Contents

1. PART I GENERAL AND TECHNICAL CONDITIONS.............................................3

1.1 SCOPE OF TENDER.......................................................................................................3
1.2 QUALITY OF PUMPED WATER..................................................................................3
1.3 WORK LOCATION.........................................................................................................3
1.4 CLIMATIC CONDITIONS..............................................................................................3
1.5 INFORMATION TO BE VERIFIED...............................................................................4
1.6 CONTRACT DRAWINGS...............................................................................................4
1.7 ACCEPTED TENDER AND WORKSHOP DRAWINGS..............................................4
1.8 DRAWINGS & SPECIFICATIONS TO BE SUBMITTED BY THE CONTRACTOR 4
1.9 PAINTINGS......................................................................................................................5
1.10 ESSENTIAL TENDER SUBMITTALS.......................................................................5
2. PART II GENERAL TECHNICAL SPECIFICATIONS.............................................6
2.1 SUBMERSIBLE PUMPING UNITS...............................................................................6
2.2 PIPES, VALVES, FITTINGS AND SPECIAL PIECES.................................................8
2.3 CONTROL SYSTSEM...................................................................................................10
2.4 Control Cables.................................................................................................................15
2.5 MEASUREMENT INSTRUMENTATIONS.................................................................16
2.6 ELECTRIC POWER SUPPLY AND DISTRIBUTION BOARD.................................19
 Electrical Material Wires...................................................................................................34
 Conduit Systems................................................................................................................34
 Lighting Switches..............................................................................................................35
 Socket Outlets....................................................................................................................35
 Led luminaires...................................................................................................................35
 General...............................................................................................................................36
 Description of Work..........................................................................................................36
 Submittals..........................................................................................................................36
 Light Emitting Diode (LED) Lamp...................................................................................36
2.7 STATION AUXILIARIES.............................................................................................42
2.8 DIESEL-DRIVEN STAND-BY ELECTRIC GENERATING UNIT............................44
2.9 SPARE PARTS...............................................................................................................49
2.10 General Specifications for Water Hammer Equipment...............................................50

1
 3. PART III TESTS AND TRIALS...................................................................................58
3.1 GENERAL......................................................................................................................58
3.2 EXPENSES.....................................................................................................................58
3.3 CALIBRATION OF INSTRUMENTS..........................................................................58
3.4 GUARANTEED FIGURES............................................................................................58
3.5 UNITS OF MEASUREMENTS AND DEFINITIONS..................................................58
3.6 TESTS OF MATERIALS AND MACHINERY AT WORKS......................................59
3.7 TESTS FOR PUMPING UINTS....................................................................................59
3.8 TESTS ON CIRCUIT BREAKERS...............................................................................59
3.9 TESTS ON LOAD BREAK SWITCHES......................................................................60
3.10 TESTS ON CABLES..................................................................................................60
3.11 TESTS ON DIESEL ENGINE AND ALTERNATOR..............................................60
3.12 TESTS AT SITE FOR MECHNICAL & ELECTRICAL EQUIPMENT..................62
3.13 CONDITIONS OF TESTS AND GUARANTEES....................................................63
4. PART IV PENALTIES AND REJECTION................................................................65
4.1 PENALTY CONDITIONS.............................................................................................65
4.2 DISCHARGE OF THE MAIN-PUMPS.........................................................................65
4.3 REJECTION CONDITIONS OF MACHINERY...........................................................65
4.4 THE ENGINE OF THE GENERATING SET...............................................................65
4.5 THE GENERATING SET..............................................................................................66
4.6 THE ALTERNATOR.....................................................................................................66
5. PART V PARTICULAR SPECIFICATIONS.............................................................67
5.1 PARTICULAR SPECIFICATIONS FOR AL FARASYA P.S......................................67

2
 PART I GENERAL AND TECHNICAL CONDITIONS

1.1 SCOPE OF TENDER

This Tender comprises supply, erection, testing and handing over new works to SOHAG
Water and Wastewater Company who will be stated as “Owner” in the rest of this document, in
perfect condition and excellent working order, of the mechanical and electrical equipment for
the sewage pumping stations for AL FARASYA located at SOHAG Governorate.
Tenderers are responsible, on their own cost, for carefully studying the sites conditions, all
necessary electromechanically equipment not mention in tender documents to consider it in
their cost without any additional cost, accessibility roads and available transportation facilities,
and work execution time schedules.

1.2 QUALITY OF PUMPED WATER

The pumping stations shall pump partially screened sewage water containing a considerable
amount of solids, rags, vegetable refuses, grit, sand, etc. The water is moreover partly septic.

1.3 WORK LOCATION

The owner reserves the right to change the site of the station as it may deem necessary to avoid
any unforeseen difficulties underlying the choice of that site without any obligation arising
from the part of the Contractor.

1.4 CLIMATIC CONDITIONS

a. Air Temperature:
The mean air temperature in shade is 37.5o C.
The minimum air temperature in shade is 7.5o C.
The maximum-recorded summer temperature in shade is 45.0o C.
b. Water Temperature:
The maximum water temperature is 35.0o C.
The minimum water temperature is 10.0o C.
The average water temperature is 14.0o C.
The average water temperature in summer is 26.0o C.
c. Barometric Pressure:
The maximum barometric reading is 770 mm Hg. occurs in January.
The minimum barometric reading is 746 mm Hg. occurs in July.
The mean barometric reading is 758 mm. Hg.
d. Relative Humidity:
The average yearly relative humidity is 77.0 %.
The minimum yearly relative humidity is 39.0 %.
The average humidity during summer is 61.3 %.

3
 The average humidity during winter is 74.3 %.
e. Dust:
The air at site is sometimes charged with a considerable amount of fine sand.

1.5 INFORMATION TO BE VERIFIED

Tenderers are responsible, on their own cost, to check or verify the information provided in this
document and to obtain any further information that may be necessary to prepare their tenders
and fix their rates. No payments, compensations or allowances shall be entitled due to extra
expenses, loss or delay which any arise from any error, missing statement or any data obtained
by the contractor differing in any way from the data given in this document. This will not
diminish the responsibility of the contractor to supply, erect and handing over to the owner all
works in conformity with modern manufacturing practice, latest models, safety measures of
facility and personnel and the contract conditions and by all means adapted to fulfill the
purpose for which it is intended.

1.6 CONTRACT DRAWINGS

The annexed Drawings are provided only for guidance. The works shall be executed according
to the Contractor’s workshop drawings that should be approved by the supervision
representative engineer.

1.7 ACCEPTED TENDER AND WORKSHOP DRAWINGS

The Contractor shall, as soon as possible after the acceptance of his offer, submit to owner 4
complete copies of all tender specifications, catalogues and drawings. The contractor shall also
submit, for the owner approval, 4 complete copies of detailed workshop drawing of every part
of machinery and foundations. The contractor shall be bound, without extra payment, to
introduce any modification that not affecting the general layout as determined by the
specifications, as may be requested by the owner representative and / or supervision engineer in
order to fulfill the purpose for which the works are intended.

1.8 DRAWINGS & SPECIFICATIONS TO BE SUBMITTED BY THE CONTRACTOR

The workshop drawings, diagrams and specifications called for in the previous article shall
include, but not limited to, the following drawings, diagrams and curves:
1.Sectional views showing the general arrangement of the new sewage pumping units with
the necessary piping, valves, and accessories.
2.Detailed drawings of all foundations and cable trenches.
3.Elevation and plan of the new switchboard showing all apparatuses and instruments.
4.Detailed wiring diagram of the switchgear.
5.Wiring diagrams of all electric connections and lighting including lighting calculations.
6.Full characteristic curves of the discharge, total manometric head, horsepower and
efficiency of the new pumping units.
7.A complete set of catalogues for the new supplied items.
8.Detailed drawing of new earthing system and calculation of the system.
9.Detailed drawings of new auxiliary equipment such as cranes, screens, ventilation units….
etc.

4
 10. Short circuit, voltage drop, load list and cables calculation to be submitted according to
actual loads.

1.9 PAINTINGS
All metal works supplied under this contract shall be sandblasted and painted with two coats of
red lead before leaving the manufacturer's works and a third coat shall be applied after
completion of erection.
Moreover, two coats of oil paint shall be applied to the metal work not subjected to the
atmosphere, two coats of water proof paint to that subjected to the atmosphere, and two coats of
bit mastic paint to that in contact with water.
The Contractor shall keep the painting in good condition during the period of guarantee and
shall repaint wherever necessary before the final take-over.
Before any paint can be applied on the work, a sample shall be taken for approval from each
container by the Owner representative either in the presence or in the absence of the Contractor
or his representative if he fails to attend after due notification, to be analyzed and the containers
shall be sealed.

1.10 ESSENTIAL TENDER SUBMITTALS

The tenderer shall submit complete set of drawings, catalogues, fully detailed information and
literature in connection with various equipment and sections of the work included in the
contract.
The Tenderer shall check all drawings and dimensions of the sewage pumping station including
piping, valves and accessories.
It is a must that the tenderer fill, sign and submit the bill of quantities and prices, guarantee
tables as well as the design tables for the specified equipment.

5
 PART II GENERAL TECHNICAL SPECIFICATIONS
2.1 SUBMERSIBLE PUMPING UNITS
The pump shall be equipped with a submersible electric motor for operation on 380 V, 50 Hz,
3-phase power supply, with jacketed type submersible power/control cable of not less than 20m
length. Each unit shall be complete with a mating grey cast iron GG25 discharge-connecting
elbow (foot bend), at least 10 meters of stainless steel 316 lifting chain of adequate strength,
guide rails complete with brackets and all appurtenances and accessories required for easy
installation and efficient operation.
2.1.1 Pump Design
The velocity at suction of the pump mustn’t exceed 4.5 m/s. The pump shall be capable of
handling unscreened sewage water contains solids. The discharge connection elbow shall be
permanently installed in the wet well along with the discharge piping.
The pump shall be automatically connected to the discharge connection elbow when lowered
into place, and shall be easily removed for inspection or service. There shall be no need for
personnel to go into the wet well. A simple linear downward motion of the pump shall
accomplish sealing of the pumping unit to the discharge connection elbow. A sliding guide
bracket shall be an integral part of the pump unit.
The entire weight of the pump unit shall be guided by not less than two guide rails (bars) and
pressed tightly against the discharge connection elbow. Sealing of the discharge interface by
means of a diaphragm, O-ring, or other devices will not be acceptable. No portion of the pump
shall bear directly on the floor of the sump. The pump with its appurtenances and cable shall be
capable of continuous submergence underwater to a depth of 10 m, without losing its
waterproofing.
2.1.2 Guides and Accessories
Each pump unit shall include complete set of standard accessories required for installation in
the pump station wet well as shown on the drawings. Length of guide bars shall be determined
in the field, furnished and cut to fit by the Contractor. These bars shall be sized according to the
pump dimension and shall be of stainless steel 316L and will be furnished by the pump
manufacturer. Accessories shall include the discharge connection 90 degree elbow with special
base support plate and anchor bolts, washers and nuts, upper guide bar brackets, intermediate
guide bar brackets, safety hook including eye nut, lateral nut springs, hex bolts, washers and
lock washers in addition to a pressure gauge installed on each pump’s discharge pipe. All bolts
and nuts inside sump shall be of stainless steel 316L. The pump manufacturer shall furnish all
the aforementioned equipment.
2.1.3 Pump Construction
The pump casing shall be of GG25 according to DIN standards.
The impeller shall be of GG25 according to DIN standards and Duplex steel is preferred.
Where watertight sealing is required, rubber O-ring shall be used. No secondary sealing
compounds, rectangular gaskets, elliptical O-rings, grease or other devices shall be used. Pump
exterior shall be sprayed with PVC epoxy primer and rubber paint finish.
The pump cable sizing shall confirm to IEC specifications for pump motors. The cable entry
shall preclude specific torque requirements to insure a watertight and submersible seal. The

6
cable entry junction chamber and motor shall be separated by a stator lead sealing gland or
terminal board, which shall isolate the motor interior from foreign material gaining access
through the pump top.
The pump motor shall be squirrel-cage, induction, and shell type design, housed in an air-
filled, watertight compartment. The enclosure protection shall be according to the IEC
requirements for submersible motor. The degree of protection shall be not less than (IP68). The
stator winding and stator leads shall be insulated with moisture resistant class ”H” insulation;
with temperature rise not exceed that of class “B”. The motor shall be designed for continuous
duty with Stare -Delta motor starter and capable for sustaining a minimum of ten (10) starts per
hour. The rotor bars and short circuit rings shall be made of aluminum. At the design point, the
motor shall not draw more than the nominal KW value at nominal working voltage of 380V line
with a voltage variation +10 %. The terminal board chamber shall be O-ring sealed from the
motor compartment.
The pump protections should be, as a minimum, the motor shall include thermal sensors for
protection against stator windings overheating (using 3 PTC sensors) and bearing overheating
(using one PT100 sensor) and moisture sensor for detection of water leakage in the oil chamber.
Any other standard protections of the proposed pump type shall be included. All protections
shall be wired to the unit control panel, and used in conjunction with and supplemental to
external motor over current protection.
The pump-motor shaft shall be of stainless steel 316 or more, provided with a balanced
tandem mechanical rotating shaft seal system consists of two mechanical seals and run in an oil
chamber. The lower seal unit, between the pump and oil chamber, shall contain one stationary
and one positively driven rotating tungsten carbide or silicon carbide ring. The upper seal unit,
between the oil chamber and motor compartment, shall contain one stationary tungsten carbide
or silicon carbide ring and one positively driven rotating carbon ring. Each interface shall be
held in contact by its own invisible spring system. The seals shall require neither maintenance
nor adjustment, but shall be easily inspected and replaceable.
The pump shaft shall be supported by two (2) permanently lubricated bearings. The upper
bearing shall be a single row deep groove ball bearing and the lower bearing angular contact
ball bearing. The bearing shall have operating life of not less than 50,000 operating hours.
The pump impeller shall be dynamically blanched, of the non-clogging type and capable of
handling solids, fibrous materials, heavy sludge and other matter found in normal sewage water.
The fit between the impeller and the shaft shall be a sliding fit with one key. The volute shall be
single piece design and shall have smooth fluid passages large enough at all points to pass
solids. Both the volute and impeller shall be provided with efficient wear rings between the
volute and impeller. Wear rings should be of the replaceable type and shall be of Gunmetal,
bronze or st.st.
The pump speed shall not exceed 1500 rpm, with motor power factor of not less than 0.8. The
rated power of motor shall have not less than 20% in excess of the maximum power absorbed
by the pump during its working range.
Pumps characteristic curves must be submitted together with the test results at the manufacturer
works to show the following curves:
- Total manometric head in meters / discharge in lit/sec and efficiency curves.
- Total manometric head in meters / discharge in lit/sec and brake horsepower curves.
Note: The pump discharge at the highest point of head working range shall be not less than
30% of the discharge at the duty point of the pump.

7
 The pumping station shall be provided with electrical low voltage distribution board and
including all the electrical power & control devices required for proper operation of the station.
Each pumping unit shall be supplied with suitable sized power cable (20m at least) protected
against short circuit by molded case circuit breaker and the unit shall be with Stare -Delta motor
starter. The motor starter component shall be selected according to IEC60947 from
manufacturer data sheets. The panel shall be provided with full interface & ability to be
connected with all other control devices for suitable operation & safety of the pumping station.
The selector switch shall be furnished for each pump to permit manual running of pumps in
addition to the automatic operation by means of ultrasonic level transmitters.
2.1.4 Name Plate
The pumping unit shall have a nameplate with the following data:
1.Origin.
2.Manufacturer name.
3.Serial Number.
4.Discharge.
5.Total manometric head in meters.
6.Speed in rpm.
7.Motor voltage.
8.Frequency.
9.Current in Amp. Corresponding to full load output.
10. Power factor at full load.
11. Degree of enclosure protection.
12. Any other data as per the manufacturer standards.

2.2 PIPES, VALVES, FITTINGS AND SPECIAL PIECES

2.2.1 Pipes and Valves
The Contractor shall supply and install the necessary pump’s suction and delivery pipes and
valves. Each suction pipe for horizontal pumps shall be provided with a wall piece, sluice valve
and the necessary pipes and fittings while each delivery pipe for horizontal and submersible
pumps shall be provided with a non-return valve, a sluice valve and the necessary pipes and
fittings. These delivery pipes shall be connected to a main header up to the valve chamber
outside the station. All Pipes and fittings shall be of D.C.I Class K9 PN10. They shall be in
conformity with the B.S. The locally manufactured pipes, etc. shall conform to the required
specifications and according to the Ministerial Decree No.164 for year 2015, and shall be tested
at works at the expenses of the Contractor and under the supervision of the Owner
representative.

2.2.2 Pipes Jointing and Painting

8
All pipes shall be treated internally and externally with an approved anti-corrosive composition.
The pipe joints must be given special attention for tightness and their joints shall be tested.
2.2.3 Flexible Joints and Wall Pieces
Each delivery pipe should be provided with wall piece where crossing a wall, and flexible joints
at the fixed points such as the foot bend and wall piece. Tenderers should submit detailed
drawings and description for these joints in their offers. As exception, the flexible joints should
be made of Ductile Cast Iron GGG40/50.
2.2.4 Valves
Sluice Valve: All Sluice/Gate valve bodies and discs shall be of Ductile Cast iron GGG40/50,
with gunmetal faces and rising stainless steel stem and nuts. Each valve shall be provided with
CI hand wheel and when appropriate an extended spindle and pedestal.

Body and disk Ductile Cast iron (GGG50)

Yoke Ductile Cast iron (GGG50)
Gland Ductile Cast iron (GGG50)
Gland packing Expanded graphite
Stem Stainless steel
Stem cone Bush Bronze
Bonnet Ductile Cast iron (GGG50)
Bonnet gasket NBR
Wedge Gunmetal or Bronze or St.St.
Wedge facing ring Gunmetal or Bronze or St.St.
Non- return Valves: The non-return valves shall be of the flanged swing type, provided with
external mild steel lever with adjustable counter weight to protect the fins from water hammer.
All non-return valve bodies and discs shall be of Ductile Cast iron GGG40/50, provided with
gunmetal sealing. The disc shaft should be one piece of high strength stainless steel.
The valves shall be tested to sustain pressure not less than 10 kg/cm2. Non-return valves shall
be mounted horizontally and shall have closing characteristics suitable for the specified delivery
condition and shall fully protect the installation against shock from reflex caused particularly by
a sudden power failure.
The valves shall have renewable joint faces, large removable cover plated to facilitate
inspection and withdrawal of flaps, and ample pockets below the flaps into which may fall any
solid matters which might otherwise prevent the flaps from closing.
The flaps shall seat at a suitable angle to the axis of the pipe and stops shall be provided to
permit the valves to open to an angle of 30o with the axis of the pipe. Bronze drain plugs shall
be fitted. The hinge pens shall be of stainless steel and shall be extended on packed glands of
adequate size and shall be extended on one side of the valve through gunmetal bushed packed
glands of adequate size and fitted with mild steel external lever. Flaps shall be positively
secured to the spindles by means of keys, splints or pins.
Penstock: The lifting penstocks shall be suitable shut-off pipes or tunnel channel and shall have
the following features:

9
 - Design according to DIN 15569.
- Seal tightness corresponding to DIN 19569-4 category "3".
Materials of Construction
- Guide frame : stainless steel 316L.
- Penstock frame : stainless steel 316L.
- Penstock yoke : stainless steel 316L.
- Rising spindle : stainless steel 316L.
- Protecting tube for spindle : stainless steel 316L.
- Sealing of penstock plate all round by wastewater resistant and easily exchangeable seal.
The seal shall be attached to the penstock plate to facilitate exchange of seal during plant
operation.
- The spindle shall be supported in wastewater and dust proof axial ball bearings.
- Spindle nut with lubricating nipple nut shall be made from brass or bronze.

2.3 CONTROL SYSTSEM

2.3.1 The scope of Work
The pump station control and monitoring system should be designed in complete coordination
with all pump station equipment. It is the responsibility of the Contractor to guarantee that all
the pump station equipment especially motor starters, MCCs, distribution board, flow meter,
actuated valves, etc shall efficiently receive the proposed control system and full interacting
with it.
The contractor scope of work under this item should cover, but not limited to, the following:
- Preparation of the system engineering documents including design, P&ID drawing,
specifications, list of materials and catalogues.
- Supply of all materials.
- Input/output list.
- Instruments List according to ISA standard.
- System assembly on the site.
- Preparation of the application programming software for the Programmable Logic
Controllers (PLCs).
- Control philosophy of operation.
- Alarm priority list.
- Commissioning and start-up.
- Control cable schedule.
- Preparation of as-built soft copy of engineering documents and gets consultant approval.
- On-site training to the plant operators.
- Earthing system for instruments and control system.
- All the design and documentation of the system shall comply with relevant ISA, ISO and
IEC standards.
- The selection of the components of the control system shall be from a single manufacturer
and in accordance to his design rules and shall comply with relevant IEC standards.

10
 2.3.2 System Description
- The required system shall be used to control and monitor the operation of the pump station
equipment.
- The control system shall be a PLC based control system.
- The system should be so designed to have the highest possible reliability and minimize the
system failure in order to achieve safe and satisfactory start up and shut downs, continuous
and accurate operation with minimum maintenance.
- The system should be provided with an Uninterruptible Power Supply (UPS).
- UPS capacity shall be sufficient to feed all instruments and control panel.
- UPS backup time shall be not less than one hour.
- The pump station should be provided with a control system to automatically start, stop and
alternate the priority of pumps starting to keep a balanced number of operating hours
between all in duty pumps.
- Controlling the levels for pumps start and stop shall be made by Ultrasonic level
transmitter. In addition, an adjustable emergency high-level audible alarm with reset button
shall be provided.
- In case of over load in any pump the other pump shall be operated automatically.
- All pumps should be shut down as dry run protection by level switches in the pump station
sump.
- The automatic operation of pumps shall be achieved according to the level in the sump by
an ultrasonic level meters these useful data which have to be taken into consideration by the
contractor as follow.
Alarm Maximum water level HHL
2nd pump start Start level of 2nd pump HL
1st pump start Start level of 1st pump
All pumps stop Stop level LL
All pumps trip and alarm Minimum water Level LLL

- The PLC shall perform the sequence of operation of the pumps and the relevant interlocks
according to the level measured by the level transmitters. Level switches shall be used for
safety interlocks. The pump behavior shall be complied with pump manufacture system
curve. Number of pump start shall be not more than pump recommendation.
- The PLC panel should be built of high-quality sheet steel of thickness not less than 2 mm,
anti-corrosion and providing a degree of protection IP54 and sections fully protected and
finished to a high standard. The control panel shall be integrated as a part of the low voltage
distribution board (MDB).
- Level switch shall be displayed status (HIHI-HI-LO-LOLO) on control panel.
- The main signal of the transmitters shall be 4-20mA with hart protocol.
- The used number of I/Os must not exceed 75% of the maximum capacity of the CPU.
- The PLC shall perform the sequence of operation of the pumps and the relevant interlocks
according to the level measured by the level transmitters. Level switches shall be used for
safety interlocks.

11
- Fuel monthly tank level to be measured by ultrasonic level transmitter and connect with
PLC. Fuel daily tank level switch to connect with PLC and interlock with generator. The
2.3.3 Design considerations
- The instrumentation and control systems shall be supplied from a 220 VAC 50Hz power
source. The grounding of all of the elements of the system should be connected to a clean
earth. (not to be connected to any power devices).
- The working ambient temperature is 45 ºC
- The enclosure should include all of the necessary protection devices that includes but not
limited to circuit breakers, fuses, isolation transformer, and surge arrestors.
- Dry type isolation transformer should be placed in the control panel. The transformer shall
supply the entire elements of the control panel. Another isolation transformer should be
used for supplying signals which shall be routed outside the control panel (commands or
status of valves, circuit breakers, starters, level switches….). All signals which shall be
routed outside the panel should be 220 VAC and separately protected by fuses. A short
circuit in the circuit of one of those signals shall only blow its fuse and with no mean shall
disturb the supply of other elements of the system.
- Analogue signals shall be connected to analogue isolators which shall isolate the signal and
supply the loop.
- The control panel, which is located in the online pump station, shall suitable to the site
condition. Heat dissipation calculation to be considered and maybe it shall have AC panel
mounted.
2.3.4 Control and monitoring of Pump station
a) The PLC unit shall be following specs:
- The PLC should be modular Type.
- The PLC shall be compatible with all of the requirements of IEC1131. The CPU must be
equipped with floating point capability and process control capabilities and real time clock
(RTC).
- All empty slots in the racks shall be covered by empty slot cover module.
- The used number of I/Os must not exceed 75% of the maximum capacity of the CPU.
- The CPU shall be equipped with a built memory of at least 2Mbyte of RAM according to
IEC1131-3.
- Analogue I/O modules shall be with minimum resolution of 12 bit channel to channel isolated.
In case of PLC malfunction, the state of the PLC outputs shall turn to a safe condition. This
condition shall be programmable to either high, low or keep last state. The PLC digital I/O
modules shall be high density 24VDC.
- All signals from transmitter shall be divided to two branches to PLC and indicators.
- The PLC shall perform the sequence of operation of the pumps and the relevant interlocks
according to the level measured by the level transmitters. Level switches shall be used for safety
interlocks.
- The PLC shall be equipped with sufficient number of digital inputs and outputs, analogue I/Ps
inputs and analogue outputs.

12
- System shall be operated by the PLC during Automatic Mode, From the HMI during Manual
remote mode and from local position in manual local mode
- System shall be capable of operation in manual mode even in case off PLC malfunctioning.
- The operator can define a sequence of operation.
- Temperature and relative humidity inside the control panel shall be monitored.
- The electrical measurements and all status of the electric feeders, circuit breakers and stand-by
generator set shall be monitored by the PLC and displayed on the HMI. The system shall include
the development Programming software and Project software (Editable) of the PLC and HMI.
- The PLC shall be ready with all devices to be connected to the central monitor room in future
shall pass test.
- The PLC programming shall be backed on a flash type removable memory.
- The spare parts shall be sufficient 2 year. I/O spare points should be at least 25% of total I/O for
each card.
- The PLC shall be included spare communication port for future connection with master SCADA
system.
- PLC environmental conditions as per (IEC1131-2). The attention of the contractor is drawn to
the fact that the sewage pumping station is a highly polluted with corrosive gases. The contractor
shall take protective actions to ensure long service life of the components proposed, and to use
conformal coating to all PLC modules.
- PLC environmental conditions
- Operating temperature: Max 60°C
- Relative humidity: Up to (95) % without condensation.
Up to 90% in case of corrosive gases.
- Corrosive environment: EIA 364-65 LEVEL III
ISA S71.04 GX severe
b) The HMI unit shall be follow the specs:
- The HMI unit shall be 17" diagonal 18-bit color touch screen TFT active matrix.
- The ingress protection of the unit shall be IP54.
- The unit must be capable of operation in ambient temperature of 45°C.
- Relative humidity up to 95% without condensation
- The HMI shall be connected to the PLC with a communication bus 10Mbit/s baud rate at
least.
- The HMI shall enable the operator to take full automatic and manual control of the
functional zone.
- The HMI shall be capable of alarming and event log keeping.
- The HMI unit shall be of the heavy industrial type with membrane protection against the
environment on site.
- The HMI shall be included hard disk not less than 128 G Byte.
- The equipments can be operated from the PLC only if the selector switches are placed in
the automatic mode and in the remote mode.
- The HMI shall in all modes of operation monitor the status of the equipments.
- The operator is to select from the HMI the mode of PLC operation of the equipment forcing
in sequence. (In case that forcing mode is selected, the operator shall be able to force the

13
 equipment to be in ON or OFF condition from the PLC disregarding the sequence of PLC
program but in case that IN Sequence is selected; the PLC shall control the equipment in
accordance to the pre-programmed sequence of operation).
- The HMI shall indicate all of the status of the equipments including but not limited to all
electrical measurements (I, V, pf, KW, . etc.) for each pump, feeder, and generator …etc.
and total run hour, last running time, last cooling time total number of starts, number of
starts in the last hour, last starting time, etc…
c) Control
- All pumps should be start/stop automatically by control system of the pump station.
- All pumps should be shut down as dry run protection by level switches in the pump station
sump.
- Control level shall be selected by selector switch installed on the MCC/Distribution board.
- Pump operation system must be prepared to achieve Manual or Automatic operation using
selector switch Manual/Automatic.
d) Monitoring
- On, Off, Fault status of all pumps should be indicated in MCC/Distribution board.
- On, Off, any Fault, Remote status of all pumps should be indicated in Control and
Monitoring software of the plant.
- Water level (Ultrasonic, Level electrodes), Flow and Pressure.
- In case of not using VFD All electrical measurements for each pump shall be monitored by
using Motor Management Monitoring & control devices or equivalent.
- “PLC- HMI - Feeders- Generator- VFD or equivalent device Full Digital Communication to
monitor All Electrical Measurements”
e) Input/output List
- Pump: DI: Running, Stopped, Emergency Stop Switch, Overload, temperature over, oil
leakage, seal leakage, auto/off/manual, VFD ready; AO: VFD control; DO called to start
and called to stop.
- Flow meter: DI: Fault, AI: flow reading.
- Level transmitter: DI: loss of echo, AI: Level reading.
- Level switch: DI: LSLL, LSL, LSH, LSHH.
- Pressure switch: DI: PSH.
- Pressure Transmitter: AI: Pressure reading.
- Incomer circuit breaker: DI: ON status, off status, Trip status, DO: ON command, OFF
command.
- Transformer: DI: Bochhlez Alarm, Temperature Alarm.
- Generator: DI: Running/Stopped, Fault, Ready, Emergency Stop Switch, Alarm. Month fuel
tank level transmitter AI:1, Daily fuel tank (LSL:DI).
- Control panel over temperature DI, control panel door open limit switch.
- Penstock& Valve: DI: totally Open, totally closed, Fault, Remote/Off/Local; DO: Open
command, Close command, stop command.
f) Interface devices

14
 - Interface devices should be used to secure complete electric isolation between the PLC
modules and the field. Interface relays should be used for digital points and signal isolators
should be used for analog points.
- For digital output modules the interface devices should provide free contact output (electro
mechanical type) for each output-point. Each output channel should be protected by a fuse.
- For digital input modules the coil of the solid state relay should be available for connection
and not grouped with other coils i.e. the two connection points of the coils are separated.
- Output interface devices shall be interchangeable solid state relay free contact with fuse for
each channel.
- For analogue input/output modules, the signal isolators should secure channel to-channel
isolation.
g) Spare parts
- The spare parts for each station should include at least 10% of all component used of each
panel (relays with different types, C. Bs, indication lamps with different types, terminal
blocks, bush buttons, labels, run hour meter, selector switch, digital indicators, Analog
isolator, Analog splitter, surge arrestors, dry transformer, ……etc) and 100% spare of the
fuses. The Contractor should take in his consideration the PLC's spare parts.
- The whole system (all stations) spare parts should include at least 20% of all component
used (HMI, PLC CPU, Switches, gateways, converters, etc..).

2.4 Control Cables

This section covers the design, calculation, delivery, installation, testing, connection,
labelling, and submission of as built drawing for, control, instrumentation, and
communication cables.
2.4.1 General
1. The conductors shall be high conductivity copper, to BS 6360 (IEC 228) unless
otherwise indicated
2. The copper conductors shall be stranded.
3. The signal control cables shall have stranded conductors.
4. Flexible cords shall have fine stranded conductors.
5. The conductor sizes shall be metric. Conductors with cross-sectional areas smaller
than those specified shall not be accepted
6. The insulation for each conductor shall be color coded or otherwise identified as
required by the Regulations.
7. The colour coding shall be maintained throughout the installation the current
carrying capacity of conductors has been determined in accordance with the
specified Regulations, the specified type of insulation and the expected conditions
of installation all cables shall be as far as practicable, of one manufacturer only. All
cables shall comply with the relevant IEC/BS.
8. The different level of voltage shall be a different color.
2.4.2 Instrumentation Cables - Analogue Signals

15
 1. To BS 5308 part 2, type 2,300-500 V.
2. The single copper conductor shall be 1.5/1 mm.
3. The insulation shall be Polyethylene insulating material.
4. The individual screen of aluminum backed polyester tape with tinned copper
stranded.
5. Drain wire.
6. The collective screen of aluminum backed polyester tape with tinned copper
stranded drain wire extruded PVC bedding
7. PVC outer sheath, blue.
8. core identification as BS 5308 Part 2.
2.4.3 Instrumentation Cables - Digital Signals
1. To BS 5308 part 2, type 2 300-500 V
2. The single copper conductor shall be 1.5/1 mm.
3. Polyethylene insulation
4. The collective screen of aluminum backed polyester tape with tinned copper
stranded drain wire
5. extruded PVC bedding
6. PVC outer sheath, Gary.
7. Core identification as BS 5308 Part 2.

2.5 MEASUREMENT INSTRUMENTATIONS

2.5.1 Electricity Supply
 The electricity supply for all instrument systems shall be at 220Vac, single phase, 50Hz.
Each instrument shall be connecting with power by MCB.
 Sun Protection
 All field mounted items, transducers etc. shall be provided with a suitable sun shield to
ensure that the device is shaded from direct exposure to the sun at all times. The sunshield
and supporting brackets shall be in stainless steel.
 Where instrument connection cables are mounted above ground they shall be installed in
conduit or mounted on cable tray which shall be fitted with a cover after all the cables on
the cable tray have been installed.
 Instrument Fixation and Support
 All brackets, supports and fixation required for the correct installation of the instrument
shall be made of stainless steel SS316.
 Instrumentation Enclosures
 Individual instrument cases and sensor enclosures shall also be of a material resistant to any
degradation by any chemicals, materials and / or UV radiation likely to been countered
within the surrounding operating environment or; be suitably protected or be located
elsewhere.

16
 Where the individual instruments own enclosure or case is unsuitable for mounting in the
intended location, it shall be installed within another enclosure suitable for the surrounding
operating environment and which shall be fitted with a viewing window to enable any
display to be read without opening the enclosure.
 All instruments shall be calibrated and validated by approved company before handover to
client.
2.5.2 Electro-Magnetic flow measurement:
Each pumping station shall be provided with Electromagnetic flow meter, flanged type,
detector head as short type, inner coating of hard rubber, body of stainless steel, electrodes of
ball-head type (stainless), conductivity of at least 20 us-cm, degree of protection IP68, power
supply 220V, 50Hz. Reading accuracy shall be ± 1% of total flow as a maximum.
Electronic transmitter must be remote version with automatic zero-point compensation
continuously adjustable span and with indicator, span of 0.5 to 2 m/s, output current 4 to 20
mA. Power supply 220 V, 50 Hz. The controller shall be housed in a self –contained
enclosure of degree of protection IP67.
Flow meter totalizer shall be transfer to PLC/HMI through Profibus or Modbus or Hart.
2.5.3 Ultrasonic flow measurement:

The pumping station shall be provided with an Ultrasonic, single Channel, and Clamp-on
Flow Meter with the following general specifications. The meter’s transducers shall be
installed on the main header, and the meter shall be suitably and secured fixed in the station
operating room. The Contractor must give high attention to the fact that the transducers may
be installed near to valves or other pipe fittings; therefore, adjustment and correction factors
should be accurately imposed to insure correct readings. The Contractor shall supply all
accessories and adequate lengths of power and control cables required for proper installation
of the meter.

The flow meter shall be of the clamp–on design to preclude the requirement of penetrating
into the pipe. The system shall be capable of providing two simultaneous flow
measurements independent of liquid, pipe diameter and flow rate. In addition, the flow meter
shall be microprocessor based utilizing the Transit–Time flow measuring technique
employing the Multi– Pulse principle in conjunction with transmission Wide Beam
transducer technology.

The flow meter shall provide liquid sonic velocity variation compensation and live zero flow
measurement. The flow meter shall have the ability to indicate flow rate, flow velocity, total
flow, signal strength, and liquid sonic velocity. In addition, the flow meter shall provide self
and application diagnostics to isolate any fault conditions to either equipment failure or
abnormal process conditions.
The flow meter shall be of not less than (IP67) enclosure and the electronics shall be housed
in an enclosure of (IP66) and powered by 220V AC, 50 Hz. The flow meter shall have an
accuracy of + 1 to 2% of flow over a 12 m/s flow velocity range. Repeatability shall be 0.5
% of flow sensitivity of 0.3 m/s at any flow rate including no flow conditions. The system
shall also include flow – totalizer with five digits (99999
2.5.4 Ultrasonic level transmitter

17
 The ultrasonic level transmitter shall provide continues measurement of water level and shall
consist of a transducer and a transmitter unit employing an ultrasonic beam to detect water
level. The signal generated and receiving components shall be encapsulated in a
weatherproof assembly.
The transmitter unit shall contain a microcomputer and electronic circuits for level
measurement and compensation for variations in gas medium temperature, density and
humidity. Sensor body material should be stainless steel rupture proof. Sensor shall be
antifoam type.
The transmitter output shall be a 4-20 m A dc signal proportional to water level inside the
elevated tank. Two alarm relay contacts shall be provided for high or low level. Switches
shall be provided for selection of level span, zero, volume-level characterization and field
diagnostics.
A digital meter unit shall be supplied for local indication of the level.
The span of the meter according to location. Accuracy shall be better than ± 0.5% FS. The
transmitter shall be suitable for operation in ambient temperature up to 50°C. The power
supply of the transmitter shall be 220V AC ± 10 %, 50Hz. Ingress protection shall be
transducer IP68 and transmitter IP67.
The levels must be (HHL, HL, LL, and LLL)
Ultrasonic level monitor complete with programmable relies to control automatic pump
operation at differential levels.

2.5.5 Level electrodes (For Submersible Pumps Only)

Only submersible pumps shall be protected against dry running when operating below
minimum recommended water levels inside the sump by means of level electrodes which
shall be mounted in an insulating high impact phenolic molding, impervious to corrosion and
having separate fixing for the flange mounted base and for the cover.
The base shall have 20 mm screwed conduit entry and be suitable for accommodating the
electrodes and incorporate provision for adjusting the electrode length. A sealing gasket shall
be fitted between the base and cap end; the whole head shall be sealed to prevent the increase
of water after installation. The electrode shall be of stainless steel tubes sealed at one end and
cut to suit the specified length.
All electrode circuits and components shall comply with B.S. 5345 and the PASEFA
requirements or equivalent. The system shall be operated by the circulation of an A.C.
current when the circuit is completed by the liquid coming into contact with the electrodes.
This current is operating a relay to initiate the events described before.
2.5.6 Pressure Transmitter
The pressure transmitter shall be electronic (preferably microprocessor based Smart
transmitter) type. The adjustment (e.g. ranges, zero setting) and tuning (e.g. damping) shall
be performed electronically). The wetted parts shall be stainless steel Grade316S31 to BS
970 and protected degree IP68. Complete with flush diaphragm or remote seal sensing
system shall be provided. To achieve optimum accuracy, transducers shall be selected to have
a range as close as possible to the anticipated operating range. Accuracy shall be +1 to 0.2%
or better. Material shall be suitable for operating conditions. Meter body cover: SS-316.

18
 Connection Process: Rc 1/2 NPT. Three-way manifold valve shall be provided. Isolation
diaphragm shall be stainless steel 316 to BS 970 with silicone fill.
2.5.7 Pressure gauge
Gauges shall have bourdon tube sensor with 270 degrees’ pointer travel. Dials shall have
black markings on white background. Dial size shall be 100 mm unless otherwise specified.
Wetted Parts and case shall be 316 stainless steel to BS 970. Accuracy shall be ±1 %.
1/2 inch NPT process connection. Isolation diaphragm shall be provided and it shall be
stainless steel 316 to BS 970 with silicone fill. Three-way manifold valve shall be provided.
2.5.8 Spare part for instrument
- Spool piece for electromagnetic flow meter one piece for each diameter
- The transmitter for flow meter one piece
- Pressure gauge one piece
- The transmitter for ultrasonic level transmitter one piece.
2.5.9 References Standards
The standards referred to for Manufacturers quality procedures and documentation are:
- BS 1646 : Symbolic representation for process measurement control functions and
instrumentation.
- BS EN 60073 : Basic and safety principles for man-machine interface, marking and
identification. Coding principles for indicators and actuators.
- BS EN 60255-22-5 : Surge protection.
- BS EN 61000-6 : Electromagnetic Compatibility.
- BS EN 61131-3 : Programming Languages for Programmable Controllers.
- BS EN ISO 9000-3 : Recommendation for the achievement of quality in software.
- BS ISO/IEC 6592 : Documentation of computer based systems
- BS ISO/IEC 9075 : Structured Query Language (SQL)
- ISO 3511: Process measurement control functions-instrumentation symbolic
Representation.
- ISO11064 : Ergonomic design of control centres.
- ISO9241 : Ergonomic requirements for office work with visual display terminals.
- IEC 60870 : Tele control equipment and systems, part 1 - 6
- IEC 61000 : Electromagnetic compatibility (EMC), part 1 – 4
- ISA99 : Industrial Automation and Control Systems Security
- ISA90 :Instrumentation and Computer Grounding
- ISA71 : Environmental Conditions for Process Measurement and Control
- ISA5 : Documentation of Measurement. and Control Instruments and Systems

2.6 ELECTRIC POWER SUPPLY AND DISTRIBUTION BOARD

2.6.1 Electric Power Source
The electric power required for operation of the pumping station shall be received from the
11/0.38kV compact package substation (Kiosk Transformer). The kiosk transformer shall be

19
 supplied and installed by the contractor according the regulation and under the supervision of
the Local Electricity Distribution Company or Rural Electricity Authority REA.
The kiosk transformer shall be capable to feed the pumping station load in the first and the
second stage. In order to cover the pumping station requirements of power at emergency
conditions one diesel generating unit as per single line diagram and electrical documents
shall be installed
The stand-by source of electric power supply for the site shall be from one diesel driven
generating sets to serve the pumping station under emergency conditions. The voltage
generated shall be 380/220 volt, 50Hz.
A source interlock system shall be provided between the main sources and the stand-by
source as indicated in the single line diagram.
Note:
The contractor shall make field survey and contact with the electricity-authority in-charge
before submitting his tender. The electrical installations related to medium voltage including
11kV panel, kiosk transformer, indoor transformer and MV cables shall be approved by the
Electricity-Company.
The contractor is responsible for supply and installation of the medium voltage cable from
main source to feed the plant by approval of electrical company for size of cross section area
and also length of the cables.
2.6.2 Low Voltage Distribution Board
2.6.2.1 General
All equipment shall be designed to withstand desert climate and ambient conditions of high
temperatures and corrosive action. The following are the climatic conditions prevailing at
site:
 Ambient temperature 45o C
 Absolute humidity 80 %
The contractors are requested to take these conditions into consideration when choosing the
materials for their equipment (suitable selection, deration of components/equipment, tropical
conditions).

2.6.2.2 Specifications of the Main Low Voltage Distribution Board (MLVDB)

A. Low voltage distribution board specification shall be in compliance with standard IEC
60439-1,
B. Construction: Form 2b separation, consist of bolted panels each panel constructed from
totally welded steel sheets with thickness not less than 2mm, floor mounted. It shall be
suitable for current rating in normal operation and fault operation e.g. short circuit (suitable
thermal & mechanical stress of Bus Bar and other components).
C. The compartment shall be located inside a metal enclosure with walls providing protection
against direct contact with live parts and guaranteeing a degree of protection (IP) requested.
Panel boards are to be totally enclosed, dead front type. The protection degree should not be
less than (IP54) for the outdoor L.T switchboards and the protection degree should not be
less than (IP42) for indoor L.T switchboards.

20
D. The effect of corrosive and sewage gases e.g. tin or silver for the Bus Bar shall be taken into
consideration in the design of the switchboards. They shall comprise also all equipment,
apparatuses, instruments and connections necessary for efficient operation, control and
protection of transformers, motors and auxiliaries in a way to ensure simplicity of access to
different sections, full reliability of service, safety and maintenance of any section without
interruption of service.
E. Main Distribution Boards shall have a short circuit withstand current as indicated in the
single line diagram for 1 sec.
F. For the outgoing motors of main low voltage distribution board, the motors should be
protected with the following:
 Over current.
 Short circuit.
 Earth fault and earth leakage.
 Under/over voltage.
 Phase sequence/phase failure.
 Over temperature for winding and bearing.
 Moisture sensor in oil chamber.
 Excessive starting time locked rote number of starts per hour.
G. For the outgoing motors of main low voltage distribution board, the following measuring
devices for motors shall be as the following:
 Phase current.
 Hour meter.
H. The main low voltage distribution board shall be suitable for front or rear connections.
I. Cable entry shall be via the bottom or the top.
J. Earthing bar is to be half size the phase bus bars.
K. The main low voltage distribution board shall have a permissible symmetrical short circuit
current up to short circuit current shown on the single line diagram for 1 second. The Bus
Bars shall be designed for mounting on insulated supports that are sufficient in number to
accept the electro-dynamic forces resulting from the flow of the peak asymmetrical short
circuit current.
L. The main low voltage distribution board shall include, but not limited to, the following as
should be necessary for the purpose:
 Safety shutters.
 Interconnections.
 Cables.
 Secondary wiring.
 Fuses.
 Links.
 Plug and socket type insulating contacts.
 Hinged instrument panels.
 Cable sockets.
M. Each main low voltage distribution board shall have a label written in Arabic and English
showing its purpose. Nameplates shall have black ground with white letters.
Furthermore, the connections between different parts of equipment shall be made in a way
so that the different circuits could be easily traced and shall have tracing marks every 2
meters. Mechanical and electrical interlocks shall be provided to ensure safety to equipment

21
 and staff. Tenderers should submit with their tender’s detailed schematic wiring diagrams
and catalogues for the supplied equipment.
2.6.2.3 Bus-Bars and Interconnections
A. Single bus-bars system shall be used, but in case of providing more than one source,
sectionalized bus-bar( R.H.S B.B , L.H.S B.B PLUS BUS COUPLER ) should be used Bus-
bars interconnections shall be made of 98% pure electrolytic copper with ample cross
section and mechanically strong supported by insulators of approved type at suitable
intervals so that they can withstand the breaking capacity of not less than 500 MVA and
shall be specified for every the main low voltage distribution board according to the
maximum calculated short circuit at installation point, Aluminium is not to be used for bus
bars.
B. The temperature rise of the bus-bars and interconnections under the full load current and due
to effect of mutual heating and lack of ventilation shall not exceed 15o C above ambient
temperature of 45oC.
C. Provision shall be made for the expansion and contraction of bus-bars and interconnections.
D. The current density shall not exceed 1.5 Amp/mm2
E. Short-circuit Duty: Bus-bars are to carry at least 125% of the maximum short-circuit level at
point of application for one second, without showing any signs of degradation.
2.6.2.4 Circuit Breakers
1- Main Low voltage circuit breakers shall be of MCCB or ACB or MCB type as indicated in the
single line diagram,
2- MCCBs generally are to be electronic solid-state trip type. All circuit breakers are to be 3-
poles unless otherwise specified.
3- Construction: Totally enclosed, molded cases, constructed from high quality, high temperature
resistant, tropicalized, molded insulating materials, for normal operation at 70 deg. C within
enclosures, to approved standards, provided with quick-make, quick-break
4- Circuit breaker ratings are to be non-current limiting, fully rated (100%) with continuous duty
at site conditions, and with frame size and interrupting capacity to IEC 60947-2, sequence II
(rated service short-circuit breaking capacity), and maximum trip rating as per the approved
design and calculations. Interrupting capacities at specified voltage and frequency are to meet
IEC 60947-2 test sequence I, II, III and IV for circuit breakers of utilization category B (with
intended short time withstand capability).
5- Accessories: Circuit breaker design is to allow addition of electrical operator, control and
interlocking functions, under-voltage release, shunt-trip coils, alarm and auxiliary switches,
padlocking devices, key-lock devices, and the like.

2.6.2.5 Motor Starters

 General
All motor starters shall be included in the main low voltage distribution board according to
the design. The recommended starting method shall be according to the manufacture
recommendations as following (unless not specified in the SLD):

22
 - Direct on line for motor rating less than 10 kW.
- Star Delta for motor rating up to 100 kW, unless otherwise specs stated in the particular
specifications in each pumping station.
- Soft starter / Variable Speed Drive for motor rating higher than 100 KW, unless otherwise
specs stated in the particular specifications and the SLD in each pumping station.
 Star Delta Starter
It shall be fully assembled, wired, contained inside the MCC panels. The star- delta starter
shall include the main contractor, star contactor, delta contactor, and timing relay and
overload relay according to type (2) coordination tables. It shall be rated by 1.4 of rated
power of the motor. The contactors should provide the changeover reliability necessary for a
smooth transition from the star to delta connection, avoids high switching currents, for
longer device life duration. Contactors should have enhanced arc-quenching characteristics.
The arcing time should not exceed ten (10) milliseconds. Safe and direct changeover should
be assured. Spare auxiliary contacts for remote indication or sequence controls shall be
provided as standard.
 Soft Starters
General
The electronic soft start-soft stop units shall be performed and tested in accordance with the
international standards (IEC, NFC, VDE), IEC 947-4-2, and recommendations related to the
industrial electrical control gear.
The motors shall be high torque machines, with soft starter including isolation contactor and
by- pass contactor. The starters shall be rated for not less than 10 starts per hour against full
load. The maximum harmonic distortion shall be 5% of the basic frequency voltage and
frequency tolerance to be ± 10%.
Electrical Configuration
Power Components
The power components shall be back-to-back thyristor pairs with a peak inverse voltage
rating (PIV) of 1600 V. the load balancing impedances shall be incorporated to provide
current sharing between parallel-connected pairs.
Starter power supplies
The electronics shall be powered when the line contactor is not closed.
Line contactor control
Either
The line contactor shall be controlled by a voltage free contact. On a start signal, the contact
will bring in the line contactor. The line contactor will be de-energized when the soft starter
has completed a stop sequence, or there is a fault.
Or
The line contactor shall be controlled by a voltage free contact. The contact will bring in the
line contactor whenever there is no fault and control power is on. The line contactor will be
de- energized when there is a fault.
Bypass contactor control
There shall be available a voltage free contact to control the bypass contactor. The Contact
shall bring the bypass contactor in when the motor is at full speed, and shall de energize

23
 the bypass contactor when the soft starter is in a stopping cycle. All functions shall remain
operative when the bypass contactor is closed.
Operation
The soft starter shall control the voltage to the motor by conducting through three wires only.
The starter shall be sized to start a motor 10 times per hour with a 300% current limit (to
reduce starting current to not more than 3 times the rated current) and duration of each start
of 6.5 seconds.

Starting
The starter shall regulate the voltage and current to the motor using the Torque control
system. To provide increased torque to overcome static friction, then initial voltage
boost level shall be adjustable from 50 to 100 % of the line voltage.
Stopping
The motor shall be linearly decelerated on a reducing voltage. The deceleration ramp
shall eliminate water hammer. The deceleration ramp shall be adjustable from one to sixty
seconds.
Adjustment
The starter parameters and set up shall be adjustable from a keypad. The keypad shall be
deactivated after commissioning to prevent unauthorized changes.
Motor Protection
The following functions shall be incorporated
- Tripping class selectable for class 2, 5, 10, 15, 20, 25, 30.
- Phase loss protection
- Phase rotation protection
- Locked rotor protection
- Under voltage
- Thermal memory, so that turning off the power does not reset the electronic motor overload.
Starter protection
The starter shall incorporate the following protective functions:
- Thermal overload protection for the thyristors.
- Thermal switch for heat sink over temperature.
Other protection
The starter shall incorporate the following protective functions
- Torque limit setting during acceleration
- Motor under load adjustable from 20 to 100 % motor torque.
- Long starting time fault.
- Soft starters shall offer several starting and stopping functions and other functions
including:
- Ramp start and stop.
- Current limit.

24
 - By-pass.
- Remote analogue control.
- Power factor control.
- Sequence start.
- Each unit shall be tested according to the following codes and standards
- Electrostatic discharges according to IEC 1000-4-2 level 3.
- Radiated electromagnetic fields according to IEC 1000-4-3 level 3.
- Shock wave according to IEC 1000-4-5 level 3.
 Variable Speed Drive System
General
Variable speed drive system, (VSD) shall be of high reliability and well provision design
and it shall comply with IEEE519-2014 and all other international standards applicable for
the VSDS Components. It shall be complete drive system, with motor, static frequency
converter and associated control and monitoring equipment.
The VFD’s local agent shall have a permanent representative office with trained and skilled
support staff in order to prove his commitment for local support and to provide a channel for
communication. The local representative shall be easily accessible and shall be able to arrive
at the site within 24 hours’ notice.
Motor shall be either same make of variable speed drive or fully compatible with variable
speed drive and at least one motor shall be tested at variable speed drive factory to verify
compatibility and noise level.

Electronic Speed Control System

The speed controller shall be of variable voltage/ variable frequency type using power semi-
conductors technology to supply power to three phase squirrel cage induction motor.
The controller shall include a rectifier stage, d. c. current link with intermediate circuit reactor
and an inverter. The inverter shall be “Voltage source” type. The scope of supply shall include
all necessary control, measuring, indicating, protection and alarm equipment required to
complete the system.
The controller will accept the speed set value input signal of 4 – 20mA to vary the speed of
the motor in the nominal range specified elsewhere in the document
The speed control system shall be equipped with speed and temperature monitoring, alarms
and trip circuits and adjustable electronic speed limit and interlocking switches required for
automatic pump start/stop sequence. Actual speed signal, alarms and trips shall be
transmitted to the control room. Actual speed shall also be transmitted to the starter panels.
A common Local/Remote mode selector switch shall be installed. The change-over from
local to remote must be bump less.
In local mode speed shall be varied manually from the motor starter panel. In remote mode
speed shall either be varied manually from the control room/TCC or automatically.
The speed Controller system shall be equipped with but not limited to the following
protections and adjustment: -

25
 1. over current protection.
2. Quick acting fused protection.
3. over temperature protection reacting to the failure of thyristor cooling fan.
4. over speed protection.
5. Earth fault protection.
6. Staring current limit adjustment.
7. Visual means to show any thyristor which has become defective similarly any component or
a printed circuit board.

Critical Speed
Critical speeds of the VSDS motor and pump unit shall not lie within the operating speed
range.
Other technical requirements
Full technical detail shall be provided in the offer including but not limited to:-
Control linearity, Transient Torque Performance, Torque Pulsations, Radio interference,
Protection. Cluster
The VSDS shall be designed to withstand the mechanical, electrical and thermal stresses
which may arise from short circuits or other fault condition and to limit the damage caused
by faults to the component concerned. Injury to personnel shall be completely prevented.

2.6.2.6 Metering Instruments

1- Current Transformers
These shall be of the bar primary pattern where practicable. Current transformers shall have a
short-time current rating of not less than that of the switch panel in which they are
incorporated.
For bar primary current transformers, this rating shall be for a period of 3 seconds and for
wound primary designs the rating shall preferably be for a period of 3 seconds but may be
reduced to not less than 0.5 second subject to the approval of the Engineer.
Current transformers for Medium voltage equipment shall be resin encapsulated, except that
for bar primary designs with ring type cores mounted on resin insulation will be accepted.
Where multi-ratio current transformers are supplied, a label shall be provided, clearly
indicating the connections required for the alternative ration. These connections shall also be
shown on panel wiring diagrams.
Identification labels shall be fitted giving, type, ratio, rating output and serial number and
duplicate rating labels shall be fitted on the exterior of the mounting chambers suitably
located to enable rating without the removal of any cover.
Current transformers for balanced earth fault protection shall be designed for a stability of
not less than six times the rated primary current.
Current transformers for unit protection schemes shall be designed for a stability of not less
than the maximum through fault current of the units.

26
 Where attracted armature relays employed the spill current with maximum stability
conditions shall not exceed one quarter of the operating current of the relay.
Magnetization characteristics calculated performance and protection setting shall be provided
by the contractor.
Current transformers for use in conjunction with a portable precision K.W.H. meter shall be
of class (0.5) accuracy.
2- Voltage Transformers:
A. Voltage transformers shall be supplied where test-metering connections are required to
terminate at test terminal blocks. They shall have a winding ratio to give a three-phase
voltage between lines of 110 volts.
B. They shall have a rated burden, at the stated accuracy, in accordance with the requirements
of all connected instruments, and relays and of any instruments or meters to which they
may be connected via test blocks.
C. The primary circuit shall be protected by H.R.C. fuses having a short- circuit rating not less
than that of the switchgear.
D. The connections between the fuses and the switchgear primary conductors shall be of
sufficient cross-section and supported to withstand the short circuit rating of the
switchgear.
3- Voltmeters :-
Moving iron type, with center zero adjuster, range 1.25 times nominal system voltage, 90
degree angle, size 76 x 76 mm..
4- Ammeters :-
Moving iron type, with center zero adjuster, range 2 times nominal circuit amperage, 90
degree angle, size 76 x 76 mm.
5- Voltmeter Selector Switch: 7-position rotary type
6- Provide ammeters and pilot lights for each phase.

2.6.2.7 Reactive Power Compensation (Power Factor Correction)

General
A. A “capacitor bank” for central reactive power compensation according to IEC 60831 shall
consist of a definite number of parallel operated 400 V - capacitors and their associated
feeders of individual contactor- fuse combinations as well as an automatic power control
relay according to relevant IEC Standards.
B. All this equipment shall be readily mounted inside suitable 400 V panels and shall be
connected ready for operation.
C. The control relay shall alternatively connect or disconnect capacitor units in order to keep
the power factor not less than 0.92 under fluctuating load conditions.
D. When dimensioning the total capacitance as well at the number of parallel operated
capacitors a design analysis shall be carried out based on the actual power factors of
motors as given by the manufacturer.
E. Over- compensation i.e. self – excitation of the circuits shall be avoided in all cases. The
control relay which is operating in principle like a wattmeter must be connected to the
manufacturer’s instructions in order to provide proper service.

27
 F. Pressure switch shall be according to IEC 60831 “next edition”
Each Capacitor for low voltage shall be equipped with discharge resistor to discharge to a
residual voltage ≤ 75 V within 3 minutes IEC 60831 “Section 4: Safety Requirements,
Discharge Device”.
G. Automatic Power Factor Control Device
1. Automatic power factor correction control devices shall be used for control of central
compensation of the reactive power in three-phase supply systems without harmonics.
2. Equipment modules shall be made of steel sheet enclosed boxes for MC mounting.
3. Automatic power factor control device shall comply with IEC publications 70 and 439.
4. Installation
Automatic power factor equipment and extension modules shall be designed for indoor-
mounting and installed in the switchboard.
H. Connection
The cable entry for each unit shall be provided from below. Power supply is necessary for
each unit and extension module. A three – pole low voltage fuse shall be used for the short
– circuit protection of each unit
I. Extension Modules
Later extension shall be possible by means of parallel connection of an extension module to
the existing equipment. Equipment and extension module shall be interconnected by the
control lines only. The number of steps shall not change in case of extension. The step-
ratings are enlarged only. For the extension module power factor relay and sight glass are
omitted from the door.
Protection Relays:
General:
The protective relaying equipment shall be of the plugging solid state type, easily adaptable
to the supply system conditions, reliable with accurate setting and high degree of safety
against noise. The components shall be of high quality, generously sized and dimensioned
to cover the worst-case conditions. All components shall be type tested.
Where protective relays are supplied in cases they shall be factory wired and assembled,
suitably sized to be accommodated in the low voltage section of switchboards or on
switchboard panels. In case the protective relaying equipment is supplied in separate
cabinets, they shall be factory wired and assembled, furthermore a special testing transformer
shall be provided for performing the functional tests.

Modules:
The modules shall contain the permanently wired and tested function groups. They shall be
equipped with a suitable number of pin-plug connectors. Comprising the printed circuit
boards besides to the major assemblies as well.
The width of the front plate shall fit with the module size. The front plate shall accommodate
the control elements comprising setting and resetting devices, light emitting diodes….etc. as
well as the plastic handle. The connectors shall comprise the plug connectors on the module
and the socket connectors on the sub-rack.

28
Sub-Assemblies:
The sub-assemblies shall be designed for accommodating the large and heavy items such as
transformers for power supply units or the like.
All devices required for the operation of circuit breaker cubicles for the purpose of instance
protection, local/remote control, and local/remote measurement shall be grouped in sub-racks
in the form of sub-blocks installed in the low voltage compartment of the switchboard.

Accessories:
Plug connectors comprising both plug connectors on the module and the socket connectors
on the sub-racks shall be fitted with a number of pins to DIN 41612. The current carrying
capacity of the connectors shall fit with the power requirements of the system and the size of
the switchboard relevant facilities.
Intelligent type relays can be accepted taking into consideration that full details and program
of work and adjustment of which must be submitted as an integral part from the Tender.
Tenders not including such details shall be disregarded.
Guides and Supporting Members:
In order to enable the socket and plug connectors to be accurately fitted together and to hold
the modules properly in place, suitable guides and supporting members shall be provided.
Locking bars and labels:
Locking bars at the top and bottom shall arrest all modules plugging into a sub-rack. These
locking bars shall bear the inspection labels.
2.6.3 Low Voltage Power Cables
Power cables shall be PVC/PVC or XLPE/PVC insulated and sheathed type. Their
conductors shall be made of strands of high conductivity electrolytic copper or aluminum as
indicated in the single line diagram. The outdoor cables shall run in uPVC conduits while the
indoor cable in the pumping room shall be fixed on cable tray as indicated on the drawing.
The power cables shall be constructed in accordance with the requirements of the latest
standard specifications of the manufacturing country and suitable for the actual loads
requirement under the contractor’s responsibilities.
 The work under this item shall comprise supply and install all low voltage and medium
voltage cables needed for the plant.
 Cables lengths shall be measured on site.
 Voltage drop calculations should be taken into consideration not exceeding 5% of the
rated voltage.
Cables shall be 0.6/1 KV for low voltage class and 12/20KV for medium voltage class, the
size of the cables shall be such that not only suitable for the current rating of the equipment
connected to, but will be also suitable for the voltage drop (not more than 5%) and for short
circuit rating at the considered voltage, Size and cross- section of the various feeder cables
shall be as indicated in the single line diagram (As minimum requirement).
Laying of Cables
a. Indoor cables
Laying in trench

29
 The trenches made in the floors of different building and laid in cable trays supported to the
sides of the trenches on steel brackets... The trenches shall be covered by chequer plates,
which are included in the civil work part. In case the cables have to pass through walls,
galvanized steel or UPVC tubes of suitable diameters complete with bends shall be used and
when crossing roads, cement or PVC pipes shall be used. The contactor shall be responsible
for insuring that the trench works is adequate for his requirements. All cable glands shall
have a non-corrodible finish and shall be supplied complete with PVC shroud.
Where cables enter or leave building, the ducts shall be sealed at the points of entry into the
building.
All cable conductors shall be terminated in a suitable copper lug and crimped. These cables
shall be efficiently connected to the terminal boxes installed in the switchboard panels and
the Contractor shall supply the necessary compound, etc.
Control and instrumentation cables shall have individual cores identified by means of
suitable permanent ferrules bearing the same numbers of letters at both ends and
corresponding with terminals on equipment.
b. Outdoor cables
Laying Cables Direct in Ground
When buried in the ground, armed cables directly cables shall be left between the parallel and
all cables for a distance of not less than outside diameter of the diameter of the big.
Taken into account before burying cables directly into the ground to verify that the soil does
not contain salts or chemicals that cause corrosion of the external layers of the cable.
If the soil contains salts or chemicals, and take into account the use of cables wrapped in
plastic resistant to corrosion.
Installation of cables directly into the ground, dig trenches in the depth of not less than 80 cm
wide enough to allow easy installation, and then settle at the bottom of the trench and
brushing by a layer of soft sand of thickness less than 10 cm do not and then placed cables on
this layer and bridging them to the thickness of another layer of fine sand of 20 cm according
to the drawings.
In the case of curvature of the path of the cable shall not be less than half diameter of the
cable for bending (3 to 12) times the cable diameter according to cable diameter according to
the Egyptian code.

Laying in trench
The trenches shall be reinforced concrete of suitable depth according to the number and
diameter of cables placed in them, but covered with cement tiles. All cables shall be
supported to the sides of the trenches on steel racks.
Laying in pipes (Cable Duct)
The cables feeding the different building or when crossing road shall be laid in cable duct,
consisting of U.P.V.C .pipe with different size diameter at condition that cable C.S.A shall
not exceed 40% of the pipe area.
 Pipes shall have a concrete surround of minimum thickness of 10 cm.

30
  The open ends of the pipes shall be sealed by caps, wooden plugs, sealant pastes or other
approved means until the cables are drawn into them.
 Spare pipes for future use as cable ducts will be installed if specified by engineer.
Manholes
The manholes shall be made of reinforced concrete with a wall thickness not less than 15 cm
(as indicated in the drawing), and are externally isolated by a heavy coat of bitumen and
these manholes shall help in pulling the cables and has the dimension as showing on drawing.
2.6.4 Kiosk Transformer Type specification
a) General
Transformers shall be of the oil-immersed, self-cooled, double-wound, core. They shall be
designed to withstand tropical conditions and shall give efficient service with minimum
maintenance. They shall be constructed in accordance with the specifications and regulations
of the country where manufactured (two English copies of these specification should be
submitted with tenders) with the exception of temperature rise which shall not exceed 65 o C
for windings measured by resistance and 60o C for the top of oil measured by thermometer
and must not reach a value that will injure the core itself or adjacent material when the
transformer carries its rated output continuously at 0.8 power factor and ambient temperature
of 45o C and may reach 60o C with IP54.
The neutral point of the low voltage side of the transformer shall be brought out to a separate
terminal, which shall be earthed.

Note:-
The transformer shall comply with electricity company requirements.
b) Medium Voltage Compartment
The medium voltage compartment containing the two incoming ring feeders and the outgoing
feeder to the transformer. Each of the two ring feeders shall be provided with load break
switch of the air type, and the outgoing feeder shall be provided with fused load break switch
with its fuses and fuse bases mechanically connected to the switch, so it is self-disconnected
if any one fuse melts. Load break switch for ring feeders shall be fitted with earthing switch
with snap action spring mechanism, which is mechanically interlocked with main load break
switch. A mimic diagram on the cubicle door indicates each circuit. Earth fault indicator
manual or automatic reset shall be supplied for incoming feeders.

c) Low Voltage Compartment

The L.V compartment shall be connected to L.V side of transformer with copper Bus-bar, the
rated current of Bus-bar shall be suitable for full load current of transformer with safety
factor, also the L.V compartment shall be equipped with circuit breaker, and the rated current
of circuit breaker shall be suitable for full load current of transformer with suitable safety
factor...
d) Ability to Withstand Short-Circuit
The transformer shall be designed to withstand without any damage the effect of external
short-circuit under the condition specified in the standard specifications of

31
 the country where manufactured. The tap changing equipment shall be capable of carrying
the same current due to external short circuit as the windings.
e) Earthling of Transformers
The core and oil tank of each transformer shall be directly and solidly connected to a separate
earthling set (and not to be connected to the common earthling set in the site), while the L.T.
neutral terminal of each transformer shall be brought out connected to this separate earthling
system.
f) Accessories for Transformers
Each transformer shall be equipped with the following accessories:
 Diagram plate showing the technical specifications.
 Oil tank.
 Earthling socket.
 Oil level indicator flush mounted.
 Tapping switch.
 Lifting lugs.
 Oil drain valve with plug.
 Filling cup.
 Four cups.
 Four steel rollers with barring holes.
 Jacking beams.
 Necessary oil for the first filling.
 Bouchholz relay with contacts (for trans. with rated 500 KVA and
above).
 Thermometer with protection tube for indicating oil temperature.
 Nameplate.
 Nameplate.
2.6.5 EARTHING
 General
All goods and products which covered by these specification shall be preferable when
variable from manufacturer approved by the client and conforming to the requirements of
specifications.
The system shall satisfy all related codes and requirements.
In case of TT earthing system, RCD (Residual Current Device) must be used for each motor
to provide protection against earth fault current.
The equipment ground resistance shall be mot exceeding 2 ohms. If the resistance value of 2
ohms cannot be obtained by driven ground rods the contractor shall submit alternate methods
to achieve the required result for review by the client.
The system ground and the equipment shall be connected to the common ground bus.
The rods shall be located a minimum of 3 meters from each other or any other electrode and
shall be loop interconnected with each other by a bare copper conductor . The system ground
resistance shall be maximum 2 ohms.
a) System Description
The contractor is responsible for the design/implementation work of a complete earthing
system.

32
 The contractor shall supply, install, test and deliver of an efficient earthing system for the site
according to the following basis:
- Separate earthing system for medium voltage of kiosk transformer (not exceeding 2Ω).
- Separate earthing system for the generator (not exceeding 2Ω).
- Separate earthing system for the main low voltage distribution board (not exceeding 2Ω).
- Separate earthing system for the control system together with the related instrumentation
and control equipment (0.5Ω).
The contractor must submit a calculation sheet and workshop drawing for earthing works
showing the number of electrodes which determined by calculations to achieve the required
resistance which shall be not more than 2Ω for electrical power system and 0.5 Ω for light
current system. All separate earthing systems shall be interconnected to form the common
earthing system except those installed for the lightning protection system.
Earthing system with the related equipment and components shall comply with the
requirements of BS 7430, BS CP 1013 and BS 7671 or approved equal. Earthing system shall
be interconnected through adequate tinned copper conductors, fixed to the wall sides of
trenches or running through galvanized steel conduits and ending with earthing electrode(s).
Each copper clad electrode shall consist of high carbon steel core of high strength and must
be rigid for easy driving into soil.
The number of electrodes to be used must be determined by calculation to achieve the
required resistance which will be not more than two (2) ohms at dry seasons. Each copper
clad electrode(s) shall be erected inside concrete inspection chamber of suitable dimensions.
Upon completion of installation of electrical earthing, the earth resistance shall be tested.
Where tests show resistance to ground is over two (2) ohms at dry seasons, the Contractor
should reduce the resistance to 2 ohms or less at no additional cost.
The Contractor shall describe in his offer the earthing system which shall be supplied and
erected.
b) Installation
Earthing conductors shall run with all three phase feeders and with all single phase branch
circuits.
Conduits stubbed-up below switchgear or switchboards shall be fitted with insulated earthing
bushings and connected to the equipment earth bus. The earthing wire shall be sized in
accordance with Table 250-95 of the National Electrical Code, except that a minimum 4
mm2 shall be used.
Liquid tight flexible metal conduit in sizes 40 mm and larger shall have bonding jumpers.
Earthing electrodes shall be driven as required. Where rock is encountered, earthing plates
may be used in lieu of earthing rods.
All equipment enclosures, motor and transformer frames, conduits systems, cable armor,
exposed structural steel and similar items shall be earthed.
Exposed connections shall be made by means of earthing clamps. Exposed connections
between different metals shall be sealed with No-Oxide Paint, Grade A or equal. All buried
or inaccessible connections shall be made by welding process.
2.6.6 Indoor lighting
General

33
 This part includes technical specification and conditions for the execution of electrical
works for lighting as specified in the technical specification and according to the
instructions and directions of the Engineer during execution.
 All equipment shall conform in all respects to the latest International Standards.
 Installations shall be carried out according to the conditions and systems for electrical
equipment for buildings in the wet and corrosive atmospheric locations and to safety
regulations.
 The contractor shall submit complete and detailed calculation sheet for interior lighting of
the different locations.
 Also, the contractor shall submit the detailed specification of the lighting units he proposes
to be used for approval.
Design Criteria
 The contractor shall follow the following recommended illumination, levels, when
preparing the drawings, related to interior lighting:
Item Description Type of Lamp Illumination Level (Lux.)
1 Switchboard room. Led Lamp 300
2 Pump stations. Led Lamp 300
3 Office. Led Lamp 300
4 W.C. Led Lamp 100
5 Store. Led Lamp 100-200

For any other building, the illumination level shall be according to IES standard, and the
type of lamp shall be according to Engineer's direction
 Electrical Material Wires
All wires shall be 300/500 volt according to IEC 227 & BS 6004 or approved equal and
shall be of single core copper conductors, drawn from annealed copper of high conductivity.
Cross section area of conductors shall be as indicated on the electrical work drawings.
The whole electrical installations shall be arranged so as to ensure ease of maintenance or
replacement of wires and conduits without any disturbance to the surrounding installations
and the junction of conduits shall be made through appropriate junction boxes.
 Conduit Systems
Approved conduit system shall comply with BS 31 for rigid galvanized steel conduits and
fittings. BS EN 50086 for rigid steel conduits with metric threads and BS EN 50086 part 1
for flexible steel conduits and adapters, as appropriate.
All conduits and fittings shall be hot dip galvanized. Any exposed metal such as ends
or conduits or threads cut on site shall be treated by a cold galvanizing process before
being finally fixed or obscured by other equipment.
In all industrial or utility areas, conduits shall be fixed to the surface wall or concealed in
the floor screed when they cross the floor.
In all areas including offices, corridors, W.C., etc.., the electrical installations for lighting
and socket outlets shall be carried out through wires laid inside polyethylene PE conduits,
conceded in ceiling or walls. In this case, the junction boxes shall be of polyethylene with
circular or square shape. The dimensions of the main junction boxes should suit the number
of wires inside it.

34
 Non-metallic conduit systems shall not be used without written permission of Engineer,
except in case of single core cable to avoid over heating due to eddy current. Conduit shall
be run on the surface and be neatly arranged, and ways shall be provided for
additional conduits at all distribution boards. The sizes of conduits used shall be determined
by the number of cables wires to be drawn in as scheduled in the I.E.E. Regulations or as
specified for a particular position but in no case shall conduit smaller than 20 millimeters
diameter be used.
Conduits shall be installed such as to permit complete re-wiring without the need to carry out
builders' work.
No single conduit serving single phase socket outlets, lighting points and switches shall
contain more than one phase.
 Lighting Switches
Surface switches shall be of the iron clad protected, heavily galvanized type. Where
appropriate they shall be of the "multiple phase" type and where possible shall be arranged in
multi-gang boxes.
Exterior lighting switches shall be metal clad, galvanized, watertight, with rotary switch action.
Rear entry shall be provided to allow concealed conduit installation.
Special care shall be taken to ensure that all switches are securely fixed truly vertical and that
flush mounted switches are flush with the wall finish so that the over-lapping cover plates seat
on the rims of the boxes.
Switches shall be mounted at 1.30 m from floor level and be heavy duty type in damp areas.
 Socket Outlets
Socket outlets for the lighting circuits shall be single phase, 16 or 25 amperes, 220 Volt. All
outlets shall be completed with earthing contacts so arranged to make and break earthing
before and after main circuit respectively.
For industrial and utility areas, the Socket outlets shall be three phase, 32 amperes, 380 Volt,
the sockets shall be waterproof, corrosion resistant, industrial type provided with cover (IP54).
 Led luminaires
- All luminaires shall be manufactured to IEC 598-1 and 598-2 for LED lighting luminaires.
- All luminaires supplied by the contractor shall be photo metrically tested.
- The contractors shall produce upon request, the photometric data for any luminaire
specified or supplied.
- All LED luminaires shall be supplied complete with LED controller as per the
manufacturer recommendations.
- All LED luminaires shall be with minimum P.F 0.9.
- All indoor LED lighting luminaires shall work at 40 ºC ambient temperature and 90ºC
relative humidity and storage temperature of 80 ºC.
- All lamp holders for flexible pendants shall be of the all insulated shirted pattern with cord
grips and for batten or wall mounting shall be of similar pattern. All lamp holders shall be
the bayonet cap pattern.
- The Whole luminaire minimum efficacy shall be ≥ 80 llm/cctW at designated ambient
temperature of 40 ºC for Indoor LED lighting luminaires and 50 ºC for Outdoor LED
lighting luminaires in accordance to LM-82 Test Report.

35
- The contractor should stick to the specified lighting fixture manufacturer for each type of
lighting fixture, if the contractor is intended to use any other manufacturer he is fully
responsible to re-calculate the Lux level in all areas and to be submitted to the consultant
for approval before submitting his offer.
- The LEDs shall only be from MacAdam Ellipse Steps ''1-3 Bins'' for Indoor LED lighting
luminaires and steps ''1-6 Bins'' for Outdoor LED lighting luminaires.
- TM-21 reported life time should be run for 10,000 hrs confirming Tsp used in (coming
from Thermal Management Test report at elevated ambient temperature 40ºC) for Indoor
LED lighting luminaires.
2.6.7 Outdoors lighting
 General
Outdoor lighting system shall be suitable for the climatic conditions in site area as specified
before. Outdoor lighting panels' subject to be controlled through photocell and timer operated
contactors.
Provide all new lighting fittings, wall brackets, lamps, poles, auxiliary lighting units and
other fixtures and materials, including proper space and complete the exterior lighting
installations as shown on drawings, specified and required all outdoor and damp area
equipment shall be weatherproof and sealed with gasket. Lighting equipment shall be
completely fabricated, assembled, wired, checked and tested at the factory.
 Description of Work
This section covers partially the work of outdoor lighting as required by the contract and
includes the following items:
- Lighting Fittings (Luminaries).
- Ballasts.
- Lamps.
Extent of lighting work and ancillary fittings covered by this section is indicated on
drawings.
 Submittals
The contractor shall submit the following:
- Original catalogs showing all luminaries technical specifications.
- Material lists and equipment data
- Shop drawings including fastening details of luminaries, ballasts wiring, Circuit
reference, wiring size, conduit size and run, junction boxes.
 Light Emitting Diode (LED) Lamp
- For each luminaire type, submit luminaire information including catalog cuts with
highlighted catalog numbers, and required accessories:
 Luminaire:
 Manufacturer and catalog number,
 Type (identification) as indicated on the plans and schedule,
 Delivered lumens,

36
  Input watts,
 Efficacy,
 Color rendering index,
 Performance data, and
 Effective Projected Area (EPA).
 Driver:
 Manufacturer and catalog number,
 Type (Non-Dimming, Step-dimming, Continuous dimming, etc.),
 Power Factor, Crest Factor, THD, etc.
- Led luminaires shall meet all design lights consortium (designlights.org) product
qualification criteria. This does not require that the luminaire be listed on the design
lights consortiums qualified products list, but they must meet the product
qualification criteria. the technical requirements that the luminaire shall meet for
each application category are:
 Minimum light output.
 Zonal lumen requirements.
 Minimum luminaire efficacy.
 Minimum cri.
 L70 lumen maintenance.
 Minimum luminaire warranty of 5 years (not pro-rated) to include led driver and
all led components.
 Luminaire shall maintain 70% lumen output (L70) for a minimum of 50,000 hours.
 Lumen output shall not depreciate more than 20% after 10,000 hours of use.
- Luminaire and driver shall be furnished from a single manufacturer to ensure
compatibility.
- Led luminaire shall be thermally designed as to not exceed the maximum junction
temperature of the led for the ambient temperature of the location the luminaire is to
be installed. Rated case temperature shall be suitable for operation in the ambient
temperatures typically found for the intended installation. Exterior luminaires to
operate in ambient temperatures of -20°f to 122°f (-29°c to 50°c).
- The luminaire shall be IP65.

Lighting Poles:

The average illumination level at the site shall be not less than 20 lux and the contractor shall
submit complete and detailed calculation sheet including but not limited to illumination level,
pole height, and cable cross-section area and voltage drop.
The poles shall be made of galvanized steel to resist corrosion affected by the sewage gasses,
Each pole shall be fixed on a concrete base (60*60 * 120 cm) by four anchor bolts complete
with nuts and washers as shown on the drawings. Each pole shall be equipped with
luminaries include a LED lamp of 150W and with minimum P.F 0.9

37
 complete with all accessories needed for the lamp as per the manufacturer recommendations,
the luminaire shall be IP65.
The height of the pole is 6 m inside the plant with thickness of 6 mm, while the height of the
pole fixed on the fence is 3 m with thickness of 4 mm.

Distribution Board:
When the photo – electric lighting control and timer unit switches on the triple pole
contactor, the outgoing phase lighting circuits shall be energized.
A- Lighting distribution board shall contain the following:
- One main circuit breaker.
- One triple pole lighting, AC1 air type contactor designed to withstand lamp load inrush
current and to carry full rated current on a continuous basis. it shall be AC operated.
- Outgoing circuit breaker the triple pole AC contactor shall be actuated by means of a
photo – electric lighting control unit mounted externally and timer module.
B- Photo – electric lighting control unit:
The distribution / control board shall be controlled to switch on and off the outdoor lighting
as a function of the ambient daylight intensity by means of a photo electric lighting control
unit.
The unit shall be facing north east to distribution / control board and shall be connected to it
by means of finely stranded copper conductor flexible wires having cross sectional area
according to the approved SLD and PVC insulation. Control unit shall be adjusted to respond
between 5 and 20 lux and its response shall be delayed by 2 minutes to prevent operation on
momentary changes in daylight intensity. An additional programmable timer shall be set to
de-energize the contactor in selected periods of time.
2.6.8 Cable Tray Work
 The cable trays shall be designed to take all cables, including future extensions.
 Cable trays shall be manufactured from not less than 2 mm thick perforated hot dipped
galvanized steel complete with approved type fixings.
 Trays shall be supported by purpose made hot dipped galvanized steel brackets or
Channels.
 Any exposed metals such as ends of channels or tray cut on site for fitting purposes shah
be treated by a cold galvanizing process before being finally fixed or obscured by other
equipment.
 Brackets shall be provided at a maximum of 1000 mm centers.
 Bends and tees shall be prefabricated and have an inside radius of not less than 300 mm and
where large cables are to be accommodated, the radius shall be sufficient to support fully the
correct cables radii.
 Cables shall be fixed to trays by means of purpose made fixing clamps.
 Cable ladder as opposed to tray will be accepted for large cables, subject to the engineer’s
approval. All cables shall be sided in position as they are installed along the route.
 Single core cables of the same circuit shall be Laid and mounted in purpose made trefoil
cleats.

38
  Particular care shall be taken on vertical rise tray in providing adequate cable fixings to
ensure distribution of load and security.

2.6.9 Fire alarm system

Description of work
Work includes a complete fire alarm system in the buildings as indicated in the drawings and
providing all materials, equipment, accessories, services and tests necessary to furnish and
install conventional fire Alarm system.
The system shall consist of, but not be limited to the following:
- Fire Alarm Control Panel (FACP)
- Power supplies.
- Conventional manual fire alarm stations.
- Conventional photoelectric/ionization smoke detectors.
- Motorized Bells.
- Conventional area Multi Sensor detectors, indication lighting.
- Fire alarm cables
Wiring
- All fire alarm system equipment and wiring must be installed in conformance with the
VDE/DIN, ICE, BS and National Electrical Code.
System supervision
- Fire Alarm Life Safety System to electrically supervised to automatically detect and report
trouble conditions as follows:
- The fire alarm system wiring (except control wiring between fans and their control zone
module) shall be electrically supervised to automatically detect and report trouble
conditions to the Fire Alarm Control Panel.
Fire Alarm Control Panel
- Each site shall be provided with a fire alarm control panel containing the number of zones.
- All control and alarm equipment, power supplies and batteries shall be mounted in a
NEMA Type 12 or approved equal cabinet enclosure, suitable for wall mounting, the
cabinet enclosure shall be constructed of heavy gauge sheet steel, designed for surface
mounting and shall have a hinged cover with viewing windows for annunciator lights.
Cover shall be furnished with a lock and two sets of keys. Unused spaces shall be fitted
with blank cover plates. Finish color shall be red.
- The control panel shall be modular, of dead-front construction using solid-state
components to operate the system.
- Alarm initiating circuits shall meet National Electrical code requirements for limited
energy applications and function with up to 100 ohms resistance in the alarm initiating
device and its associated wiring.
- The control unit shall contain an internal audible signal with audible acknowledge switch,
and auxiliary master box disconnect switch. Control unit shall be double-supervised so that
a trouble signal shall sound in the event of loss of either operating or supervising power.
Two light-emitting diodes (LEDs) shall be installed and shall remain illuminated to
indicate both operating and supervisory power are energized. Trouble audible acknowledge
switches shall be furnished with its associated LED so that indication of

39
 trouble on alarm initiating circuits, alarm indicating circuits and supervisory circuits shall
initiate a control panel audible and be silenced independent of each other.

- The silencing of a trouble condition in any zone shall not prevent the resounding of the
control panel audible in the event of a subsequent trouble condition in other circuits. When
trouble conditions are restored to normal, the audible acknowledge switch shall not require
restoration to normal.
- The system should be provided with an Uninterruptible Power Supply (UPS).
Provisions shall be made for alarm indicating circuits:-
- Each circuit shall be supervised to provide a trouble condition in the event of an open or
short in either circuit. A means shall be provided so that alarm indicating appliances may
be discontinued before the actuated initiating device has been restored to normal; but shall
not prevent the resounding of subsequent alarms received from another zone.
- A visual indication shall be provided so that operating personnel can readily determine that
the signals have been discontinued.
- The alarm initiating circuits shall be class “A” and shall allow the receipt of alarms even in
the event of a single open or a single ground in the alarm initiating circuit.
- Each zone shall have a separate zone trouble and alarm indicator.
- All field wires connected to alarm initiating devices necessary to activate an alarm shall be
electrically supervised and a single open or ground on such wires shall not cause an alarm
condition. An open in any alarm initiating circuit shall cause the associated visual trouble
indicator to flash and the control panel audible to sound steady, until the audible
acknowledge switch is actuated at which time the trouble indicator shall go steady and the
control panel silenced.
- On alarm condition in any alarm initiating circuit, its associated visual alarm indicator shall
flash and the control panel audible shall pulsate and the alarm indicating appliances shall
sound. When a zone audible acknowledge switch is activated, the indicator shall be lit
steady and the control panel audible silenced.
- The silencing of a trouble or alarm condition in any zone shall not prevent the resounding
of the control panel audible in the event of a subsequent alarm or trouble condition in other
circuits, or loss of either operating or supervising power. Each alarm initiating circuit shall
have associated dry, fused Form “C” alarm contacts for its associated zone. This contact
shall transfer upon alarm condition in its associated zone.
- Means shall be provided to sound the control panel audible upon a ground fault between
any supervised circuit and ground. This ground fault shall also light a visual indicator on
the control unit for rapid identification of the trouble cause.
- All visual indicators on the control panel shall be supervised so that an open or short in any
visual indicator shall provide a trouble indication.
- Provide a 24 volt dc power supply in each alarm panel for the fire detection alarm system.
The power supply shall consist of battery and battery charger. The battery charger shall
operate to maintain the battery in a fully charged condition. The battery shall have the
capacity to operate the system for a minimum of 24 hours and then shall sound all alarm
signaling devices for 5 minutes. The battery charger shall be suitable for use on 220 volt,
50 Hz, ac power supply.
Smoke Detectors
- Detector heads shall be plug-in, twist lock units which may be installed or removed from

40
 the base with one hand or by the use of a special installation tool. The base assembly shall
be the twist lock type with screw type terminals. Connections shall be made to terminal
blocks.
- Detectors shall operate on the ionization principle having normal sensitivity and activated
by the presence of combustion products.
- Sensitivity shall be adjustable. Detectors shall contain two ionization chambers. One
chamber shall be for fire detection, and the second chamber shall function as a reference to
stabilize the detector for environmental changes in temperature, humidity, and pressure.
The units shall contain a solid state amplifier switching circuit and an indicator lamp. There
shall be no moving parts. Operating voltage shall be a nominal 24 volts dc. The detectors
shall meet UL standards. The detector sensitivity shall remain within proper limits at an
ambient temperature up to 50 C.

- Detectors shall have a signal (to alarm) to noise ratio exceeding 2.0 and a minimum of two
senses before alarm to decrease probability of false alarms. Detectors shall not give false
alarm or change sensitivity substantially when subjected to wind velocities of 5
meters/second or when subjected to wind gusts to 10 meters/second lasting two seconds.
Alarm Horns
- Alarm horns shall be the combination audio-visual type rated 97 dB at a distance of 3
meters. Horns shall be the vibrating type with stainless steel diaphragms. Vibration shall be
generated by an electromagnet operating at 24 volts dc. Frames and single projector horn
shall be cast aluminum, surface mounted. Finish color shall be red with the word “FIRE” in
white lettering. Additional signage shall be provided in Arabic.
- Combination audio-visual horn/lamp units shall be installed on supervised circuits and
visual portion shall flash on alarm
Manual Fire Alarm Pull Stations
- The station shall be double action, with non-break glass, coded type with a pull-down lever
and a push-in tab. The housing shall be cast metal or moulded material, and the body shall
be hinged to a back plate assembly having an Allen head locking screw. After operation,
the device shall be reset by opening the station and relocking the body to the back plate.
Mounting shall be surface or semi flush. The device shall contain an alarm lamp and a key
operated switch. Rating shall be nominal 24 Volt DC. Connections shall be made to screw
terminals. Pigtail splices or in-line taped splices are not allowed.
Installation
- The system shall be wired with 1.5 mm2, solid copper, cable throughout in accordance
with the manufacturers' diagrams and requirements. All wiring shall be installed in
conduits.
- Upon completion of the installation, check and test the entire system with and to the
satisfaction of the Engineer.
- The fire alarm system shall be free from defects in workmanship and materials, under
normal use and service as specified elsewhere in these specifications for a period of one
year from the date of final acceptance of the building by the Employer. All equipment
shown to be defective in workmanship or material shall be repaired, replaced or adjusted,
free of charge.
- The equipment manufacturer shall be represented by a local service organization and the
name of this organization shall be furnished to the Engineer and Employer. The local
service organization shall be available to furnish maintenance and inspection in accordance

41
 with NFPA 72 A, B, and D.
Certification of Compliance
- Upon completion of the installation of fire alarm equipment, provide to the Engineer a
signed written statement substantially in the form as follows:
- Upon completion of the installation of fire alarm equipment, the Contractor confirms that
the fire alarm equipment was installed in accordance with the specification and also in
accordance with wiring diagrams, instructions and directions provided by the equipment
manufacture.

2.7 STATION AUXILIARIES

2.7.1 Rotary crane
The Contractor shall supply, install and test a Rotary crane with hoist for serving the basket
screen, the height of lifting hoist according to the actual conditions in site. The crane shall be
electrically operated for lifting motions only (2 moves) and manually operated for other
motions.
The pillar shall be made of heavy duty steel tubes of adequate diameter according to
manufacturer. The height of pillar shall be not less than 3 meters above ground level. The
crane shall provide 270⁰ of rotation for different maintenance and service works. A lifting
chain made of stainless steel 316L shall be of sufficient length to serve the basket screen
while the lifting hook shall be of forged steel with hardened steel balls under the head. The
crane shall be tested at 25% excess load of its rated load capacity. The crane shall be
complete with the control and operation panel.
The contractor shall submit detailed specification and drawings required before installation.
The contractor should check the sump dimensions and submit his offer according to the
actual conditions since he bears full responsibility for suitability of the crane to the operation
conditions.
2.7.2 Fire Extinguisher
1. Portable chemical dry powder fire extinguisher of 6 Kg Capacity shall be supplied
fitted with a squeeze grip, valve and swivel horn, for each building.
2. The jet length shall be not less than 2 meters and the extinguisher shall be suitable for
operation in an ambient temperature which may reach 50oC and be subjected to a test
pressure not less than 87 Kg/cm2.
3. The base of each extinguisher shall be flat to enable the unit to be rested on the floor.
4. Each extinguisher shall be completed with a wall-mounted bracket and a sign in
English and Arabic giving operating instruction, which shall be fixed, in positions
designated by the Engineer.
2.7.3 Basket Screen
Each pumping station shall be provided with one basket screen to be installed in the sump
inlet. The screen, in order to prevent solids from entering into the pump station sump and
consequently protect the pumps from such big solids, shall trap solid contents in the sewage
water by limiting the space between bars to be less than the pump solid handling by 1 inch.
The basket screen shall have the base and top from suitably sized stainless- steel 316 with
special treatment against the effects of sewage water and emitting gases.The overall
dimensions of the screen shall be as indicated in the relevant drawings. thickness of the base
and top plates shall be not less than 1/2”. The stainless- steel bars (cage) shall be of nominal

42
 diameter not less than 20 mm. The basket components i.e. top and base plates together with
the body shall be assembled by welding. The basket screen shall be installed on reinforced
concrete cantilever inside the pump station sump. The basket screen shall be lifted
periodically for cleaning of the screened matters. At its vertical travel, the screen shall be
guided at least by two round stainless steel 316 pipes of not less than 2” nominal diameter.
The screen body shall be provided with two (No.), guide bearings.
The lifting action shall be effected by suitable stainless steel 316 chain to be hooked from
one end to the top of the basket while the other end shall be hanged on the top of the guide
bar.
The basket screen shall have two rolling bearing of each side
2.7.4 Ventilating Sets
Ventilating sets shall be able to change the volume of air 8 times every hour for pump house
and the Low voltage distribution board room.
 General
Ventilating fans shall be of the type and arrangement as specified herein after. All fans shall
be rated and constructed in accordance with VDE/DIN. Fans shall be furnished completely
with motor, drive equipment, vibration isolators, supports, appurtenances, and disconnect
switches.
Direct driven fans shall have the fan wheel mounted on an extension of the motor shaft. The
motor shall be mounted in a rigid streamlined frame designed to provide vibration isolation
for the motor and so that the wiring can be run to the motor unexposed.
 Wall fan
For Submersible Pumping stations: Both suction and exhaust ventilation fans shall be axial
wall mounted type with backward inclined aluminum blades, direct driven by an electric
motor, stationary discharge.
For Wet & Dry Pumping stations: Both suction and exhaust fans shall be an in-line
centrifugal tubular fan with backward inclined aluminum blades, direct driven by an electric
motor, stationary discharge, conversion vanes. Inlet and outlet connections for the fan casings
to duct-work and equipment casings shall be of the flanged type. Inlets shall be stream-lined
and conversion vanes shall eliminate turbulence and provide smooth discharge air flow. Air
ducts shall be made of galvanized steel extending down till one meter higher than the floor of
pump room.
Fan bearings and drive shafts shall be enclosed and isolated from the air stream. Motor
bearings shall be mechanically sealed against dust and dirt and shall be permanently grease-
lubricated ball type.
The speed shall be 1500 rpm as maximum. Motors shall be totally enclosed fan cooled with
class B insulation, and rated for an ambient operating temperature of 45 C, shall have degree
of protection IP44.
- All fans shall have vibration and sound-absorbing mountings.
- All motors shall be 3 Ph., 380 volt, 50Hz.
- Fan wheel and casing inside and outside for the supply and exhaust.
- Fans for pump station shall be given an acid-resistant coating of easiness, latchet, here site
or acceptable equivalent corrosion-resistant coating.
- All fans shall be supplied with thermostatic control of heavy duty type.

43
 2.7.5 Mechanical& Electrical Instruments and Furnishings
The contractor shall supply the following list of mechanical tools:
 Four steel saws with handles.
 One scraper, one 6" and one 12" (straight half round).
 One complete set of 12" and 6" files and three different sizes of screw drives.
 One set of feelers in metric.
 One steel straight edge 2" wide and one meter long.
 One speed tachometer of reliable make for speeds up to 3000 rpm.
 One protected thermometer reading up to 100 C.
 One protected thermometer reading up to 500 C.
 One ladder 3 meters.
 Two hammers of one kilo and 4 kilos.
The Contractor shall supply the following list of electrical tools:
 One relay tester of switches and starters in a suitable bag and box with the necessary
variable resistances, current transformers, voltmeters, ammeters, etc.
 One set of electricians' tools complete in a suitable case.
 One Megger for insulation testing, complete with its case (500 volts)
 One substandard "E" voltmeter with suitable potential transformer.
 One rheostat 5 amps. 50 ohms.
All above standard tools/instruments shall be supplied in suitable cases.
The Contractor shall supply the following furnishings:
 One complete set of spanners, tools ….etc. necessary for dismantling adjustment and
erection of all machinery with one suitable steel cupboard to accommodate these tools.
 Two grease guns.
2.7.6 Steel Ladder with skid
The contractor shall supply one portable steel ladder with skid to be kept at the pump house
in order to serve the maintenance works for valves, pipes and special pieces on the discharge
side of horizontal pumps. It shall be of sufficient height to ease the installation and/or
dismantling works for valves and pipes. The ladder and skid are welded as a one unit and
provided with at least four wheels for easy movement inside the pump room. The overall
dimensions shall be suitable for passing the ladder between the horizontal pumps concrete
foundations according to drawings.

2.8 DIESEL-DRIVEN STAND-BY ELECTRIC GENERATING UNIT

2.8.1 Generating Set
This specification covers the requirements for design, fabrication, testing installing,
commissioning and maintenance during the guarantee period of a complete Diesel electric
generator unit, including all devices and equipment specified, as required for trouble free
service. Materials and equipment furnished under this specification shall be delivered to the
site completely equipped, wired, tested and ready for operation.
Note:
Generating unit shall be Prime Power, Sound & Weatherproof Enclosure Type.

44
Design Criteria
Enclosure main dimensions are well selected to provide optimum performance and mainly made of
galvanized or electrostatic painted metal sheets with suitable thickness not less than 6mm, and
provided with suitable rigid supports to protect it from any curvature.
Enclosure is designed in a way that insures efficient sound and weatherproof that support well
performance and ease of preventive maintenance.

1-Doors:
- Hinged lockable door, provide access to both sides of engine and alternator.

2-Air intake:
- Air intake and outlet shall be provided with louvers and shall be sized for the requirements of the
genset.

3-Exhaust silencer:
- Canopy supplied with isolated heavy-duty industrial exhaust silencers (mufflers).

4- emergency stop push buttons:

- Emergency stop push buttons shall be installed outside the enclosure, near the door,
wired to shutdown circuit of the generator control system.

5-Internal components and systems:

- Fuel system with fuel daily tank, fuel connections
- Gen set control panel
- Internal lighting, close to the ceiling, provides illumination inside the canopy
- Junction box with lockable door is provided for connection of load cables

6-Earthing:
Earthing stud linking internally all major components including engine alternator, fuel tank, control
panel enclosure, with a facility to connect it to external Earthing cable.

7-Easy in control:
Enclosure is equipped with a window to in front of the control panel to provide easy control panel
observation.

The Diesel electric stand-by generator shall include the following:

1- Diesel-engine generator to serve stage 1 requirements.
2- One set of batteries with battery charger for starting of the engine as outlined.
3- Engine-generator controls and distribution panels.
4- All necessary control devices to provide a complete, operable system.
5- Station auxiliaries including daily and monthly fuel storage tanks.

2.8.2 Requirements
The Engine-Alternator system shall supply sufficient power to the loads in normal operation
and in starting mode taking into account the deration due to ambient & installation conditions
according to ISO 3046 & 5828 and IEC 60034.
2.8.3 Engine

45
 The engine shall be Diesel-fuel, four strokes, water cooled with mounted radiator, fan and
water pump. It shall have multi-cylinders, in line or V-type and supercharged.
Diesel engine will be started electronically but there are some conditions such as:
- Should use copper cables between Starter and battery.
- Built-in battery charger shall be used for charging the batteries to be ready for operating
the engine at start.
- Speed of Diesel engine = 1500 rpm.

a) Margin of Capacity
The engine rated output should be at least 10% more than the power required by the
alternator to produce its rated output when its speed doesn’t exceed 1500 rpm. The engine
shall be able to support a load of 10 percent in excess of its continuous rated output, for a
period of not less than one hour without over heating or other mechanical trouble.
Free rotating exhausts valves. Exhaust valve seat inserts shall be provided. A positive
displacement lube oil pump shall supply full pressure lubrication. The engine shall have air,
fuel and oil filters with replaceable elements, and a fuel transfer pump. Engine speed shall be
governed by an automatic governor to maintain alternator frequency within 5 percent of
alternator output, from no-load to full-load. The engine shall have a 12-volt battery charging
DC, alternator with a transistorized voltage regulator. Remote 2-wire starting shall be by a
low volt, solenoid shift, and electric starter. M.P.S. should not exceed 10 m/sec and the
M.E.P. Not exceeds 20 kg/cm2.
b) Engine Instruments:
The engine instruments panel shall contain an oil pressure gauge, coolant temperature gauge,
and battery charge rate ammeter.
c) Engine Controls:
The generating set shall contain a complete engine start stop control which starts engine on
closing contact and stops engine on opening contact. A cranking limiter shall be provided to
open the starting circuit in approximately 45 to 90 seconds if the engine is not started within
that time. The engine controls shall also include a suitable 3 position selector switch with the
following positions: RUN - STOP - REMOTE, high engine temperature, low oil pressure and
over speed shutdown with signal light and alarm terminals shall also be provided.
The efficiency of alternator must be not less than 85% and power factor 80%.

2.8.4 Brush-less Alternator

The alternator shall be a pole revolving field design with temperature compensated solid state
voltage regulator and brush-less rotating rectifier exciter system. No brushes shall be
allowed. The stator shall be directly connected to the engine fly wheel housing, and the rotor
shall be driven through a semi flexible driving flange to ensure permanent alignment.
The insulation system shall be class “H” with temperature rise class “F” or “B” and enclosure
protection not less than IP23.
The three phases, board range alternator shall provide 3 phase voltage 4 wire system 400/220
volts, 50HZ and nominal power rating. The supplier shall submit a necessary suitable control
panel under his responsibility.

46
2.8.5 Excitation system
An exciter is a small source of direct current (DC) that energizes the rotor. The rotor
generates a moving magnetic field around the stator, which induces a voltage difference
between the windings of the stator. This produces the alternating current (AC) output of the
generator. The excitation system specifications shall be according to manufacturer design
parameters.
2.8.6 Unit Performance
Frequency Regulation shall not exceed 3 Hz from no load to rated load. Voltage regulation
shall be within ±2 % of rated voltage, from no load to full rated, The instantaneous voltage
drop shall be less than 16 % of rated voltage when full, 3 phase load at 0.8 power factor is
applied to the alternator.
Recovery to stable operation shall occur within 2 seconds. Stable or steady state operation is
defined as operation with terminal voltage remaining constant within plus or minus 1 % of
rated voltage.
A rheostat shall provide a minimum of ± 5 % voltage adjustment from rated value the
efficiency of the unit should not be less than 85 %
2.8.7 Alternator Instrument Panel
The alternator instruments panel shall be wired tested. It shall contain panel lighting manual
reset circuit breaker, frequency meter, running time meter, voltage adjusting rheostat, AC
voltmeter (dual rang, indicates all voltages), AC ammeter, (dual range, indicates current each
phase), meter switch, voltmeter - ammeter phase selector with OFF position.
Single-phase instrumentation includes voltmeter, two ammeters and no selector switch. The
panel shall include built-in charger for battery charging.
The controller shall be contain communication port to connect with the control system
via ( MODBUS / TCP )
2.8.8 Generating Set Mounting
The electric generating set shall be equipped with vibration isolators and mounted on a
welded steel base, which shall provide suitable mounting at any level surface.
The mobile unit can be mounted on a trailer with four wheels and can be towed by any
tractor or any track. It will be equipped with any approved type of brakes. The stability and
rigidity of the trailer shall be responsibility of the supplier.
2.8.9 Accessories
All accessories needed for the proper operation of the generating set shall be furnished. These
shall include a muffler, flexible exhaust connection, starting batteries, battery cables, battery
rack, fuel tank lines and detailed operation and maintenance manuals with parts list.
The accessories shall also include transfer pump complete with all necessary facilities.
2.8.10 Fuel System:
The fuel system for the engine shall consist of the items listed below.

47
a) Fuel oil strainer and filter full-flow:
Strainers shall be provided ahead of the engine fuel pump. The full-flow filters shall be
provided after the engine fuel pump. Strainers shall be of the metal edge or screen type as
recommended by the engine manufacturer. The filter plainly marked. The case shall be
mounted in an accessible location, which will permit changing strainers and filter elements
without disconnecting the piping or other engine-mounted equipment.
b) Fuel-pump:
Engine fuel pump shall be of the positive displacement, engine driven type and capable of
supplying the necessary quantity of fuel under all conditions of operation. Relief valves shall
be provided to prevent equipment damage due to buildup of excessive pressures, which
might result from restrictions in the discharge lines. In addition a hand-operated fuel oil
priming pump shall be provided.
c) Fuel oil drip:
Nozzle drip lines overflow.... etc shall not drain on the floor. A means shall be provided for
collecting these lines and return of excess fuel to the day tank automatically.
d) Fuel oil lines:
Shall be provided with solid connections between fuel piping and engine as required
e) Fuel oil daily and monthly storage tanks:
One fuel daily tank shall be included with the generating unit. The daily tank capacity should
be enough to operate the unit for continuous 8 hours based on the engine fuel consumption
rate. It shall be included level switch and connect with generator hardwire for interlock. And
to be connected with PLC.
A monthly storage tank shall be supplied and installed in the pumping station as shown on
the layout drawing. The tank capacity shall be 10 time the capacity of the daily tank. The
tank shall be complete with all piping and valves.
The tank shall be double shell type constructed of steel plate free of imperfections and
constructed as a rigid unit with internal partitions or bracing if necessary with thickness 6
mm. All seams shall be welded from both sides or with penetrating welding methods. The
tank shall be installed in an elevated position. A large clean out opening shall be provided in
the tank top. The tank shall be fitted with a level gauge and an inlet valve arranged for
gravity feed. High and low level alarms shall be provided with indicators in the engine
control panel. Fittings for overflow piping shall be provided. All fuel piping between the day
tank and engine shall be factory completed. It shall be included ultrasonic level transmitter to
given the fuel in the tank by litre. It shall connect with PLC/HMI
It’s a must that the Tenderer submit in his technical offer a detailed description and drawings
for the fuel system.
2.8.11 Voltage Regulator:
The voltage regulator shall be solid state using no electron tubes or electrolytic capacitors
and of the type and size as recommended by the generator and regulator manufacturers. It
shall be designed to provide an overall general performance as follows:
Steady State:
A. With any constant load between no-load and full-load and at any power factor from 0.80 to 1.0
and in the ambient temperature specified, voltage regulation shall be 1 %.

48
B. With a constant load and ambient temperature, voltage drift shall not exceed 1% during any one-
hour period.

Transient:
A. 12% maximum voltage drop with application of 50% rated load with two seconds maximum
recovery time to steady state when operating at 50% load.
B. 12% maximum voltage rise with removal of 50% rated load with two seconds maximum
recovery time to steady when operating at 100% load.

2.9 SPARE PARTS

Tenderers shall submit with their tenders a detailed price list of all spare parts required
hereunder. The price of each individual item in the schedule must be given separately.
Tenderers shall include in their tenders also any other spare parts, which may have not to be
included herein to suit the type of machinery offered. The word "set" in the list shall mean one
complete set for the pump or the motor ...etc. as the case may be.
2.9.1 Spare Parts for Submersible pumping units
- Two complete sets of pumps wearing rings.
- Two complete sets of pump bearing.
- Two complete sets of pump mechanical seals.
- Two sets of all pump O-rings and gaskets.
- One complete impeller with shaft.
2.9.2 Spare parts for Low Voltage Distribution Board
- One C.B from each type and size.
- One set of relays in motor control center
- One set of current transformers in the motor control center of each rating.
2.9.3 Spare parts for Diesel Generator
- 10 No. of air filter.
- 10 No. of oil filter.
- 10 No. of fuel filter.
- Two sets of bearing.
- A.V.R unit.

49
2.10 General Specifications for Water Hammer Equipment
2.10.1 Applicability

- This specification covers the minimum requirements, for design, manufacture,

testing at manufacturer's works, supply, site testing, and commissioning of the
surge vessels. This specification shall be read in conjunction with the relevant
datasheets, drawings, and other relevant sections of the Tender Documents.
Compliance with this specification shall not relieve the CONTRACTOR from
any of his contractual obligations and responsibilities towards fulfilling the
performance requirements.

- No deviation from this specification shall be allowed unless specifically

approved in writing by the ENGINEER.

- This specification and the associated drawings shall be considered the

absolute minimum requirements for performance & quality and shall be
considered in the extension of "not in limitation".

- The Contract drawings indicate the general arrangement of the surge vessels
and all the auxiliary equipment required for a complete surge vessel package.
The CONTRACTOR should review all Contract drawings so that all items
affecting the operation of the complete system are considered in the design
and supply of the engineered package.
2.10.2 Applicable Standards and Codes
All materials and workmanship shall comply with the latest edition of the
applicable standards and codes which shall include but not be limited to
the following:
 ASME Sect. II Part C Welding Rods, Electrodes and Filler Metals
 ASME Sect. V Non-Destructive Examination
 ASME Sect. VIII Div. l Pressure Vessels
 ASME Sect. IX Welding and Brazing Qualifications
 ISO 8501 Preparation of Steel Surfaces before Application of Paints and
Related
 Products
 ISO 9000 Quality Management and Quality Assurance Standards Guidelines
for selection and use
2.10.3 Evaluation of Water Hammer protection needs
The need of water hammer protection means is based on the maximum and minimum
transient pressures resulting from the analysis of pressurized systems under
transient potential scenarios.

2.10.3.1 Transient potential scenarios

50
 A. Pump Trip: pump trip is the main transient scenario to be studied assuming power
failure conditions using the pump inertia to simulate the transient event
B. Pump start up after trip: the startup scenario is simulated to ensure safe starting of
pumps and avoid any potential air valve slamming transient pressures, the pump
start up shall be modeled in the same scenario after pump trip to admit air first
during the pump trip at air valve locations, then expel the air at pump start up,
ensuring no occurrence of air valves slamming

2.10.3.2 Limiting transient pressures

A. Maximum pressure: Maximum transient pressure shall not exceed the larger
between 1.2 × pipeline design pressure or 1.5 × the maximum steady state pressure
in order to avoid fatigue phenomena
B. Minimum pressure: Minimum pressure shall not exceed -3 m for plastic pipes and -
5 m for ductile iron pipes

2.10.3.3 Transient study input data

All the data required for the transient study shall be collected by the contractor
consultant and shall cover but not limited to the following:
A. The As-Built profile drawings
B. The As-Built sump drawings
C. The end pipe connection elevation
D. The used pump catalogues
E. The used air valves catalogues
F. The used non-return valve catalogues
G. The potential operating scenarios & the operation philosophy
H. The used pipes catalogue

2.10.4 Protection means

2.10.4.1 Dipping tube surge vessel
Dipping tube surge vessel is the first preferable choice in sewage flat terrain force mains
for its cost and reliability advantages
Design basics

A. The vessel shall be designed to achieve satisfactory transient pressures with minimum
vessel volume.

B. The vessel volume shall be larger than the maximum expanded gas volume with 15-35 %
margin of safety.

C. The vessel maximum expanded gas volume shall be larger than the compression
chamber volume (volume around dipping tube) with more than 20 % margin of safety at
the trip scenario of one pump or multiple pumps.

51
D. The vessel shall be supplied with a sewage air valve at the top tank that can allow
unobstructed air flow that can compensate for the maximum outflow/inflow from the
vessel when the air valve is working.

E. The vessel shall be supplied with a magnetic level indicator with a minimum size of 2 inch
and the indicator height & installation shall cover the highest/lowest water levels inside
the vessel.

F. The dipping tube diameter shall be large enough to allow unobstructed flow during
transient conditions and it shall not be less than the air valve diameter.

G. The vessel design pressure shall not be less than the force main design pressure

H. The test pressure shall not be less than 1.5 times the design pressure

I. The inspection manhole shall not be less than 500 mm

J. The vessel shall be supplied with a pressure gauge installed at lower location to allow
easy examination

K. The vessel shall be supplied with a drainage pipe along with a gate valve both size is
designed to allow suitable draining duration time

L. The vessel connection to the main line shall be supplied with a gate valve. The size of the
connection along with the valve shall not be more than the pipeline size and shall be
designed based on the transient study

M. The vessel thickness shall be designed according to the Egyptian code/ASME

N. The vessels shall be installed downstream the final non-return valve in the flow path

O. The transient study shall include all the related details and shall be equipped with a
schematic drawing for the vessel geometric details and all critical elevations

2.10.4.2 Compressor vessel

Compressor surge vessel is the second preferable choice in sewage force mains due to
its cost and reliability advantages
Design basics

A. The vessel shall be designed to achieve satisfactory transient pressures with minimum
vessel volume.

B. The vessel volume shall be larger than the maximum expanded gas volume with 15-35 %
margin of safety.

C. The minimum air pressure inside the vessel shall be not less than the atmospheric
pressure (1 bar absolute).

D. The vessel shall be supplied with a magnetic level indicator with a minimum size of 2 inch
and the indicator height & installation shall cover the highest/lowest water levels inside the
vessel.

E. The vessel design pressure shall not be less than the force main design pressure.

52
F. The test pressure shall not be less than 1.5 times the design pressure.

G. The inspection manhole shall not be less than 500 mm.

H. The vessel shall be supplied with a pressure gauge installed at lower location to allow easy
examination.

I. The vessel shall be equipped with a pressure safety valve installed at the top of the vessel
adjusted with a brake pressure equal to the vessel deign pressure

J. The vessel shall be supplied with a drainage pipe along with a gate valve each size is
designed to allow suitable draining duration time.

K. The vessel connection to the main line shall be supplied with a gate valve. The size of the
connection along with the valve shall not be more than the pipeline size and shall be
designed based on the transient study.

L. The vessel shall be equipped with compressors unit and Scada to ensure all time
readability for transient conditions.

M. The minimum number of compressors are two compressors to be used as one duty and
one stand-by.

N. The compressor flowrate shall be designed to compensate the dissolved air in a 5-30
minutes

O. The compressor pressure shall be larger than the air pressure inside the vessel with 2 bars

P. The compressor shall be equipped with an air receiving tank

Q. The vessel thickness shall be designed according to the Egyptian code/ASME

R. The vessels shall be installed downstream the final non-return valve in the flow path

S. The transient study shall include all the related details and shall be equipped with a
schematic drawing for the vessel geometric details and all critical elevations

2.10.4.3 Air valves

Air valves can be used as a stand-alone protection equipment or an additional equipment

added with the surge vessels main protection.
Air valves types

The air valve type can be one of two types

A. Combination air valve

Combination air valve is the typical air valve used on the pipeline that can fulfill four
functions using two diameters:

1- Safe expelling of air during pipeline filling from the large diameter

53
 2- Safe draining of air during pipeline draining from the large diameter

3- Admitting air during transient to protect from negative pressures

4- Expelling small amount of obstructed air during steady state conditions from the
small diameter

This air valve can be added as a water hammer protection equipment after checking
that no slamming occur from this valve

B. Three phase anti slam air valve

This air valve is especially used for water hammer protection and can fulfill five
functions using three diameters:

1- Safe expelling of air during pipeline filling from the large diameter

2- Safe draining of air during pipeline draining from the large diameter

3- Admitting air during transient to protect from negative pressures

4- Expelling small amount of obstructed air during steady state conditions from the
small diameter

5- Preventing air valve slamming by switching to anti-shock orifice during expelling of

air

This air valve can be added as a water hammer protection equipment, this valve
ensures no slamming occurrence
Design basics
1- The air valve large diameter shall be sized to ensure safe filling/draining of pipeline
2- The air valve small diameter shall be sized to ensure safe expelling of obstructed air
volumes during steady state
3- The air valve anti-shock orifice shall be sized to ensure no slamming, the switching
pressure shall be specified to switch to the anti-shock orifice before slamming
occurrence

2.10.5 Transient study report

The transient study report shall cover but not limited to the following:
A. Introduction:
The study introduction shall declare the brief description of the study subject and the
objective of the study.
B. The input data:
The input data section shall mention all the data used for the study which shall cover but
not limited to:
1- The pipes related data: the used material, the pipes pressure rating, the pipes thickness,
the pipes length, the inner diameters, the pipes catalogues, Hazen William coefficient,
young’s modulus of elasticity, Poisson’s ratio, the wave speed calculations, etc...

54
 2- The pumps related data: the number of operating/stand-by pumps, the flow rate, the
manometric head, the efficiency, the rotational speed, the power consumption, the
inertia calculations, the pump branch connection diameters, the used pump catalogue.
C. The system related data:
The operation philosophy of the system and the potential scenarios
D. Steady state analysis:
includes the results of the system steady state like the pumps actual operating point, the
flow velocity, the maximum pressure, the hydraulic grade line graph
E. Without protection analysis:
includes the results of transient analysis for the system without any protection means under
the worst-case transient event (usually the pump trip). The results shall include the
minimum/maximum transient pressures, the minimum/maximum hydraulic grade line graph
F. With protection analysis:
This section shall cover but not limited to
1- The required surge protection means.
2- The maximum/minimum resulted transient pressures.
3- The maximum/minimum hydraulic grade line graph.
4- The gas volume variation curve inside the surge vessel.
5- The gas pressure variation curve inside the surge vessel.
G. Pump room & Non-return valves:
This section shall cover special considerations regarding the pump room components and
the recommended types of non-return valve to be used in order to avoid valves slamming.
H. Summary and conclusion:
This section shall cover but not limited to:
1- The summary of the study findings and the protection means.
2- The surge vessel tabulated data which shall include:
 Total vessel volume
 Number of vessels
 Outlet/inlet nozzle diameter
 Initial compressed gas volume
 Compression chamber volume (for dipping tube vessel only)
 Maximum expanded gas volume
 Dipping tube length (for dipping tube vessel only)
 Medium
 Internal design pressure
 External design pressure (internal negative pressure)
 Diameter
 Orientation
 Vessel type
 Bottom dish elevation
 The elevation difference between the connection pipe elevation and the bottom
dish elevation
 The connection pipe invert elevation
3- The added/replaced air valves for protection data which shall include:
 The air valve status (replaced/added).
 The valve stations
 The valve elevation
 The number of valves

55
  The diameter of valve
 The anti-shock orifice diameter (only for anti-slam air valves)
 The switching pressure (only for anti-slam air valves)
 The fluid medium
 The design pressures
 The air valve type
4- The operation & maintenance recommendations which include the pumps shutting
down sequence and time interval, the pumps start up sequence and time interval, the
time interval between shut down and start up
5- Schematic drawing for the surge vessel declaring the geometry of the vessel, the
dimensions, elevations of all vessel components, the vessel connection to the main
pipeline details
I. Surge vessel technical data
This section shall include but not limited to:
A. The vessel thickness calculations
B. The coating specifications.
C. The surge vessel data sheet
D. The reinforced concrete base details
E. The magnetic level indicator details
F. The drain connection details
G. The pressure safety valve details (only for compressor vessel)
H. The pressure gauge details.
J. Appendices
This section shall include the detailed outputs of the software and shall cover the steady
state results, the without protection results, and the with protection results.
2.10.6 Fabrication requirements
- The surge vessels and associated piping/nozzles shall be of welded steel
type.
- The surge vessels shall be fitted with the following fittings and connections
as a minimum:
- Water delivery pipe to pumping main with isolating valve.
- Non-return valve and by-pass on the water delivery pipe (if required) or non-
return valve with bleeding capacity (if required).
- Direct reading level gauge (differential pressure type).
- Level transmitter.
- Level switch (minimum 3 No.) for local control.
- Level switch (high level alarm).
- Level switch (low level alarm).
- Direct reading pressure gauge.
- Drain point with drain valve.
- Safety pressure relief valve. (only for compressor vessel)
- Lifting lugs.
- Suitably sized Manhole/door with davit arm/hinges.
- Compressed air supply pipe with isolating valve and solenoid valve. (only
for compressor vessel)
- Access ladders and platforms.
- Solenoid air vent valve with isolating valve. (only for compressor vessel)
- All solenoid valves should have manual control capability.

56
 - All nozzles emanating directly from the air vessel shall be flanged and have
a minimum internal diameter of 100 mm.
- All safety valves shall be fitted with manual isolation valves.
- All isolation valves and solenoid valves shall be of the same size wherever
possible for reduced spares stocks.
- The surge vessel and all fittings shall be rated at a pressure equal to or
greater than the pressure rating of the main pumping line and shall be tested
both at the works and on site to the appropriate test pressure.
- Level switches shall function into time delay circuits to ensure that the
detected condition is not transient before the appropriate alarm or control
circuits are operated. These timers are to be set such that the alarms and
controls are only activated as a result of changes in quantity of air in the
vessel and not as a result of surge conditions. (only for compressor vessel).
- The drain valves and pressure relief valves shall be piped to discharge into a
site drainage manhole.
- Surge vessels shall be provided with complete automatic air charging
systems with manual control capability as specified. (only for compressor
vessel)
- The access ladders and platforms shall allow access to all instrumentation
valves and the manhole cover.
- In the event of the low-level alarm being activated the solenoid air vent
valve shall operate until the level rises above the alarm and then for a further
predetermined time. (only for compressor vessel)
- The isolating valve for the surge vessel shall be manually operated and shall
be provided with position indicator to indicate if it is fully open. The
isolation valve for the vessel shall be locked in the fully open position.
- The surge vessel shall be grit blasted to SA 2.5 and coated externally using 4
coat anticorrosion system as follows:
- Primer Coat: Inorganic zinc silicate primer to a DFT of 75 microns.
- Second Coat: Polyamide cured tie coat to a DFT of 40 microns.
- Third Coat: Amine or Polyamide cured high build epoxy to a DFT of 125 to
175 microns.
- Top Coat: Polyurethane high gloss finish to a DFT of 50 to 75 microns.
- Total dry film thickness 325 microns.

2.10.7 Inspection and Testing

The ENGINEER reserve the right for shop inspection/stage inspection by their
authorized representatives.
The factory tests for each surge system shall include, but shall not be limited to:
a. Visual examination of the surge vessels to ensure compliance with specifications.
b. Hydrostatic test of the surge vessels.
c. Coating thickness check.
d. Welding inspection by X-ray (10% of welding area).

57
 PART III TESTS AND TRIALS
3.1 GENERAL
In addition to the manufacturer's standard tests, all equipment and materials shall be tested
according to the latest standard specifications of the country of manufacture except where
otherwise stated in these specifications.
The requirements of special tests on equipment and materials are deal with below. Unless
clearly stated in these specifications, the nature procedure and details of these tests shall be in
accordance with the latest standard specifications of the country of manufacture.
All tests shall be carried out in the presence and subject to the control of the inspection office
delegate at works and the Owner representative at site except in specified or approved cases
where tests certificates shall be accepted.
The contractor shall not be entitled to any payment whatsoever or to any extension of time on
completion by reason of or in respect of any such tests or the failure of any tests or the
rejection of any part of material or plant as a result of any tests.
Three copies in English of all testing standard and procedure shall be submitted to the Owner.
The acceptance of the contractor's tender including his design, specifications and drawings
shall not bind the Owner to accept any of the contract works until they have passed the tests
prescribed and have been approved by the Owner in writing.

3.2 EXPENSES
The expenses of all tests carried out during manufacture and at works shall be included in the
prices of the equipment. The cost of the tests at site shall be included in the schedule of prices
and shall cover all expenses, including cost of apparatus used, equipment (lubricating oil, test
pieces...etc) labor required and in general all expenses necessary for the efficient carrying out
of the tests. All instruments and apparatus used during the tests shall be considered as property
of the Owner when the tests are over.

3.3 CALIBRATION OF INSTRUMENTS

All instruments used for the purpose of testing shall be approved and shall be calibrated by a
recognized official laboratory, which must be approved by the Owner representative.
Particulars of the calibration shall be carried out at the desire of the Owner representative.
3.4GUARANTEED FIGURES
A guarantee figure shall mean a figure contained in the guarantee tables signed by the
Contractor or a figure, which may be obtained by calculation or by interpolation from these

58
 figures or by the use of the correction curves supplied by the contractor at the time of
tendering.

3.5 UNITS OF MEASUREMENTS AND DEFINITIONS

All units used in the tests shall follow the kilogram-meters second system.
The units shall be those defined in the international standards.

3.6 TESTS OF MATERIALS AND MACHINERY AT WORKS

The Owner representative shall have the right to make or get access to be made either at the
works of the Contractor or at the works of any firm from which the Contractor obtains
material or machinery to be supplied under this contract all such tests and trials as may in his
opinion be necessary to enable him to satisfy himself that the whole material, machinery and
equipment conform with the specification in all respects and that the guarantee given by the
Contractor have been or will be fulfilled. Two sorts of tests shall be made, namely:

a) Type tests to verify the characteristics and performance of equipment and materials.
b) Routine tests to eliminate defective equipment and materials.
Three copies of all testing standards, procedures and certificates shall be submitted to the
Owner representative.

3.7 TESTS FOR PUMPING UINTS

3.7.1 Tests at works
The following tests shall be carried out on the motors at the maker's works:
1- The motor shall be run for two hours at 10% over-load-followed by 6 hours on full load
corresponding to its continuous rating. The temperature rise of any part of the motor as
determined by the test shall not exceed the limits specified otherwise the motor shall be
rejected.
2 - Dielectric tests:
The motor windings shall be subjected for higher test voltage level (one minute to a test
voltage of 2000V) to measure the dielectric withstand voltage of the motor winding to be an
indication of withstanding higher operating voltage for a limited time.
3 - Megger test:
The measurement of the motor winding insulation resistance shall be made immediately after
tests (1) and test (2).
4 - Efficiency test:
The efficiency of the motor shall be determined at different loads and rated speed by method
of separate losses and by direct measurement for the motor subjected to the heating test No.1.
5 - Mechanical:
The induction motor shall be capable of withstanding for 15 second without abrupt change in
speed (under graduated increase of torque) a maximum torque at least 60% in excess of that
corresponding to the rating.

59
3.8 TESTS ON CIRCUIT BREAKERS
3.8.1 Tests at Works
a) Performance Tests:
The type tests shall be carried out on each type of circuit breakers, test certificates from
approved laboratory can be accepted. One circuit breaker of each type shall undergo these
tests. All making and breaking capacity tests shall be made by the direct method by applying
the full test power on the three poles of circuit breaker from a suitable testing source. The
recovery voltage of the source shall be not less than 95 % of the rated voltage of the circuit
breaker.
Test certificates certifying the rating of a circuit breaker shall be provided. They shall be based
on test reports containing data of series of test.
The series shall include as a minimum tests at the standard operating duty 10%, 30 % and not
less than 100 % of the rated breaking current at an average power factor of 0.15.
The test shall include also one duty cycle at 100 % rating and low load, low power factor. The
drawings oscillograms and any other relative data to prove the statements of the performance
tests shall be included in the test report.
b) Routine Tests:
All circuit breakers shall pass one minute medium voltage A.C. tests of 2.5 K.V.50 cycles per
second.
3.8.2 Tests at Site
All circuit breakers shall undergo the following test after installation:
1 - Mechanical test consisting of opening and closing of circuit breakers, several times to the
satisfaction of the Owner representative.
2 - High voltage test as given above shall be applied for one minute between insulated
conductors and structure

3.9 TESTS ON LOAD BREAK SWITCHES

3.9.1 Routine Tests
All isolating switches shall be manually operated to the satisfaction of the Owner
Representative.
3.9.2 Tests at Site
All isolating switches shall undergo a high voltage test of one minute duration and of the same
value as above.

3.10 TESTS ON CABLES

3.10.1 Factory & Site Tests
All tests at factory and on site shall be carried out in conformity with B.S. 480/1954. Tests
reports for trials carried out at works shall be submitted to the Owner.
3.10.2 Other Tests:
The Owner may carry out, if found necessary any other routine tests on the equipment or
material already tested at the factory at the expense of the Contractor.

3.11 TESTS ON DIESEL ENGINE AND ALTERNATOR

60
3.11.1 General
In addition to the manufacture's standard tests, all equipment and material shall be tested
according to the latest standard specification of the country of manufacture, except where
otherwise stated. All tests at works shall be carried out in presence and subject to the control
of OWNER approved Inspection Office.
Moreover, efficiency and fuel consumption test shall be carried out at works in the presence of
OWNER engineer who shall attend these tests. The contractor shall notify OWNER of the date
of such tests three months before hand. All tests and trials expenses at works and at site, such
as fuel and oil, shall be borne by CONTRACTOR at their own account.

3.11.2 Hydraulic Tests

Castings shall be subjected to hydraulic tests whenever possible. Compressed air reservoirs
together with all valves and pipes shall be tested to not less than double the maximum working
pressure.
3.11.3 Test for generator set
The engine shall be tested at the maker's works for fuel consumption per KWH at one-quarter,
half, three quarters and at the rated output and at ten percent in excess of the rated output at the
rated speed and not exceeding the maximum guaranteed pressures in the power cylinders or
exhaust temperatures.
The permanent and momentary speed variations on the sudden throwing off of the load shall
be tested.
3.11.4 Cooling Water
The consumption of the cooling water shall be tested at the various loads at the maker's works
and no site.
3.11.5 Tests of Indicators
The indicators springs shall be tested at the maker's works and on site before and after the
trials and the I.H.P and I.M.P shall be corrected accordingly.
The Contractor shall supply the necessary testing apparatus.Springs giving a smaller reading
than one millimeter per kilogram per square centimeter shall not be used.
3.11.6 Engines Reliability Trials at Site
The engine shall be tested at site for fuel consumption per KWH at one-quarter, half, three
quarters and at the rated output and at ten percent in excess of the rated output at the rated
speed and not exceeding the maximum guaranteed pressures in the power cylinders or exhaust
temperatures as follows:

61
 Load 25 % 15 minute
Load 50 % 15 minute
Load 75 % 20 minute
Load 100 % 45 minute
Load 110 % 60 minute

Sudden load test to be from 55% until 60% from rated gen-set rated power for one time only.
3.11.7 Tests for Generator Set
The following tests shall be carried out on the alternator at the Contractor's works:

a) Dielectric Tests:
The high voltage tests shall be applied between the winding and the frame with the core
connected to the frame and to the winding not under tests, and shall be applied only to a
complete machine with all its parts in place under conditions equivalent to normal working
conditions. The test shall be carried at the conclusion of the temperature test of the machine.
The voltage shall be alternating and shall be as near as possible to sine wave form.
The test shall be commenced at a voltage of about one - third the test voltage and shall be
increased to the full test voltage as rapidly as is consistent with its value being correctly
indicated by the measuring instruments. The full test voltage shall then be maintained for one
minute in accordance with the value indicated hereafter.
For rotor and exciter windings 2,000 volts
For stator windings twice the rated voltage plus 1000 volts

b) Mechanical Tests:
The alternator shall be capable of withstanding on test for 15 seconds a current 50 percent in
excess of its rated current, the voltage being maintained as near the rated value as possible
consistent with the maximum capacity of the prime-mover, the exact value of the voltage is
not important.
c) Test of Efficiency:
The efficiency of the alternator at normal pressure speed and excitation shall be determined
indirectly by measurements of load losses viz.
(a) Copper losses
(b) Iron losses
(c) Winding and friction losses
The tenderer shall specify the method of carrying out the tests for the measurements of the
losses mentioned in this article and also the method of determining the efficiency. The tests for
the measurement of the losses as well as the efficiency will be made in accordance with the
latest specifications issued by the leading electrical institution of the country in which the
alternators will be manufactured. The methods of carrying out the tests for measurements of
losses and determination of the efficiency must be approved. The determined

62
 efficiency shall not be less than the value guaranteed by tenderer for unity, and 0.8 power
factors respectively. The permissible tolerance in the guarantees figures for efficiency of the
generator is three percent (3%) of the sum of the total losses guaranteed. The said tolerance
shall be deemed to cover all errors of observation, etc... In determining the efficiency of the
alternator.

3.12 TESTS AT SITE FOR MECHNICAL & ELECTRICAL EQUIPMENT

Tests on completion shall be carried out to ensure that the plant is complete, has been correctly
installed, is reliable in operation under the conditions at site and is able to cover its whole
working range. In addition the efficiency and performance of the plant shall be checked as far
as possible over the whole working range and the values obtained will be compared with those
obtained during the tests on the contractor's premises.
The cost of these tests shall be borne by the contractor including cost incident to resets
occasioned by defects or failure of materials, equipment or work, to meet the specified
requirements. Any damage resulting from the tests shall be repaired and any damaged items or
any defective work shall be replaced all to the satisfaction of the Engineer and at the expense
of the Contractor.
The contractor shall at his own expense make all necessary arrangements regarding temporary
connections, openings, interconnections, sealing, plugging, isolation ...etc. for the purposes of
carrying out the tests and making good thereafter and regarding the provision and disposal of
sewage or other approved liquid required for such tests.
Before the electrical installation is made alive, testing shall be carried out in accordance with
the regulations of the electricity supply authority
A completion certificate the form and content of which has to be agreed upon with the
Engineer shall be completed and submitted to the Engineer at the completion of the tests. The
Engineer reserves the right to verify the results obtained at the expense of the contractor.
Primary injection tests shall be carried out on all M.V. and L.T. switchgear to verify the
integrity of the protective circuits and relays. The tests shall be carried out at full load 125 and
150 percent and twice full load current and in such a manner that bus-bar joints are included in
the tests. Values of current and appropriate tripping times shall be submitted to the Engineer's
Representative in writing. The Contractor shall check all motor control and other control
wiring for correct operation.

3.13 CONDITIONS OF TESTS AND GUARANTEES

3.13.1 Conditions of Tests
1- All tests shall be carried out at the expense of the Contractor who shall supply test pieces,
specimens as well as all necessary testing apparatus or equipment except where otherwise
stated.
2- The acceptance of the Contractor's designs, specifications and drawings shall not bind OWNER
to accept any of the contract works until they shall have passed the tests described in his
section and have been approved in writing by the Owner.
3- The Contractor shall not be entitled to any payment whatever or to any extension of the time for
completion by reason of any tests or the failure of any tests or the rejection of any part of the
works as a result of any test.

63
4- All instruments used in the tests shall be certified by a recognized official laboratory approved by
the Owner.
3.13.2 Guarantee
1- The Contractor shall guarantee that the equipment and material furnished in accordance with the
terms of this contract are of first rate and good workmanship throughout, that they have been
tested in accordance with these specifications and that the results of the tests comply with the
requirements of these specifications and in lieu of other claims against him, he agrees to replace
any equipment, apparatus, instruments, extra found defective in material or workmanship during
installation or during normal and proper use within two years from the date of placing in service
provided in each case that immediate written notice of such failure is given to the Contractor and
is given all reasonable opportunity to inspect such failure.
2- The date of placing in service is the date on which operating voltage is first applied for
continuous service.
3- All replacements by the contractor under the provision of this section shall be made free of
charge and on the sole responsibility of the Contractor.
4- Tenderers shall nominate in their offers two competent and well known consulting firms who
may be entrusted with the testing of materials and equipment at works at the expense of the
Contractor.
3.13.3 Guarantee Schedules
The Tenderer shall carefully fill in and sign the attached schedules of guarantee.

64
 PART IV PENALTIES AND REJECTION
4.1 PENALTY CONDITIONS
If the results of the tests on site do not correspond with the guarantee figures submitted by the
Contractor, a penalty at the following rates shall be payable by Contractor to Owner. A
tolerance of 3% allow for measurements of equipment tests.

4.2 DISCHARGE OF THE MAIN-PUMPS

A penalty at the rate of 3% of the Contract price of the pump for each full percent less than the
guarantee figure and up to 98% of the guarantee discharge.
A penalty at the rate of 2% of the contract price of the pump for each full percent less than
98% and up to 95% of the guaranteed discharge.
A penalty at the rate of 1% of the contract price of the pump for each full percent less than
95% and up to 91% of the guaranteed figure.

4.3 REJECTION CONDITIONS OF MACHINERY

All materials and machinery are to be rejected if they do not pass satisfactorily the
aforementioned tests made at factory or on sits, or any additional tests of current practice to
determine their quality and their standard of worship, also if the results of tests do not
correspond with the guaranteed figures submitted by the Contractor within the following
limits:
- Motors are rejected:
At factory tests the electric consumption per brake horsepower hour at full load exceeds the
guaranteed figure by more than 8%.
At factory tests, the motor fails to maintain satisfactorily a margin of capacity of 10%
overload, in accordance with the aforementioned specifications.
- Pumps are rejected if:
At factory tests or on site the pump fails to give 90% its guaranteed discharge at the specified
total manometric head.
- Pumping units are rejected if:
At the test on site the actual electric consumption per water horse power hour under any
load condition within those specified in the table of guarantee exceeds by more than 8% the
electric consumption guaranteed under same condition for the motor pumping units.

4.4 THE ENGINE OF THE GENERATING SET

Owner may reject the engine if:
A) If, at the work test, the fuel consumption per KWH at about normal load exceeds the
guaranteed figure by more than (8%) eight percent.
B) If, at the work tests or at the provisional test on site, the mean indicated pressure at rated
output exceeds the guaranteed figure by more than (5%) five percent.
C) If, at the work test or at the provisional test on site, the exhaust temperature of any power
cylinder at full rated load exceeds the guaranteed figure by more than 40C.

65
 D) If, at the work test or at the provisional test on site, the engine fails to maintain
satisfactory a margin of capacity of ten percent overload for two hours.
E) If the engine fails to run satisfactory at site.

4.5 THE GENERATING SET

Owner may reject a set consisting of engine and alternator:
If, at work tests, the neutral fuel consumption per KWH obtained under any load condition
within those specified in the table of guarantee exceeds by more than (8%) eight percent the
fuel consumption guaranteed under the same conditions.

4.6 THE ALTERNATOR

Owner may reject the alternator:
a) Should the arithmetic mean of tested efficiencies 4/4 and 3/4 load of any alternator be less
than the corresponding arithmetic mean of the efficiencies guaranteed by the contractor for
0.8 power factor, by two and half percent (2.5%) after taking account of the permissible
tolerance.
b) Should the tested temperature rise of the stator and/or the rotor of any alternator be more
than 10C (ten degrees centigrade) higher than the maximum temperature rise specified.
When and in any such cases the alternator or alternators shall be rejected and the contractor
shall remove the said alternators and provide new alternator or alternators within (12) twelve
calendar months which shall be operated at the efficiencies guaranteed and the maximum
temperature specified at his cost, charge and risk and shall not be entitled to any compensation
whatsoever by the said removal and replacement, not for any work or works directly
connected therewith.
In case of the rejection of the alternator Owner shall have the right to retain it and make use of
it for service until the contractor furnishes the new alternator.
The contractor shall not be entitled to any payment for the alternator during this period or any
additional payment for the replacement of the rejected alternator.

66
 PART V PARTICULAR SPECIFICATIONS
5.1 PARTICULAR SPECIFICATIONS FOR AL FARASYA P.S
5.1.1 Submersible sewage pumping units
AL FARASYA P.S shall pump sewage water through a force main of 450 mm outside the
pump station boundary and 400 mm inside the pump station from pumping unit to main valve

The station shall be furnished with three complete submersible pumping units (2duty + one
stand-by). In addition, one complete unit shall be delivered as a spare unit at store.
The pumps shall be according to general technical specifications as per item (2.1).

AL FARASYA P.S
Type of pumps Submersible
3 installed (2 duty + 1 stand-by) and one complete unit
No. of units
shall be at store as a spare unit
Discharge of pump (lit/s) 85 (duty Point)
Total Manometric head (m) 24 (duty Point)
Working range (m) 19-27
Speed of pump (rpm) 1500 (max.)
Solid diameter (mm) ≥ 75
Overall Efficiency Not less than 50 % at duty point

The electric motor power factor shall be not less than 0.80. The rated power of motor shall have not
less than 20% in excess of the maximum power absorbed by the pump during its working range.
Submersible electric motors shall be according to general technical specifications as per item (2.1).
5.1.2 Pipes, valves, fittings and special pieces
The contractor shall supply, install and test all pipes, fittings, special pieces and valves which shall
be according to general technical specifications as per item (2.2).
The following table shows the diameter, number, working and testing pressures for valves:
AL FARASYA P.S
Pumping Station
Delivery
Valve type Gate valve Non- Return valve
Diameter (mm) 400 400
No. of units 3 3
Working Pressure (bar) 10 10
Testing Pressure (bar) 16 16
5.1.3 Pump Control
Pump control system shall be according to general technical specifications as per item (2.4).

5.1.4 Measurement instrumentations

67
 All Measurement devices shall be according to general technical specifications as per item
(2.5). The submersible pumps shall be protected against dry running by using level electrodes
as specified as per item (2.5.4).
5.1.5 Electrical works Specs
5.1.5.1 Electric Power Source
The electric power required for operation of the pumping stations shall be received from the
medium tension network of the city at 11 KV/50 Hz through two transformers (Kiosks Type)
from two independent sources. The rating of the transformer for shall be rated at 400 KVA.
The transformer and ring main unit shall be supplied and installed by the contractor under the
directions and direct supervision of the Local Electricity Distribution Company or Rural
Electricity Authority REA.
One of the two transformers shall be capable to feed the station while the other one shall be
stand by.
The contractor is responsible for supply and installation of the medium voltage cable from
main source to feed the pump station by approval of electrical company for size of cross
section area and also length of the cables.
One Stand-by (Enclosure Type) Diesel generating sets rated at 300 KVA for AL FARASYA
P.S (prime power rating), 380 V and 3-phases shall be supplied to serve the pumping stations
under emergency conditions.
5.1.5.2 Low Voltage Distribution Board
The details of main low voltage distribution board shall be according the following details in
addition to the specification which described in the general technical specification item 2.6.2:
The details of main low voltage distribution board shall be according the following:
A) Feeders No (1 ,2 & 3) for incoming feeders from the transformers and bus coupler
each feeder shall contain the following:
- One set of 3 – phase, copper bus- bars 800A, 36 K.A, 380/220 volt, 50Hz.
- One 3-ph, MCCB, 800 A, 36 KA complete with thermal overload and short circuit
protection.
- Three phase indicating lamp and three indicating lamp (on – off – failure).
- Three current transformers 800/5A.
- Three moving iron ammeters 0 – 800/1600 A.
- One moving iron voltammeter 0-500 V complete with selector switch.
- One power factor meter, frequency meter, kilowatt meter with maximum demand
indicator.
- One phase failure relay, under/over voltage protection relay
- One earth fault relay.

B) Feeder No (4) for incoming feeder from the diesel generator shall contain the
following:
- One set of 3 – phase, copper bus- bars 800A, 36 K.A, 380/220 volt, 50Hz.
- One 3-ph, MCCB, 800 A, 36 KA complete with thermal overload and short circuit
protection.
- Three current transforms 600/5 A.
- Three moving iron ammeters 0 – 600/1200 A.
- One moving iron voltammeter 0-500 V, complete with selector switch.

68
 - One frequency meter, kilowatt meter with maximum demand indicator.
- Three phase indicating lamp and three indicating lamp (on – off – failure).
- Under and over voltage relay
- Under and over frequency relay
- Over-excitation relay.
- Reverse power relay.
N.B The incoming feeder from transformer and generator shall be electrically and mechanically
interlocked with automatic and manual operation (one out of three).

C) Feeders No. (5, 6, and 7) outgoing for pump motors, each feeder shall contain the
following:
- One set of copper bus-bars
- One 3-ph, MCCB, (100-125) A, 36 kA complete with thermal overload and short circuit
protection.
- Star-Delta drive of rated motor power (55 kw).
- Three current transformers 125/5 A.
- Three moving iron ammeters 0 – 125/250 A.
- Run hour meter
- Three phase indicating lamp and three indicating lamp (on – off – failure).
- Three push buttons.
- One phase failure, unbalance and incomplete phase sequence relay.
- One under/over voltage protection relay.
- One earth fault and earth leakage relay.
- Over temperature for winding (3 PTC) and bearing (1 PT100).
- Moisture sensor in oil chamber.
- Dry running protection.
- Number of starts per hour.
- Excessive starting time/locked rotor.

D) Feeder No. (8) (Spare for Pump):

- One set of copper bus-bars
- One 3-ph, MCCB, (100-125) A, 36 kA complete with thermal overload and short circuit
protection.
E) Feeder No. (9 &10) Outgoing feeder for P.S indoor lighting and spare including the
following:
- One set of copper bus- bars.
- One 3-ph, MCCB, 40A, 36 kA complete with thermal overload and short circuit
protection.

F) Feeder No. (11) Outgoing feeder for external lighting including the following:
- One set of copper bus- bars.
- One 3-ph, MCCB, 40A, 36kA complete with thermal overload and short circuit
protection.

G) Feeder No. (12 &13) Outgoing feeder for store lighting and spare including the
following:
- One set of copper bus- bars.
- One 3-ph, MCB, 32A , 36 kA complete with thermal overload and short circuit
protection.

69
H) Feeder No. (14) Outgoing feeder for water hammer protection including the following :
- One set of copper bus- bars.
- One 3-ph, MCCB, 40A, 36 kA complete with thermal overload and short circuit
protection.

I) Feeders No. (15 and 16) Outgoing feeders for operation panels of rotary crane and
monorail crane, each feeder include the following:
- One set of copper bus- bars.
- One 3-ph, MCCB, 32A, 36 kA complete with thermal overload and short circuit
protection.
- Three phase indicating lamp.

J) Feeder No. (17 &18 ) Outgoing feeder for gen. shed and spare including the following:
- One set of copper bus- bars.
- One 3-ph, MCCB, 25A, 36 kA complete with thermal overload and short circuit
protection.

K) Feeder No. (19) Outgoing feeder as a spare including the following:

- One set of copper bus- bars.
- One 3-ph, MCCB, 32A, 36 kA complete with thermal overload and short circuit
protection.

L) Feeder No. (20) Outgoing feeder for control panel:

- One set of copper bus- bars.
- One 3-ph, MCCB, 16A, 36 kA complete with thermal overload and short circuit
protection.

M) Feeder No. (21 &22) Outgoing feeder for ventilation:

- One set of copper bus- bars.
- Two starter (D.O.L) 1.1 KW, 36 kA complete with thermal overload and short circuit
protection.

N) Feeders No. (23 &24) Outgoing feeder for power factor correction (80KVAR) including
the following:
- One set of copper bus- bars.
- One 3-ph, MCCB, 200A, 36 kA complete with thermal overload and short circuit
protection.
- Three phase indicating lamp.
- Ammeter, voltammeter, power factor meter, kilovar meter and kilowatt meter with
maximum demand indicator.
5.1.5.3 Power cables
- Power cables shall comply with the general technical specifications which described in
item 2.6.3.
5.1.5.4 Power Transformers (Kiosks)
- The power transformer shall be comply with the specification which described in item
2.6.4
- Data of the required transformers as the following:

70
 Pump station AL FARASYA P.S
No. Of transformers required 2
Rated output KVA 400
Primary voltage KV 11  5 %
Secondary voltage V 380 / 220
Percentage impedance 4-5%
Primary winding connection Delta
Secondary winding connection Star
Cooling method ONAN
Max temperature rise of oil 45 ͦ c
Max temperature rise of winding 55 ͦ c
No. Step 7 steps

5.1.5.5 Earthing system

- The Earthing system in the pumping station shall comply with the specification which
described in the general technical specifications item no (2.6.5).
5.1.5.6 Indoor lighting
- Indoor lighting in the pumping station shall be complied with the specification which described
in the general specification item no (2.6.6).
5.1.5.7 Outdoor lighting
- Outdoor lighting in the pumping station shall be complied with the specification which
described in the general technical specifications item no (2.6.7).
5.1.5.8 Fire alarm system
- Fire alarm system in the pumping station shall be complied with the specification which
described in the general technical specifications item no (2.6.9).
5.1.6 Station Auxiliaries
The station auxiliaries shall be according to general technical specifications as per item (2.7)
with the following technical data:

1 Electrically operated - 1 Tons capacity

Rotary crane
As per item (2.7.1)
Monorail crane 1 Electrically operated - 3 Tons capacity
6 fire extinguishers (2 at MDB room + 2 for generator
Fire extinguishers and 2 for transformers)
As per item (2.7.2)
Clear distance between bars shall not exceed 50 mm
Basket screen
As per item (2.7.3)
Q ≥1000 m /hr (1 suction + 1 exhaust) at L.T.S.B room
3
Ventilation units
Axial wall mounted fans as per item (2.7.4)
Mechanical& Electrical
As per item (2.7.5)
Instruments and Furnishings
5.1.7 Diesel-Driven Stand-by Electric Generating Unit Enclosure Type

71
 The diesel generator unit shall be according to general technical specifications as per item (2.8).
- The generating unit rated output shall be 300 KVA (Prime power rating).
5.1.8 Water hammer protection
this protection system is a Preliminary design and the supplier is responsible for providing detailed
water hammer protection system design to the pump station and force main (included in his
contract price).

5.1.9 Spare parts

All spare parts shall be according to general technical specifications as per item (2.9).

Submersible pumps As per item (2.9.1)

MDB As per item (2.9.2)
Diesel Generator As per item (2.9.3)

72
5.1.10 DESIGN DATA TABLES FOR AL FARASYA P.S
5.1.10.1 Pumping Units (Submersible)

Maker's name .....................................................................................Origin : ……………

Type of pump .....................................................................................
Rating :
Pump will discharge …………. Lit/sec of sewage water at ............meters
Total manometric head
Consuming (H.P) ..............................................................................................
Working range .......................................................................................
Suction diameter................................................................................... mm
Material of casing....................................................................................
Number of impeller vanes ....................................................................mm
====================================================
Material from which impellers are made ....................................................
Material of shaft .........................................................................................
Solids diameter .................................................................................. mm
Number of bearings on which pump shaft is supported ..................…..
Type of bearings and how lubricated .....................................................
Quantity of water required for cooling pump glands ..........................lit/hr.
Standard specification with which pump complies ...................................
Rated output (50 c/s) and number of phases .............................................
Type of motor ...................................................................................
Method of ventilation and cooling ......................................................
Type and method of starting ...................................................................
Total weight of motor ..........................................................................
Approximate overall height of motor .......................................................
Performance :
Continuous rates output at 50 cycles/second .......................................H.P
Permissible overload and duration at 50 c/s .............................................
Voltage at full load ....................................................................................
Current at full load per phase .........................................................amps
Starting current per phase .................................................................
Speeds of motor .....................................................................................
Temperature rise at maximum continuous rating :
Class of insulation:......................................................................................
Efficiency of motor :
At full rated load ......................................% at P.P .................................
3/4 rated load .....................................% at P.P...................................
1/2 rated load ....................................% at P.P ...................................
Ratio of motor excess power ...............................................................

73
74
 5.1.10.2 CIRCUIT BREAKERS
Particulars :
Type and make .........................................................................................
Standard specification with which air circuit breaker complies .....................
Total length of breaker per phase .........................................................cm
Number of breaking points per phase .........................................................
Type of main contacts ................................................................................
Current density at contact area amp/cm2
Drop of voltage across contacts at nominal
Rated current ...........................................................................................
Type of arcing contacts and mill volts or are control device ......................
................................................................................................................
Type of operating mechanism ...................................................................
Metal of tank and top cover .......................................................................
Thickness of tank and top cover ................................................................
Minimum clearance in air:
a) Between live parts to earth ....................................................cm
b) Between phases ...................................................................cm
Weight of circuit breaker complete ............................................................
Performance :
Rated voltage at 50 cycles coed ...........................................................volt
Normal current rating ..........................................................................amp
Breaking capacity :
a) Symmetrical in amperes ........................................................amp
b) A- Symmetrical in amperes ..................................................amp
Making current ..................................................................................amp.
Short time current for 1 second ................................................................
Total break time ................................................................................cycle
Ditto with 100% short circuit breaking
current .............................................................................................. cycle
Total make time .................................................................................cycle
Total make break time .......................................................................cycle
Normal voltage of tripping coil ...........................................................volt
Power at normal voltage required by grip coil ...................................watt.
Summary of work's tests ..........................................................................

75
5.1.10.3 STANDBY DIESEL GENERATOR
5.1.10.3.1 Engine

Origin : ……………
Make of engine
Continuous rating of engine to kW
Continuous rating of engine at site (24 hours) kW
Full load speed rpm
Number of cylinders
Bore of cylinders mm
Stroke of pistons mm
Swept Volume liters
Compression ratio
M.E.P. at full load rating bars
Maximum pressure in cylinders bars
No. of exhaust valves per cylinder
No. of inlet valves per cylinder
Cyclic irregularity
Maximum short circuit turning moment kg/m
Diameter of main bearings mm
Diameter of big end bearings mm
No. of main bearings
Thermal efficiency at full load %
Full consumption at full load kg/kw/h
Engine
Output
Lubrication oil consumption liters/h

5.1.10.3.2 Alternator

Origin : ……………
Make of alternator
Type of alternator
Efficiency full load
Efficiency 3/4 load
Efficiency 1/2 load
Alternator output KVA
Class of insulation and windings
Temperature rise C
Method of radio suppression
Method of mounting
Weight kg
Degree of protection

76
5.1.11 GUARANTEE TABLES FOR AL FARASYA P.S
5.1.12 Table of Guarantee No. (1) Pumping-Units:
Purpose of unit:
Make and type of pump unit: Origin:

Total Manometric Head …. …. …

Discharge liter/sec.
Speed of pump
Water horse power
Manometric efficiency of pump %
Shaft horse power
Efficiency of driving motor %
Input to motor in K.W measured on the switchboard.
Overall efficiency of unit percent
Energy consumed in K.W.H.

We guarantee the above performance of the motor pumping units we are offering at site conditions
according to ……….

Date: / / 20
Signature of Tenderer
……………………………….

77
5.1.12.1 Table of Guarantee No. (2) Diesel Engine
Diesel Engines: Maker: Type:
Table showing figures guaranteed by the contractor for the performance of the Diesel Engines
during the official tests on site under the supervision of OWNER representative.

Rated output in percent 110 100 75 50 25 0

Indicated horse power (metric)
Mechanical efficiency %
Brake horse power (metric)
Revolution per minute
Mean effective pressure in kg/cm2
Fuel consumption in gr./B.H.P.H
Temperature of exhaust gases in C
Lubricating oil consumption in gms/engine hr.
Max. indicated pressure in kg/cm2
Power cylinder compression pressure in kg/cm2
Stroke/Bore ratio
Percentage of turbo charging

We guarantee the above performance of the Diesel Engine we are offering.

The gross calorific value of the fuel oil being taken.... Cal/kg.

Date: ...../...../ 20
Signature of Tenderer
………………………………….

5.1.12.2 Table of Guarantee No. (3) Alternators

78
Alternators: Maker: Type:
Table showing figures guaranteed by the contractor for the performance of the Alternator during the
official tests on site under the supervision of OWNER representative.

Percentage load 110 100 75 50 25 0

Output K.V.A. at volts

Power factor

Efficiency percent

Output of alternator in K.W.

Excite current in amperes

Excite output in K.W.

Max. Temperature rise in oC over the ambient temperature

of 45 C

We guarantee the above performance of the Alternator we are offering.

Date: ...../...../20
Signature of Tenderer
....................................

5.1.12.3 Guarantee table No. (4) for the Generating set

Maker ...................................type .......................origin.............

79
 Speed .......................................................RPM

Percentage load 110 100 75 50 25 0

Rated out of the engine Hp
Rated speed rpm
Mechanical efficiency
Compressing ratio
Mean piston speed M/sec
Mean effective pressure
Cylinder KG/CM2
Lubricating oil consumption GM/H
Fuel consumption GM/BHP/H
Efficiency of the alternator at
0.8 power factor %
Ambient temperature 45oC

We guarantee without tolerance the above performance of the generating set at sits.

Date: / / 20
Signature of Tenderer
....................................

80