reciprocating machinery shall be statically and dynamically balanced to
eliminate excessible vibration. Where necessary, special vibration isolators shall be utilized.
Page 446 of 486

3.2.16 Sample Cocks, Meters and Gauges
Sample cocks shall be provided on the discharge of each pump used to transport sewage.
Meters and gauges shall read on metric units as approved by the Engineer.
3.2.17 Tools
A complete set of special tools shall be provided for each item of furnished equipment.
Sufficient tools shall be furnished to perform all normal maintenance on the equipment. A
complete set of instructions, in English shall be supplied to describe the proper use of all
tools.
3.3 PROTECTION
3.3.1 All Equipment
All equipment shall be boxed, crated, or otherwise completely enclosed and protected for
overseas shipment, handling and storage. All equipment shall be protected from exposure
to the elements and shall be kept thoroughly dry at all times. Pumps, motors, electrical
equipment and other equipment having antifriction or sleeve bearings shall be stored in
weather-tight storage facilities such as warehouses.
3.3.2 Painted Surfaces
All pipes chased in walls and floors are not to be painted. All other bare piping (except
UPVC pipe and other plastic pipe), vents, metal sheathing, pipe hangers, supports, valves,
equipment, steelwork and all other work covered in this Specification, except where
specified to be chromium plated, shall be cleaned and painted as described below:-
Outdoor Galvanized Steel

Dry Film
No. of
Coating Sequence Type of Paint Thickness
Coats
(Microns)
Primer 1 Nippon Galvaprimer 20
Intermediate coat 1 Nippon Polyurethane Recoatable Finish 50
Finishing coat 1 Nippon Polyurethane Recoatable Finish 50
TOTAL AVERAGE MINIMUM DRY FILM THICKNESS 120
Indoor Galvanized Steel

Dry Film
No. of
Coats
(Microns)
Primer 1 Nippon Galvaprimer 20
Intermediate coat 1 Nippon Protective Finish 45
Finishing coat 1 Nippon Protective Finish 45
Page 447 of 486

Outdoor Mild Steel

Dry Film
No. of
Coats
(Microns)
1
Primer Copon 8048 Indian Red 1462 100
1
Finishing coat Nippon Polyurethane Recoatable Finish 50
Indoor Mild Steel

Dry Film
No. of
Coats
(Microns)
Primer 1 Nippon Zinc Phosphate Primer 50
Intermediate coat 1 Nippon Protective Finish 45
Finishing coat 1 Nippon Protective Finish 45
Directional flow arrows approximately 150 mm long shall be painted if required at intervals
of 2 m. The arrows shall be stenciled and painted with one coat of selected colour.
3.3.3 Electrical Equipment
Controls and insulation shall be protected against moisture or water damage. All space
heaters provided in the equipment shall be connected and operating at all times until
equipment is placed operation.
3.3.4 Temporary Storage Facilities
The Contractor shall erect and maintain on the site temporary storage facilities approved by
the Engineer. At his option and with the Engineer's approval, the Contractor may utilize
storage space off the site. The Engineer shall have access to the on-site and off-site
storage facilities at any time to inspect the equipment stored therein. All costs for on-site or
off-site storage facilities shall be borne by the Contractor.
3.3.5 Approved Storage Facilities
All equipment shall be stored from delivery until installation in storage facilities approved by
the Engineer.
3.3.6 Inspection and Preparation
(a) Inspect Each Item - of Equipment for damage, defects, completeness and correct
operation before installing. Inspect previously installed related work and verify that it
is ready for installation of equipment.
(b) Notify - the Engineer in the event that any equipment or material is damaged.
Repairs to damaged products shall not be made without prior approval by the
Engineer.
(c) Prior to Installing Equipment - ensure that installation areas are clean and that
concrete or masonry operations are completed. Maintain the areas in a broom-clean
condition during installation operations. Clean, condition, and service equipment in
Page 448 of 486

accordance with the approved Instruction Manuals and requirements in other

Sections of these Specifications before installing.
3.3.7 Coordination
The Contractor shall take all measurements for his work at the installation sites, verify all
Contract drawings and be responsible for the proper installation, within the available space
of the apparatus specified and shown on the Drawings and must secure the approval of the
Engineer for any deviation before making any changes.
3.3.8 Shop Painting
(a) Except as Specifically Supplemented and/or superseded by requirements herein,

shop paintings shall conform to requirements in these Specifications.
Unless otherwise specified, electric motors, gears, starters, and other similar self
contained or enclosed components shall be shop primed and finished with a high
grade oil-resistant acrylic enamel. Surfaces which will be inaccessible after assembly
shall be painted or otherwise protected before assembly by a method which provides
protection for the life of the equipment.
(b) Surfaces to be painted at the plant site shall be shop painted with one or more coats
of a primer which will adequately protect the equipment until finishes are applied at
the site. Primers shall be as specified in this Specifications.
(c) Machined and Polished metallic surfaces which are not to be painted shall be coated
with rust preventive compound, Rust-Oleum "R-9" or equal.
3.3.9 Equipment Installation
(a) All Equipment shall be installed in full accordance with the drawings, specifications,
equipment manufacturer's recommendations and good practice. For major
equipment items, the equipment manufacturer's factory-trained service personnel
shall be on-site to supervise the installation.
(b) At Least 14 days notice shall be given to the Engineer prior to equipment
installations in order that the Engineer or his representative may be present during
installation.
(c) Installation Practices shall be as follows:-
1. Examine Equipment for damage in shipping and handling, the examination
shall include checking for corrosion, poor workmanship, dirt or deleterious
substance, and poor fits.
2. Level the base plate or bedplate.
3. Install equipment.
4. Check alignment of couplings.
5. If grout has been used, check alignment and levelness after the grout has
set.
6. Check direction of rotation and correct, if necessary, to ensure proper
operation.
(d) Contractor shall have an experienced, competent, and authorized representative of
the manufacturer or supplier of each major item of equipment visit the site of the
work and inspect, check, adjust if necessary, and approve the equipment
installation. In each case, the equipment manufacturer's representative shall be
present when the equipment is placed in operation. The Contractor shall have the
equipment manufacturer's representative revisit the job site as often as necessary
until all trouble is corrected and the equipment installation and operation is
satisfactory to the Engineer.
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(e) Prior to Being Placed in Operation equipment shall be inspected by the

manufacturer's factory-trained personnel. All defects discovered during this
inspection shall be corrected prior to initial equipment start-up. Internal coatings
applied at the factory shall be removed if required. Lubricant shall be applied in the
proper place and levels shall conform to the manufacturer's recommendations. If
required, full load tests shall be performed and results of such tests shall be
recorded. Unsatisfactory performance shall be corrected and tests shall be repeated
until the equipment's performance meets the specifications.
(f) Upon Completion the entire installation, the Contractor shall submit to the Engineer
a formal notice of completion, stating that the equipment is ready for acceptance
testing.
3.3.10 Acceptance Testing
Operational Demonstrations and Equipment System Testing

(a) General
Operational demonstrations and equipment systems testing shall be performed by
each equipment manufacturer or supplier in accordance with the approval
procedure plans to demonstrate to the Engineer's satisfaction.
(b) Scope of Demonstrations and Equipment Testing
Operational demonstrations and equipment system tests are required for all work,
equipment and systems specified in these Specifications including all associated
and related electrical/mechanical systems and control devices and instrumentation
and control systems.
1. Equipment and work to be operationally demonstrated as defined as individual
equipment items such as pumps, fans, air compressors and like equipments
items. Demonstrations shall be performed simultaneously on groups of
identical equipment items and groups of items supplied by one manufacturer to
the extent feasible.
2. Equipment Systems to be tested are defined as complete systems that perform
a discrete function of the wastewater treatment plant or pump station and shall
include each package of furnished equipment. Each system shall include
associated structures, tanks, piping, utilities, instrumentation and controls and
like related items.
(c) Operational Demonstrations
Demonstrate that the performance of installed equipment complies with all
requirements indicated and specified. Operate each equipment item through entire
no-load to full-load range in accordance with the approved procedure plan.
(d) Equipment System Tests
All equipment components of each system shall have successfully completed the
required operational demonstration before the system is tested. Perform testing in
accordance with the approved procedure plan.
1. Test Period - Test each system, including standby systems by continuous
operation under "In-service" condition.
2. Testing Methods - Operate systems continuously under constant inspection of
trained operators. Cycle system operation full load to light load and back to full
load.
3. Induce simulated alarm and distressed operating conditions, and test control
and protective devices for correct operation in adjusting systems functions or
causing system shutdown.
4. Simulation of Conditions - Subject to Contractor's request and ENGINEER's
approval in each case, the Contractor may simulate certain operating
Page 450 of 486

conditions relating to flow rates, water levels, and malfunctions. Permission for
simulations will be granted only where it is unwise or impossible to obtain the
conditions covered by the capability or ranges of equipment. The simulation
methods shall reflect reasonable anticipated operating conditions.
(e) Range for Testing
1. Flow metering systems shall be tested at not less than 3 values corresponding
approximately to minimum, average and maximum capacity respectively.
2. Liquid level indicating systems shall be tested at not less than 6 levels
corresponding approximately to low, average, normal, maximum and high
alarm levels, respectively. Low level alarms and system reaction shall also be
tested where equipment or instruments are required to react to such
conditions.
3. Remotely controlled valves shall demonstrate suitable operation both from
local controls and remote controls. As a minimum, these procedures shall
include full-open and full-close positioning. Each test shall be repeated not less
than 3 times. In addition to these minimum requirements, and subject to
approval, all throttling valves and modulating valves shall be operated at not
less than 3 intermediate positions and shall demonstrate the ability of each
valve to hold the set position under operating conditions.
(f) Automatic Response of Equipment
Response of equipment to appropriate manual or automatic controls, or
combinations of both automatic and manual controls, shall be demonstrated to be
correct and accurate. Where applicable, all components shall be tested for both
manual and automatic operation. Where a component performs more than one
function, every function shall be validated.
3.4 PUMPING EQUIPMENT
3.4.1 General
The Contractor shall furnish all tools, equipment and materials and shall perform all labour
required to complete an operable pumping system and appurtenant work, as indicated on
the drawings and specified herein and to the satisfaction of the Engineer.
The pumps shall capable of handling raw unscreened domestic sewage and shall be
electrically operated, unchokeable centrifugal pumps.
The pump shall run on automatic mode with a manual override facility provided.
Pumpsets: Guarantees and Particulars
The Contractor’s guarantee when tendering, in respect both of performance and efficiency
of the pumping plant and equipment will be binding and considered as the essence of the
Contract.
The fulfilment of these guarantees shall be verified by the Works tests to be carried out in
accordance with the procedure given in the latest edition of BS 5316 Part 2 (Class B Test).
All electrical measuring instruments, pressure gauges, etc. used at these tests must be
calibrated under guarantee.
For the purpose of the Contract, the following definitions of hydraulic head shall apply: -
“Static head” is the vertical distance between free water level on the pump suction side
and free water level on the discharge side.
“Net effective lift” is the sum of the static head and the various external losses of all
pipework, etc. not compromised under this Contract.
“Total plant losses” is the sum of the various friction losses in all pipework, valves,
specials, etc. comprised within the limits of this Contract.
Page 451 of 486

“Total head” is the sum of the net effective lift and the total plant losses.
Tenderers shall furnish with their tenders, performance curves in respect of each pumpset
offered. The curves shall show the head/quantity, NPSH, efficiency, brake and water
horsepower and energy consumption characteristics of the respective units over the whole
of their working ranges. Performance curves shall incorporate both single and parallel
operation.
Official Trial for Pumpsets
During the period of Maintenance, the guaranteed duties specified in the Schedule of
Guarantees and Particulars must be performed continuously by each pumping unit for a
period of up to 8 hours or as the Engineer may determine under the control of the
Contractor’s accredited representative and the supervision of the Engineer or his
representative.
The Contractor shall provide an accredited representative, indicators, gauges, measuring
instruments, vibration meter and all other apparatus for the official trials.
The test shall be carried out generally in accordance with BS 5613 part I (Class C Tests).
The energy consumption shall be determined by suitable wattmeters, etc. The Contractor
shall have all electrical apparatus and pressure gauges calibrated under guarantee of an
approved Authority to the satisfaction of the Engineer.
The static level of water in the pump suction well shall be measured by means of a level
gauge whilst the delivery head shall be obtained from a simultaneous reading of pressure
gauge of minimum diameter 150mm connected to a tapping provided immediately
downstream of the delivery valve. The reading of the water level shall be corrected to the
centre line of the pressure gauge on the suction and delivery flange of the pump.
The head for the calculation of the duty point water horsepower shall be the difference
between the level gauge reading and the pressure gauge reading, plus any velocity head in
the delivery branch of each pump.
The quantities delivered by the pumpsets shall be measured by means of the existing flow
meters or by other suitable methods.
3.4.2 Sewage Pumps Operation Requirement
The sewerage pumps required to be installed in this Contract shall be for two (2) nos.
submersible pumps of the wet pit installation type for Pump Station (1,100 PE).
The operation of pumpset shall be such that when one (1) pumpset is on duty, the other
one (1) pumpset is on standby.
The capacity of the pumps and cutting in, cutting out, and alarm levels are depicted on the
Drawings.
After one pre-programmed cycle of operation, the duty pump and standby pump shall
alternate.
The operating sequence for the Pump Station shall be as follows:
Sequence First Duty Pump Standby Pump 1
1 Pump A Pump B
2 Pump B Pump A
Only a maximum of one (1) pump shall operate at any one time. Logic circuit to check
whether the duty pump is operating shall be provided.
The operation of the pumpset shall be controlled by an appropriate logic system connected to
the float switches.
PLC (Programmable Logic Control) shall be provided for the control of the operation of pump.
The following are the operating conditions of the pumps at various water levels for Pump
Station (1,000PE):-
Page 452 of 486

Pump Level at Function Remarks

Pump Station
(1,000PE)
High Water High Water Indicator

1. ‘High Water’, Audio Alarm
Level Light remain on when alarm
IL -3.588 m 2. High Water Indicator Light is silenced
On
3. Rotating Beacon Light to
be On
IL -3.738 m This is treated as

1. First Standby Pump On
“mechanical failure”. First
2. First Standby Pump Duty Pump shall be cut-off
Indicator Light On before first standby pump is
operated automatically.
IL -3.888 m
1. First duty pump on
-
2. First duty pump indicator
light on
IL -4.625 m -
1. Pump Cut Off
2. Indicator Light Off
Low Water Low water level indicator

1. 'Low water level' Audio
Level light remain on when alarm
Alarm
IL -4.775 m is silenced
2. Low water level indicator
light on
3. Rotating beacon light on
3.4.3 Duty of Submersible Pumps
The pump motors shall be capable of handling not less than 6 starts/stops per hour.
Each pump shall be equipped with submersible explosion proof electric motor (IP68)
connected for operation to the power supplying 85kW 50Hz.
The capacities of pumps shall not be less than that specified as follow:
Pump Station (1,000PE)
Two (2) pumps (1 duty and 1 standby) shall be installed. Capacity of each pump shall be of
6.12 l/sec at Total Discharge Head of 72m. The pump hydraulic efficiency when operating
at the design point shall not be less than 94%.
Page 453 of 486

3.4.4 Sewage Pumps Details
General
The raw sewage pumps shall be of the submersible type suitable for wet pit installation,
electrically driven at constant speed. Maximum speed of rotation shall not exceed 1480rpm.
The impeller selected shall not be maximum or minimum size of the pump / motor size.
The pumps are to be installed in a wet pit sump and the submersible motors shall be
suitable to drive the pump over its range at operation without overloading. Submersible raw
sewage pumps shall be complete with matching suction bend and suitable length of
submersible cable. The pumps shall be proven in service and shall be guaranteed with
back up service by an accredited local agent.
The design of the pumps and shafts and the associated pipe work and valve, and the
selection of materials for construction shall be carefully married out to obviate the effects of
electrolytic corrosion or any silt which may be carried in the water being pumped.
Pump Construction
Major pump components shall be of grey cast iron, ASTM A-48 Class 35B, BS1452 Grade
260 or DIN 1691 GG25 with smooth surfaces devoid of blow holes or other irregularities. All
exposed nuts, bolts and washers shall be of AISI type 304 stainless steel or better. All
metal surfaces coming in contact with the pumped liquid, other than stainless steel or brass,
shall be protected by a factory applied spray coating of alkyd primer with oxiranesther
(Duosolid) paint finish on the exterior of the pump. Sealing design of major pump
components shall incorporate metal to metal contact between surfaces. Critical mating
surfaces where watertight sealing is required shall be machined and fitted with Nitrile or
Viton O-rings. Fittings will be that of controlled compression of rubber O-rings in two planes
and O-ring contact of four sides without the requirement of a specific torque limit.
Neither rectangular sectioned gaskets that require specific torque nor sealing compound
shall be considered as equal.
Cooling System
Each unit shall be provided with an adequately designed cooling system. The water jacket
shall encircle the stator housing, thus providing heat dissipation for the motor regardless of
the type of installation and enable the pump to operate continuously at rated output
regardless of whether the motor is above or below the liquid level. Impeller back vanes shall
provide the necessary circulation of the cooling liquid through the water jacket. The cooling
media channels and ports shall be non-clogging by virtue of their dimensions. Provisions for
external cooling and seal flushing shall also be provided. The cooling system shall provide
for continuous pump operation in surrounding temperature of up to 40oC.
Cable Entry Seal
The cable entry seal design shall prelude specific torque requirements to ensure a
watertight and submersible seal. The cable entry shall consists of a single cylindrical
elastomer grommet, flanked by washers, all having a close tolerance fit against the cable
outside diameter and the entry inside diameter and compressed by the body containing a
strain relief function, separate from the function of the sealing cable. The assembly shall
provide ease of changing the cable. The cable entry junction chamber and motor shall be
separated by a terminal board, which shall isolate the interior from the foreign metal gaining
access through the pump top. Epoxies, silicones, or other secondary sealing systems shall
not be considered acceptable.
Motor
The pump motor shall be a squirrel cage induction motor, shell type design, housed in an
air filled, watertight chamber. The stator windings and stator leads shall be insulated with
moisture resistant Class H insulation rated for 180C°. The stator shall be dipped three times
in Class F varnish and shall be heat-shrink fitted into the stator housing. The motor shall be
designed for continuous duty handling pumped media of 40C° and capable of up to 15
evenly spaced starts per hour. Thermal switches set to open at 125oC and close at a
minimum of 70oC, shall be embedded in the stator lead coils to a monitor the temperature of
Page 454 of 486

each phase winding. These thermal switches shall be used in conjunction with and
supplemental to external motor overload protection and shall be connected to the control
panel. The junction chamber containing the terminal board shall be hermetically sealed
from the motor by an elastomer o-ring seal. Connection between the cable conductors and
stator leads shall be made with threaded compression type binding posts permanently
affixed to a terminal board. Wire nuts or crimping type connection devices are not
acceptable. The motor and pump shall be designed and assembled by the same
manufacturer. The combined service factor (combined effect of voltage, frequency and
specific gravity) shall be a minimum of 1.15. The motor shall have a voltage tolerance of
plus or minus 10%. The motor shall be designed for operation up to 40 oC ambient temp,
with a temperature rise not to exceed 85 oC. A motor performance chart shall be provided
showing curves for torque, current, power factor, input/output kW and efficiency. This chart
shall also include data on starting and no-load characteristics. The motor and the cable
shall be capable of continuous submergence under water without loss of watertight integrity
according to protection class IP68 (20m). The rated power shall be adequate so that the
pump is not over-loading throughout the entire indicated pump performance curve. Power
cable shall include two conductors 1.5mm 2 for the monitoring of thermal switches and
optional protecting sensors.
The pump motor shall be of explosion proof type (minimum rating shall be IEC:- EEx d IIB
T4).
Bearings
The pump/motor shaft shall rotate on two permanently grease lubricated bearings. The
upper bearing shall be a single row roller bearing. The lower bearing shall be a two row
angular contact ball bearing to compensate for axial and radial forces.
The upper and lower bearing temperature shall be monitored using temperature sensor and
the alarm value of which shall be adjustable between 50oC and 150oC.
Mechanical Seal
Each pump shall be provided with a tandem mechanical shaft seal system consisting of two
independent seal assembly. The seals shall operate in an oil reservoir that
hydrodynamically lubricates the lapped seal faces at a constant rate. The lower, primary
seal unit, located between the pump housing and the oil chamber, shall contain one
stationary and one positively driven rotating corrosion resistant tungsten carbide ring. The
upper, secondary seal unit, located between the oil chamber and the motor housing, shall
contain one stationary and one positively driven corrosion resistant tungsten carbide seal
ring. Each seal interface shall be held in contact by its own spring system. The seals shall
require neither maintenance nor being dependant on direction of rotating for sealing. For
special applications other seal face material shall be available. Other seal types shall
neither be considered acceptable nor equal to the dual independent seal specified. The
seal cavity for the outer seal shall be equipped with means for wear reduction such as spiral
grooves for particle removal. Each pump shall be provided with an oil chamber for the shaft
sealing system, the drain and inspection plug, for the oil, shall be accessible from the
outside.
Oil
The oil chamber shall be filled with a medical white oil of paraffin type. The oil shall be free
from aromatic hydrocarbons, be medically clean and be approved according to
FDA172.878.
Moisture sensor shall be provided to give an alarm if the amount of water in the oil chamber
exceeds a certain level.
Pump Shaft
Pump and motor shaft shall be the same unit. The pump shaft is an extension of the motor
shaft. Couplings shall not be acceptable. The shaft materials shall be AISI type SAE C 1035
Carbon steel. The shaft shall be completely isolated from the pumped liquid.
Page 455 of 486

Impeller
The impeller(s) shall be semi open multi vane, backswept, non clog design. The impeller
vanes shall be self cleaned upon each rotation as they pass across a relief groove(s)
located. In the pump housing (or in an insert ring in the pump housing) and shall keep the
vane clear of debris, maintaining an unobstructed pumping. The impeller(s) shall have a
heavily back swept leading edges with a specific angle distribution enabling the capability of
handling solids, fibrous materials, heavy sludge and other matter found in wastewater.
Impellers shall be locked to the shaft. The clearance between the pump housing/insert ring
and the impeller shall be adjustable.
Volute
Pump volute(s) shall be a single-piece grey cast iron (ASTM A-48 Class 35B) non-
concentric design with smooth passages large enough to pass any solids that may enter
the impeller. Minimum impeller throughlet shall be 75mm. The volute shall have a mating
flange machined, and provided with a blind flange, correct positioned for a flushing valve.
3.4.5 Pumping Auxiliaries
Small Pipe and Fittings

The pump shall have tapped openings for air relief, drainage and gauge connections. All
small piping associated with each pumping unit shall be of copper tubing or brass pipe and
nipples. All tapped holes shall be fitted with bronze plugs. Suitable air relief valves and
strainers shall be provided.
3.4.6 Pump Protection and Control
In addition to the normal protection and control of pumpsets mentioned elsewhere in the
Specifications, the Contractor shall include provision for specific protection and control to all
the pumpsets as follows: -
(a) Over-load of the motor.
(b) The pump motor shall be prevented from being started if the suction plug valve is not
fully open.
(c) The motor shall be prevented from starting if the suction level is not above
predetermined level.
(d) The pump motor shall be automatically stopped when the water level in the suction
well drops below the predetermined level.
(e) The pump motor shall automatically stop on high delivery pressure.
(f) When the emergency stop button is operated the motor shall stop immediately
irrespective of the condition of the delivery valve.
(g) The pump motor shall automatically stop on high bearing temperature.
3.4.7 Witness Testing of Pumpsets
Where specifically included in the Bill of Quantities or Schedule of Prices, the Contractor
shall allow for witness testing (overseas) for the sewage pumpsets at the place of
Page 456 of 486

manufacture. The cost of this item must be included in the rate proposed and the
Contractor shall allow for two (2) persons from the Engineer/Engineer’s Representative for
the witness testing. The cost shall include for the following:
(a) Air travel
(b) Hotel accommodation and subsistence
(c) Local travel
(d) Allowances
(e) Inspection Before Delivery.
All equipment and plant must be inspected by the Engineer or Engineer’s Representative in
Kuala Lumpur or whichever location of origin in Malaysia before delivery to site. One (1)
week’s notice must be given to the Engineer/Engineer’s Representative as to the date of
the proposed inspection. The cost shall include for the following:
(a) Air travel
(b) Hotel accommodation and subsistence
(c) Local travel
(d) Allowances
3.4.8 Pump Test Sheets
The Contractor shall submit three certified pump test sheets (Head / Flow rate curves and
pump efficiency / flow rate curves). The pumps shall be factory tested in accordance with
grade 1 of ISO 9906.
3.4.9 Plug Valves
Plug valves shall be quarter-turn, non-lubricates, eccentric type with a moulded elastomer
covering the plug surface. Port shall be round with a minimum of 80% flow area on size
DN65 to DN350. Valves DN400 and larger shall be of rectangular port design.
Valves shall be rated at 16 bar. Valves shall be designed and manufactured to shut off
bubble tight at PN16. The flange shall be faced and drilled in accordance with BS 4504
PN16 or equivalent.
Each valve shall be given a hydrostatic shell test of 24 Bar and seat test of 16 Bar with the
test results being certified.
Valve bodies shall be BS2789 Gr.500/7 ductile iron. Valve 80mm and larger shall be
furnished with a weld deposited nickel seat. Sprayed, plated or screwed-in seats are not
acceptable.
Plug shall be of ductile iron to BS 2789 Gr. 500/7. The plugs shall be of one piece
construction with PTFE thrust washers on the upper and lower bearing journals to reduce
torque and prevent foreign particles from entering the bearing and seal area.
Valves shall be furnished with replaceable sleeve type bearings. Bearings shall be of
sintered, oil impregnated austenitic stainless steel for valves up to and including DN500,
larger sizes have bronze bearings. Valve shaft seals shall be of the “U” cup type. Seals
shall be self adjusting and replaceable without removing the bonnet from the valve. The
valve bonnet seal shall be of the “O” ring type allowing metal to metal body / bonnet
assembly (up to DN700).
Wrench operated valves, DN65 to DN200, shall be capable of being converted to worm
gear or automated operation without removing the bonnet or plug from the valve. All
wrench operated valves shall be equipped with a 50mm square nut for use with removable
levers or extended “T” handles. All valves larger than DN200 shall have worm gear
operations.
Page 457 of 486

Worm gear operators, where required, shall be of a heavy duty SG iron quadrant supported
by oil impregnated bronze bearings. The worm gear and shaft shall be manufactured of
hardened steel and be supported in roller bearings. The worm gear shall be sized to
operated at the full pressure rating of the valve.
3.4.10 Non Slam Check Valves
Check valves shall be of swing type, full body flange to BS 4504 PN16 or equivalent.
Design facilities the unrestricted, uni-directional flow of liquids along the full-bore, internal
epoxy coating, whilst enabling easy manual access for inspection purposes via the domed
cover. The valves disc shall be the only moving part.
The seating surface is constructed at a 45 degree angle, moderating disc travel and
permitting optimum flow rates. The disc’s resulting 35 degree stroke, combined with it’s
flexible action significantly reduces valve closing time, restricting both flow reversal and the
water hammer effect.
The disc shall be of one piece construction, the precision moulded, fully-encapsulated steel
disc incorporates nylon reinforcement in the flex hinge and o-ring profile seat face to ensure
a bubble tight shut-off.
The flex portion of disc shall be warranted for 25 years. The check valve shall been cycle
tested 1,000,000 times with no signs of wear or distortion to the valve disc or seat and shall
remain drop tight of both high and low pressure. The test results shall be independently
certified.
Backflush capabilities shall be available by means of an optional screw type external back
flush device. The device shall be field installable without modification to the valve or a need
for special tools or removal of the valve from pipeline.
The check valve body and cover shall be of Ductile Iron material with pressure rated to 16
bar. The disc shall be of Nitrile material.
Each valve shall be given a hydrostatic shell test of 24 Bar and seat test of 16 Bar with the
test results being certified.
3.4.11 Tools
One complete set of regular and any necessary special tools, shall be supplied by the
Contractor to enable any erection, dismantling or testing to be carried out on any part of the
plant whether of an electrical, mechanical or any other nature. The tools shall be supplied in
a lockable metal box.
3.4.12 Submersible Sump Pump
The Contractor shall supply and install submersible type sump pumps for the pump station
as shown in the Drawings. The pump shall be of a type suitable for handling raw
unscreened domestic sewage and shall be electrically-operated and unchokeable, with a
minimum throughlet diameter of 35 mm. The pumps shall be explosion-proof rated
(minimum IEC : - EEx d llB T4).
The pump located in the Pump Room shall be automatically operated by level sensor. A
manual override facility shall be provided to bypass the automatic activation by the level
sensor. Operating speed shall not be greater than 2900 rpm.
3.4.13 Sewage Air Relief Valve
Sewage air relief valves shall be of the type that automatically release air, gas or vapour
under pressure during system operation. The valve shall have a suitable NPT inlet with a
suitable NPT outlet and a 11mm venting orifice for a maximum working pressure of 10 bars.
Valve shall be constructed of cast iron body and cover, stainless steel trim and float, with
adjustable resilient orifice button to ensure positive seating.
The sewage air relief valve shall be fitted with facilities for backwashing. Backwash
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accessories shall be furnished and assembled to the valve, consisting of an inlet shut-off
valve, blow-off valve, clear water inlet valve, rubber supply hose and quick disconnect
couplings.
3.5 PENSTOCKS
This section covers all heavy duty penstocks required on the project. Each penstock shall
be furnished and installed complete with wall thimble or anchor bolts, operation stem, gate
lift operator and other appurtenances as specified or needed to make a complete and
operable installation.
3.5.1 General
Gates, stems, lifts and other appurtenances shall be of the size, type, material and
construction as shown on the drawings and specified herein. Penstock shall be designed to
handle not less than 10m water pressure. Penstocks shall meet the requirements of AWWA
Specifications C-501 (latest revision) or as modified per these specifications. All
component part shall be of the type of material shown, and interchangeable where size and
material are the same without grinding, chipping or special fitting in the field. The penstocks
shall be the product of one manufacturer having five or more years of experience in the
manufacture of similar gates for similar use. All mating and sliding lift, shall be designed for
the heads shown with a minimum safety factor of five.
All materials used in the construction of the penstocks and appurtenances shall be the best
for this application.
Frame - Cast Iron

Cover / Door - Cast Iron
Thrust Nut - Bronze
Side Wedge Assembly - Bronze
Guide Rail - Cast Iron
Lift Collar - Bronze
Seat - Bronze
3.5.2 Frame and Guide Rails
The frame guide rails shall be cast one-piece construction or may have guides dowelled
and bolted to the frame. Frames shall be of the flange back or flatback type with round or
rectangular opening as indicated on the plans and in the penstock schedule.
A machined dovetail groove for the mounting of the bronze seat facings shall be provided
on the front face of the frame around the full periphery of the opening. The frame shall be
provided with cast-on pads which shall be machined. drilled, and tapped for the mounting of
the wedge devices. The back of the frame flange shall be machined to a plane and drilled to
match the wall flange, pipe flange, or anchor bolt pattern. Guide rails shall be of such length
as to retain at least one-half of the vertical height of the slide when it is in the fully opened
position. A groove running the full length of the guide rail shall be accurately machined to
receive the slide tongue, with a nominal clearance of 1.5mm.
3.5.3 Cover or Slide
The cover shall be of one piece cast construction with vertical and horizontal ribs, a
reinforced pocket to receive the thrust nut, pads to receive the wedges, and a reinforced
periphery around the back side of the cover for machining of the dovetail grooves in which
the seating faces shall be mounted. All wedge pads shall be machined, drilled and tapped
to receive the wedge devices. The cover shall have fully machined tongues running the full
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length of each side to properly engage the guide rail grooves. A thrust nut shall be provided
to attach the slide to the stem. The nut shall be threaded and, in the case of rising stems,
provided with keys or two set screws locked into indents in the stem to prevent rotation of
the stem. For non-rising stems, the stem shall turn freely in the thrust nut, to open and close
the slides as the stem is rotated.
3.5.4 Seating Faces
All seating faces for both covers and frame shall be malleable extruded corrosion resistant
material of a shape that will fill and permanently lock in the full width dovetail grooves of the
slide and frame. (No other means of attachment will be allowed). They shall be machined to
a 63 micro-inch finish, or better.
3.5.5 Wedges
All wedges and wedge blocks shall be solid corrosion resistant material and shall be of
sufficient number to provide a practical degree of water tightness. All wedge bearing
surfaces and contact faces shall be machined to give maximum contact and wedging
action. Wedges shall be fully adjustable, but once set shall not rotate or move from the
desired position. All fasteners and adjustment screws shall be corrosion resistant.
3.5.6 Wall Thimbles and Anchor Bolts
Wall thimbles shall be provided with all penstocks except those to be mounted on pipe
flanges or those penstocks to be attached to concrete headwalls with anchor bolts, as
shown on the plans. Each thimble shall be of one-piece cast iron construction and of the
section and depth as specified in the plans and penstock schedule. There shall be integrally
cast water stop around the periphery of the thimble. The front flange of the thimble shall be
machined, drilled and tapped to receive the penstock attaching studs. Bolt pattern shall
match gate bolt pattern. After machining, the front flange shall be marked with vertical
centerline and the word "top" for correct alignment. Large square and rectangular opening
thimbles shall be provided with grout holes in the invert to permit entrapped air to escape.
The hole shall be 38mm in diameter, no more than two feet apart and shall be upstream
and downstream of the water stop.
A mastic type gasket shall be provided between the penstock and the wall thimble. Anchor
bolts shall be corrosion resistant.
Penstocks mounted directly upon the headwall shall be sealed between the gate back and
wall with a non-shrink grout.
3.5.7 Stems and Stem Couplings
Operating stems shall be of a size to safety withstand, without buckling or permanent

distortion, stresses induced by normal operating forces. Stems shall be fabricated from
round bar stock of cold-finished steel, stainless steel or bronze, as shown on the plans or
penstock schedule and shall be provided with 29o modified or full acme threads. Stem
composed of two more sections shall be joined by bronze couplings threaded and keyed to
stems, or couplings of the same material as the stems, pinned, bolted or welded and pinned
to the stems. In section, coupling shall be stronger than the stems. Rising stem shall be
provided with adjustable limit nuts or stop collars.
3.5.8 Stem Guides
Stem guides shall be cast, with bronze bushings, and mounted on cast brackets. Guides
shall be adjustable in two directions shall be so constructed that when properly spaced they
will hold, the stem in alignment and still allow enough play to permit easy operation. Stem
guide spacing shall be as recommended by the manufacturer. Brackets shall be attached to
the wall by anchor of sufficient strength to prevent twisting or sagging under load.
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3.5.9 Manually Operated Lifts
Penstocks shall be operated manually by handwheel or crank operated pedestal floor

stands or bench stands required. Each lift shall be provided with a threaded cast bronze lift
nut to engage the threaded portion of the stem. The lift nut shall have a machined flange,
fitted above and below with thrust ball bearings. Handwheel lifts shall be without gear
reduction while crank operated lifts shall have either a single or double reduction. Lifts
having a reduction greater than 4:1 shall be two-speed. A maximum effort 18kg pull on
hand wheel or crank, shall operate the penstocks under the specified operating head. The
gears, when required, shall be steel or cast iron with machined out teeth. Pinion gears shall
be supported by bronze bushings. The lift mechanism shall be totally enclosed within a cast
iron housing adequately provided with lubrication fittings. The pedestal shall be structural
steel or cast iron.
The crank shall be of cast iron with a revolving handle and shall be removable. The crank
shall be 15" long. All lifts for rising stems shall be provided with a counter type position
indicator and a galvanized steel stem cover or a transparent plastic stem cover. Non-rising
stem penstocks shall be provided with a counter type position indicator unless extension
stems, valve boxes, or T-handle wrenches make an indicator impractical. Handwheels and
crank input shafts shall be approximately 900mm from the operating floor unless otherwise
shown. The word "open" shall be cast onto the housing or handwheel indicating of rotation
to open the penstock.
3.5.10 Self-Contained Penstocks with Rising & Non-Rising Stems
When a self-contained penstock is specified, a heavy yoke shall be mounted on the

machined pads provided on the upper ends of the guide rails. The yoke shall have a
machined bearing surface for the lift nut or pedestal mounting plate. On non-rising stem
penstocks the nut pocket shall be cast on top of the slide so that the stem does not project
into the waterway when the penstock is fully opened. The thrust generated by penstock
operation shall be transferred to the yoke by the stem thrust collar of lift. When the
operating floor is above the self-contained gate, a stem extension of cold-roller or stainless
steel shall be coupled to the operating stem with a bronze coupling or cast stem extension
bracket. Operation shall be by a T-handle wrench or floor stand, shown on the plans and
gate schedule. In a T-handle arrangement the stem extension shall be supported by at least
on stem guide or a floor box with integral guide embedded in the operating floor.
3.5.11 Flushbottom Penstocks
When a flushbottom closure is specified, a resilient seat shall be attached to the frame so
that it flush with the invert. It shall be supported by a cast iron bracket which shall be bolted
to machined pads provided on the frame. The seal shall be held in place by a bronze or
stainless steel bar which shall be bolted through the seal to the bracket with stainless steel
fasteners. The cover (slide) shall be shortened and provided with a smooth rounded surface
along the bottom to depress the seal. When unseating heads are to be acting on a
flushbottom gate, top wedges shall be added, But bottom wedges will not be required.
Sealing pressure shall be varied by adjusting side and top wedges.
3.5.12 Painting
All cast iron parts of the penstocks (not in bearing or sliding contact) and stem guides shall
be painted to suit the expected duty in these specifications. That portion of the wall thimbles
which will be in contact with concrete shall not be painted.
3.5.13 Storage and Installation
Penstocks and equipment shall be stored and installed in accordance with the installation
manual furnished by the penstock manufacturer. After installation the completely
assembled penstock, stem, guides and lift shall be operated through one full cycle to
demonstrate satisfactory operation. Such adjustments as necessary will be made until
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operation is approved by the Engineer. The penstock shall be subjected to leakage tests
and pass the standard requirements for maximum leakage as specified in AWWA
standards AWWA-C-501.
3.6 PUMP LIFTING EQUIPMENT
3.6.1 General
The Pump Lifting Equipment shall be of a reputable make. The cross travel motors and
horizontal travel motors (where applicable) shall be of adequate size and suitable for the
duty and operating environment. All wheels of the crane shall be of forged steel. The
runway rail (where applicable) shall be of suitable hardened steel.
Limit switch shall be provided to prevent over-winching and also to stop the crane at the
end of the girder and runaway. Lifting hooks rails shall be of forged steel and shall comply
with BS 482 with regard to shape and material.
The motor and gears shall be housed in a body cast from malleable iron, high tensible alloy
steel or aluminium. The brake shall be fully integrated and synochronised with the motor
unit for quiet and smooth performance. All electrical devices shall be of the highest quality
and shall allow for easy replacement and repair. Hoist shall be of the high performance
type which allows for trouble-free continuous winching and frequent operations. Limit
switches shall be provided to prevent over winding of the clain.
Lift movement shall be controlled by a push-button control handle which shall be
suspended by means of a special, high-tensible flexible hose pipe designed to take the
mechanical strain and for mechanical protection of the interior cable.
Lifting chains shall be made of electrically-welded, heat-treated steel which are polished
and accurate to pitch and shall comply with BS 1663 or other approved standard. Pinions
and intermediate spur wheels of the gear assembly shall be made from high-grade heat-
treated steel and shall have precision machine-cut teeth. The gears shall be accurately
mounted and rigid and shall provide an exceptionally high level of overall mechanical
efficiency. The combined load wheel and pinion cage shall be carried on precision ball
bearings. Bronze pre-lubricated bearings shall be incorporated at all other rotating points in
the mechanism. Hooks shall be made of forged steel and shall be heat-treated for strength
and toughness. They shall comply with regard to shape and material with BS 482 or other
approved standard.
The Contractor shall apply for Testing and Approval by the Jabatan Keselamatan dan
Kesihatan Pekerjaan and pay all fees arise there from.
3.6.2 A-Frame (Fixed Type) Electric Chain Hoist (Pump Station 1,000PE)
The Contractor shall supply and install one (1) unit of electric chain hoist to the following
requirement:-
(a) Safe Working Load : 500 kg

(b) Lifting Speed : 6.7 m/min (single speed)
(c) Cross Travel Speed : 16 m/min (single speed)
(d) Span : 5.5 m
(e) Lifting Height : 12 m
3.7 SURGE SUPPRESSION EQUIPMENT
3.7.1 General
The Contractor shall furnish and install the surge suppression apparatus and associated
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equipment as specified hereunder in connection with the pumping system at the Pump
Station. The equipment to be provided shall be able to limit the maximum surge pressure to
that permissible in the force main and pumps in this Contract. The system shall include a
hydro-pneumatic surge arrestor, valves, piping and all appurtenances necessary to protect
the pumps and discharge sewer against upsurge and down-surge pressures due to power
loss.
The Contractor shall submit details of the equipment he proposes to supply together with
his surge analysis report endorsed by a Professional Engineer registered with Board of
Engineer, Malaysia for approval by the Engineer before fabrication works. The submittal
shall include all pertinent information upon which sizing is based as well as a performance
graph showing the calculated transient surge pressure with the equipment installed at
various locations along the pipeline over a sufficient time duration. The graph shall show
the minimum and maximum pressures exerted as a result of pump shut down and that no
negative pressures are created. The Contractor shall also furnish a written guarantee that
the performance of the surge control equipment meets the requirements of the pumping
system and that the equipment is suitable for use in sewerage systems.
Alternatively, the Contractor may propose (with no variation to the Contract) a surge
suppression system using surge anticipating air relief valves complete with surge analysis
report endorsed by a Professional Engineer registered with the Board of Engineers,
Malaysia.
3.7.2 Surge Vessel, Air Compressor and Associated Equipment
Surge vessel
The surge vessel shall be fabricated from carbon steel plate to ASTM A516 grade 70 or
equivalent. The surge vessel shall be of vertically mounted cylinder, supported on four
channels and shall be suitably sized and designed such that under the most severe
conditions of surge, the vessel and fittings are able to withstand the pressure of the water
column and the generated air pressure.
The surge vessel shall be provided with suitable pressure gauge with isolating valve, glass
level indicator furnished with a graduated scale and isolating cock which shall shut
automatically in the event of breakage of the gauge glass, drain pipe, compressed air
pipework connection, mild steel access ladder, inspection access of at least 600mm in
diameter with hinged cover, safety valves to BS 1123, by-pass, non return valve and
isolating valves.
The surge vessel shall be externally and internally sand blasted to Swedish Standard
SA2.5 and lined with the following painting system:-
Internally
1st coat COPON EA9 Red Oxide Primer @ 80 micron dry film thickness.
2nd coat COPON EA9 HB Finish @ 80 micron dry film thickness.
3rd coat COPON EA9 HB Finish @ 80 micron dry film thickness.
Externally
1st coat NIPPON Zinc Chromate Primer @ 30 micron dry film thickness.
2nd coat NIPPON Zinc Chromate Primer @ 30 micron dry film thickness.
3rd coat NIPPON Micaceous Iron Oxide @ 50 Micron dry film thickness.
4th coat NIPPON 9000 Gloss Finish @ 30 Micron dry film thickness.
5th coat NIPPON 9000 Gloss Finish @ 30 Micron dry film thickness.
The surge vessel shall be approved by Jabatan Keselamatan dan Kesihatan Pekerjaan
and a test certificate shall be provided to this effect.
Air Compressors
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Two air compressors shall be suitably rated and arranged for alternative operation, so that
each compressor shall be capable of pumping sufficient air and at such pressure into the
surge vessel to overcome the surge caused by the column of water in the rising main due
to sudden stoppage of the pumps sets for one reason or other.
Each air compressor shall be electrically driven by a suitable rated horsepower motor and
suitably wired for automatic/manual operation. The motors shall be horizontal, V-belt
coupled, base-plate mounted, TEFC construction and suitable for operating on 415V 50
Hertz 3 phase supply. Motors shall be of 1500 rpm constant speed, squirrel cage induction
type. The design, construction and performance characteristics for the motors shall
conform with current applicable standards for motors of this class and rating. The motors
shall be new, of current manufacture and shall be fully capable of performing in accordance
with the manufacturer's nameplate rating.
The air compressor shall have a capacity of not less than 10% in excess of the requirement
under the worst conditions. The air compressor shall be connected to the surge vessel by a
25mm diameter galvanised steel heavy grade pipe to BS 1387 provided with screw down
stop-tap. Belt guards, inlet muffle filter and removable pressure gauge shall also be
provided.
Automatic operation of the air compressor shall be controlled by an adjustable pressure
switch actuated by the receiver pressure. The unit shall have a bayonet type oil-level
gauge and low oil-level shutdown. In the event that the duty air compressor trips due to any
fault, the standby air compressor shall automatically become the duty air compressor.
Under manual mode, the duty air compressor shall be started and stopped from the
start/stop push buttons.
The air compressor shall be equipped with an air-cooled after cooler mounted on the
receiver and piped between the air compressor and the receiver tank and shall cool the
compressed air to within 14C of ambient temperature at full rated operation.
The compressor system shall be equipped with an automatic drain valve to release
accumulated condensate. The valve shall be provided with a manual by-pass.
Air Receiver
An air receiver of adequate capacity, complete with appropriate fittings and accessories
shall be provided. The equipment shall be painted in colour to be decided by the Engineer.
3.8 LEVEL CONTROL SYSTEM & WATER LEVEL INDICATOR
A suitable level measuring and level control system for the automatic operation of the
pumps shall be installed at the pump station.
The Level Control System shall be of float switch type and suitable for operation using 230V
50Hz AC supply. It shall be of environmentally friendly mercury and lead free design. It shall
be resistant to a wide range of chemicals and suitable for use in sewerage system.
3.9 PRESSURE GAUGE
The pressure gauge shall be suitable for use in sewerage systems. It shall be diaphragm-
separated and shall have an isolating valve for ease of removal of the gauge.
The pressure gauge shall have a brass case and bezel, polished and lacquered with local
and remote readings. It shall be calibrated to show readings within the range of -5m to +5m
for pump suction (where applicable) and 0m to 30m for pump discharge in Pump Station
No. 1 and 0m to 70m for pump discharge in Pump Station No. 2.
The digital pressure gauge shall be equipped with a local indicator capable of displaying the
instantaneous pressure reading within the range -5m to +5m for pump suction (where
applicable) and 0m to 30m for pump discharge in Pump Station No. 1 and 0m to 70m for
pump discharge in Pump Station No. 2. It shall also be connected to a remote digital
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display which shall be mounted on the pump control panel. The unit shall incorporate an
adjustable electronic damping device. Accuracy of the gauge shall be within +0.2% of the
calibrated span, over the required temperature range of 0 to 90C and humidity range of 0
to 100% R.H.
3.10 ELECTROMAGNETIC FLOW METER
The electromagnetic flow meter shall be neoprene-lined, fully welded, fully sealed and
suitable for use in the measurement of sewage flow within the range of 0 to 40 l/s for the
Pumping Station. It shall be suitable for 100mm diameter and 150mm diameter pipe
connection for Pump Station No. 1 and Pump Station No. 2 respectively. It shall
incorporate a design of reference circuit which uses flux sensing oil placed in the detector
head magnetic field and shall provide exceptionally long term stability and repeatability. It
shall have field replaceable component parts and shall be capable of operating while
completely submerged in 9m head water for an indefinite period of time. The field winding
shall be completely encapsulated in epoxy resin and connections shall be made via a
sealable coat aluminium terminal box. Magnetic coil insulation should be able to withstand a
temperature of 120oC (248oF). Primary flow-head must not have any electronic parts. The
meter shall be made of fibre glass housing and to be mounted directly to the pipeline. The
supply shall be single phase 230V and 50Hz. It shall be calibrated accurately and shall be
better than +0.25% of actual flow from full scale flow rate to 50% flow rate, increasing
progressively to +0.5% of actual flow at 10% flow rate.
The flowmeter shall have a local and remote display mounted in the instrumental panel and
shall have a digital read-out.
3.11 FLOW RECORDER
The Flow recorder shall be capable of continuous recording of flow rate of on circular
weekly chart using two pens. The measuring range shall be 0 to 40l/s for the Pumping
Station. The Recorder shall have an indicator showing instantaneous flow. The fibre-tipped
pen with a built-in ink capsule which shall be replaced in seconds shall need no priming.
The pen drive shall be directly driven by a D.C. linear motor. The chart shall be capable of
weekly output by electronic pulse generator and stepping motor. The response time shall
be 1 second maximum to 95% of final reading. The supply shall be single-phased 230V and
50Hz. The recorder shall be suitable for operation at ambient temperatures of 40C (104F)
and Relative Humidity of 95%.
The accuracy of the counter shall be + 0.015% reading and that of the instrument be +
0.5% span plus + 0.5% reading. The recorder shall be provided with 6 month's supply of
charts and a year's supply of ink capsules.
Alternatively, the Contractor may propose (with no variation to the Contract) an electronic
type of flow recorder using latest digital technology which records the instantaneous flow
and cumulative flow of sewage in digital format. Remote data transmission from the
recorder shall be through Ethernet, RS 232/ RS 485 or USB.
The electronic flow recorder shall have reliable data archiving with internal memory and
separate Compact Flash Card (mechanically locked) to ensure that there shall be no data
loss even in the event of power failure.
3.12 VENTILATION SYSTEM
3.12.1 Fans
The axial fans shall be the tubeaxial or vane axial, direct driven with aerofoil blades and
manufactured from heavy gauge metal or other approved materials. Fan blade material
shall be of hot dipped galvanized steel. Fan motors shall be non overloading over the
characteristic curve at the required rpm to deliver the specified airflows. Fan motor shall be
explosion proof rated (minimum rating shall be IEC:- EEx d llB T4).
The impellers shall be of steel or other equally approved materials and shall be accurately
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balanced after assembly. The blades shall be fastened to the hub or the blades and hubs
shall each be formed in one piece.
Fans shall be suitable for application in a sewerage pumping station. Extended lubricators
shall be provided with a suitable size access panel for fans fitted in a run of ductwork.
Fan speeds shall not exceed 1450 rpm unless specified otherwise. The fans shall be
directly coupled to totally enclosed squirrel-cage induction motors suitable for three-phase
50-Hz supply.
Fans noise shall not exceed 55 dBA measured at the boundary of pump station or building
property boundary (whichever is applicable to the Project).
3.12.2 Ductwork and Accessories
General
This section sets out the requirements of materials and standards of construction with
respects to ducting and grilles and accessories to be used on this project. All ductwork
shall not be less than the clear internal dimensions as indicated in the drawings and shall
be installed generally as shown.
It is the responsibility of the Contractor to check actual spaces available on site, prior to
fabrication of the ducts. If any departures from the drawings are deemed necessary, the
Contractor shall submit details of such departures and reasons to the Engineer for
approval.
All ductwork shown in the drawings shall be properly supported and anchored to the
building structure in approved manner using steel hangers, anchors, brackets and supports
which shall be fixed to the buildings structures by means of inserts on expansion shields of
adequate size and number to support the loads imposed thereon.
All ductwork shall be fabricated from first class quality galvanised sheet metal and all
ductwork and fittings shall be constructed in accordance with the practice as recommended
by the American Society of Heating, Refrigeration and Air Conditioning Engineers
(ASHRAE), SMACNA or other equivalent authority.
The gauges of sheet metal, type of joints and bracings shall be constructed in accordance
with the Sheet Metal and Air-Conditioning Contractors’ National Association (SMACNA) of
United States of America, ‘HVAC Duct Construction Standards Metal and Flexible, Third
Edition (2005)’.
Ductwork
All ductworks shall be machine bent and be free from buckles and waves. Transitions shall
be made with sides pitched not exceeding 200 (or 400 included angle) for diverging air flow
or as indicated in the Drawings. Duct may be constructed around obstructions at beams,
etc., provided duct construction practice conforms to ASHRAE recommendations and
overall air flow performance is not affected.
Each duct section shall be of 1220mm length to facilitate painting of internal surface before
installation.
After each duct section is fabricated but before installation the internal surface shall be
painted as follows:-
(a) One coat of DULUX GALVPRIME A931-10420 or approved equivalent.
(b) One coat of Dulux Red Oxide Primer A 500-PJ-0076 or approved equivalent.
(c) Two coats of approved compatible bituminous paint.
The external surface of the duct shall be painted as follows:-
(a) After each section is fabricated but before installation.
1. One coat of DULUX GALVPRIME A931-10420 or approved equivalent.
2. One coat of Dulux Red Oxide Primer A 500-PJ-0076 or approved equivalent.
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(b) After complete installation.

1. Two coats of ICI Dulux Gloss Finish A 365-Line or approved equivalent.
Colour Chart shall be forwarded to the ENGINEER for selection of colour.
2. Surface shall be free from all millscale, rust, dirt, grease and other chemical
contaminants before painting proceeds. Roller or brush shall be used for the
painting. The dried film thickness of each coat shall not be less than 30
microns.
Joints
Joints shall be made substantially air tight, and there shall be no ducts marks from air leaks
at duct joints or connections to grilles and diffusers. Longitudinal joints of ductwork shall be
made at corners only with Pittsburgh or equally approved seams. Transverse joints either
shop-made or field-made shall be flanged on ducts 451 mm and above with matching
angles bolted together. Angles shall be of size as per SMACNA and shall be riveted to
ducts. Angles shall be painted with two coats of Red Oxide Primer prior to installation.
Before bolting up, angle shall be coated with approved non-setting compound. After
complete installation of the duct, the angle shall be painted with two coats of ICI Dulux
Gloss finish A 365-Line or approved equivalent as specified for duct. Surface preparation,
method of application and thickness of each coat shall be as specified for duct. No
ductwork joints, bends or fittings shall be permitted within the thickness of the walls, floor or
ceiling structures. Laps at joints shall be made in the direction of air flow. Button punchy
or bolt connections in standing seams shall be spaced as fixed centres not greater than
140 mm.
Ductwork Supports and Openings
All ductwork shall be supported at intervals not greater than 2.4m and shall be supported
rigidly from the building structure in approved manner using steel hangers, anchors,
brackets and by means of inserts on expansion shields of adequate size and number to
support the loads imposed thereon. Wooden plugs will not be acceptable. Steel angle iron
hangers shall be of similar size to the bracings of that duct section. Ducts shall be so
constructed and installed as to be completely free from vibration under all conditions of
operation. All steel hangers, anchors and brackets shall be painted as specified for angle
in the previous clause.
Where ducts pass through floors, walls or particulars, the free space shall be adequately
caulked with suitable diameter asbestos rope or felt gaskets and a neat sheet metal angle
flange arranged to cover the free space. Where ducts penetrate the roof construction,
flashings shall be provided.
Dampers
Dampers shall be provided and installed in the sizes, types and locations as indicated on
the drawings and as may be necessary for the smooth functioning of the ventilation
system. Fully finished samples of types of dampers to be installed shall be submitted to
the Engineer for approval prior to ordering.
Multi-louvred dampers shall be of the opposed blade type and the frames shall be iron,
enameled after fabrication and reinforced where necessary to prevent vibration. The
blades shall be streamlined and fabricated of galvanised sheet of not less than 1 mm
thickness. Each damper blade shall be tipped with 6 mm thick hard felt to ensure silent
operation. The shafts shall be of steel and the bearings shall be graphite impregnated
bronze bushes or similar bearings.
Manual dampers shall be provided with adjustable locking quadrants of approved
manufacturer. Automatic dampers shall have a suitable connecting rod and base plate for
mounting the electric motor or pneumatic thruster as may be necessary. The permanent
open and close position shall be marked and labelled, and after installation and complete
satisfactory balancing, the normal working position of each damper lever shall be clearly
labelled.
Splitter dampers shall be operated by quadrant operators or 5 mm rod brought through the
side of the duct with locking set screw and bushing. Splitters shall be two gauges heavier
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than the duct in which they are installed.

Access doors or panels shall be provided for all concealed damper operators and locking
set screws.
Grilles
Grilles shall be installed in the sizes and locations shown on the drawings. They shall be
factory fabricated of steel or aluminium and shall be cleaned, primed and enamel baked
finished to approved colours and to a high quality. The duct collar connecting the duct grille
shall fit inside of the neck.
Grilles are to have the free area of not less than 60% or as specified in the drawings and
shall be of the louvred type. The static pressure drop across the grille when tested with
damper shall not exceed 0.13 in.wg and 0.2 in.wg at gross velocity of 370 fpm and 470 fpm
respectively.
3.12.3 Air Flow Balancing
Upon completion of the installation, the air flow of each inlet/outlet shall be balanced by
opposed blade volume control damper and the measurement should fall within 10% of the
specified quantities. Records of such air quantities and motor currents shall be submitted to
the Engineer.
3.12.4 Fans Control
An adjustable timer shall be incorporated to operate the fans for a prescribed time at the
pre-set interval.
A manual override facility shall be provided to bypass the automatic activation by the timer.
3.13 PORTABLE FIRE EXTINGUISHERS
3.13.1 General
Portable fire extinguisher shall be supplied and installed as shown in the Drawings and as
specified hereinafter. All materials shall be new and unused, be of best quality and comply
in all respect to the requirements of Jabatan Bomba Dan Penyelamat Malaysia.
Each fire extinguisher shall be supplied in fully charged condition and equipped with
automatic safety valve, outer lid, hose, nozzle, brackets and all accessories.
All the components shall be approved make, reliable, heat resistant and designed to suit
the pressure and chemical used.
All extinguishers shall be located in conspicuous positions on brackets or stands at a
height of about 1 meter above the floor. The exact location shall be determined on site by
the ENGINEER to avoid exposure to excessive heat and corrosive atmosphere.
3.13.2 Standards and Regulations
The type and capacity of the extinguishers shall be as indicated in the Drawings and in the
Bill of Quantities. They shall comply in all respects to the requirements of Jabatan Bomba
Dan Penyelamat Malaysia and conform to MS1539:- Part 1.
The Contractor shall be responsible for obtaining the necessary approval and certification
by Jabatan Bomba Dan Penyelamat Malaysia.
Page 468 of 486

3.14 COLD WATER AND SANITARY PLUMBING SYSTEM
3.14.1 General
The whole of the works covered by this Specification shall be carried out in accordance with
the latest British Standards Specifications, Codes of Practice and the local By-Laws. In
addition, works performed under this Contract shall also be to the approval of the relevant
Authorities for Sanitary and Water Plumbing Works.
All materials used in connection with the piping installation shall be of the quality specified
and where not specified, shall be in accordance with the relevant British Standards
Specification.
Water plumbing and sanitary plumbing shall be executed only by plumbers registered with
the appropriate Authorities.
All pipework, which are to be concealed and/or buried underground, shall be inspected by
the Engineer or his representative and the relevant Authority before covering up. The
Contractor shall make all necessary arrangements to have the pipes inspected and
approved.
The Contractor shall apply for and obtain all necessary certificates and approvals for the
work done from the relevant authorities and shall lodge the same with the Engineer.
3.14.2 General Requirements For Piping Works
Installation of Pipes
All pipes shall be fixed clear of each other and shall be arranged so as to provide easy
access for maintenance and repair. The pipes shall be easily replaceable for their full
length.
All pipeworks, except those chased in walls and floors, shall be installed at least 32 mm
clear of the surface of the supporting structure to give free access for painting of the full
external surface.
All water pipes, other than those within plantrooms, which are not concealed in ducts or
within ceiling space shall be concealed in walls or slabs up to a point as near as possible to
the fitting or appliance.
Where it is necessary to avoid sound transmission, a P.V.C. insert shall be provided
between the bracket and the pipe.
The number of pipe joints shall be kept to an absolute minimum. Long radius bend shall
generally be used on all changes of direction. Elbows shall only be used due to site
constraints.
Where manufacturer’s instructions differ from the Specification or the requirements shown
on drawings, the manufacture’s instructions shall be followed.
Pipe Sleeves
When pipe passes through walls, slabs, beams etc, pipe sleeve shall be provided.
Galvanised pipe sleeve shall generally be used except that brass or copper pipe sleeve
shall be used for the case of copper pipe. The size of pipe sleeve shall be at least one size
larger than the size of the pipe subject to a minimum annular space of 15mm between the
sleeve and the pipe.
Sleeves through floor slabs shall be extended 25mm above finished floor level while
sleeves through walls, beams etc shall have the sleeve ends flushed with the walls, beams
etc.
The annular space between pipe and pipe sleeve shall be fully packed with non-
combustible material to form an effective fire seal without hindering pipe expansion and
contraction.
Page 469 of 486

3.14.3 Pipe Supports and Fixings
All pipes shall be adequately and properly supported by steel hangers, brackets and
anchors. Brackets or support spacing shall be as follows:-
Diameter Maximum Spacing of Hangers / Brackets

Material of Pipe of Pipe Vertical Runs (m) Low Gradient Runs
(mm) (m)
Cast Iron or 50 1.8 1.8
Spun Iron 75 2.7 2.7
100 2.7 2.7
150 3.6 3.6
Unplasticized 32-40 1.2 0.5
PVC 50 1.2 0.6
75-100 2.0 1.0
150 2.0 1.2
Stainless Steel All sizes 2.0 2.0
Polypropylene 20 0.75 0.75
Random 25 0.85 0.85
Copolymer
32 1.00 1.00
40 1.10 1.10
50 1.30 1.30
63/65 1.50 1.50
75 1.60 1.60
90 1.60 1.60
At least one hanger or support shall be provided for each unit length.
All hangers shall be carefully aligned and spaced. In the case of horizontal drain lines, the
hangers shall facilitate the proper adjustment in the level of the pipeline.
Hangers or supports shall be secured to the structure by means of expansion bolts or
power driven bolts. Grouting of fixings to the structure shall not be permitted.
All pipes installed shall be flexible enough to allow for expansion and contraction due to
temperature changes, by taking advantage of change in direction of pipes.
Terminations for future expansion shall be fitted with a plugged or blanked valve.
3.14.4 Casting In of Pipes
Pipes passing through external walls shall have a short section of pipe cast into the wall at
the time of pouring of concrete. This section shall have a weld-on or cast-on blank flange at
the mid-section to prevent ingress of water. The ends of the pipe shall project at least
150mm from the face of the wall to facilitate jointing. The ends shall be of the proper
configuration for the method of jointing to be adopted.
3.14.5 Jointing of Pipes
Joints and connections in the plumbing system must be made watertight and care shall be
taken to ensure that no jointing material projects inside the bore of the pipe.
Flexible connection shall be used where differential movement may occur between two
sections of a system, or where excessive expansion or contraction may take place.
Page 470 of 486

Adequate number of mechanical couplings, flanged joints or union couplings shall be

provided, especially in plantrooms, service ducts, and adjacent to equipments, fittings and
valves so as to facilitate removal of pipe, fittings, and equipments for inspection and
repairs.
Care shall be taken to ensure that the pipes are properly aligned and laid at the required
gradient before the joints are permanently affected. Joints not properly made shall be cut
and remade.
The methods of jointing for the various pipes shall be as described hereafter in the
appropriate sections.
3.14.6 Prefabrication
Wherever possible, sections of the pipework shall be prefabricated in the shop and
delivered to the site ready for fixing and jointing. The Sub-assemblies shall be of such
sizes and weight so as to allow for easy handling and shall be tested at the place of
fabrication.
3.14.7 Inspection and Care of Pipework
All pipes, fittings and sub-assemblies shall be carefully examined on arrival on site, to see
whether they bear where appropriate, the proper British Standards and/or the Local
Authorities' mark.
Cast iron pipes shall be examined for damage to the protective coating. Minor damage shall
be made good by painting over with bitumen, but if major defects in the coating exist, the
pipes shall be returned to the workshop for recoating.
All open pipe ends, connection openings and access openings shall be temporarily plugged
to prevent the entry of foreign matter including during storage and transport.
Upon completion of each section, the pipework shall be inspected to ensure that all pipe
brackets, clips, etc. are correctly spaced and securely fixed, and that the pipework is well
jointed and all access covers, caps or plugs are accessible.
3.14.8 Cold Water System
(a) Stainless Steel Pipes and Fittings

The stainless steel pipes shall comply to ASTM A312. The fittings used shall be suitable
for screw jointing. All screw joints for pipe sizes up to 80mm ND shall be made water tight
with PTFE cord or thread sealing tape. Standard hemp shall not be used.
The pipings shall be installed in accordance with the best commercial practice. Care shall
be taken to ensure that the diameter is not restricted due to fabrication.
The pipings shall be supported suitably with allowance for the expansion. It shall not be
subjected to mechanical or other damage.
The pipes shall be reamed and cleaned before assembly and the entire piping system
shall be cleaned thoroughly prior to the installation of the fittings.
(b) Polypropylene Random Copolymer (PP-R) Pipes and Fittings

i. General
PP-R (Polypropylene Random Copolymer) pipes and fittings for Cold Water System shall
conform to ASTM D 635-91 / EN ISO 15874 / DIN 8077:1999 / DIN 8078:1996 / DIN
16962.
Pipes and fittings for cold water system shall be PP-R 80 rated to PN10.
PP-R pipes and fittings shall be suitable for use with potable water and shall have passed
the test of “Effect on the Quality of Water” under BS 6920 or AS 4020.
Page 471 of 486

ii. Jointing For ABS Pipe System

Electrofusion fittings welding method shall be used to join a piece of PP-R pipe with
another piece of PP-R pipe or any PP-R fitting by using the appropriate heating tool
conforming to the manufacturer’s specifications. The joints shall be made in accordance
with the manufacturer’s instructions.
Threaded joints shall be used for the connections between the Cold Water System with
other system or valves. The thread shall be made of brass complete with axial alignment
and free of dezincification process. Threaded joints shall be reinforced with suitable
amount of Polytetrafluoroethylene (PTFE) tape.
(c) Underground Pipe Installation

The depth of cover for the pipe, measured from the top of pipe to finished grade shall be at
a suitable depth, to prevent mechanical injury to the pipework but in any case shall not be
less than 1.0m.
The clear width of the trench shall not be less than the external pipe diameter plus 300mm
for pipes not exceeding 460mm in diameter.
Granular bedding shall be provided. The granular material shall be of size ranging from BS
mesh 0.3mm to 10mm. Coarse river sand may be used but the proportion of material finer
than BSS mesh 0.3mm should not exceed 5% by weight. The pipes shall be laid evenly at
the required level. There should be no hollows, voids or foreign material under the pipe.
The bedding should be compacted to the correct profile.
(d) Valves, Gauges and Accessories

i. General
All valves shall be supplied, installed, connected up and tested as required for the
satisfactory operation of the systems.
All valves, gauges, strainers etc shall be fitted in accessible positions for operation and
repair. All valves shall be suitable for the working and test pressures of the systems in
which they are installed and shall be of approved manufacture.
The connection between each valve and the adjacent equipment shall be made with a
union or a flange, for ease of dismantling. The size of the valve shall be of the same
diameter as the pipe for which they are to be fitted unless otherwise specified.
Before installation, all valves shall be blown out to remove any foreign matter. Valve
spindles shall be adequately lubricated with graphite and all glands shall be freshly packed
before installation.
ii. Gate and Globe Valves
Gate and globe valves 65mm and below shall be of the screwed bronze body type,
complying with B.S. 5154 : 1991. Pressure rating shall be PN16 or the expected pressure
encountered, whichever is higher. Gate Valves shall have solid wedge disc, rising stem
and union or screwed-in bonnet. Globe valves shall have union or screwed-in bonnet.
Gate and globe valves 75mm and above shall be flanged cast iron body type complying
with B.S. 5150 and B.S. 5152 respectively. Pressure rating shall be PN16 or the expected
pressure encountered, whichever is higher. Gate Valves shall have bolted bonnet, wedge
disc and rising stem. Globe valves shall have bolted bonnet and rising stem.
iii. Check Valves
Check valves of nominal bore below 100 mm shall comply with B.S. 5154, PN16 and shall
be of bronze with female screwed or flanged cast iron type with bronze discs. Check
valves with swinging disc shall be provided except that lift checks shall be used where
frequent operation of the valve is expected.
Check valves of nominal bore 100 mm and above shall be the spring loaded, dual plate,
Page 472 of 486

flat seat type with independent springs for each plate. The construction shall be of a cast
iron body, aluminium bronze plate, Buna-N seal, SS316 spring, hinge pin and stop pin.
Pressure rating shall be per ANSI 16.1 Class 125.
iv. Butterfly Valves
Butterfly valves shall be capable of operating and giving tight closure with up to 1035kPa
differential across the disc. Valve body and seat clamp shall be of cast iron. Discs shall
be of cast iron or stainless steel. Material of seats and sealing rugs shall be suitable for
the operating temperatures. Spindle shall be stainless steel.
v. Strainers
Approved Y-type strainers shall be provided upstream of all pumps, motorised and
solenoid valves. All strainers of sizes up to and including 50mm diameter shall be of steel
or bronze body type and threaded. For sizes of 65mm and above, they shall be of the cast
iron flanged type. A removable self-aligning screen of stainless steel or bronze shall be
provided in each strainer. Pressure rating shall be ANSI Class 125
Isolating valves shall be arranged to allow cleaning of the strainers without draining the
systems. Mesh sizes shall be to the recommendations of valve manufacturer and shall
suit the equipment installed.
vi. Ball Float Valves
All ball float valves shall be supplied and fitted complete with back nuts, ball float and arm.
Ball floats shall be of soldered copper, brass or PVC. Float valves shall be of the low
pressure type complying with B.S. 1212.
vii. Pressure Gauges
Pressure gauges shall be of the Bourdon tube type with a minimum dial size of 100 mm
diameter. The pressure gauges shall be calibrated in kN/m2 and m head with a full scale
reading of approximately double the average working pressure. All pressure gauges shall
be provided with gauge cocks and upper tubing. Accuracy of pressure gauges shall be +
1.5% of full scale reading.
viii. Drain Cocks
Gunmetal drain cocks shall be provided as necessary to ensure that all sections of the
pipework and plant can be effectively drained. Sizes of drain cocks shall be as stated
below :-
1. Pipes up to and including 65mm diameter - 13mm diameter.
2. Pipes 75mm diameter up to and including 150mm diameter - 20mm diameter.
ix. Automatic Air Release Valves

Automatic air release valve shall be provided at all high points of the piping system for
automatically releasing air which may accumulate in the pipe while the system is in
operation and under pressure. Automatic air release valve shall have steel or cast iron
body and cover. Float, leverage mechanism and all other internal trim shall be stainless
steel. Valve outlets shall be tapped for connection of drain lines.
A shut-off valve shall be provided at the inlet pipe to the automatic air release valve.
Automatic air release valve shall have drain plug or shall have a drain line with shut-off
valve, connected to the inlet pipe to the automatic air release valve above the inlet pipe
shut-off valve.
Automatic air release valve shall be rated for working pressure of 10 Bar or the expected
working pressure, whichever is greater. The orifice size shall be selected based on
flowrate in pipe and system pressure.
Automatic air release valve shall be installed at the downstream side of each loop in the
pipeworks. The discharge from these valves shall be piped to the nearest floor drain or
drain pipe.
Page 473 of 486

x. Surge Relief Valve

It shall be point controlled and back pressure shall not affect its set point. The relief
pressure adjustment range shall be 6.9 bar to 13.8 bar. The valve shall open fast in order
to limit system pressure, close gradually to control surges and reset drip tight within 5% of
its pressure setting.
The main valve shall be of the hydraulically operated pilot controlled, diaphragm type
globe valve rated at 20.7 bar. The main valve body and cover shall be of bronze material.
(e) Mechanical Level Indicators
Each tank compartment shall be fitted with a float and cable operated mechanical level
indicator, located at the front of the tank. The floats, guides, cables and pulleys shall be
constructed of durable, corrosion resistant materials. The scales shall be fixed to the front
of the tank and shall be of metal construction with a hard and durable paint finish. The
cable systems, moving indicators, and counter-weights shall be arranged so that the scale
is direct reading, that is, the indicator shall move up as the level rises. The scale shall be
positioned so that the water level as indicated by the indicating pointer corresponds as
closely as possible to the actual level in the tank.
(f) Water Storage Polyethylene Feed Tank
The tanks shall be Polyethylene tank complying with MS1225 and approved by SIRIM and
Jabatan Bekalan Air Negeri Sembilan. The Polyethylene Tank shall be warranted against
manufacturing defects for ten (10) years. The polyethylene tank shall be manufactured
from premium grade UV resistant polyethylene which shall allow the tank to last for more
than 20 years for all outdoor installation. The capacity of the tanks shall not be less than
those indicated on the Drawings.
Each tank shall be fitted with an inlet with manually operated valve, float-operated valve,
flanged outlets, overflow pipes, warning pipe and scour pipe.
The overflow pipe and warning pipe shall be brought to a position so that the discharge
from such overflow pipe and warning pipe will be readily visible and shall be to the
approval of Engineer.
(g) Testing and Commissioning
i. Cleaning out Pipework
After installation and before hydrostatic tests are carried out, the pipework shall be cleaned
out thoroughly.
Temporary connections shall be made from the mains to each section of pipework to be
flushed out. The discharge of each section of pipework shall be led to a suitable gully or
drain.
Pipework shall be disconnected from tanks, control valves and equipment before being
washed out.
ii. Testing
After cleaning the pipework shall be tested for water tightness. Subject the pipes, pipe
fittings and connected appliances to a test pressure of at least 1.5 times the maximum
working pressure with the pressure applied and maintained for at least 1 hour. When all
draw-off taps are closed, the service shall be absolutely watertight. Each tap shall be
opened and tested for the rate of flow. Any fault discovered shall be made good.
iii. Sterilization of Installation
The tanks shall be scrubbed down and flushed out with water containing a solution of
chloride of lime.
The tank shall then be filled with water and a sterilizing chemical containing chlorine added
gradually while the tank is filling to ensure thorough mixing. Sufficient chemical shall be
used to give the water a dose of 50 parts of chlorine to one million parts of water. If
ordinary `bleaching powder' is used, the proportions shall be 1.5 kg. of powder to 10,000
litres of water, the powder shall be mixed with water to a creamy consistency before being
Page 474 of 486

added to the water. When the tank is full the supply shall be shut off. All the taps on the
distributing pipes shall then be opened successively, working progressively away from the
tank. Each tap shall be closed when the water discharged begins to smell of chlorine. The
tank shall then be topped up and the whole system shall remain charged for at least three
hours, whereupon a test shall be made for residual chlorine; if none is found, the
sterilization must be carried out again.
Finally the tanks and pipes shall be thoroughly flushed out before any water is used.
3.14.9 Sanitary Plumbing
(a) General
The Contractor shall supply, install, test and set into perfect operating condition the whole
of the sanitary plumbing system comprising all soil, waste and vent piping. The sanitary
plumbing installation shall comply with the requirements of the latest Sewerage and
Sanitary By-Laws applicable to the locality.
The specification and the accompanying drawings indicate the extent and general
arrangement of the system. If any departures from the Contract Drawings are deemed
necessary by the Contractor details of such departures and reasons therefore shall be
submitted to the Engineer for approval, prior to installation.
All materials, fittings, fixtures, apparatus and all other items shall be of the best quality of
their respective kinds, sound, free from defects and approved for use by the respective
Authorities.
This specification is general and covers the various methods and materials which may be
required. It is the responsibility of the Contractor to ascertain from the specification the
specific requirements of this project.
It is not to be construed that an omission of a specific reference to any part of the works in
the specification and/or the drawings means that work is excluded from the contractual
requirements.
(b) Piping Material
Above ground level : U.P.V.C. pipes and fittings to B.S. 4514 (for soil pipes
and fittings) and B.S. 5255 (for waste pipes and
fittings).
Above ground level : U.P.V.C. pipes and fittings to M.S. 979 Part 2 (for
pipes of 200mmØ)
Underground level : U.P.V.C. pipes and fittings to BS 5255 (for pipes of
50mmØ and below)
Underground level : U.P.V.C. pipes and fittings to BS 4514 (for pipes and
fittings of 80mmØ)
Underground level : U.P.V.C. pipes and fittings to BS EN 1401-1:-2009/MS
979:-Part 1:-1985 (for pipes of 100mmØ and 150mmØ)
Underground level : D.I. pipes and fittings to BS EN 598:2007+A1:2009 (for
soil pipes between WC and service manhole, for waste
pipe between GT and service manhole and for soil
pipes between service manhole and sewer manhole)
(c) Joints and Fittings for UPVC Pipes
Joints and fittings for the use with UPVC shall be in accordance with B.S. 4346.
Jointing procedures for UPVC pipes shall generally comply with CP312 : Part 2:1973.
(d) Access Opening
Sufficient access shall be provided to enable all pipework to be cleared and tested. Access
openings of adequate size shall generally be provided on the vertical stack directly opposite
a branch line, at the extreme end of a main branch line, at the junction of subsidiary branch
Page 475 of 486

to a main branch and at bends.

(e) Fixture Trap
Plumbing fixtures, except those having integral traps, shall be provided with a water-seal
trap, placed as close to the fixture outlet as possible.
Trap seals, if not provided with union connections at each end to permit removal for
rodding, shall have an accessible trap screw of ample size protected by this water seal.
(f) Floor Wastes
The Contractor shall supply and install floor wastes comprising 100mm × 75mm gully
complete with inlet riser and chromium plated screwed grating, at a level to enable the floor
to be graded to same and connect to the drainage system complete with all necessary
inspection eye fittings.
(g) Pipework Installation
Pipework shall be securely fixed in position with plastic pipe clips, hanger supports, clamps
and U-bolts.
Pipe clips shall be correctly aligned and shall provide a flat smooth surface for contact with
the pipe. The straps shall not clamp the pipe tightly.
Horizontal lines shall be arranged to have the maximum grade with cleaning eyes and
inspection openings in accessible locations.
The pipework in branch connection shall always be arranged to allow free drainage of the
system. Connections to main or branch pipes shall be so arranged as to prevent cross flow
from one appliance to another. Connections shall be made with an easy sweep in the
direction of flow. Bends shall be of long radius where applicable.
The venting pipes shall be extended through the roof to the required height with the open
end protected by means of a UPVC vent cowl.
(h) Anti-Syphonage Pipes
An anti-syphonage arm shall be installed where necessary. Anti-syphonage pipe shall be
connected from each fixture to branch or main vent pipe above the level of such fixtures.
Except in special cases and with the approval of Local Authorities, anti-syphonage pipes
shall be connected to the waste, soil or combine pipes on the opposite side of the water
seal to the fixture to a point not less than 75mm or not more than 300mm from the highest
point of the traps. No fixtures shall be connected to the soil, waste or combined pipe at any
point of the anti-syphonage pipe.
(i) Testing
The completed plumbing system shall be tested for water and gas tightness as well as for
hydraulic performance.
(a) Water Test shall be applied before the appliances are connected and carried out in
sections so as to limit the static head to 5m. All openings affected by the test shall
be sealed and the system filled with water. Some time shall be allowed for
absorption by the pipes and joints to take place, after which the level shall be
topped up. The pipes and joints shall be inspected for leakage. If no appreciable
fall in water level occurs during a period of 10 minutes the system shall be deemed
to have passed the test.
(b) Air Test may be applied by inserting expanding rubber testing plugs in the lower and
upper ends of the main sanitary and vent pipes and sealing the plugs with water.
The testing plug at the upper end of the ventilating pipe shall be fitted with a tee-
piece with a cock on each branch, one branch being connected by a flexible tube to
a Manometer. Air pressure is then introduced into the system through the other
branch of the tee-piece until a pressure of 65mm water gauge is shown on the
Manometer scale.
Alternatively, the air pressure may be applied by passing a flexible tube from a tee-
Page 476 of 486

piece attached to manometer through the water scale of the trap of the sanitary
appliance, the test then being carried out as described above.
The system shall be deemed to have passed the test if the pressure remains
constant for a period of three minutes.
(c) Smoke Test shall be employed to locate faults indicated by the air test. Smoke is
pumped into the system with a smoke machine, care being taken to ensure that the
system is filled with smoke before sealing with plugs.
(d) Hydraulic Performance discharge tests shall be made for all appliances, singly and
collectively. Obstruction in any of the pipe lines shall be traced and the whole
system examined for proper hydraulic performance, including the retention of an
adequate water seal in each trap.
Any defects revealed by the tests shall be made good and the tests repeated until a
satisfactory result is obtained.
3.15 SERVICE AND MAINTENANCE
3.15.1 General
The work covered by this section is for the supply of all materials, appliances, labour and
necessary incidentals for the service and maintenance of the Contract Works.
3.15.2 Workmanship and Materials
The works described in this section shall be performed by workmen skilled in the service,
maintenance and repair of sewerage pump station.
All materials to be supplied in connection with works under this section shall be new and
unused, and shall generally be of the best quality as regards to manufacture and
performance.
3.15.3 Supervision
The foreman in charge of the service, maintenance and repair work to be carried out under
this Specification shall be thoroughly competent in supervising the service, maintenance
and repair of pump station mechanical system, and be acceptable to the Engineer.
3.15.4 Scope of Work
All machinery and equipment comprising the complete pump station mechanical system
under this Contract shall be serviced and maintained strictly in accordance with the
servicing and maintenance schedule as set out below.
The Contractor shall advise the Engineer of any defects in any part of the Works observed
during the routine inspection and service, and shall repair such defects.
The Contractor shall also provide emergency repair services during normal working hours
and also during overtime hours if required to do so by the Engineer.
3.15.5 Servicing and Maintenance Schedule
The Contractor shall submit manufacturer recommendations on servicing and maintenance

schedule for every mechanical item in the O&M Manual.
The Contractor shall inspect and service all equipment comprising the Works at least once
a month.
At each such monthly inspection and service of the Works, the works detailed below shall
be performed by the Contractor:
(a) Mechanical Items
Page 477 of 486

All mechanical items shall be inspected/serviced following manufacturer’s

recommendations stated in O&M Manual.
(b) Electrical Motors
Inspect all electric motors, and
• Check all motor bearings, and lubricate with grease as necessary.
• Check all motor bearings and slip rings of all motors, and clean as necessary.
Renew carbon brushes as necessary.
• Check safety devices fitted to all motors, and clean, adjust and lubricate as
necessary.
(c) Electrical equipment
Inspect and check the routine operation of all electrical starters, electrical control
gears, and ancillary electrical apparatus, and
• Clean, adjust and lubricate all bearings, pivots and other moving parts as
necessary.
• Clean or renew electric contactors as necessary.
(d) Temperature controls
Inspect and check the routine operation of all automatic temperature controls and
relays, and
• Clean, adjust and lubricate all bearings, pivots and other moving parts as
necessary.
• Clean or renew electric contactors as necessary.
• Renew electric fuses as necessary.
(e) Performance
Check the performance of the complete air conditioning system, and adjust air
volume control dampers as necessary.
(f) Correct operating method
Instruct the operators responsible for the operation of the plant and equipment on
correct method of operating the plant and equipment, and on the maintenance
points to be watched.
(g) Report on defects
Report in writing to the Engineer of defects discovered in any part or parts of the
Works. The report shall state the cause/s of the defect/s observed, and shall
include an estimate of the cost of repairs required.
3.15.6 Consumable Materials
The Contractor shall supply the following consumable materials as and when required:
• All oils and greases required for lubrication of fan bearings, motor bearings, pivots
and other moving parts.
• All consumable filter elements.
• All carbon brushes required to replace worn brushes in electric motors.
• All electric contact points required to replace worn electric contact points in
switchgears, motor start gears, electrical control gears and electric relays.
• All electric fuses required to replace blown fuses.
• All cotton waste, soap detergent and other cleaning materials required for cleaning
Page 478 of 486

purposes.
The Cost of these consumable materials shall not be charged for separately by the
Contractor, but shall be included in the respective sum entered in the Bill of Quantities for
service and maintenance.
3.15.7 Service and Maintenance Records
(a) Service/Maintenance record book

The Contractor shall provide a service and maintenance record book for the Works
being serviced and maintained by him. This record book shall be kept in the pump
station and brief details of all services, maintenance and repairs carried out on the
Works shall be entered by the Contractor into this book for checking purposes. The
address and telephone number of the Contractor's service station shall also be
entered into this record book to facilitate emergency service calls.
(b) Maintenance/Repair sheet
The Contractor shall also keep an accurate detailed record in duplicate of all
service, maintenance and repair work carried out by him on the Contract Works.
This record shall be in the form of a maintenance/repair sheet, and shall be
counter-signed by the Building Owner and/or the Engineer each time the Works is
attended to by the Contractor.
Page 479 of 486

Specification - Pump Station

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Exhibit II – Specifications and Contract Drawings

SPECIFICATION FOR PUMP STATION

1.1 CODES, STANDARDS AND REGULATIONS

1.2 SCOPE OF WORKS

1.3 GENERAL REQUIREMENT ON PLANT AND INSTALLATION

Page 421 of 486

Item Submissions Submission Date Nos. of Copy

2. Method Statements 2 Weeks After Award and 4

3. Technical Data and Samples 2 Weeks After Award and 2

4. Shop Drawings 8 Weeks Before 4

5. Site Inspection and Test 6 Weeks Before 4

6. Factory Test Report for Major Before Shipment of 4

7. Final Draft As Built Drawings 4 Weeks Before Testing 2

8. Final As Built Drawings 2 Weeks After Completion Refer to Section

9. Testing and Commissioning 6 Weeks Before Testing 4

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Item Submissions Submission Date Nos. of Copy

11. Final Draft of O&M Manual 4 Weeks Before Testing 2

12. Final O&M Manual 3 Weeks After Testing and 6

1.5 REQUIREMENTS AND CONTENTS OF SUBMISSIONS

1.5.2 Builder’s Work and Drawing

1.5.3 Method Statements

List of Method Statements to be submitted:

1.5.4 Technical Data and Samples

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• Tabulation of motor rating and electrical data (where applicable)

1.5.5 Schedule of Shop Drawings Submission

1.5.6 Shop Drawings

The shop drawings shall include the following information:-

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1.5.7 Site Inspection and Test Procedures and Forms

1.5.8 Factory Test Report for Major Equipment

1.5.9 As Built Drawings

The requirement for as built drawings shall be

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1.5.10 Testing and Commissioning Procedures and Forms

Testing and Commissioning procedures shall include:-

1.5.11 Testing and Commissioning Reports

The testing and commissioning reports shall include:-

1.5.12 Operation and Maintenance Manuals

The complete O&M Manual shall comprise the following documents:-

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1.6 TOOLS, APPLIANCES AND TEST EQUIPMENT

1.7 OPERATIONS AND MAINTENANCE TRAINING PROGRAM

1.7.2 Scope of Training

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(b) Recommended procedures for collecting and interpreting specific performance

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JPP - Jabatan Perkhidmatan Pembetungan

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SWG - Standard Wire Gauge

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SPECIFICATION FOR PUMP STATION

2.1.2 Erection Marks on Multipart Assemblies

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painting or galvanising, shall be clearly legible after painting or galvanizing.

2.1.3 Cleaning, Protection of Surfaces and Painting

2.1.5 Rating Plates and Name Plates

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2.1.7 Protection of Materials Against Weather

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2.2.1 Nuts, Bolts, Studs and Washers

Galvanising shall conform to BS EN ISO 1461 : 1999.