EMPLOYER'S REQUIREMENT - Relevant Soil Specs

MUNICIPAL CORPORATION OF GREATER MUMBAI
Mumbai Sewage Disposal Project

Stage II - Priority Works
BID DOCUMENT
FOR
180 MLD VERSOVA WASTEWATER TREATMENT FACILITY
Design, Build and Operate Contract
VOLUME – 2
EMPLOYER’S REQUIREMENT
EMPLOYER
Municipal Corporation of Greater Mumbai

3rd Floor, Municipal Head Quarters, CST,
Mumbai 400 001
India
DBO Contract – Versova WwTF Municipal Corporation of Greater Mumbai
Table of Contents
1 Introduction ...................................................................................................................... 2
1.1 Introduction ............................................................................................................. 2
1.2 Background to Scheme........................................................................................... 2
1.3 Objectives of the Contract ....................................................................................... 3
1.4 Description of the Works ......................................................................................... 4
1.5 Future Expansion.................................................................................................... 7
1.6 Sustainability .......................................................................................................... 7
1.7 Charges related to Power supply ............................................................................ 7
2 Existing Works, Structures and Services ....................................................................... 9
2.1 Existing Treatment Facility ...................................................................................... 9
2.2 Demolition of Existing Structures ............................................................................ 9
2.3 Existing Services to the Site.................................................................................. 10
2.4 Existing Boundaries .............................................................................................. 10
3 Contract Interface........................................................................................................... 13
3.1 Catchment Works ................................................................................................. 13
3.2 Operation and Maintenance of existing level of treatment through the Design-Build
Period 13
3.3 Related Contracts ................................................................................................. 13
3.4 Blocking of Flow to Lagoons ................................................................................. 14
3.5 Lagoon Decommissioning ..................................................................................... 15
3.6 Existing Approach Road and Associated Structures ............................................. 15
3.7 Access to the Site ................................................................................................. 16
3.8 Access for Other Contractors ................................................................................ 16
3.9 Outfall Channel ..................................................................................................... 17
4 Contractor’s Documents ................................................................................................ 19
4.1 General ................................................................................................................. 19
4.2 Format of Contractor’s Documents ....................................................................... 19
4.3 Programme and Project Execution Plan ............................................................... 19
4.4 Design Stage Documents ..................................................................................... 21
4.5 Construction Stage Documents ............................................................................ 23
4.6 Plant and Equipment Documents .......................................................................... 24
4.7 Control System Development ............................................................................... 24
4.8 Tests on Completion of Design-Build documents .................................................. 24
4.9 As-built Documents ............................................................................................... 25
4.10 Operation and Maintenance Manuals ................................................................... 25
4.11 Progress Photographs .......................................................................................... 25
4.12 Monthly Progress Reports during Design-Build Period.......................................... 26
4.13 Contractor’s Responsibilities Under Digital Project Management System (5D BIM)
during Design-Build Period ............................................................................................... 27
5 Health, Safety and Environment .................................................................................... 31
5.1 CEMP ................................................................................................................... 31
5.2 Safe Systems of Work .......................................................................................... 31
5.3 Lead in Paint ......................................................................................................... 35
5.4 First Aid and Life-Saving Apparatus ...................................................................... 35
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5.5 Electrical Safety .................................................................................................... 35

5.6 Asbestos ............................................................................................................... 35
5.7 Supply of Potable Water and Sanitation Facilities ................................................. 35
5.8 Measures against Insect and Pest Nuisance ........................................................ 36
5.9 Measures against Sunburn and Heat Exhaustion ................................................. 36
5.10 Alcoholic Liquor or Banned Substances ................................................................ 36
5.11 Arms and Ammunition........................................................................................... 36
5.12 Festivals and Religious Customs .......................................................................... 36
5.13 Employment Records of Workers.......................................................................... 36
5.14 Repatriation of Labour .......................................................................................... 36
5.15 Epidemics ............................................................................................................. 36
5.16 Burial or Cremation of the Dead ............................................................................ 36
5.17 MCGM Health Department Guidelines .................................................................. 37
6 Quality Management System ......................................................................................... 39
6.1 General ................................................................................................................. 39
6.2 Principal Requirements of the Quality Plan ........................................................... 40
6.3 Employer’s Representative’s Monitoring of the Contractor’s Performance ............ 41
6.4 Particular Requirements of the Quality Plan.......................................................... 41
6.5 Monitoring during the Operation Maintenance Service Period............................... 46
6.6 Submission of Quality Plan ................................................................................... 47
6.7 Review of Nominated Laboratory .......................................................................... 47
7 Licenses and Consents ................................................................................................. 50
7.1 General ................................................................................................................. 50
8 Key Programme Requirements And Staffing ............................................................... 52
8.1 Design-Build ......................................................................................................... 52
8.2 Design Review by Employer’s Representative ...................................................... 53
8.3 Operation Service ................................................................................................. 54
8.4 Key Staff ( Design Build Period) ............................................................................ 54
9 Design Requirements..................................................................................................... 57
9.1 Codes and Standards ........................................................................................... 57
9.2 Deviations for More Stringent Requirements ......................................................... 58
9.3 Technology Incorporation ..................................................................................... 58
9.4 Proprietary or Patent Design for Technology Incorporation ................................... 59
9.5 Design Life............................................................................................................ 59
9.6 Units of Measurement ........................................................................................... 60
9.7 Plant Access, Lifting and Maintainability ............................................................... 60
9.8 Drawings............................................................................................................... 61
9.9 Climatic Conditions ............................................................................................... 61
9.10 Asset Register ...................................................................................................... 62
9.11 Labels ................................................................................................................... 62
9.12 Hazardous Area Classification .............................................................................. 63
9.13 HAZOP Studies .................................................................................................... 63
9.14 CHAZOP Studies .................................................................................................. 64
9.15 General Arrangement of Plant .............................................................................. 64
9.16 Orientation ............................................................................................................ 65
9.17 Draining System ................................................................................................... 65
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9.18 Standby Requirements ......................................................................................... 66

9.19 Bypass Requirements ........................................................................................... 66
9.20 Plant Water System .............................................................................................. 66
9.21 Potable Water System .......................................................................................... 67
9.22 Clean Development Mechanism (CDM) ................................................................ 67
9.23 Renewable Energy Certificates ............................................................................. 68
9.24 Ventilation and Air Conditioning ............................................................................ 68
9.25 Room Area Classification ...................................................................................... 68
9.26 Odour Control ....................................................................................................... 69
9.27 Modular Design Approach .................................................................................... 70
9.28 Noise Control ........................................................................................................ 71
10 Process Design .............................................................................................................. 73
10.1 General ................................................................................................................. 73
10.2 Inlet Chamber ....................................................................................................... 76
10.3 Preliminary Treatment........................................................................................... 76
10.4 Primary Treatment ................................................................................................ 78
10.5 Biological Treatment ............................................................................................. 79
10.6 Tertiary Treatment ................................................................................................ 91
10.7 Disinfection ........................................................................................................... 92
10.8 Tertiary Treatment System and Arrangement for Re-Use Effluent ........................ 93
10.9 Not Used............................................................................................................... 94
10.10 Sludge Handling and Treatment ........................................................................... 94
10.11 Sludge Transport ................................................................................................ 102
10.12 Flow Measurement, Sampling and Monitoring .................................................... 102
10.13 Hydraulic Design................................................................................................. 104
11 Mechanical Works Design ........................................................................................... 109
11.1 General Arrangement of the Works..................................................................... 109
11.2 Pumping Systems ............................................................................................... 110
11.3 Chemical Storage and Dosing Systems .............................................................. 110
11.4 Chemical Safety Facilities ................................................................................... 110
11.5 Materials of Construction .................................................................................... 111
11.6 Isolation and Drain Down .................................................................................... 112
12 Electrical Works Design ............................................................................................... 114
12.1 General ............................................................................................................... 114
12.2 Measurement of Electricity Usage....................................................................... 119
12.3 Cabling and Earthing .......................................................................................... 119
12.4 Building and Site Services .................................................................................. 122
13 Instrumentation, Control & Automation (ICA) Design ............................................... 130
13.1 Plant and Equipment to be provided ................................................................... 130
13.2 Drawings and information to be provided ............................................................ 130
13.3 Control Room ICA Panels ................................................................................... 130
13.4 MV / LV Substation PLC System ........................................................................ 132
13.5 Surge Protection Devices for Electronic Equipment ............................................ 132
13.6 Plant Control System .......................................................................................... 132
13.7 SCADA System .................................................................................................. 134
13.8 Deleted ............................................................................................................... 136
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13.9 Instrumentation ................................................................................................... 136

14 Civil Design................................................................................................................... 138
14.1 General ............................................................................................................... 138
14.2 Site Works .......................................................................................................... 138
14.3 Loadings ............................................................................................................. 138
14.4 Earthworks, Ground Improvements and Foundations ......................................... 139
14.5 Wastewater Treatment Structures....................................................................... 140
14.6 Administration Facilities ...................................................................................... 141
14.7 Building works and Finishes................................................................................ 143
14.8 External Works ................................................................................................... 146
14.9 Site Drainage ...................................................................................................... 146
14.10 Services to the Site ............................................................................................. 147
14.11 Reinforced Concrete ........................................................................................... 148
14.12 Liners to Concrete Material ................................................................................. 151
14.13 Design Requirement of Concrete ........................................................................ 151
14.14 Design Philosophy .............................................................................................. 151
14.15 Detailed Design Calculations & Submission........................................................ 153
14.16 Design Criteria for Underground Liquid Retaining Structures .............................. 154
14.17 Foundations ........................................................................................................ 155
14.18 Design Requirements ......................................................................................... 155
14.19 Buildings and Structures ..................................................................................... 157
15 Construction Activities ................................................................................................ 161
15.1 The Site .............................................................................................................. 161
15.2 Possession of the Site ........................................................................................ 161
15.3 Access to the Site ............................................................................................... 161
15.4 Environmental Mitigation during Construction ..................................................... 162
15.5 Public Liaison & Communication ......................................................................... 166
15.6 Parking for Construction Vehicles ....................................................................... 167
15.7 Contractor’s Temporary and Working Areas ....................................................... 167
15.8 Site Security ....................................................................................................... 167
15.9 Storage of Plant and Materials ............................................................................ 167
15.10 Protection against Damage ................................................................................. 168
15.11 Utilities and Other Services ................................................................................. 168
15.12 Archaeology ........................................................................................................ 168
15.13 Setting out, Datum and Surveys ......................................................................... 168
15.14 Project Signs ...................................................................................................... 169
15.15 Staff and Materials to Assist the Employer’s Representative............................... 169
15.16 Meetings ............................................................................................................. 169
15.17 Method Statements ............................................................................................. 169
15.18 Supply of Materials and Services ........................................................................ 170
15.19 Temporary Works ............................................................................................... 170
15.20 Construction Plant and Equipment ...................................................................... 170
15.21 Smoking.............................................................................................................. 171
15.22 Blasting and the use of Explosives...................................................................... 171
15.23 Contractor’s Accommodation and Facilities ........................................................ 171
15.24 Accommodation for the Employer’s Representative ............................................ 172
15.25 Vehicles for the Employer’s Representative ........................................................ 172
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15.26 Returns of Labour and Plant Reports .................................................................. 173

15.27 Staff Welfare Management ................................................................................. 173
15.28 Site and Laboratory Testing ................................................................................ 173
15.29 Daily Records ..................................................................................................... 173
15.30 Inspections and Testing (except Tests on Completion of Design-Build) .............. 173
16 Training of Employer’s Operatives by the Contractor ............................................... 177
16.1 General ............................................................................................................... 177
16.2 Off The Job Training ........................................................................................... 177
16.3 On The Job Training ........................................................................................... 178
16.4 Training Programme ........................................................................................... 180
16.5 Training Personnel .............................................................................................. 180
16.6 Instrumentation, Control & Automation Training requirements ............................ 181
16.7 Operations and Maintenance Training ................................................................ 181
16.8 Training Assessment .......................................................................................... 182
17 Tests on Completion of Design-Build ......................................................................... 184
17.1 Definitions ........................................................................................................... 184
17.2 General ............................................................................................................... 185
17.3 Equipment Validation .......................................................................................... 187
17.4 Process Commissioning ..................................................................................... 188
17.5 Plant Proving Period ........................................................................................... 189
18 Operation Service Performance Requirements.......................................................... 193
18.1 General ............................................................................................................... 193
18.2 Measurement of Qualitative and Quantitative Performance ................................ 193
18.3 Performance Standards ...................................................................................... 193
18.4 Monitoring, Sampling and Analysis ..................................................................... 195
18.5 Failure to Meet Performance Requirements ........................................................ 199
19 Operation Management Requirements ....................................................................... 203
19.1 General ............................................................................................................... 203
19.2 Employer’s Communication ................................................................................ 203
19.3 The Site .............................................................................................................. 203
19.4 General Requirements ........................................................................................ 203
19.5 Management, Operation and Maintenance Personnel ........................................ 204
19.6 Health and Safety Requirements during Operation Service ................................ 205
19.7 Suppliers and Subcontractors ............................................................................. 205
19.8 Operation Service Monitoring Group ................................................................... 206
19.9 Real Time Reporting ........................................................................................... 206
19.10 Monthly Status Report ........................................................................................ 207
19.11 Service Delivery Review Report .......................................................................... 207
19.12 Operational Change ............................................................................................ 208
19.13 Management Meetings ....................................................................................... 208
19.14 Hours of Operation ............................................................................................. 208
19.15 Routine Reporting ............................................................................................... 208
19.16 Spares ................................................................................................................ 208
19.17 Public Liaison ..................................................................................................... 209
20 Operation and Maintenance Plan ................................................................................ 211
20.1 Overview of Requirements .................................................................................. 211
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20.2 Preparation and implementation of the O&M Plan .............................................. 212

20.3 Auditing the O&M Plan........................................................................................ 212
20.4 Operation and Maintenance Manual ................................................................... 213
20.5 Plant Manager .................................................................................................... 215
20.6 Plant O & M Staff ................................................................................................ 215
20.7 Operational Cost Model ...................................................................................... 216
21 Operation Management Plan ....................................................................................... 218
21.1 General ............................................................................................................... 218
21.2 Procedures for the Operation Service ................................................................. 218
21.3 Non-Compliant Operation ................................................................................... 218
22 Maintenance Management Plan .................................................................................. 220
22.1 General ............................................................................................................... 220
22.2 Plant Maintenance Plan ...................................................................................... 220
22.3 Facility Maintenance Plan ................................................................................... 221
22.4 Asset Management Database ............................................................................. 222
22.5 Asset Management and Replacement Schedule................................................. 223
23 Independent Compliance Auditing.............................................................................. 223
23.1 General ............................................................................................................... 223
24 Handback Requirements ............................................................................................. 225
24.1 General ............................................................................................................... 225
24.2 Residual Life and Planned Asset Replacement at Handback .............................. 225
24.3 Notification of Expiry of the Operation Service Period and Joint Inspection ......... 225
24.4 Tests Prior to Contract Completion ..................................................................... 226
24.5 Handback of the Works to the Employer ............................................................. 227
24.6 Training of the Employer’s Operators .................................................................. 228
24.7 Final Documentation ........................................................................................... 228
25 Inspection, Testing and Commissioning Requirements ........................................... 234
25.1 Inspection and Testing During Manufacture ........................................................ 234
25.2 Tests at Manufacturer's Premises – Mechanical Equipment ............................... 240
25.3 Chlorination and Gas Pipeline System ................................................................ 240
25.4 Mechanical Equipment Test at Site ..................................................................... 241
25.5 Plant Tests at Site............................................................................................... 241
25.6 Pumps, Piping and Valves .................................................................................. 241
25.7 Motors ................................................................................................................ 241
25.8 Cranes ................................................................................................................ 242
25.9 Screens and Grit Removal System ..................................................................... 242
25.10 Gates and Penstocks .......................................................................................... 242
25.11 Laying and Joining of Reinforced Cement Concrete Pipes ................................. 242
25.12 Laying and Joining of Steel Cylinder Pipes and Specials .................................... 242
25.13 Laying and joining of Cast Iron, Ductile Iron Pipes and Fittings ........................... 243
25.14 Manufacturer's Works Acceptance Tests on Electrical Equipment ...................... 244
25.15 Manufacturer's Works Acceptance Tests on ICA Equipment .............................. 244
25.16 Manufacturer's Works Acceptance Tests on Uninterruptible Power Supplies ...... 250
25.17 Inspection at Site ................................................................................................ 250
25.18 Plant Protection on Site ...................................................................................... 250
25.19 Erection Staff ...................................................................................................... 250
Volume 2 Page vi Employer’s Requirement

25.20 Erection and Building-in ...................................................................................... 251

25.21 Civil Inspection (Water Leakage Test) ................................................................ 253
25.22 Site Acceptance Test Document ......................................................................... 254
25.23 Deleted ............................................................................................................... 254
25.24 Dry Test Requirements ....................................................................................... 254
25.25 Process Plant Item / Equipment .......................................................................... 255
25.26 Hydraulic Wet Test Requirements....................................................................... 255
25.27 Safety Audit ........................................................................................................ 256
25.28 Process Wet Tests (with Raw Sewage) .............................................................. 256
25.29 Effluent Quality Criteria for Passing the Tests On Completion ............................ 257
25.30 Co-operation with other Contractors in the Execution of their Tests .................... 257
25.31 Tests after Completion ........................................................................................ 257
25.32 Performance Certificate ...................................................................................... 260
List of Tables
Table 8.1 – Key programme requirements during design and build ........................................... 52
Table 8.2 – Programme during operation service ...................................................................... 54
Table 9.1 – Design Life ............................................................................................................. 59
Table 9.2 – Lifting limits ............................................................................................................ 60
Table 9.3 – List of drawings ...................................................................................................... 61
Table 9.4 – Minimum Standby Requirements ............................................................................ 66
Table 9.5 – Air changes ............................................................................................................ 69
Table 10.1 – Sludge storage ..................................................................................................... 96
Table 10.2 – Class A EPA Standard ......................................................................................... 97
Table 10.4 – Polyelectrolyte dosing limits.................................................................................. 99
Maximum speed for pump sets ............................................................................................... 110
Table 11.1 – Pipe materials..................................................................................................... 111
Table 14.1 – Schedule of Internal Finishes ............................................................................. 144
Table 14.2 – Minimum concrete requirements......................................................................... 149
Table 14.3 – Minimum section thicknesses ............................................................................. 150
Table 14.4 – Material densities ............................................................................................... 152
Table 15.1 – Environmental regulations .................................................................................. 162
Table 15.2 – Noise limits ......................................................................................................... 164
Table 15.3 – Vibration limits .................................................................................................... 164
Table 18.2 – Sludge Product Quality Requirements ................................................................ 193
Table 18.3 – Noise Performance Levels Outside of the Site.................................................... 194
Table 18.4 – General Performance Requirements for the Works ............................................ 194
Table 18.5 – Failure Events and Allowable Exceptions ........................................................... 199
Table 18.6 – Catchment Pollution Incident Influent Characteristics ......................................... 200
Table 20.1 - Minimum Staff and Qualifications Requirements during O&M Period ................. 215
Table 24.2- Items to be examined at the End of 15 Years O&M Period ................................... 226
Table24.2- Minimum Documents to be handed over at the End of 15 Years O&M Period ....... 228
Table 25.1 - Sampling/Analysis Locations and Frequencies.................................................... 258
Table B1.1 – Influent Parameters ............................................................................................ 268
Volume 2 Page vii Employer’s Requirement

Table B1.1a –Minimum Design Load Parameters ................................................................... 268

Table B1.2 – Treated Wastewater Quality (for Disposal ) ........................................................ 269
Table B1.3 – Treated Water Quality of effluent from Lagoon during construction of WwTF in one
stream of Lagoon (for disposal) ............................................................................................... 269
As per MPCB consent order number : BO/JD (WPC)/CC/ 1703001394 dated: 21/03/2017 ..... 269
Table B1.4 Tertiary treated effluent standards (for reuse) ....................................................... 269
Table B1.5: Treated sludge quality requirements .................................................................... 270
Table B1.6 - Lookup table for 95%ile compliance.................................................................... 271
Table B2.1 – Suite of analyses and measurement for Influent and Effluent ............................. 273
Table B2.3(a) – Performance during plant proving period (Effluent for Disposal) .................... 274
Table B2.4 – Performance tests concerning sewage screening and screenings handling ....... 274
Table B2.5 – Performance Tests Concerning Grit Separation and Handling ........................... 276
Table B2.6 – Performance Tests Concerning Primary Settlement ........................................... 276
Table B2.7 – Performance Tests concerning Biological Treatment ......................................... 277
Table B2.8 – Performance Tests concerning Final Settlement System ................................... 277
Table B2.9 – Performance Tests Concerning Thickening of Sludge (Primary and Secondary) 278
Table B2.10 – Performance Tests Concerning Dewatering of Sludge ..................................... 279
Table B2.11 – Performance Tests Concerning Digestion of Sludge ........................................ 280
Table B2.12 – Performance Tests Concerning Sludge Generally ............................................ 281
Table B2.14 – Performance Tests concerning the Whole WwTF............................................. 282
Table B2.15 – Performance Tests Concerning Noise .............................................................. 282
Table B3.1a – Minimum monitoring, sampling and analysis during normal operation .............. 284
Table B3.1b – Minimum monitoring, sampling and analysis during normal operation .............. 285
Table B3.2 – Main programme of analyses – for compliance purposes ................................... 286
Table B3.3 – Programme of analysis – for payment purposes ................................................ 287
Volume 2 Page viii Employer’s Requirement

List of Appendices
APPENDIX A – DESIGN STAGE CONTRACTOR’S DOCUMENTS ....................................... 262

APPENDIX B – PERFORMANCE REQUIREMENTS.............................................................. 267
APPENDIX B1 – DESIGN FLOWS AND LOADS .................................................................... 268
APPENDIX B2 – PERFORMANCE TESTS DURING PLANT PROVING PERIOD .................. 272
APPENDIX B3 – MONITORING, SAMPLING AND ANALYSIS ............................................... 283
APPENDIX C – EMPLOYER’S ACCOMMODATION .............................................................. 289
APPENDIX C1 – EMPLOYER’S ACCOMMODATION FOR DESIGN-BUILD PERIOD ........... 290
APPENDIX C2 – EMPLOYER’S ACCOMMODATION FOR OPERATIONS PERIOD ............. 294
APPENDIX D – TYPICAL PLC INPUT/OUTPUT (I/O) SCHEDULE ........................................ 296
APPENDIX E – MONTHLY STATUS REPORT IN OPERATIONS PERIOD ........................... 299
APPENDIX F – PROCEDURES FOR CONSTRUCTION PERMIT.......................................... 306
APPENDIX G – SAMPLE ASSET HIERARCHY ..................................................................... 307
APPENDIX H – LIST OF InDICATIVE SUPPLIERS ................................................................ 308
Volume 2 Page ix Employer’s Requirement

Introduction
Volume 2 Page 1 Employer’s Requirement

1 INTRODUCTION
1.1 Introduction
This volume describes the Employer’s specific Requirements for the Versova
Wastewater Treatment Facility (WwTF) Design, Build and Operate (DBO) Contract. The
Contract includes the Design-Build of the Works and the Operation and Maintenance
Service.
The general technical specifications are included in Volumes 2A, 2B, and 2C and
describe the general requirements of the civil, mechanical, electrical and Instrumentation,
Control and Automation(ICA) works. Volume 2D contains the Contract drawings. By
reference in this clause Volumes 2A, 2B, 2Cand 2D form part of the Employer’s
Requirements.
If there is a conflict between the specific requirements of this Volume 2 and the general
technical specifications and drawings in Volumes 2A, 2B, 2C, and 2D, then the specific
requirements of this Volume 2 and the drawings take precedence in accordance with
Clause 1.5 of the Conditions of Contract.
The terms of the Contract are based upon the FIDIC Conditions of Contract for Design,
Build and Operate Projects (the gold book).
1.2 Background to Scheme
This Contract forms part of the Mumbai Sewage Disposal Project (MSDP): Stage II -
Priority Works. The basic objective of the project is to provide a healthier and improved
environment for the people of Mumbai by improving the quality and reliability of
wastewater collection, treatment and disposal, whilst minimizing the impact of
wastewater on the environment.
The sewage collection system in Mumbai comprises seven zones, each operating
independently and comprising a sewage collection network, pumping stations, pumping
mains, wastewater treatment facilities and outfalls.
The sources of the Influent in the Versova catchment comprise domestic and commercial
premises. Background Information for the Versova Catchment is included with this RFP
including:
• Estimated annual raw sewage generation projections for the Versova WwTF
catchment;
• Historic data of the raw sewage flows pumped by the Versova Influent Pumping
Station (IPS) in the recent past.
At present the Influent is conveyed to the Versova WwTF by means of the existing
Versova IPS located at the junction of Link Road and Jayprakash Narayan Road near D.
N. Nagar Metro station. It is planned to convey influent by gravity from Versova
catchment area to new pumping station proposed (by other contractor) in WwTF Versova
premises through a Tunnel (by other Contactor) and further will be pumped to treatment
facility.
Currently the flows received at the Versova IPS near D. N. Nagar Metro station and the
maximum capacity it is able to deliver, are less than the required design capacity of the
Works required under this contract. As network connectivity is improved, the flows
arriving at the existing IPS will increase to exceed its design capacity. Therefore new
pumping station will be installed at WwTF (by other contractor), Versova area and
sewage will conveyed through tunnel by gravity. All of this work will be managed by the
Employer and carried out by others in separate contracts.

The scope of this tender starts from connecting the break pressure tank. The distance
from the break Pressure Tank of new Pumping station to proposed WwTF site boundary
is approximately 200m.
The Influent at the existing Versova WwTF currently receives preliminary treatment and
biological treatment through aerated lagoons. The two streams of aerated lagoons treat
the incoming sewage from Existing Pumping station.
1.3 Objectives of the Contract
The main objectives of this DBO Contract include:
• Reconfiguration of the existing facilities to ensure treatment of existing flows are
maintained through one existing lagoon throughout construction of the new facilities
in other stream.
• Demolition and disposal of existing structures within the WwTF site boundary on the
Site, including dismantling the floating surface aerators, emptying the lagoons and
redundant section of the outfall channel, Treatment of the settled sludge in lagoon to
get USEPA Class B dewatered sludge & Safe disposal, filling, ground improvement,
and site clearance including the removal of bushes and trees etc..
• The Employer has hatched the area within site boundary in plant layout (refer volume
2D-Contract drawings) which is not available for new WwTF construction, however
Contractor has to construct access road through this area to approach construction
area and it is also responsibility of contractor to construct boundary wall all around
the whole versova WwTF premises as specified in drawing in Volume 2D and all
around the area provided for WwTF construction (unhached area in drawing).
Tenderer is encouraged to use minimum unhatched site plot area within Plant
playout. The saved useful piece of land can be utilised by employer for future
development or upgradation of plant.
• Design & Construction of a new treatment facility having 3 modules and having
additional space for same one module for future expansion that will treat the Influent
sewage and Sludge to the standards required by these Employer’s Requirements.All
the modules to be designed for the equal capacity and construct in unhatched area
within the site boundary.
• Design of 100% of plant capacity for Tertiary treatement system to get treated water
for recycle and reuse within unhatched area provided for new WwTF construction
and construct 50% of plant capacity in 2 module of 25% each of plant capacity. Other
2 modules of 25% shall be specified in proposed plant layout. The Employer, either
directly or through agencies appointed by it, would distribute the treated water to end
users.
• Operation and Maintenance of existing WwTF during construction of new WwTF to
maitian the plant for meeting disposal standard. It is Contractors’ responsibility to visit
the site to get aquainted the actual site condition.
• The demolition of the existing inlet works, screen house and other facilities after
commissioning of new WwTF.
• Operation and maintenance of the constructed facility for a period of 15 years
following the Design-Build Period, including safe transportation of sludge produced to
designated site i.e. proposed Malad WwTF.
• The Contractor will work in close coordination and offer all possible co-operation to
the third party agencies that the Employer may appoint for;
• Marketing of the tertiary treated water;

• Laying of infrastructure (including pumping and network) to convey tertiary

treated water to end users and its operation and maintenance;
• Processing further, if required and/or Disposing of the Class A sludge to
suitable end users;
• Monitoring / auditing quality of the outputs of the WwTF
• Handing over of the Works to the Employer in a well maintained and operating
condition at the end of the Contract.
Contractor shall ensure quality of treated water as per tender requirements, failing which
penalties would be applicable. The Employer reserves the right to appoint independent
monitoring / auditing agencies to verify the quality of the effluents from the plant. The
Contractor shall provide all possible co-operation and assistance to such agencies
appointed by the Employer.
Throughout the construction and operation of the project, the requirements of all
approvals and consents and all relevant legislation and environmental regulations must
be complied with.
1.4 Description of the Works

The Works comprise the design, specification, procurement, supply, construction,
commissioning, testing, operation and maintenance of a fully functioning wastewater
treatment facility which is fit-for-purpose including all necessary pumping, sludge
digestion and dewatering plant, with associated power generation from biogas. The
Contract also includes the safe transporation of grit, screenings and the final dewatered
and stabilized class “A” sludge.
The Site is located within an existing treatment plant site. The Contractor must plan and
carry out the Works in such a manner as not to cause any disruption to the Employer or
to the Employer’s ability to operate and maintain the existing facilities until completion of
the Design-Build stage of the Works.
The Works shall be constructed in 4 Stages as follows:
Stage 1
• Provision of approach road from existing access, upgrading of approximately 450 m
of existing earthen road from existing Creek Road to entrance of Versova WwTF site,
site clearance, Maintenance of existing inlet screen works, existing grit removal
system before desludging the lagoons, blocking of flow to the one stream of lagoon
to be decommissioned, dismantling the existing floating aerators in the same lagoon,
emptying the lagoon including desludging them and dewatering and desludging the
redundant section of outfall channel, demolishing the structures and utilities within
that lagoon area, ground preparation including installing band drains (if applicable),
piles, backfilling and compacting to meet the requirements set out in Section 14. All
aerators and allied equipment dismantled from this lagoon can be used in adjacent
lagoon as per design requirement to maintain the BOD/COD level of treated effluent
during construction of new WwTF on area of other lagoon or will be stored at a place
shown by the Employer at WwTF premises.
• All sludge extracted from existing lagoons shall be treated for converting it into
USEPA class B standard. It is Contractor’s responsibility to dispose off this sludge

safely. However Contractor can also use this sludge in backfilling of lagoons, if
contract’s design suits it.
• The electricity charges and water bill charges for O & M of existing facilities shall be
borne by the Employer. However, the contractor shall not tap and utilize the electric
power and water supply from the existing WwTF except for operation & maintenance
of existing WwTF. If such incidence is observed, a penalty of Rs. 50,000 per
incidence for each will be directly deducted/recovered from the pending
bills/Retention money / Bank Guarantee of the contractor.
• The Contractor shall be fully res
• ponsible for the operation and maintenance of the existing facility to the satisfaction
of the sewage treated level as specified in Table B1.3, Appendix B1 of Employer’s
Requirement and Regulatory Agencies. Other parameters shall be compliant to the
copy of consent letter attached in Volume 5. The Contractor shall also maintain /
renew the approvals of the Statutory Authorities for the operation of the plant till the
new one is commissioned. In existing treatment facility, the Contractor shall install
'Online Effluent Monitoring Systems' for the parameters namely pH, TSS, COD, and
BOD within 3 months of the issue of Letter of Acceptance. The Contractor shall
connect and upload the online effluent monitoring data with the server of the
Maharashtra Pollution Control Board and Central Pollution Control Board in a time
bound manner but not later than timelines mentioned above. The Contractor shall
ensure regular maintenance and operation of the online system with temper proof
mechanism with facilities for calibration. The Contractor should follow guidelines
prescribed by CPCB for Online Continuous Monitoring System for effluents and
Standard Operating Procedure (SOP) for verification of installation and Calibration of
UV-Vis Dual Beam Scanning & Multipoint calibration mechanism technology based
OCEMS (Effluent) used in STPs.
Stage 2
• Design, Construction and operation of the treatment facilities (60 MLD X 2 module in
one stream of lagoon) including preliminary treatment for full design capacities,
biological treatment, sludge treatment and dewatering for the design flows as per
modular design approach and loads specified in Appendix B1. Construction of a
workshop, administrative building-cum-laboratory, SCADA building and all necessary
ancillary buildings and services, commissioning of the new Works, Temporary
arrangement for pumping the flow from existing distribution box to inlet works of new
facilities. Tertiary treatment shall also be constructed and commissioned by
contractor having capacity of 50% of plant capacity.
• Open Space to be provided for Tertiary Treatment of remaining 50% flow to enable
future reuse/recycling of treated effluent.
• While designing and laying out the plant, the Bidder has to take care of the following:
a. Maximum care is to be taken to minimize the cutting of trees.
Stage 3
• On successful commissioning of new works in first lagoon, blocking of flow in
adjacent lagoon, demolition of structures in that lagoon , dismantling of existing
floating aerators, emptying the lagoon including desludging them and dewatering and

desludging the redundant section of inlet and outfall channel, demolishing the
structures and utilities within the lagoon area, backfilling and compacting,
Construction and operation of the treatment facilities (60 MLD X 2 modules in other
stream of lagoons in which 60 MLD X 1 module is for space reservation for future)
including preliminary treatment for full design capacities, biological treatment, sludge
treatment and dewatering for the design flows as per modular design approach and
loads specified in Appendix B1, commissioning of the new works.
Stage 4
• On successful commissioning of all new works, Contractor shall operate and maintain
the all new works for 15 years.
• Provide Tertiary Treated Water to the capacity required by the Employer as per the
quality defined in the Tender documents at the periphery of the WwTF (at a mutually
agreed location). The Employer reserves the right to draw upon the tertiary treated
water according to their requirement .
• Safe Transportation of the Class A Sludge from the plant to the designated location
for disposal i.e. proposed Malad WwTF. The transportation cost of the same shall be
included within the O&M costs quoted by the Tenderer. There shall not be any tipping
fee involved in the disposal under this Contract. The vehicle transporting the sludge
shall be properly covered to prevent any spillage, odour etc. and shall comply with the
environmental requirements and shall be GPS enabled so that the same can be
tracked. In the event that the Employer decides to change the designated disposal
location for any reason, the transportation cost shall be adjusted as per the prevalent
SOR of MCGM Storm Water Department for silt transportation (Ref R2-SWD-11 / R2-
SWD-12 in the USOR of SWD Department).
• Safe transportation of Grit and screening from new WwTF facility to designated site i.e.
existing Versova Influnet Pumping Station
• The Contractor will work in close coordination and offer all possible co-operation to the
third party agencies that the Employer may appoint for;
a. Marketing of the tertiary treated water;
b. Laying of infrastructure (including pumping and network) to convey tertiary treated

water to end users and its operation and maintenance;
c. Processing further, if required and/or Disposing of the Class A sludge to suitable

end users;
d. Monitoring / auditing quality of the outputs of the WwTF
The land shall remain in possession and control of the Employer. The Contractor shall
not be allowed to use any part of the land and facility for any works other than O & M of
the plant. Contractor shall not be allowed to construct any kind of structure/shed on any
piece of land without approval of Employer during entire period of O & M.
• The Contractor shall install 'Online Effluent Monitoring Systems' for the parameters
namely pH, TSS, COD, BOD, Total Nitrogen, Total Phosphorous, Feacal Coliform and
Flow Meter at the plant intake and effluent discharge points. The Contractor shall
connect and upload the online effluent monitoring data with the server of the
Maharashtra Pollution Control Board and Central Pollution Control Board in a time
bound manner. The Contractor shall ensure regular maintenance and operation of the

online system with temper proof mechanism with facilities for calibration. The
Contractor should follow guidelines prescribed by CPCB for Online Continuous
Monitoring System for effluents and Standard Operating Procedure (SOP) for
verification of installation and Calibration of UV-Vis Dual Beam Scanning & Multipoint
calibration mechanism technology based OCEMS (Effluent) used in STPs.
1.5 Future Expansion

The Contractor shall design and construct the Works to ensure that future expansion of
the facility and tertiary treatment facility of capacity 90 MLD can be accommodated with a
minimum of cost and environmental impact and with minimum disruption to the ongoing
treatment being provided at the facility.
In Phase II, the employer has envisaged future expansion of about 60 MLD for
secondary treatment, EPS and the 90 MLD for tertiary treatment.
All above work shall be designed by bidder and specified in proposed plant layout within
area provided for new WwTF construction (unhatched area) within site boundary.
It is clarified that the Contractor has to plan for 100% of tertiary treatment plant in the
area used for development. However, they need to build only 50% of the capacity of
tertiary water. The power, equipment and other requirements for the balance 50% of the
tertiary treatment is not part of this Contract. Also, the pumping out of tertiary treated
water from the storage tank and associated works are also not part of this Contract.
1.6 Sustainability
The Contractor shall design, construct, and operate the Works to ensure that the
infrastructure that is procured through this assignment is sustainable over the long term.
The Contractor shall educate themselves on the role of asset management systems in
achieving this objective. When decisions are to be made by MCGM throughout the
duration of the Contract, the Contractor shall provide information to facilitate an informed
decision making process that is based on the long term sustainability of the infrastructure.
1.7 Charges related to Power supply
The responsibilities of obtaining and maintaining the Power Supply shall be as follows:
• Construction Power – To be obtained and paid for by the Contractor
• For existing plant O&M – Employer will pay the recurring charges for power
• New Power Connection – Contractor to obtain the same from suitable utility
company and the deposits, charges and capital costs associated would be
reimbursed by the Employer. The above price shall not be included in the contract
price.
• O&M of new plant components (till commissioning of entire new plant) if
commissioned, The Contractor will make the payments of power charges and
consider the cost of power usage within his contract prices.
• O&M of new plant (from commissioning till end of contract) – The Contractor will
make the payments of power charges and consider the cost of power usage within
his contract prices.

Existing Works, Structures and Services

2 EXISTING WORKS, STRUCTURES AND SERVICES

2.1 Existing Treatment Facility
The existing wastewater treatment facility consists of:
• Structures in Preliminary treatment area:
o Inlet chamber, screen chamber with 3 no. vertical bar screen with raking system,
4 no. aerated grit removal systems with 1 no. overhead crane;
o Blower house, electrical sub-station, workshop/ stores;
o Administration building;
o Underground pipes, electrical & instrumentation cable runs.
• Main Lagoon areas:
o Distribution boxes with pipes and isolation valves for feeding sewage to the
lagoons;
o 2 nos. streams of earthen basin aerated lagoons with individual cable posts for
the floating surface aerators, small jetty for boats, overflow weirs and entry and
exit pipes;
o Each stream of lagoon has 3 stages ponds (1st Fully aerobic pond, 2nd Facultative
pond and 3rd Polishing pond)
o 2 nos. outlet chamber with bypass penstock arrangement.
• Other structures and civil/landscaping features include:
o Internal asphalt roadways;
o Landscaped garden areas;
o Overhead main electrical power feed system and underground electrical cable
runs;
o City/potable water supply.
• Other ancillary structures or areas include:
o The earthen approach road from the Creek road to entrances of Versova WwTF
site;
o The Outfall channel of site where the effluent is discharged.
2.2 Demolition of Existing Structures

The Contractor shall obtain the written agreement from the Employer prior to
commencing any demolition. Contractor shall submit detailed program and schedule for
demolition of existing structures.
All existing structures within the Site boundary of WwTF identified on drawings No.
TCE.10201A-CH-2032-GA-20002 and TCE.10201A-CH-2032-GA-20001 located within
the construction Site area including underground pipe work and other services shall be
demolished.
Demolition shall include the excavation of all underground materials relating to the
existing facility to natural ground and disposal of surplus materials off site to an
appropriate disposal location, leaving the ground in a tidy finished state.
The Contractor shall be responsible for determining the location and proper disposal
route for all waste materials arising as a consequence of demolition including sludge,

and for paying all tipping fees and other associated costs. The Contractor shall dispose
off any hazardous materials off-site in accordance with existing laws and regulations. All
permissions and consents from respective authorities including MCGM shall be obtained
by the contractor. The contractor shall submit Debris Management Plan (DMP) 28 days
prior to excavation/demolition/existing sludge removal. The Employer shall have a period
of 5 (five) Business Days to review the DMP and either accept or reject it. If the DMP is
not acceptable, it shall be returned to the Contractor for amendments and resubmission.
The failure of the Employer’s Representative to respond within such 5 (five) Business
Days period, unless extended by mutual agreement, shall be deemed acceptance of the
DMP.
The Contractor shall carry out demolition in a prudent manner and shall dispose of
materials according to local statutory procedures. The Contractor shall identify building
materials and take appropriate measures to handle them in a safe manner.
Prior to commencement of the demolition, the Contractor shall carry out all necessary
pre- demolition surveys to ensure that demolition will be carried out correctly and safely.
The Contractor’s attention is drawn to Clause 15.22 of the Employer’s Requirements
which forbids blasting and the use of explosives.
The Contractor may sell any materials in order to obtain the salvage value of the same
However, prior to giving possession of the Site to the Contractor, the Employer may
remove any equipment or materials he so chooses.
2.3 Existing Services to the Site

Where information is provided concerning existing services this information must be
verified by the Contractor with the relevant service provider or authority as its accuracy
or relevance cannot be guaranteed.
The Contractor shall be responsible for all service connections to the site required for
construction of the Works and operation of the new facility. For clarity, the Contractor
shall be responsible for the connection and continued provision of all necessary services
(electricity, water, gas, telecommunications, etc.) to the Site for the Design-Build Period
and for the provision of the Operation and Maintenance Service. The Contractor shall be
responsible for the payment of all such services for the entire Contract Period.
The Employer shall be responsible for the services to the existing WwTF until such time
as it is decommissioned. However, if any such services have to be diverted in order to
allow the Works to proceed, then the Contractor shall be responsible for such diversion
which shall be carried out. The Contractor shall use the dismantled aerators from
inactive stream to the working stream at proper locations in lagoons without affecting the
performance of the existing WwTF as per Appendix B.
2.4 Existing Boundaries

The Contractor shall provide temporary fencing around the construction Site area and
permanent boundary wall (RCC retaining wall with proper supporting structure up to
proposed road level followed by RCC compound wall of minimum height 2.4m along with

barbed wire fencing of height 600mm above compound wall), around the proposed
WwTF Site area as shown on drawing. No. TCE.10201A-CV-3051-SI-30001.
Temporary fencing, Hoarding & Barricading shall be as per MCGM Circular U/NO.
MGC/F/6342 dated 05-05-2018.

Contract Interfaces

3 CONTRACT INTERFACE
3.1 Catchment Works
It is envisaged that there will be a number of other contracts being undertaken on the
sewerage network in the Versova catchment during the course of this Contract, both
during the Design-Build Period and the Operation Service Period. There will be variation
of the flows arriving at the WwTF as work progresses on other contracts within the
catchment area.
During the Contract, the Contractor shall be required to liaise and co-operate with others
engaged by the Employer.
The Employer shall be responsible for the operation and maintenance of the existing
Versova IPS. It is envisaged that an increase in capacity of this pumping station by
others shall take place within the Operation Service period. This will necessitate the
construction of a new pumping station and a sewer Tunnel which connect existing IPS /
proposed IPS. These works will be done by other contractors under separate contract.
During the Design-Build Period and Operation Service Period the Contractor shall liaise
with the Employer on general operational issues.
3.2 Operation and Maintenance of existing level of treatment through the Design-
Build Period
During the construction of new facilities in one stream of lagoon, It is necessary to
maintain the existing preliminary treatment, biological treatment and disposal of flows to
the outfall channel throughout the Design-Build Period. The existing preliminary
treatment, biological treatment (using one stream of the aerated lagoons) and associated
processes shall be operated and maintained by the Contractor until the Contractor is
ready to commission the new works.
The Contractor shall liaise with the Employer on general operational issues and be
responsible for arranging the transfer of flows to the new Works.
The Employer shall collect and disposed-off all the screened and de-gritting material
from existing facilities till the new Waste Water Treatment Facility shall be commissioned.
During O & M of new WwTF plant the contractor shall be responsible to transport the
Screened & De-gritted Material from the site to designated location i.e. Existing Versova
Pumping Station.
3.3 Related Contracts

It is anticipated that the MCGM may engage the following third parties for handling
aspects in relation to the project:
1 Agency to set up and monitor 5D BIM project of MCGM
2 Agency to identify and market the tertiary treated water from the plant
3 Agency to lay down the infrastructure for distribution of tertiary treated water
(including pumping and pipelines).
4 Agency to carry out the O&M of the tertiary distribution network including
pumping and pipelines.
5 Agency to monitor / audit the quality parameters of secondary and tertiary
treated water
6 Maharashtra Pollution Control Board (either directly or through an agency) will
monitor the quality of input and output parameters online.

The Contractor shall fully co-operate and facilitate the working of all the above agencies
(or any other agency appointed by the MCGM for works related to the site) on a
seamless manner. The co-operation shall inter-alia include the access to the facility as
required, sharing of data requested through the Employer etc.
3.4 Blocking of Flow to Lagoons

The Works are to be constructed on two existing streams of lagoons. Initially the works
are to be start on one stream of lagoon which must be decommissioned before
construction of new works on the site of the existing lagoons. Influent is delivered to
these lagoons by buried reinforced concrete culvert. The culvert does not include any
valves or penstocks to permit isolation. The Contractor shall be responsible for blocking
the culvert by appropriate means such that flow continues to the other lagoon which will
remain in service during the Works, but is stopped from passing to the lagoon which form
most of the Site for the construction of new works.
The Contractor shall be responsible for designing and constructing and maintaining the
blockages. The existing inlet work includes bypass facilities such that flow can be
diverted away from the culvert during construction of the blockage.
Prior to commencing this work the Contractor shall submit a proposed design and
construction methodology to the Employer’s Representative for approval. The
methodology shall include details of the period of time for which the lagoons will have to
be bypassed to allow the works to be carried out. The Contractor shall take all
reasonable measures to ensure that any such period of isolation is minimised, since
during this period untreated wastewater will bypass the treatment facilities.
On completion of the New Works the blockage shall be demolished as part of the
general demolition of the existing facilities.
Details of responsibility of operation and maintenance of the existing WwTF and Lagoons
shall be as follows:
1. The contractor shall be responsible towards security, operation and maintenance of the
existing plant except IPS and Rising main up to the inlet of screen chamber.
2. Existing IPS and Rising main up to the inlet of the screen chamber and all infrastructure
upstream of IPS shall be operated & maintained by the Employer
3. All expenses/costs involved during operation and maintenance including all consumables
shall be borne by the contractor except IPS and Rising main up to the inlet of screen
chamber.
4. All power and water charges shall be borne by the Employer till issue of commissioning
certificate. However, the contractor shall not tap and utilize the electric power from the
existing WwTF & Lagoon power sources for any other purpose except for operation &
maintenance of existing WwTF & Lagoons. If such incidence is observed, a penalty of Rs.
50,000 per incidence will be directly deducted/recovered from the pending bills/Retention
money / Bank Guarantee of the contractor.
5. In case of any extension of contract beyond contractual period due to the fault of the
contractor, all costs except for power and water charges shall be borne by the contractor.

6. The contractor shall be responsible to ensure that all the equipment necessary/required
to operate the plant satisfactory are properly maintained and are in working/operating
condition. Any costs involved in Repairs/Rehabilitation/Replacement shall be borne by
the contractor.
7. The maintenance shall be carried out for all civil, mechanical, Electrical Instrumentation
component of the plant including piping, electrical cables , housekeeping of plant,
maintenance of tree plantation, Garden etc., as a whole, in accordance with standard
engineering practice, statutory regulations, system requirement and as per instructions
and in consultation with of Municipal Engineers.
8. The contractor shall be responsible to ensure that the discharge effluent standards as
per MPCB consent are achieved within 6 months from date of award of DBO contract
and shall be maintained during the period of operation and maintenance. Any penalty
levied by pollution control board due to non-adherence to specified discharge effluent
standards, shall be borne by the contractor.
3.5 Lagoon Decommissioning

Contractor shall submit existing lagoons decommissioning proposal to Employer’s
Representative for approval. Contractor shall ensure that:
• Second stream of lagoons shall be remains under operation when first stream of
lagoon are under decommissioning and make ready for constructional activities. The
Contractor has to operate and maintain second stream of lagoon .
• Second stream of lagoon shall be remains under operation till all the WwTF modules
constructed at first stream are ready for commissioning
• Once constructed WwTF modules in first stream are under operation, contractor shall
decommission second stream lagoons and make it ready for construction activities
for other proposed modules of WwTF
• All underground structures including foundation structures shall be demolitioned
• Safe disposal of the lagoon sludge shall be the responsibility of contractor.
• If required contractor shall make temporary arrangement to dewater the sludge to a
consistency not less than 25% for safe disposal.
• Contractor shall ensure that sludge quality shall meet the disposal requirement
specified as per local regulations and laws.
3.6 Existing Approach Road and Associated Structures
The Contractor shall carry out improvements i.e. construction of road on the existing
approach road (approximately 450 m length and 6 m wide) connecting the MCGM Back
road (Creek road) and existing Versova WwTF entrance as shown on drawing
No.TCE.10201A-CV-3054-SI-30001.
The level of new approach road shall match with the adjoining main road level. The
construction of new approach road shall be commence only after laying and
commissioning of sewer tunnel along the approach road. During the Design Build period
of WwTF, The contractor shall improve existing earthen approach road to rigid concrete
road for ease and smooth movement of transportation. The Contractor shall design and
provide appropriate number of lighting poles along the approach road as per prevail
norms.

The Contractor shall also design and construct the cable duct of 300 mm diameter on
both side of road.
The approach road to the Site leads off the MCGM Back road (Creek road) and is the
only means of road access to the Versova WwTF. The road is also used to access solid
waste site. It is therefore essential that vehicular access is maintained along the road
during the improvement works to allow continued access by MCGM to operational
premises and to permit access by emergency services or others if required. Prior to
commencing this work the Contractor shall submit a proposed construction methodology
to the Employer’s Representative for approval. The methodology shall include details of
the Contractor’s proposed traffic management plans demonstrating how access will be
maintained at all times.
The Contractor shall take care of trees and lighting poles (If any) adjacent to the existing
approach road. The Contractor shall take care when accessing the Site, not to touch or
damage the marker posts installed by the forest department on both sides of the road, if
any.
The Contractor shall be responsible for obtaining all approvals, permits, NOCs etc.
required in order to improve the approach road. The Employer will make reasonable
endeavours to assist the Contractor to obtain such approvals.
The Contractor shall be responsible for maintaining the approach road connecting the
MCGM Back Road (Creek road) and the Versova WwTF site throughout the Design-
Build and Operate Period.
The Contractor shall be responsible for protecting, diverting under propsed flexible
pavement road, if requried and keeping in operation all the existing utilities (electricity,
potable water, telecommunication, drainage, etc.) along this approach road throughout
the Design-Build and Operate Period.
3.7 Access to the Site
With the exception of components of the Works (Improvement/upgrade to the existing
approach road and boundary wall), the Contractor shall not have the right to access any
areas outside the Site defined on drawing No. TCE.10201A-CV-3054-SI-30001 as this
may interfere with existing operations. This includes the existing access area to the
facility. The exceptions are:
The Contractor shall make reasonable endeavors to minimise the impact on the
Employer’s activities during the construction of any works on the Employer’s operational
premises, or works which have an impact on access to the Employer’s premises. The
Contractor shall liaise with the Employer to agree the construction methodology, time for
construction, and access arrangements. Immediately on completion of the work the sites
shall be left in a tidy state and cleared of construction debris.
3.8 Access for Other Contractors
The Contractor shall allow reasonable access to other Contractors engaged on the Site or
on areas adjoining the Site to carry out their works.
In the event of a dispute over access or priority between Contractors, the Engineer shall
be informed in writing. The Engineer shall inform all parties concerned in writing of his
decision. Where any part of the Works is associated with or in physical contact with plant
supplied under a separate contract, the Contractor shall satisfy himself that the work
carried out by the other contractor is consistent with the correct operation of the Plant. In
the event of the Contractor considering any work being carried out or any work already
completed to be detrimental to the ultimate operation of the Plant, he shall report the
matter at once to the Engineer. If the work of the Contractor is delayed because of any

acts or omissions of any other Contractor, the Contractor shall have no claim against the
Employer on that account other than for an extension of time.
3.9 Outfall Channel
Each of the existing active lagoons discharges effluent into an effluent channel which in
turn discharges into Malad Creek.
After one stream of lagoon have been decommissioned then the section of outfall
channel into which they discharge will become redundant. The area occupied by this
section of the outfall channel forms part of the Site and is available to the Contractor to
use temporarily or as part of the works. In this case the Contractor is required to fill the
redundant section of channel to the same level as the finished ground level in the filled
lagoons.
Prior to commencing this work the Contractor shall submit a proposed design and
construction methodology to the Employer’s Representative for approval.

Contractor’s Documents

4 CONTRACTOR’S DOCUMENTS
4.1 General
The Contractor shall submit the Contractor’s Documents to the Employer’s
Representative in accordance with Clause 5.2 of the Conditions of Contract and more
particularly as required in this Section. All Contractor submissions referred to in the
Employer’s Requirements shall be deemed to be part of the Contractor’s Documents as
defined in the Conditions of Contract.
4.2 Format of Contractor’s Documents
The Contractor shall submit six paper copies and one editable copy in electronic format
of each drawing or document required to be submitted. The Contractor shall mark
incomplete areas of drawings ‘hold’. Any revisions to drawings or documents shall be
clearly highlighted by the Contractor. The Contractor shall note drawing amendments in
the title box and mark amendments with a triangle containing the revision number.
Amendments to documents shall either be redlined/struck out or marked in the margin.
Drawings shall all have a similar title block which shall include the name of the designer,
the Contractor and the Employer, the name of the Contract, a unique description of the
content and a unique reference number complying with a formalised numbering system.
The title block shall be such that the whole title block is visible including space for
amendment information when folded to A4 size.
Piping and instrumentation diagrams (P&IDs) shall show in symbolic form the process
plant and systems of measurement, control and automation.
Documents shall be in Microsoft Office format or equivalent approved by the Employer’s
Representative. Programmes shall be in the latest version of Primavera or MS Project.
Drawings shall be in AutoCAD or compatible equivalent.
4.3 Programme and Project Execution Plan
4.3.1 Programme
The Contractor shall submit a programme within the times specified in Section 8, in
accordance with Clause 8.3 of the Conditions of Contract and clearly indicate the
strategic milestones, periods for delivery of Plant and Materials to Site, periods for
construction, erection, testing and commissioning.
Key milestones to be identified shall include as a minimum:
• Finalization of all licenses and consents for the construction of the Works;
• Completion of design;
• Decommissioning of existing lagoons;
• Construction of treatment plant units;
• Ordering and importation of major equipment;
• Transfer of flows to the new Works;
• Tests on Completion of Design-Build;
• Issue of Commissioning Certificate.
In addition the programme shall:

1. Show fully the Contractor’s programme for submission of Contractor’s Documents for
review by the Employer’s Representative. It shall show adequate time for review by
the Employer’s Representative (minimum of 22 Business Days ) and other review
bodies according to the volume and complexity of the data presented in each
submission.
2. Be in accordance with the Employer’s Requirements.
3. Include as an appendix, a schedule of intended submissions showing clearly the
content of each submission and its relationship to construction activities in sufficient
detail for its significance and status to be understood.
4. Show Subcontracts to be placed.
5. Show critical path and float.
6. Include as an appendix the resources required for each task.
4.3.2 Project Execution Plan
The Contractor shall submit to the Employer’s Representative within the time specified
for the programme in Clause 8, his proposals for project control during the Design-Build
Period. They shall clearly set out the Contractor’s intentions and procedures for
controlling and managing the project including areas such as:
1. Cost control
2. Document control
3. Progress control
4. Change management
5. Specification deviations
6. Payment profiling
7. Contractual issues
8. Schedule of testing
9. Site management manpower and labour (health & safety)
10. Plant and equipment control
11. Detailed subcontract strategy
12. Detailed subcontract methodology
13. Quality Plans
14. Reporting and reviewing.
These shall all be addressed in a project execution plan which provides the detailed
framework, with scope for being revised/supplemented as work progresses.
4.3.3 Failure to Provide Programme and Project Execution Plan
If the Contractor fails to provide a programme or project execution plan within the
timescale specified, or to provide a satisfactory improved or revised programme or
project execution plan with a period of two weeks from being requested to do so by the
Employer’s Representative, then the Employer’s Representative shall be entitled to
reject all further Contractor’s Documents, after giving three instruction in writing and in
this case any or all of the Works on Site shall be ceased until the same are provided. In
such an event the Contractor shall not be entitled to an extension of Time for Completion

of Design-Build or additional payment as a result of any delay incurred as a result of the

Employer’s Representative’s instructions.
4.4 Design Stage Documents
4.4.1 General
Design documentation shall be submitted to the Employer’s Representative in two

distinct stages comprising a draft Contractor’s design report and a final Contractor’s
design report. The proposed content of the two reports is set out below. The Contractor
shall submit his proposals for submission of design details to the Employer’s
Representative, which shall be in accordance with these sections.
Design details shall be submitted in a coordinated succession of drawings, calculations
and reports. They shall be in distinct packages having been finished and been checked
by the Contractor’s design reviewers and approved by the Contractor’s Representative.
Subcontractor’s documents shall be submitted with a clear statement to show that they
have been approved by the Contractor. Documents, including Subcontract enquiries or
tenders shall not be submitted as a means of getting them checked by the Employer’s
Representative.
Typical details for submission of design stage Contractor’s Documents are contained in
Appendix A.
4.4.2 Contractor’s Draft Design Report
This report shall be submitted by the Contractor to the Employer’s Representative in a

clear and logical format, sectionalised for each significant element of the Works. The
report shall as a minimum include the following elements:
1. Process design calculations, results of dynamic simulation of process modelling
using BioWin® or equivalent software, at designed average flows, peak flow and PFF
with all assumptions, process flow diagrams and mass balance diagrams, including
flows in each area of the facility with one unit out of service condition for PFF flow.
The report from the software must be shared with the employer in the software
prescribed format.
2. Hydraulic calculations and profiles for liquid and solid streams
3. Computational Fluid Dynamics (CFD) modeling for biological treatment, secondary
clarifier (If proposed) and anaerobic digesters (if proposed)
4. Treatment Plant Layout showing details of all proposed structures, buildings, existing
structures, roads, connections with existing road networks, fencing, permnanet
compound wall, area covered, disposal point, landscaping, green belt, trees, etc.
5. Fully dimensioned general arrangement drawings for the buildings, tanks,
foundations, process units, access road, utility routes and general construction
details
6. Piping and instrumentation diagrams (P&IDs)
7. Plant drain philosophy reports
8. Plant Water Requirements
9. Mechanical equipment, valves and piping detailed documents
10. Power single line diagrams
11. Process data sheets to define design criteria, installed capacities and loading rates of
principal items of plant and equipment. Drawings to show physical sizes and layouts

of plant and equipment.

12. Operation and Control philosophy report
13. Draft works operating strategy
14. Draft user requirement specification for PLC and SCADA systems
15. Load test schedules
16. Instrument schedule
17. I/O schedule for each Motor Control Centre (MCC)
18. SCADA/Instrumentation/Process Control system architecture
19. Instrument list
20. Equipment electrical control schematics
21. Structural calculations for the structural components of the Works
22. Cut and fill balance and hard and soft landscaping proposals
23. Site drainage details
24. Architectural elevations and perspective sections
25. Building materials and finishes schedule
26. Materials handling procedures
27. Pipe work and ducting layout
28. Cable and wiring layout
29. Hazardous area classification details
30. Odour control system
31. Access, Lifting and maintenance proposals
32. Standby philosophy
33. Statement detailing measures to protect Site from flooding
34. Geotechnical Investigation Report
35. Safety and health report
36. Disposal of unwanted materials offsite
37. Design and layout of earthing and lightning protection system
38. Design and layout of lighting system
39. Any other details/data/design required as per the proposed technology
40. 3D modelling and Animation of proposed Works
4.4.3 Final Contractor’s Design Report
This report shall include any amendments to the draft report and inter-alia the following
elements:
1. Geotechnical interpretive report
2. Calculations for earthworks and foundations
3. Structural calculations of all components of the works
4. Finishes layout for all internal and external finishes

5. Process design, process control, piping and instrumentation diagrams

6. PLC/SCADA System architecture drawing and SCADA screen list
7. General arrangement drawing of instrument and control panels fully dimensioned in
plan and elevation views, showing foundation and fixing details, access doors,
clearances, cable-entry positions, weight and lifting arrangement.
8. Layout drawings of panel fascias showing instruments, controls and details of all
labels.
9. Layout drawings of panel interior showing equipment, terminal blocks and cable ways.
10. Fully dimensioned and coordinated general layouts of mechanical, electrical, lighting
and building services equipment
11. Civil calculations and reinforcement drawings for all reinforced concrete structures
12. Final craneage/ layout (including clear description of how individual items of plant are
to be handled, lay-down area and loading procedure)
13. Air duct layout and sections
14. Electrical load schedules
15. Electrical single line diagrams
16. Cable routing diagrams and schedules
17. Fire, gas and security alarm system schematics and layout
18. Pipe work layout diagrams including all valves and penstocks
19. Longitudinal pipeline sections
20. Routing diagrams for services
21. Zonal and hazardous areas classification
22. External works detailed layout including roads, lighting, drainage
23. Final user requirement specification and outline functional design specification for
PLC and SCADA control philosophy
24. I/O list, Alarm list, Cable and Junction box schedule,
25. Instrument hook up drawings
26. Loop schematics and interconnection wiring diagram
27. Instrument data sheet, Instrument test and calibration report
28. Instrument operation and maintenance manual
29. Equipment schedule
30. Hazard and risk assessment
4.5 Construction Stage Documents
Construction or fabrication of any element of the Works and delivery or installation of
Plant and Materials shall not commence until relevant Contractor’s Documents have
been submitted and the review has been completed by the Employer’s Representative.
Relevant Contractor’s Documents shall include inter-alia:
1. All required approval and consents
2. Approved Construction Environmental Management Plan (CEMP)
3. QA and QC Plan, Safety Plan

4. An integrated earthworks balance calculation for the whole of the Works

5. An assessment of the existing ground water table and the measures proposed to
ensure no deleterious effect on same
6. Construction method statements
7. Specifications
8. Final design calculations
9. Detailed construction drawings
10. Materials, equipment and instruments approval documents
11. Schedules
12. Inspection and test procedures
13. Inspection and test certificates
14. Safety certificates
15. Proof load tests
16. Performance curves
4.6 Plant and Equipment Documents
Plant shall not be delivered to Site until relevant Contractor’s Documents have been
submitted and the review has been completed by the Employer’s Representative.
Relevant Contractor’s Documents shall include inter alia:
1. Drawings of Plant and equipment
2. Schedules of Plant and equipment
3. Plant and equipment handling and installation method statements
4. Test and inspection method statement
5. Test and inspection certificates
6. Performance curves
7. Safety certificates
8. Certificate for equipment to be used in potentially hazardous atmospheres (where
relevant)
9. Proof load tests for all lifting equipment
10. Plant delivery documents
11. Vesting certificates (when equipment is to be placed into store and payment certified
by the Employer’s Representative).
4.7 Control System Development
Within the time scale detailed in the programme, the Contractor shall submit a control
system functional design specification for review by the Employer’s Representative.
4.8 Tests on Completion of Design-Build documents
The Tests on Completion of Design-Build shall not commence until relevant Contractor’s
Documents have been submitted and consent to commence tests has been granted by
the Employer’s Representative. Relevant Contractor’s Documents shall include inter-alia:
1. Site installation, inspection and test certificates
2. Tests on Completion of Design-Build method statement and programme

3. Final Contractor’s design report

4. Draft Operation & Maintenance Plan
5. Test schedules and performance data schedules
6. Plant inventory and data sheets
7. Operation and Maintenance Manuals
8. Populated Asset Management Database
4.9 As-built Documents
The Contractor shall prepare and submit as-built documents including drawings and
records during the Design-Build Period and shall submit them to the Employer's
Representative following completion of each part of the Works, and within the periods
stated in Section 8 of this Volume or as otherwise agreed with the Employer’s
Representative.
As-built documents shall constitute a permanent record of the Works as completed or
executed.
As-built documents shall consist of final versions of those Contractor’s Documents as are
necessary to fully record the design and construction of the Works, incorporating any
additional information that will assist the operator of the facility. They shall include inter
alia:
1. The final version of the design calculations
2. Key construction records and tests
3. Final versions of all drawings and documents prepared during the Design-Build
Period
4. Final versions of the specifications
5. Quality control records for Materials
6. Asset sheets
7. Borehole records and soil test reports
8. Survey records
9. Any information requested to be provided in the form of as-built records elsewhere in
the Employer’s Requirements.
Final approved as-built drawings shall consist of three copies on CD/DVD in AutoCAD
and Editable Microsoft Office formats, plus three A1 and three A3 printed and durable
translucent film copies.
4.10 Operation and Maintenance Manuals
The Contractor shall submit three hard copies of the Draft Operation and Maintenance
manuals for review and approval of the Employer’s Representative. Comments if any by
the Employer’s Representative shall be incorporated by the Contractor and six (6) hard
copies and three (3) soft copies on CD of the approved final version shall be submitted
by the Contractor.
4.11 Progress Photographs
A weekly progress report with photographs of the Design-Build shall include 24
photographs of the Site based activities and six other photographs as required by the
Employer’s Representative. The photographs shall be submitted (along with the labour
and plant returns) weekly by the Contractor to the Employer’s Representative and shall

be:
• dated and labelled
• mounted in albums
• accompanied by digital files
The Contractor shall arrange to have the progress photographs taken by a person
acceptable to the Employer’s Representative during the course of the Design-Build. The
Contractor shall submit the entire set of photographs as 150mm x 100mm colour proofs
from which the Employer’s Representative will select progress photographs. The
Contractor shall supply up to 10 suitably annotated prints not less than 250mm x 200mm
from the selected proofs, each week, as required. These photographs shall also be
dated and labelled and presented in separate albums.
The Contractor shall also arrange video film at various stages of construction milestones
including time lapse video footages.
All negatives, prints, and electronic versions shall be the property of the Employer and
shall not be supplied to any other persons without the authority of the Employer’s
Representative.
4.12 Monthly Progress Reports during Design-Build Period
The Contractor shall prepare and submit monthly progress reports at least one week in
advance of the monthly site meetings described in Section 15.16 of this Volume. In
addition to the requirements identified in Clause 4.21 of the Conditions of Contract, each
monthly report shall:
• provide the Employer with information reasonably required to assess the progress of
the construction and commissioning of the Works;
• highlight current and potential future issues that may hinder progress.
Each monthly report shall include, as a minimum:

• a summary;
• project summary data including the planned date for the commencement of the
Operation Service Period (as amended by any approved extensions of Time for
Completion of Design-Build);
• labour resource data including a histogram of the actual and projected workforce on
Site;
• a progress update.
Progress updates within each monthly report shall include:

• reference to the up-to-date construction programme;
• progress against key milestones and key dates;
• a commentary on areas that are behind programme and details of measures being
taken to mitigate delays;
• an update on any proposed changes to the Contract;
• an update on the submission and review of Contractor’s Documents;
• progress in obtaining all necessary approvals or permits;

• the health and safety record (including accident records);

• an update on toolbox talks;
• environmental records (including records of complaints, breaches of permit
conditions and other environmental incidents, such as spillages on Site);
• details of any security incidents and changes to the Contractor’s security measures;
• details of any public relations incidents or activity;
• records of labour utilised and Contractor’s plant and equipment on Site;
• copies of quality assurance documents, test results and certificates of Materials;
• details of the projected and actual payment profiles and estimated future expenditure
in quarterly periods.
4.13 Contractor’s Responsibilities Under Digital Project Management System (5D
BIM) during Design-Build Period
4.13.1 General
The Employer has the discretion to manage and monitor its Projects online by deploying
a Digital Project Management System consisting of 3D Civil Infrastructure Modeling,
Virtual Construction Validation, Centralized Project and Works Management & ERP
System to leverage virtual models for cost control and ensure smooth collaboration
between all the project stakeholders.
4.13.2 Licensing and Access to 5D BIM
To access Employer’s digital platform, minimum login credentials shall be provided by

MCGM, free of licensing costs to the Contractor. The access to MCGM’s digital platform
shall be provided through user credential only. The Contractor shall provide staff and
other resources to meet the responsibilities to maintain the system.
4.13.3 Particular Responsibilities of Contractor
The responsibilities of the Contractor for undertaking the above are spelt out in
ANNEXURE A to this Addendum.
Sr. Activity Responsibilities of Contractor

No.
(1) 3D Models & Drawings Create/Change
Engineering Change Approvals
BOQ with change Control
Cost Estimate with change control
Engineering issues Management etc.
(2) Construction plan validation Propose time and resource plan
Constraints validation & Alternate
solutions
Technical simulation - structural fatigue
etc.

(3) Work order Management Create/change Measurements &

Works progress Dashboards Primary Data. Review / Accept
Measurement Entries Milestone status / bill Book
Bill Book Generation / Reconciliation entries etc.
Milestone Progress
Payments Trigger
Engineering change approval during
execution
Maintenance during DLP
Claims & dispute etc.
Review / Reject / Approval powers of the actions shall vest with the Employer.
Staff of Design and Build Contractor shall attend all training / Seminar / Workshops
organized by MCGM and its digital project management solution Implementation Agency
related to project.
4.13.4 Expected Deliverables from Contractor
Following are the expected deliverables in form of collaboration with 5D BIM by the DBC:
• Creation of 3D engineered intelligent Models using discipline specific modelling/

engineering applications.
• Creating 2D drawings extracted from 3D engineered intelligent Models, in CAD plan,
section, elevation and other relevant details (based on specific engineering
disciplines) on which the actual construction will be carried out.
• Comply with the requirements in regards to the production of all the CAD (3D/2D)
data files and building information modeling (BIM) work.
In view of the above, the Contractor shall be required to comply with the following points:
a) Follow and comply the system guidelines to be issued by MCGM.

b) Work on the Platform which MCGM will finalize.
c) Update Works Plans online using platform defined by the MCGM.
d) Maintenance and updating measurement entries and construction milestone entries
in software used by the Platform finalized by MCGM during construction and O&M.
e) Create and Upload of drawings / designs as per the classification and standard on
the software platform defined by the MCGM.
f) Key contract related communication and progress related data as per processes
defined on the software platform deployed by the MCGM
g) BOQ/Non-graphical details need to be updated in the system in the format prescribed
by the MCGM.
h) Initiation of engineering change management process on the platform
i) Acceptance of milestone bill book as provided by the platform based on physical
works progress and quality review.
The Contractor shall access digital platform for mentioned functions as applicable as per
Contractor’s respective scope of work. However the function list is indicative and precise
activities from the Contractor on the digital system will be updated and communicated to
Contractor from time to time basis.


Health, Safety and Environment

5 HEALTH, SAFETY AND ENVIRONMENT

The Contractor shall comply at all times during the Contract with all relevant Indian
health, safety and environmental legislation, and all amendments thereto and also
IS 18001:2007 Occupational Health and Safety (OH&S) management system.
This standard prescribes requirements for an OH&S management system, to enable an
organization to formulate a policy and objectives, taking into account legislative
requirements and information about significant hazards and risks, which the organization
can control and over which it can be expected to have an influence, to protect its
employees and others, whose health and safety may be affected by the activities of the
organization.
The Contractor shall immediately notify the Employer’s Representative or, in his absence,
the Employer, if any accident occurs whether on or off the Site in connection with the
Works which results in any injury to any person whether directly concerned with the Site
or a third party. Such notification may initially be verbal and shall be followed by a written
report within 24 hours of the accident.
5.1 CEMP
The Contractor shall be responsible for preparing the Construction Environmental
Management Plan (CEMP) and obtaining the approval of the relevant authority. The
Contractor shall be responsible for implementing the approved CEMP.
5.2 Safe Systems of Work
The Contractor shall be responsible for all safety systems on site. Throughout the
Design-Build and Operation Service the Contractor shall:
• at all times maintain a safe system of working and shall comply with all enactments,
regulations and working rules relating to safety, security, health and welfare of all
persons who may be affected by his work;
• ensure that only persons who are properly trained for their duties are employed, that
the correct tools and procedures are used and that adequate personal protective
equipment is provided to all persons who may be affected by the work;
• carry out toolbox talks for all Contractor’s Personnel at least once per week;
• erect suitable warning signs, barriers, etc. as necessary for the activity which is being
carried out – the Contractor shall maintain such signs, barriers, etc for the duration of
such activities;
• submit to the Employer, no later than 28 days before work commences on the Site,
his Health and Safety Plan containing comprehensive proposals relating to the
management of health, safety and welfare of all his personnel on the Site and all
persons who may be affected by his work.
The Contractor shall be responsible for the safety of all of his personnel and other
persons directly or indirectly employed for the Works and shall take all measures
necessary to ensure their safety. In particular such measures shall include the following:
i) Provision of proper safety and emergency plans and regulations; fire, gas and
electric shock precautions, stretchers and first aid box together with rescue
facilities generally for each place of working;
ii) Provision of appropriate and effective safety work gear, including certified safety
helmets and certified work boots for all personnel including the Employer’s
Representative and each of his staff and any authorized visitors to the Site (see
further data in Section 15.24 and Appendix C);

iii) Safe control of the water table, including provision of ample standby generating
and pumping plant to maintain dry conditions;
iv) Provision and maintenance of suitable lighting to provide adequate illumination of
works with appropriate spares and standby equipment;
v) Provision and maintenance of safe, sound mechanical equipment, each item of
plant having an up-to-date testing certificate;
vi) Provision and maintenance of safe, sound ropes, slings, pulleys and other lifting
tackle, each appliance having an up-to-date testing certificate, where appropriate;
vii) Provision of notices on weather-proof boards measuring 1.25m x 1.5m in size,
written in bold letters in English, Marathi and Hindi languages to be erected on
existing footpaths and at points of access likely to be used by the public, which
shall warn the public of the existence of the Works. These notices shall be in
addition to any statutory requirements demanded of the Contractor;
viii) Suitable scaffolds shall be provided for workmen for all activities that cannot be
safely executed from the ground, or from solid construction except such short
period work as can be done safely from ladders. When a ladder is used, an extra
person shall be engaged for holding the ladder and if the ladder is used for
carrying materials as well, suitable footholds and handholds shall be provided on
the ladder and the ladder shall be given an inclination not steeper than ¼ to 1 (¼
horizontal and 1 vertical);
ix) Scaffolding or staging more than 3.25m above the ground or floor, swung or
suspended from an overhead support, or erected with stationary support, shall
have a guard rail properly attached, bolted, braced and otherwise secured at least
1 metre above the floor or platform of such scaffolding or staging and extending
along the entire length of the outside and ends thereof with only such openings as
may be necessary for the delivery of materials. Such scaffolding or staging shall be
so fastened as to prevent it from swaying from the building or structure;
x) Working platforms, gangways and stairways shall be so constructed that they do
not sag unduly or unequally, and if the height of a platform or stairway is more
than 3.25 metres above ground level or floor level, it shall be closely boarded,
have adequate width and be suitably fenced;
xi) Every opening in the floor of a building or in a working platform shall be provided
with suitable means to prevent fall of persons or materials by providing suitable
fencing or railing with a minimum height of 1 metre;
xii) Safe means of access shall be provided to all working platforms and other
working areas. Every ladder shall be securely fixed. No portable single ladder
shall be over 3 metres in length;
xiii) All scaffolds, ladders and other safety devices shall be maintained in a safe
condition and no scaffold, ladder or equipment shall be altered or removed while
it is in use.
xiv) The Contractor shall take adequate precautions to prevent danger from electrical
equipment.
xv) No material on the Site shall be so stacked or placed as to cause danger or
inconvenience to any person or the public;
xvi) Excavation and trenching: All trenches 1.5 metres or more in depth shall be
considered confined spaces and shall at all times be supplied with at least one
ladder every 30 metres, or fraction thereof. Ladders shall be extended from the
bottom of trenches to at least 1 metre above the surface of the ground. Sides of a

trench which is 1.5 metres or more in depth shall be stepped back to give suitable
slope, or securely held by timber bracing, to avoid the danger of sides collapsing.
Excavated material shall not be placed within 1.5 metres of the edge of a trench,
or half of the depth of the trench, whichever is more. Cutting shall be done from
top to bottom. Under no circumstances shall undermining or undercutting be
done.
xvii) Demolition : Before any demolition work is commenced and also during the
process of the work:
a) All roads and open areas adjacent to the work site shall either be closed or
suitably protected;
b) No electric cable or apparatus which is liable to be a source of danger other
than a cable or apparatus being used by an operator shall remain electrically
charged;
c) The Contractor shall take all practical steps to prevent danger to persons
employed from risk of fire or explosion, and the Contractor shall ensure that
no part of a building shall be so overloaded with debris or materials as to
render it unsafe.
xviii) All necessary personal safety equipment shall be provided by the Contractor for
use by persons employed on the Site and maintained in a condition suitable for
immediate use, and the Contractor shall take adequate steps to ensure proper
use of equipment by those concerned:
a) Workers employed on mixing asphaltic material, cement and lime mortars /
concrete shall be provided with protective footwear, gloves and goggles;
b) Those engaged in handling any material which is injurious to eyes shall be
provided with protective goggles;
c) Those engaged in welding works shall be provided with welder’s protective
eye- shields;
d) Stone breakers shall be provided with protective goggles and protective
clothing and seated at sufficiently safe intervals;
e) Those working with loud machinery or near loud activities shall be provided
with appropriate ear protection such as ear muffs;
f) When workers are employed in sewers and manholes, which are in use, the
Contractor shall ensure that manhole covers are opened and manholes are
ventilated by mechanical means for at least one hour before workers are
allowed entry. Gas detection devices shall be used to ensure the atmosphere
inside the sewer or manhole is safe before man entry is allowed. Manholes so
opened shall be cordoned off with suitable railing and provided with warning
signals or boards to prevent accident to public.
xix) When work is done near any place where there is a risk of drowning, all
necessary equipment shall be provided by the Contractor and kept ready for use
and all necessary steps taken for prompt rescue of any person in danger and
adequate provision made for prompt first aid treatment of all injuries likely to be
sustained during the course of the work;
xx) Use of hoisting machines and tackle including their attachments, anchorage, and
supports shall conform to the following:
a) These shall be of good mechanical construction, sound material and
adequate strength and free from patent defects and the Contractor shall keep
same in good repair and in good working order;

b) Every rope used in hoisting or lowering materials or as a means of

suspension shall be of durable quality and adequate strength, and free from
patent defects;
c) Every crane driver or hoisting appliance operator shall be properly qualified
and no person under the age of 21 years shall be in charge of any hoisting
machine including any scaffold winch or give signals to operator;
d) In the case of every hoisting machine and of every chain ring hook, shackle,
swivel and pulley block used in hoisting or lowering or as a means of
suspension, safe working load shall be ascertained by the Contractor by
adequate means. Every hoisting machine and all gear referred to above shall
be plainly marked with safe working load by the Contractor. In case of a
hoisting machine having a variable safe working load, each safe working load
and the conditions under which it is applicable shall be clearly indicated by
the Contractor. No part of any machine or of any gear referred to above in this
paragraph shall be loaded beyond safe working load except for the purpose
of testing;
e) The Contractor shall notify safe working load of each machine to the
Employer’s Representative whenever he brings it to Site.
xxi) Motors, gearing, transmission, electric wiring and other dangerous parts of
hoisting appliances shall be provided with efficient safeguards. Hoisting
appliances shall be provided with such means as will reduce to the minimum risk
of accidental descent of load. Adequate precautions shall be taken to reduce to
the minimum risk of any part of a suspended load becoming accidentally
displaced. When workers are employed on electrical installations which are
already energized, insulating mats, wearing apparel such as gloves, sleeves and
boots, as may be necessary, shall be provided. Workers shall not wear any rings,
watches and carry keys or other material which are good conductors of electricity;
xxii) Adequate washing facilities shall be provided at or near places of work;
xxiii) These safety provisions shall be brought to the notice of all concerned by display
on a notice board at a prominent place at the work spot. Persons responsible for
ensuring compliance with the safety provisions shall be named with contact
details therein by the Contractor;
xxiv) To ensure effective enforcement of the rules and regulations relating to safety
precautions, arrangements made by the Contractor shall be open to inspection by
the Employer’s Representative and any safety inspection officer.
Notwithstanding the above provisions, the Contractor is not exempted from the
requirements of any other Laws in force.
The Contractor shall submit to the Employer’s Representative for review detailed
proposals under (i) above in conjunction with detailed construction and
installation method statements for each element of work to be undertaken. When
accepted by the Employer’s Representative, and before the work is started, the
Contractor shall distribute copies in English or in other language as appropriate to
all his employees and to the Employer’s Representative.
The Contractor shall ensure that all his employees are fully conversant with the
plans and regulations and the Contractor shall enforce the rule that any employee
committing a serious breach of such plans and regulations shall be instantly
dismissed and shall not be re- employed.
xxv) Minimum requirement for Barricading shall be as per MCGM circular vide u/no.
MGC/F/6342 dt. 05.05.2018 including annexure I, II and III with this circular

(circular is enclosed as Appendix D). Contractor shall provide additional safety

measures required, depending on site conditions and construction methodology.
5.3 Lead in Paint
Paint or other products containing lead shall not be used.
5.4 First Aid and Life-Saving Apparatus
The Contractor shall provide on the Site such life-saving apparatus as may be
appropriate and shall provide, equip and maintain at the Site of the Works first aid boxes
as directed and shall be subject to approval by the Employer’s Representative for the
use of his own as well as Employer’s Personnel on Site.
In addition, the Contractor shall instruct an adequate number of persons permanently
employed at the Site in the use of the apparatus and equipment, and the Contractor shall
make known the persons so designated to all employees by posting their names and
designations in a prominent position on Site.
The Contractor shall advise the Employer of measures to be taken in the event of a
serious accident.
The Contractor shall post a list of emergency telephone numbers (including ambulance)
at several locations on Site.
5.5 Electrical Safety
While any electrical equipment is being installed or tested, the Contractor shall ensure
that all necessary precautions are taken to safeguard personnel working on Site. If
necessary, this shall include fencing off areas that are considered to pose a risk, and
erecting warning notices.
The Contractor shall ensure that the installation of electrical equipment is carried out by
suitably trained competent personnel and that the work is carried out in a safe manner.
No electrical cables shall be laid across rebar. No joints or repairs shall be made to
cables except by suitably trained competent personnel using appropriate protective
equipment. All power sockets used on the Site shall be protected by a residual current
device.
The Contractor shall be responsible for the operation on the Site of a permit to work
system during the period of electrical equipment installation and testing. This system
shall regulate the installation, the energising and the use of electrical Plant installed and
the method of work adopted.
5.6 Asbestos
The Contractor shall not use any product that contains crocidolite (blue asbestos). Prior
to use of any asbestos materials, whether in permanent works or temporary works, the
Contractor shall submit to the Employer’s Representative for review evidence that his
insurance policies provide appropriate cover for the use of asbestos. The Contractor
shall notify the Employer’s Representative of the presence of asbestos on site
throughout the entire Contract Period, including the Operation Service Period. When
handling any asbestos materials he shall comply with all appropriate national and
internationally accepted regulations and codes of practice relating to the handling and
disposal of asbestos.
5.7 Supply of Potable Water and Sanitation Facilities
The Contractor shall, having regard to local conditions, provide on the Site an adequate
supply of fresh and potable water suitable for drinking and other water for the use of the
Contractor’s staff on a daily basis. The Contractor shall also provide proper sanitation
facilities for his staff employed on the site with prior approval from employer

representative for the duration of the Contract.

5.8 Measures against Insect and Pest Nuisance
The Contractor shall at all times take the necessary precautions to protect the
Contractor’s staff employed on the Site from insect and pest nuisance, and to reduce
their danger to health. The Contractor shall comply with all the regulations of the local
health authorities, including use of appropriate insecticide.
5.9 Measures against Sunburn and Heat Exhaustion
The Contractor shall at all times take the necessary precautions to protect the
Contractor’s staff employed on the Site from sunburn and heat exhaustion, including
provision of adequate breaks.
5.10 Alcoholic Liquor or Banned Substances
The Contractor shall not allow alcoholic liquor or banned substances on site. The
Contractor shall not import, sell, give, barter or otherwise dispose of any alcoholic liquor
or drugs, or permit or allow importation, sale, gift, barter or disposal thereto by
Contractor's staff.
5.11 Arms and Ammunition
The Contractor shall not allow arms or ammunition of any kind on the site. The
Contractor shall not give, barter, or otherwise dispose of, to any person, any arms or
ammunition of any kind, or allow Contractor's staff to do so.
5.12 Festivals and Religious Customs
The Contractor shall respect the Country's recognized festivals and religious or other
customs. As a minimum, the statutory/mandatory holidays as declared by the Central
and State governments shall be adhered to by the Contractor.
5.13 Employment Records of Workers
The Contractor shall keep complete and accurate records of the employment of labour at
the Site. The records shall include the names, ages, genders, hours worked and wages
paid to all workers. The Contractor shall summarise these records on a monthly basis
and submit to the Employer’s Representative, and the Contractor shall make these
records available for inspection during normal working hours. The Contractor shall
include these records in the details to be submitted by the Contractor under Clause 6.10
of the Conditions of Contract.
5.14 Repatriation of Labour
The Contractor shall be responsible for the return of persons (recruited and employed for
the purpose of or in connection with the Contract) to the place from where they were
recruited or to their domicile and shall maintain such persons in a suitable manner until
they shall have left the Site or, in the case of persons who are not nationals of and have
been recruited from outside India, shall have left India.
5.15 Epidemics
In the event of any outbreak of illness of an epidemic nature, the Contractor shall comply
with and carry out such regulations, orders and requirements as may be made by the
Government, or the local medical or sanitary authorities, for the purpose of dealing with
and overcoming the same.
5.16 Burial or Cremation of the Dead
The Contractor shall make all necessary arrangements for the transport, to any place as

required for burial or cremation, of any of his expatriate employees or members of their
families who may die in India. The Contractor shall also be responsible to the extent
required by the local regulations, for making any arrangements with regard to burial or
cremation or any of his local employed who may die while engaged upon the Works.
5.17 MCGM Health Department Guidelines
The Contractor shall keep a check on the health of all labour / employees as per MCGM
Health Department Guidelines, including the appointment of a MBBS doctor to carry out
regular checks at the site.

Quality Management System

6 QUALITY MANAGEMENT SYSTEM

6.1 General
The Contract requires the Works to be executed and completed to a uniformly high
quality, to provide a treatment facility that is reliable, economic in operation with ease of
maintenance for the design life specified. The Contractor shall be responsible for
providing and operating his own quality control and checking procedures that shall be
demonstrably independent of those actually responsible for design and construction.
The Contractor shall institute, maintain and operate for the Contract Period a Quality
Management System complying with ISO 9001 as appropriate (accreditation is not a
requirement) or other equal and approved equivalent standard and of the Contract, for
the purpose of ensuring and demonstrating that all aspects of the Works and all other
matters for which the Contractor is responsible under the Contract are carried out in
conformity with the relevant provisions of the Contract.
The Contractor shall make a condition in each and every Subcontract and order for Plant,
Materials and services including design services whereby Subcontractors and suppliers
shall institute maintain and operate for the Design-Build Period a Quality Management
System complying with ISO 9001 as appropriate (accreditation is not a requirement) or
other equal and approved equivalent standard and of the Contract for the purpose of
ensuring and demonstrating the services or goods provided conform with the relevant
provisions of this Contract. Any such Subcontractor or supplier can achieve compliance
with the other provisions of this sub-clause by adopting and operating under the Quality
Management System and the Quality Plan as referred to elsewhere within this section.
The Contractor shall make a condition within each and every Subcontract to provide for
the Employer’s Representative’s access to facilities of a standard sufficient to enable him
to take such actions as he may consider necessary under this Section.
Subject to the other requirements of the Contract the Contractor shall submit to the
Employer’s Representative for review his Quality Management System and his Quality
Plan within the times stated in Section 8.
The Contractor shall comply with the Quality Plan referred to in this section and shall
ensure that:
• the designer complies with the Quality Plan in respect of the design supervision of
the Works;
• the Contractor’s subcontractors and suppliers comply with the Quality Plan referred
to within this Section.
Where the Quality Plan refers to, relies on, or incorporates any quality manual or
procedure or method statement, then such quality manual or procedure or method
statement, or the relevant parts thereof, shall be submitted by the Contractor to the
Employer’s Representative at the time that the Quality Plan is submitted in accordance
with this section. The Employer may require the amendment of any such quality manual
or procedure or method statement to the extent necessary to enable the Quality Plan to
satisfy the requirements of this Section.
The Contractor shall employ, for the duration of the Contract, a Contract Quality
Manager who shall have no other management role under this Contract. The
appointment of the Contract Quality Manager shall be subject to approval by the
Employer’s Representative.
Without limitation to the foregoing the Contract Quality Manager shall be required to:
• Ensure the effective operation of the Quality Management System and the Quality

Plan;
• Audit the Quality Management System and the Quality Plan at regular intervals and
report the findings of such audit to the Employer’s Representative;
• Review the Quality Management System and Quality Plan at intervals to ensure
their continued suitability and effectiveness; and
• Liaise with the Employer’s Representative on all matters relating to quality
management.
Without limitation to any other provision of this Contract, where required by the Employer,
any representative of the Employer may carry out audits of the Quality Management
System (including without limitation the Quality Plan and any quality manuals and
procedures) at approximate intervals of 3 months and may carry out periodic monitoring,
spot checks and auditing of the Quality Management System and Quality Plan.
The Employer’s Representative reserves the right to audit, without prior notice, the
quality of Works and the Contractor’s Quality Management System to verify compliance
with the specified quality requirements. The Contractor shall render every assistance and
provide free and unhindered assistance to the Employer’s Representative or any person
authorised by him to carry out any such audit.
All materials and workmanship shall be of the respective kinds described in the Contract
and in accordance with the Employer’s Requirements or the Employer’s
Representative’s Instructions and shall be subjected to the samples and tests required or
reasonably implied by the terms of the Contract and set out in the method statements, or
which may be ordered by the Employer’s Representative.
The acceptance by the Employer’s Representative of any part of the Quality Plan and
the giving of his consent to the procedures, proposals, records and certificates contained
therein shall not be construed as approval by the Employer’s Representative that the
Works or any part of them have been constructed or manufactured in accordance with
the Contract.
The application of a Quality Management System by the Contractor shall in no way affect
either the Contractor’s other obligations or the powers and duties of the Employer or
Employer’s Representative under the terms of the Contract.
6.2 Principal Requirements of the Quality Plan
The Contractor shall institute, maintain and operate a Quality Management System in
accordance with the provisions of this section. The Quality Management System shall be
as described in a written ‘Quality Plan’ that shall be submitted by the Contractor to the
Employer’s Representative. The principal requirements that apply to the Quality Plan are
set out below. The Quality Plan shall be deemed to be part of the Contractor’s
Documents.
The Quality Plan shall cover but not be limited to the following items:
i) Contractor’s Organisation and management of the Contract;
ii) Contractor’s Control of design;
iii) Contractor’s Method statements and procedures for the Works;
iv) Contractor’s Supervision of the Works;
v) Contractor’s Quality control for the construction of the Works;
vi) Contractor’s Quality control for the Operation Service; and
vii) Subcontractor’s or supplier’s Quality Plans.

The Quality Plan shall show quality hold points where no further works or activity shall
proceed without the written approval of the designated person identified in the related
quality procedure, method statement or works instruction and quality witness points
where no further works or activity shall proceed without the designated person being
given the appropriate notice to visually inspect such works or activity as set out in the
related quality procedure, method statement or works instruction.
The Quality Plan shall contain, or incorporate by reference, documents which contain
requirements to produce quality records which shall include inter alia documents which
demonstrate the achievement by the Contractor of the Contract requirements such as:
• office and site logs,
• records of visits to any location or party in connection with the Works,
• office and site test results,
• records of verification,
• records of all supervision and witnessing with results carried out by the Contractor,
• all certificates and statements required by the Contract in respect of the Works.
Such records shall identify inter alia all design changes to products and specifications
and verification and traceability of all processes in connection with the design of the
Works.
The Quality Plan shall be demonstrated to be capable of controlling, indexing and cross-
referencing records of all drawings, designs, specifications, documents, test results,
certificates and construction documents which have relevance to the Works. The Quality
Plan shall be auditable and be subject to review by the Employer.
6.3 Employer’s Representative’s Monitoring of the Contractor’s Performance
The Contractor shall take due cognisance of any reports from the Employer’s
Representative and action them and integrate them into the Contractor’s working quality
procedures, method statements or works instructions.
6.4 Particular Requirements of the Quality Plan
The Quality Plan shall conform with but not be limited to the requirements shown in
Clauses 6.4.1 to 6.4.7, as follows:
6.4.1 Contractor’s Organisation and Management of the Contract
This part of the Quality Plan for the Contractor’s organisation and management of the
Contract shall include but not be limited to:
i) the definition of the Contract and its documentation;
ii) the organisation of the Contract including the line of command and
communication links between all the parties involved in the Contract in the form of
annotated chart(s);
iii) the names, roles, responsibilities, curriculum vitae and authority of principals and
key personnel involved in the design, construction, operation and maintenance of
the Contract. These will include, where appropriate, the roles undertaken by the
project director, contracts manager, site agent/Contractor’s project manager,
operatives, technicians, analysts, subcontractors, Contract Quality Manager,
representative for environmental protection, general foreman, foremen, engineers,
quantity surveyor, safety officer, Contractor’s and Designer’s supervisor(s) for the
Works, Designer’s team leader(s) and Site representative(s), checker’s team
leader(s), Contractor’s and Designer’s health and safety co-ordinators and any

other principal party involved in the Works;

iv) documented procedures for the control of consultations, liaison and meetings
with third parties including the police, statutory bodies, undertakers and any other
companies;
v) the identification of the Contractor’s staff responsible for overseeing and co-
coordinating each major activity including design, design checks, safety audits
and all Subcontract activities;
vi) documented procedures for the control of Subcontracts which must include the
assessment of the Subcontractor’s quality assurance and quality control
capabilities, the identification and implementation of additional controls needed
on such Subcontractors to fulfill the Contractor’s obligations in respect of this
section and the Contract;
vii) documented procedures for the control of all documentation including inter alia
documentation which has to be provided by the Contractor to the Employer’s
Representative or the Employer;
viii) a programme for submission of designs, associated documentation, method
statements and Quality Plan;
ix) the Quality Plans for Subcontractors and suppliers of work, Plant and Materials
which are the subject of quality management schemes;
x) documented procedures and method statements for the preparation, review and
adjustment of programmes for the effective progression and completion of the
Works in accordance with the other provisions of the Contract and the recording
of same;
xi) documented procedures and method statements for the control and approval of
purchases of Materials;
xii) documented procedures and method statements for the control of off-Site
activities;
xiii) documented procedures for the regular review and recording by the Contractor
which demonstrates that the Works meet the requirements of the Contract;
xiv) documented procedures for the control of personnel selection which demonstrate
that such personnel have appropriate skill and experience for undertaking their
appointed role;
xv) documented procedures for the management review/audits to monitor and
demonstrate control over the implementation of the Quality Plan;
xvi) documented procedures for the quality control of the Operation Service;
xvii) any other relevant item which may during the Contract be brought to the attention
of the Contractor by the Employer’s Representative.
6.4.2 Contractor’s Control of Design
This part of the Quality Plan for the design shall include but not be limited to the
provision of:
i) the names and curricula of the key personnel who carry out the design;
ii) documented procedures and method statements for ensuring compliance with
the Employer’s Requirements;
iii) documented procedures for the review of the design including the frequency of
and personnel responsible for such reviews;

iv) a description of arrangements for the checking of the design and liaison with the
checker;
v) a description of arrangements for the interface with supervision of the Works;
vi) any other relevant item which may during the Contract be brought to the attention
6.4.3 Contractor’s Method Statements and Procedures for the Works
This part of the Quality Plan for the Contractor’s method statements and procedures for
the Works shall include but not be limited to:
i) the names and curricula vitae of the key personnel who will carry out the
management;
ii) a list of Subcontractors to be employed on the Works;
iii) a list of the quality procedures and method statements to be provided;
iv) identification of specialist activities and personnel to be employed carrying out
such activities;
v) arrangements for quality control of purchased Plant and Materials;
vi) arrangements for quality control of all Plant and Materials sourced on or off site;
vii) detailed written method statements for each major activity whether such activities
are directly controlled by the Contractor or subcontracted;
viii) The written method statements shall identify quality hold points and witness
points and invoke for all activities:
a) work instructions;
b) quality control procedures;
c) compliance testing/inspection arrangements; and
d) work acceptance procedure.
Method statements shall inter alia describe each stage of the construction, including the
layout of the Works and of the Operation Service. The method statements shall also
identify the Plant and Materials to be used in the Works, Temporary Works, safety
measures, working space considerations, and where appropriate the requirements for
skilled labour and/or special supervision and similar. Method statements shall show how
the proposed operations ensure that impacts are restricted to the best possible
environmental option and shall include contingency plans and environmental procedures
to minimise damage caused by accidents, spillages or other unforeseen events. The
method statements shall include procedures for notifying the public or statutory bodies
and authorised authorities.
The Contractor shall state where work is subject to environmental requirements, for
example, temperature, noise and dust control, working hours, traffic conditions, vehicle
routings, screening and the like.
The Contractor shall identify “hold points” at stages of work where checks are necessary
before continuing. The authority for release of the “hold points” shall also be identified by
the Contractor in the method statements.
The Contractor shall identify “witness points” at stages of work where such witness
points are required. Such witness points shall include Employer’s Representative’s
witness points. The Contractor shall state in the method statements the notice required
to be given to personnel carrying out such witnessing.

i) The identification of the relevant procedures in the Contractor’s own Quality

Management System. Procedures invoked by method statements shall include
procedures from the quality controls required by the Contractor’s construction
quality control:
a) the control, identification and traceability of materials;
b) procedures for the prevention of inadvertent use, installation or covering up of
non-conforming work; and
c) any other corporate and/or contract specific work instructions to be applied.
ii) Schedules of tests and inspections proposed.
iii) Any other relevant item which may during the Contract be brought to the attention
6.4.4 Contractor’s Supervision of the Works
This part of the Quality Plan for the supervision of the Works shall include but not be
limited to:
i) the names and curricula vitae of all personnel to be employed in the supervision
of the Works;
ii) a description of arrangements for the interface with procedures and method
statements in respect of the construction of the Works;
iii) a description of the interface with procedures for design;
iv) arrangements for liaison and meetings with interested parties;
v) arrangements for the control of personnel selection which shall be based on
consideration of skill, care, diligence and experience qualities;
vi) a statement of the Contractor’s (and his designer’s) responsibility to supervise the
Works including the duty to supervise the construction, completion and testing of
the Works;
vii) documented procedures for undertaking the supervision of the Works detailing:
a) the stages of work when the inspection(s) is to be undertaken;
b) the personnel carrying out the inspection(s);
c) the frequency of inspection(s);
d) the procedures to be followed when detailing with non-conforming works; and
e) the recording of inspection(s)
viii) documented procedures for the review of the extent and frequency of supervision;
ix) documented procedures for the issuing of construction certificates;
x) documented procedures for document control including the receipt, control and
retention of all documents;
xi) documented procedures for reporting progress and the identification of problems;
and
xii) documented procedures for the observation of sampling, testing and the reporting
of results of testing; and
xiii) any other relevant item which may during the Contract be brought to the attention

6.4.5 Contractor’s Quality Control for the Construction of the Works
This part of the Quality Plan for the Contractor’s quality control for construction of the
Works shall include but not be limited to:
i) a statement of the Contractor’s organisation for quality control and shall identify the:
a) responsibility for the initiation and updating of the Quality Plan;
b) responsibility for the adequacy of the quality records produced.
ii) documented procedures for the arrangements for “receiving” and “in-process” testing;
iii) documented procedures for the control of test laboratories;
iv) documented procedures for the control of test, measuring and inspection equipment;
v) documented procedures for document control and shall include their identification,
traceability requirements, control of document issues and their status. Documents
recording the verification, review, approval, release and amendment of the Works
shall similarly be controlled;
vi) documented procedures for monitoring and recording the inspection, test and
approval status of the construction/installed work including the identification of “hold
points”;
vii) documented procedures for tests and inspections for the purpose of the Contractor
certifying that prior to covering up, each part of the Works is complete and conforms
to the Contract. The procedures shall identify the proforma and/or database to be
used for recording the inspection and test results, and the proforma to be used for
recording the certification of compliance of all items of the Works by authorised key
personnel. The Contractor shall identify each submission separately;
viii) documented procedures for the review of work submitted for review but not accepted
as conforming to the Contract. These procedures shall include options for
identification of non-conforming work and proposals for reworking and remedial work;
ix) documented procedures for the collation of quality records;
x) documented procedures for inspection and testing of Plant, Materials and equipment;
and
xi) any other relevant item which may during the Contract be brought to the attention of
the Contractor by the Employer’s Representative.
6.4.6 The Contractor’s Quality Control for the Operation Service
This part of the Quality Plan for the Contractor’s operation and maintenance quality
control for the Works shall include but not be limited to:
i) a statement of the Contractor’s organisation for quality control and shall identify the:
a) responsibility for the initiation and updating of the Quality Plan;
b) responsibility for the adequacy of the quality records produced;
ii) documented procedures for the control of test laboratories;
iii) documented procedures for the control of test, measuring and inspection equipment;
iv) documented procedures for identifying the procurement of Plant conforming to the
design requirements and for ensuring the continued performance to these standards;
v) Documented procedures for identifying the introduction of new legislation, standards,
Laws and regulations and their implementation;

vi) documented procedures for document control and shall include their identification,
traceability requirements, control of document issues and their status. Documents
recording the verification, review, approval, release and amendment of the Works
shall similarly be controlled;
vii) documented procedures for the review of work submitted for review but not accepted
as conforming to the Contract. These procedures shall include options for
identification of non-conforming work and proposals for reworking and remedial work;
viii) documented procedures for the collation of quality records; and
ix) documented procedures for inspection and testing of Plant, Materials, equipment and
any other relevant item which may be brought to the attention of the Contractor by
the Employer’s Representative.
6.4.7 Subcontractor’s or Supplier’s Quality Plans
The Quality Plan for Subcontractors (including suppliers of Plant and Material) shall
include but not be limited to:
i) a definition of the product or service which is to be provided;
ii) annotated chart(s) showing the organisation structure of the Subcontractor describing
the line of command and stating the name of the senior manager responsible for the
contracted work and the name of the Subcontractor’s on-site management
representative. The Subcontractor shall provide contact addresses, telephone
numbers and the like. This must address all activities, including those which have
been sub-let. The Subcontractor shall provide names of any suppliers involved in the
production;
iii) the identification of the relevant parts of the Subcontractor’s Quality Management
System relevant to the product or service being provided;
iv) documented procedures for the control of personnel selection (at Works and on Site),
including special requirements for skilled personnel for example; certification of
welders, training of operatives, experience requirements and the like. The
Subcontractors shall provide evidence that the training and experience requirements
given in the appropriate Quality Management System are being met;
v) documented procedures for the receipt and examination of certificates of conformity
and test results for purchased products;
vi) documented procedures for product identification and traceability. Each piece or
bundle of delivered product shall be indelibly marked and where appropriate, the lot
identification shall be included on each package;
vii) documented procedures for handling, storage, packaging and delivery to Site and
storage and handling on site, including instructions for repair of damaged products
where appropriate; and
viii) documented procedures for compiling records which shall include documents to
demonstrate the achievement of the requirement standard for example; site logs,
record of visits, records of verification, review and release, certificates of conformity
and records of all design modifications to products and specifications.
6.5 Monitoring during the Operation Maintenance Service Period
The Contractor shall develop monitoring and sampling plans as part of Contractor’s
Quality Plan for the Operation Service. These plans shall be implemented to ensure that
all required analyses and reports are completed fully and accurately to exacting
specifications, following standard methods and procedures, in a timely manner and in
support of other performance requirements of the contract.

The plans shall clearly distinguish between the monitoring required to meet regulatory
requirements and the monitoring required to meet the Contract requirements. The plans
shall include:
• A list of all parameters to be monitored as part of these plans. These plans shall
include a schedule of the proposed monitoring quality control requirements,
describing which parameters will be monitored on a daily, weekly, biweekly and
monthly basis.
• A laboratory manual, which shall describe the Contractor’s approach to attaining the
highest standards of laboratory performance. The manual must outline the methods
for each test to be performed. The plan shall identify which tests will be conducted
in-house and those to be performed by Contract laboratories. All laboratories
performing tests shall be subject to approval by the Employer’s Representative. In
addition, the laboratory manual shall specify the type and model of all equipment to
be used in performing all tests by the Contractor.
• Minimum experience and qualifications of individuals or Contract laboratories
performing testing services.
• A description of analysis techniques that will be implemented to ensure that all
regulations and standards are met. The plan must provide examples of any tools
such as flow charts, check sheets or any other data presentation and evaluation
techniques that will be utilised.
• A description of all calibration techniques, quality control procedures, including those
to be utilised for all equipment used for testing and measuring different parameters
within the treatment process and at the in-house laboratory and Contract
laboratories. The description shall address the calibration practices, including the
frequency and accuracy requirements. The calibration procedures shall consider
intermediate spot and cross checks, in addition to the scheduled formal calibration
checks.
6.6 Submission of Quality Plan
Sections of the Quality Plan as far as they relate to the Design-Build Period, shall be
submitted by the Contractor to the Employer’s Representative for his approval within the
date stated in Section 8 for the submission of the Quality Plan, the remaining sections
being provided as soon as practicable thereafter.
Sections of the Quality Plan as far as they relate to the Operation Service Period, shall
be submitted by the Contractor to the Employer’s Representative for his approval within
the date stated in Section 8 for the submission of the Quality Plan, the remaining
sections being provided as soon as practicable thereafter.
The Contractor shall submit the remaining parts of the Quality Plan to the Employer’s
Representative for review at least two weeks prior to commencement of any associated
work or activity and to the programme included with item 6.4.1.
6.7 Review of Nominated Laboratory
Nominated Laboratory shall mean one or more laboratories located on Site or off Site
and used for the purpose of undertaking all tests for acceptance, compliance or payment
purposes, nominated by the Contractor. A Nominated Laboratory shall be nationally
accredited (NABL) or internationally accredited (ISO 9000, NAMAS or similar INAB
standard) for all tests that are to be undertaken. The Contractor shall ensure that the
accreditation is maintained throughout the Operation Service Period. The Nominated
Laboratories shall operate to ISO 17025.
At least one month prior to any testing or analysis at the proposed laboratories the

Contractor shall inform the Employer’s Representative of his intended Nominated

Laboratories and which tests are to be undertaken in each of the Nominated
Laboratories. This may be more than one laboratory. The Contractor shall carry out an
assessment of the Nominated Laboratories to ensure that they are accredited. The
Contractor shall provide an assessment report to the Employer’s Representative for
review.
The Nominated Laboratories shall be subject to the approval of the Employer’s
Representative, which approval shall not be unreasonably withheld.
The sampling gathering and testing protocol(s) shall be based on or equal to the latest
edition of APHA/AWWA/WEF Standard Methods for the Examination of Water and
Wastewater. The accredited testing laboratory shall be fully conversant with these
methods.
“Employer shall nominate one NABL accredited laboratory for conducting independent
tests as per Appendix B of Volume 2. The cost of the testing through this laboratory shall
be borne by the Employer. For payment purposes, the lowest value of COD results of;
• Employer nominated NABL accredited laboratory
OR
• One or more nominated by the Contractor
OR
• Online measurement shall be considered.”

Licenses and Consents

7 LICENSES AND CONSENTS

7.1 General
The Operating Licence signed as part of this Contract allows the Contractor to operate
the Works on behalf of the Employer.
The Employer has consent from the MoEF, GoI to construct a wastewater treatment
facility at Versova.
The Bidder shall provide compliance as per Environmental Clearance from MOEF,
No. 11-49/2007-IA-III Dated 28th January 2008 which is incorporated into the details
contained in Appendix B.
The Employer has consent from the Maharashtra Pollution Control Board (MPCB) in
relation to the discharge of treated effluent for the present facilities.
The requirements of the Environmental Management Plan (EMP) issued by the National
Environmental Engineering Research Institute (NEERI) have been incorporated into the
Employer’s Requirements.
The Contractor shall be responsible for obtaining all consents, permits, licenses and
approvals/clearances (including pending, re-validation and renewals) required for the
project . The Contractor shall also allow sufficient time for the necessary procedures in
his programme. Any delays associated with obtaining any licenses, permits, and
consents shall be the responsibility of the Contractor.
The Contractor shall carry out the Operation Service in accordance with all consents,
permits, licenses and approvals required.
Appendix F contains a sample list of procedures for general construction works. The
Contractor is cautioned that Appendix F is not an exhaustive list. The Contractor shall be
required to identify all other licenses or approvals required.
The Contractor shall submit to the Employer in advance a list of licenses, permits and
consents required for the Contract and the Employer shall determine which of these shall
be in the name of the Employer. However, the Contractor shall bear all costs associated
with the licenses, permits and consents.
In case, during period of operation and maintenance any additional permits, consents
clearances etc. are required due to change in government laws, policy etc, the
contractor shall obtain the same on behalf of Employer and any charges or cost of the
same shall be reimbursed by Employer.
Tenderer shall note that the land under proposed project falls in CRZ II. The project
therefore attracts certain statutory clearances under provisions of relevant Government
Notification/Act, before starting the actual work as the case may be. The Environmental
clearances already obtained by MCGM may require revalidation/renewals/fresh
approvals etc as the case may be. Before submitting the tender, the tenderer shall go
through and study all the documents at MSDP office. Tenderer shall have to obtain all
necessary clearances, revalidation/renewal of necessary clearances. Tenderer shall
comply with all the necessary Government requirements at their own cost before starting
the actual work. No extra cost or additional cost or escalation or cost due to delay or cost
due to overhead or claim on this account will be entertained. Also, no extension in time
period of completion of work will be granted on this account.

Key Programme Requirements

8 KEY PROGRAMME REQUIREMENTS AND STAFFING

The Contractor is required to complete each of the following activities, items of work or
stages in the performance of the Contract in full in accordance with the Contract by the
date or within the period specified for each such activity or item or stage in the table
below. Week numbers refer to weeks after the Commencement Date unless otherwise
stated. Other submissions as specified in the Contract shall be required in addition to the
key submissions identified below.
8.1 Design-Build
Table 8.1 – Key programme requirements during design and build
Date or period by which item is to be
No. Activity/item of work/stage
completed
Submission of programme in
As per Clause 8.3 of the Conditions of
1. accordance with Clause 8.3 of
Contract
Conditions of Contract
Within 28 days of receipt of Notice of
2. Submission of project execution plan
Commencement Date
Submission of controlled copy of Within 28 days of receipt of Notice of

3.
Quality Management System Commencement Date
Submission of Health and Safety No later than 28 days before

4.
Plan commencement of Works on Site
No later than 28 days before

5. General method statement
commencement of Works on Site
Submission of Quality Plan for

6. By end of week 4 (from LOA)
Design-Build
Submission of draft Contractor’s

design report(s)
Submission of HAZOP
recommendations
Submission of all licenses, consents,
clearances, NoCs, etc required for
commencement of Construction
Work
Submission of final Contractor’s
10 By end of week 30 (from LOA)
design report(s)
Submission of construction stage
No later than four weeks prior to
11 documents (excluding method
commencement of that element
statement)
Submission of construction and No later than four weeks prior to
12
installation method statements commencement of that element
Submission of plant delivery No later than three weeks prior to
13
documents commencement of that element

Date or period by which item is to be

No. Activity/item of work/stage
completed
Submission of Testing Plan and No later than 6 months prior to
14 Testing Programme in accordance commencement of the Tests on
with the requirements of Section 17 Completion of Design-Build
No later than 4 weeks prior to
As-built documents submission of
15 commencement of the Tests on
asset sheets
Completion of Design-Build
Draft Operation and Maintenance No later than 8 weeks prior to
16 Plan and Asset Management commencement of Tests on Completion of
Database Design-Build
Final Operation and Maintenance No later than 4 weeks prior to the date for
17 Plan and Asset Management commencement of Tests on Completion of
Database Design-Build
No later than 6 months before the
18 Nomination of Plant Manager anticipated date for commencement of the
Commissioning
Commencement of Tests on
No later than 2 months before the date for
19 Completion of Design-Build
completion of the Design-Build
(Process Commissioning)
Commencement of Tests on
20 Completion of Design-Build (Plant
Proving Period) No later than 6 weeks before the date for
completion of the Design-Build
21 Submission of Quality Plan for
Operation Service
22 Final approved as-built documents
No later than the date set out for the
Final Operation and Maintenance commencement of the Plant Proving
23 Plan and Asset Management Period or 28 days after completion of the
Database commencement of the Commissioning
Final Operation and Maintenance whichever is the earlier
24
Manual
As stated in the Particular Conditions
25 Time for Completion of Design-Build
Part A - Contract Data
8.2 Design Review by Employer’s Representative

The Contractor’s final detailed design including basic engineering and detailed
civil/mech/Electrical/ Structural GAD & datasheets shall be completed within 30 weeks
on prorata basis from the Notice of Commencement. The design review team of the
Employer’s Representative will be available to carry out design review up to 36 weeks
period.
If the Contractor is late in submission of either the draft or final designs for review, or
proposes changes to a reviewed design such that additional design reviews are required,
then the cost of such reviews shall be borne by Contractor.

8.3 Operation Service

Table 8.2 – Programme during operation service
Activity / Item of Work

No. Date or period by which item is to be completed
/ Stage
1. Full implementation of No later than the date set out in the Commissioning
the O&M Plan Certificate in accordance with General Conditions Sub-
Clause 11.7, or 28 days after Completion of the Tests
on Completion of Design-Build whichever is the earlier
2. Service Delivery Initial review report within one month of the date set out
Review Report in the Commissioning Certificate in accordance with
General Conditions Clause 11.7 and subsequent
reviews every 3 months thereafter with a complete
review annually
3. Update of the O&M At least every 3 months and when required to meet
Plan recommendations of the Service Delivery Review
Reports
4. Submission of draft Within 3 months of the date set out in the
O&M Manuals Commissioning Certificate in accordance with General
Conditions Clause 11.7
5. Submission of final Within 6 months of the date set out in the
O&M Manuals Commissioning Certificate in accordance with General
Conditions Clause 11.7
6. Update of O&M At intervals of no more than 12 months
Manuals
8.4 Key Staff ( Design Build Period)
8.4.1 Contractor’s Representative/ Project Manager
The Contractor’s Representative shall be experienced in the construction of large

infrastructure projects and shall meet the minimum requirement as specified below:
• 15 years’ relevant experience
• 5 years’ experience specifically in construction of large wastewater treatment plants
similar size and at least 5 years experience as Project Manager.
• Shall be available till the commissioning of the project
• Shall be present for all the review meetings
• Bachelor Degree in Engineering;
8.4.2 Design Manager
The Design Manager shall be experienced in the design of large wastewater treatment
plants and shall meet the minimum requirement as specified below:
• 5 years’ experience specifically in complete design management of wastewater
treatment with power generation and alternative sludge management facilities of
similar sizes, process technologies, complexity and capacity

8.4.3 Process Expert
The Process Expert shall be experienced in the design of large wastewater treatment
plants and shall meet the minimum requirement as specified below:
• 15 years’ relevant experience in process design and technology selection
• 10 years’ experience specifically in process design of large wastewater treatment
plants with power generation and alternative sludge management facilities of similar
sizes, process technologies, complexity and capacity
• Shall be present for the review meetings as and when required
• Master Degree in Engineering (Environmental / Public Health / Chemical / Sanitary
Engineering);
8.4.4 Lead Planner
The Lead Planner shall be experienced in the planning of construction projects and shall
meet the minimum requirement as specified below:
• 7 years’ experience in planning of large wastewater treatment plants
• Shall be familiar with latest Project Planning tools at least MS Project or Primavera.
8.4.5 Environmental Expert
The Environmental expert shall be experienced in the planning of construction projects

and shall meet the minimum requirement as specified below:
• 5 years’ experience in large wastewater treatment plants for obtaining
Environmental clearances etc.,
• Master Degree in a relevant field;
8.4.6 Sludge Management

Expert
The Expert shall be experienced in the design and execution of large wastewater
treatment plants and shall meet the minimum requirement as specified below:
• 10 years’ relevant experience in process design and technology selection for sludge
management and disposal alternatives
• 7 years’ experience specifically in design of Anaerobic Digesters, Biogas handling
and power generation, process technologies, complexity and capacity
• Degree in Engineering (Environmental / Public Health / Chemical / Sanitary
Engineering);

Design Requirements

9 DESIGN REQUIREMENTS
9.1 Codes and Standards
The Works shall be designed, manufactured, constructed, tested and operated in
accordance with the following standards and codes of practice. In the event of any
conflict the standards or codes of practice shall be interpreted in the order of precedence
given below:
1. As specified in this Contract including those in this Volume 2 – Employer’s
Requirements and in the general technical specifications in Volumes 2A, 2B, and 2C;
2. For Plant and Materials they shall comply with those standards of the country of
manufacture which are relevant to the item concerned, in addition to the standards
cited in the general technical specifications;
3. Relevant standards and codes of practice of India.
Each item of equipment, Plant and Materials shall comply with those standards of the
country of manufacture which are relevant to the item concerned. The Contractor shall
also ensure that each item of equipment, Plant and Materials comply in all respects with
the standards cited in the general technical specifications.
For items which have not been specified in either Indian codes/standards or in this
Contract the Contractor shall ensure the following standards are met:
a) European codes of practice, such as those Euro norms which are codes of practice;
and
b) International Electro technical Commission (IEC) and International Organisation for
Standardization (ISO) of codes of practice.
References in these documents to standards shall be deemed to be to their equivalent
current standard in the event that they have been withdrawn or new more applicable
standards are in force.
References in these documents to standards shall be deemed to be to their equivalent
current standard in the event that they have been withdrawn or new more applicable
standards are in force.
If any design data which are not covered in CPHEEO and Metcalf Eddy documents, the
tenderer can offer design based on, as a minimum, the latest editions of the following:
I. Design
o Manual of British Practice in Water Pollution Control
o British – Water Research Centre (WRc)
o European Standards
o USA- Environmental Protection Agency
o USA-Water Environmental Federation Manuals of practice.
o USA-“10 States” Standards of Wastewater Facilities
o Ministry of the Environment for Design Guidelines for Sewage Works (Ontario,
Canada)
II. Area Classification and Ventilation Requirements
o USA National Fire Protection Agency No.820
o Manuals of British Practice

III. Operation & Maintenance

o Manual of British Practice
o USA Environmental Protection Agency - Considerations for Preparation of
Operation and Maintenance Manuals
o USA Water Environment Federation manuals of Practice
IV. Laboratory Testing Protocol:
o APHA/AWWA/WEF Standard Methods for the Examination of Water and
Wastewater
9.2 Deviations for More Stringent Requirements

Where the requirements of the standards cited in the general technical specifications are
more stringent in any respect than the requirements of the standards, in the opinion of
the Contractor, the proposed manufacturer or any manufacturer or dealer or supplier in
the country reasonably cannot meet these more stringent requirements, then the
Contractor shall submit to the Employer’s Representative for approval a list of all the
deviations from the standards cited in the Contract.
If requested to do so by the Employer’s Representative, the Contractor shall submit to
the Employer’s Representative at least one copy of each code of practice, standard, and
reference work which is referred to in the general technical specifications or elsewhere in
the Contract or proposed by the Contractor. All such documents shall be in the language
stated in the Contract Data in accordance with Clause 1.4 of the Conditions of Contract.
The Employer’s Representative reserves the right to reject any Plant or Materials
manufactured to a different standard which he considers to be unacceptable.
The project delay out of this activity shall be on account of Contractor.
9.3 Technology Incorporation
Only proven technologies shall be incorporated in the Works. The Contractor may only
incorporate new technology in the works subject to his being able to demonstrate each of
the following to the Employer:
• the new technology has a proven track record and plant with new technology shall
be in successful Operation for last 5 years (of similar or higher size and same
application);
• the application of the new technology will not be detrimental to the life of and the
safe, environmentally sound, reliable, cost efficient and correct operation of the
WwTF;
• the incorporation of new technology in part of the Works will not result in any
undesirable incompatibility or monopoly;
• the application of the new technology will yield benefits to the operation and
maintenance of the Works, for example by reducing operating & maintenance costs,
by providing more user-friendly operation, by enhancing the automatic collection and
storage of data relating to the operation and maintenance of the Works, etc.
• Contractor shall arrange for Site Visit for Employer’s Representative (Along with
three Engineers) for witnessing the performance of existing sizable treatment
facilities (India / Abroad) which are based on new technology proposed by
contractor for approval of designs and drawings as a part of design requirement.
Contractor shall consider all cost towards travelling, lodging & boarding etc for at his

own cost.
9.4 Proprietary or Patent Design for Technology Incorporation

All proprietary or patent designs for technology incorporation shall meet the following
additional design requirement apart from the requirements specified elsewhere in this
tender document
• All associated rotating equipment including standby shall be operated with VFD.
• MOCs of all wetted parts, vessels, internal piping and valves within design shall be of
SS316L.
• Design shall have a fully integrated PLC based master control system and same
shall be integrated to main SCADA system that monitor and controls the overall
WwTF.
• An expert from Proprietary or Patent design technology shall be present full time
throughout the installation, startup and commissioning of the facility. Expert shall be
knowledgeable and experienced in all aspects of the design, commissioning and
operation of such system.
9.5 Design Life

Unless stated otherwise in the Employer’s Requirements, the Contractor shall design the
Works such that the expected design life shall be of:
Table 9.1 – Design Life
Expected Design
Item Life
(Years)
Civil engineering and building works (including

50
underground services and pipes)
External pipe work and valves 50
Roads 25
Steel tanks and Support Frames 25
Mechanical - Internal pipe work and valves 25
Mechanical – Rotating machinery and complex

15
equipment
Electrical - Cables 25
Electrical - HT Electrical and Transformers 20
Electrical - LT Electrical, Switchgear 15
Instrumentation 7

PLC system 10
Diffuser Membrane 07
MBR Membrane 10
All Plant, Materials, and equipment utilized in the Works shall be new. No existing Plant,
Materials, buildings or equipment from the facility, or element of the existing facility shall
be reinstalled or reused in the final Works. The Contractor shall look for opportunities to
design Works with a longer design life than those listed above for equipment that is paid
for by the Employer through the Asset Replacement Expenditure Provision.
9.6 Units of Measurement
All correspondence, drawings, data sheets, calculations, labels, nameplates, field
instruments etc shall be expressed in metric SI units where such unit exists.
9.7 Plant Access, Lifting and Maintainability
The arrangement of all works shall include for ease of operation and maintenance:
• Access to all items such as valve operating handles, gauges, sample points, etc to
which access is needed during normal operation;
• Access for maintenance, including suitable lay down areas;
• Access for the removal of each equipment without disturbing adjacent equipments,
and to enable the equipment to be loaded on to a vehicle;
• Access for visual inspections, except in the case of buried pipelines.
The Contractor shall ensure that all working areas have adequate access, lifting
equipment, lighting, air-conditioning, heating and ventilation.
All plant, equipment housings, etc, which may be handled during the course of normal
operations or maintenance, shall be provided with the following facilities:
Table 9.2 – Lifting limits
W ≤ 25kg No special arrangements required
25kg < W ≤ 35kg Arrange for two man lifting
35kg < W ≤500kg Provision of suitably rated lifting equipment
Provision of suitably rated lifting beam with
500 kg< W ≤1 tonne
manual chain block
Provision of suitably rated overhead crane with
1 tonne < W ≤2 tonnes
manual chain block and manual travel
Provision of suitably rated overhead crane with
2 tonnes < W
electric lift and electric travel
Each building which houses process equipment shall include provision for that
equipment to be lifted by a `hoist/crane and extended beam system, such that the
equipment is hoisted within the building and easily moved outdoors (on the same
hoisting system) and can be lowered directly on to or raised directly from a transport
vehicle.
Where it is necessary for the regular delivery of chemicals, fuel, skips, etc. into a building
and/or for the collection of skips, screenings, ash, bag filter residue, etc., each
loading/unloading area shall incorporate a covered canopy structure adjacent to the

access door. The access door may be either an electrically operated / gear operated
roller shutter door or a two leaf outward opening door both designed to suit the hoisting
system. Where it is necessary for large vehicles to enter a building regularly, the building
shall be arranged so that each vehicle can drive through the building without the need to
reverse inside the building. It shall be possible to close both the vehicle entrance and exit
doors while the vehicle is being loaded or off-loaded inside the building.
A pedestrian access door shall be provided adjacent to each vehicle access door.
Vehicular routes within buildings shall be clearly marked and:
• process equipment, pipes, cables etc. shall not be located within 1 metre of a
marked vehicular route;
• appropriate physical protection shall be provided for equipment, pipes, cables etc
located close to a vehicle access route to minimise the risk of damage;
• there shall be a marked pedestrian access route not less than 1.5 metre wide
alongside each vehicular route.
9.8 Drawings
Refer also to Section 4 of the Employer’s Requirements in relation to Contractor’s
Documents.
The Contractor shall provide all drawings with dimensions in metric units.
The Contractor shall use ISO standard size sheets only. All electrical drawings shall
include a key legend of symbols and references used.
All drawings issued by the Contractor shall have a common title block bearing the name
of the Employer, Consultants and the Contractor and shall include the name of the
Subcontractor or supplier where appropriate.
Volume 2D contains the drawings listed below issued for the purposes of illustrating and
clarifying the Works described in the Employer’s Requirements, and which form part of
the Employer’s Requirements:
Table 9.3 – List of drawings
Drawing No. Title

Approach Road from Existing Creek Road to
TCE.10201A-CV-3054-SI-30001
Entrance of Versova WwTF
TCE.10201A-CH-2032-GA-20001 Existing WwTF Layout Plan For Versova
Site Area and Contract Interfaces for Versova
TCE.10201A-CH-2032-GA-20002
WwTF
TCE.10201A-CV-3051-SI-30001 Boundary Wall for Versova WwTF
TCE.10201A-CV-3005-TR-30001
Topographical Survey Drawing for Versova WwTF
(3 sheets)
TCE.10201A-EL-3013-AU-40001
Power Distribution Scheme
(2 sheets)
TCE.10201A-IC-5007-CC-50001 Control System Architecture Drawing
9.9 Climatic Conditions

The Contractor shall ensure the Works are suitable for continuous operation in all

climatic conditions likely to be encountered at the Site. The Contractor shall ensure all
Plant and Materials located outside are suitable for a temperature range of at least 10ºC
below the minimum to 10ºC above the maximum temperatures recorded in the area by
the meteorological service. As a minimum the Contractor shall ensure that all Plant and
Materials are designed and suitable for the following:
• Temperature: 0ºC to + 50ºC
• Humidity: 100% (including enclosures)
• Saline / coastal conditions
9.10 Asset Register
During the design of the Works the Contractor shall develop a numbering system for
each item of Plant and Materials that will be compatible with his proposed Operation and
Maintenance Plan and his proposed Asset Management Database.
The Contractor shall apply the numbering system to the method of physically identifying
each item and to the referencing on the drawings and in the ICA and SCADA design.
The Contractor shall submit the format of asset sheets to be included in the Operation
and Maintenance Manual and Asset Management Database to the Employer’s
Representative for review.
9.11 Labels
All signs, notices, on-site instructions, name-plates, monitors, etc. at the Works shall be
in Marathi, Hindi and English.
All Plant items shall to be fitted with a rating plate, which contains as a minimum, the
manufacturer’s name, the type reference, the serial number, the date of manufacture and
the rating of the machine or Plant item.
All Plant items are to be fitted with a unique name plate bearing the individual plant
reference for the Plant item, e.g. “Blower Motor No. 4”. In the case of removable Plant
items, the name plate shall be fitted alongside the item.
In addition each item of Plant and equipment shall carry an asset number label which
may be electronic to comply with the requirements of the Operation and Maintenance
Plan to be developed.
Name plates and rating plates shall be either traffolyte (black letters on white label) or
316 stainless steel labels stamped with black lettering as directed by Employer
Representative. The lettering shall be of a size suitable for the application, but shall not
in any case be less than 6mm high. All labels shall be visible from an operator access
way.
Each switchboard, motor control centre, ICA panel, pump, valve, etc. and any other item
of Plant and equipment shall be fitted with an identification label with letters not less than
12mm high. Additionally, each individual switch shall have an identification label at both
the back and front of the unit, where applicable. These labels shall carry the
unambiguous switch name and number, in letters not less than 8mm high, which will
denote the service or Plant items which they control.
Fuse or MCB sizes and circuit numbers must be clearly indicated adjacent to each
device to facilitate identification and replacement.
Where more than one power supply is connected to a distribution board or plant item,
clear indication of the danger must be given and the voltage between phases shall be
made obvious by the Contractor
All cables shall be clearly labelled so that their source, destination, and function can be

identified.
All labelling or types of labelling shall be subject to approval by the Employer’s
Representative before installation.
All pipe work above ground shall be labelled with contents and flow direction. Pipe work
of diameter less than 50mm may have tags or clamped signs unless it is less than 1.0m
in length where labelling shall not be necessary.
All storage tanks shall be labelled with contents, sizes and volume. Letters shall be of a
size suitable for the application but shall not be less than 100mm high. Labels shall be
painted at 90 degree intervals at a suitable elevation.
9.12 Hazardous Area Classification
As part of the Contractor’s design, the Contractor shall carry out a risk assessment of the
possibility of the existence of potentially explosive atmospheres during the operation of
the Works by means of a Hazardous Areas Classification.
All zonal classification and Plant and Materials shall be in accordance with
IEC/EN60079-10 series of standards.
Plant shall be of an approved type and be “Ex” rated according to the Hazardous Areas
Classification as necessary.
9.13 HAZOP Studies
The Contractor shall carry out a hazard and operability (HAZOP) study for the Works at
an appropriate stage in the design design and well before start of procurement activities.
Modifications to the Contractor’s design or construction that are required as a result of
the HAZOP shall be implemented by the Contractor.
The HAZOP shall be carried out in accordance with the Indian Standard- HAZARD
IDENTIFICATION AND RISK ANALYSIS—CODE OF PRACTICE IS 15656:2006.
The Contractor shall appoint from his staff the chairman and the secretary for the
HAZOP meetings subject to agreement with the Employer’s Representative. Other
members of the Contractor’s staff familiar with the details of the Contractor’s design shall
attend the HAZOP meetings, as appropriate. These HAZOP meetings shall be held in
Mumbai and the Employer’s Representative shall be given adequate notice to attend the
meeting.
The following shall be included in the studies:
• The design, including all process and instrumentation diagrams, all single line
diagrams, plant layout drawings, pipeline drawings, and block diagrams for the
control system
• An ICA design appraisal including the control philosophy
During the HAZOP study the following topics shall be considered as a minimum:
• Disaster resilience as per the requirements of Disaster Management Act 2005 as
modified.
• the adequacy of the vehicle and personnel access to plant, plant rooms, switch
rooms, control rooms, etc, together with the means of escape – safety aspects such
as confined spaces, areas where high noise levels are expected, etc.
• the facilities for delivering sludge, chemicals, fuel, etc. to the Permanent Works and
for collecting and removing waste materials such as grit and ash
• the facilities for transferring screenings
• the impact of various climatic conditions

• the facilities for removing items of plant for maintenance

• safety facilities such as safety showers, fire alarms, etc.
• operation of the Permanent Works under normal conditions
• the impact of abnormal conditions such as high or low temperature, pressure or flow
on the operation of the Permanent Works
• the impact of an electricity supply failure, cooling water supply failure, etc on the
operation of the Permanent Works
• other topics as determined by the HAZOP study team.
The HAZOP meetings shall be conducted in a systematic manner and the outcomes
shall be recorded by the secretary. A two stage approach shall be used. The first stage
will be carried out at the stage when process and instrumentation diagrams are available
and the results shall then be used to further develop the design. The second stage will
review both the process and instrumentation final diagrams and the ICA systems to
ensure that the overall system design provides adequate operational security.
Following the HAZOP meetings, the Contractor shall consider each of the hazards which
have been identified and assign to it:
• a likelihood of occurrence, i.e. high, medium or low; and
• a severity of the consequences when the hazard does arise, i.e. severe, medium or
low.
From these two factors the overall risk associated with each hazard shall be determined
by the Contractor.
Following this risk assessment, the Contractor shall recommend the action which is to be
taken in relation to each hazard. The Contractor shall submit these recommendations to
the Employer’s Representative for review.
9.14 CHAZOP Studies
The Contractor shall be responsible for the completion of the comprehensive CHAZOP
which shall be undertaken immediately flowing HAZOP studies. The CHAZOP study
shall comprehensively cover all hardware and software of SCADA system provided as
part of this contract along with interfaces with any existing works. The Contractor shall
employ an independent entity, approved by the Employer’s Representative to perform
the CHAZOP study which shall be considered in conjunction with the Employer staff.
The recommendations of the CHAZOP studies should be discussed and finalized with
Employer through CHAZOP Discussion and finalization of the recommendation of the
CHAZOP to be done through conference attended by all concerned parties (The
Employer, The Consultant, The Contractor, and CHAZOP entity). If the CHAZOP study
identifies the need to modify the new works or provide and install further equipment
associated with new or replacement plant items, the Contractor shall do so at no extra
cost to the Employer.
9.15 General Arrangement of Plant
The following general guidelines shall be followed in the preparation of general
arrangement of Plant:
• Minimum 3m of space shall be allowed between units of plant and adjacent Plant or
fixed structures to permit safe and convenient access for operation and maintenance
• An area adjacent to all mechanical Plant shall be provided as maintenance lay down
area

• fixed runways, lifting eyes or other means shall be provided to permit the removal of
Plant that may be required to be removed during the course of its normal operational
life for maintenance or any other purpose;
• areas where leakage is likely to occur whether in normal use or during maintenance
shall be provided with covered drainage channels which shall direct spillage either to
a suitable plant drain or to a sump from where it can be pumped to plant drain.
• All electrical equipment shall be located 500mm above the high flood level elevation
for the site or for the effluent receiving water body, whichever is higher.
• All necessary precuastions and evaluate options to be taken by Contractor to reduce
the cutting of tree.
• If contractor wish to propose multi-stacking of process units then following
parameters shall be ensured:
o Minimum clear height between two process units shall be of 4.5m excluding any
beams and piping arrangement
o Contractor shall take all precautionary measures while proposing such
arrangement
o In case of aeration basin, ensure the arrangement to lift the retrievable diffusers
9.16 Orientation
The works shall be laid out and fully contained within the respective designated site
boundaries so as to logically interface with any and all existing infrastructure or roadways
that may be present at the site and that must remain in service. Contractor’s proposed
site layout shall clearly show the space allocated for all plant components, including
those components and/or unit processes that may be designated for future construction
or installation. Setbacks and clearances from the site boundary shall be provided as
appropriate and as required by local laws and regulations. All existing utilities (including
water, sewer, power, or others, whether overhead or underground and whether
physically located on the site or not) requiring to be relocated to accommodate the
Contractor’s proposed and approved site layout shall be relocated by the Contractor with
the approval of Employer’s Representative and without interrupting provision of such
utility services to users and customers.
9.17 Draining System
All structures, whether liquid-holding or not, shall be designed such that they can be fully
and completely drained and will not float or move when empty, because of groundwater
buoyancy or any other reason. The structures shall be designed to counteract any
possible floatation without the use of any type of groundwater pressure relief valves.
The floors of all liquid-holding structures shall be appropriately sloped and trenches and
drain sumps shall be provided at the bottoms of such slopes to facilitate complete
drainage of liquid. Appropriate drain pipes and valves connected to the drain sump(s)
shall be provided for all structures. Where the drain pipe connects to the structure, the
top-of-pipe elevation shall be at least 150 mm lower than the lowest floor elevation for
the structure. The drain piping shall be routed from the structure being drained to the
plant drain system and shall be continuously sloped downward in the direction of flow.
For liquid-holding structures, the drain piping and fittings shall be sized such that the
entire structure can be drained by gravity in no more than Eight (8) hours.
The plant drain system, Plant drain pumps, and other related equipment and controls
shall be designed and sized to allow draining of the structure with the largest volume
from full to empty within Eight (8) hours. The highest design water level in the plant drain

system shall be at least 300 mm lower than the lowest pipe invert elevation amongst all
drain pipes connecting to the plant drain sump.
Non-liquid-holding areas, structures, or buildings where leakage or other wet activities
can occur, whether in normal use or during maintenance, shall be provided with covered
drainage channels which shall direct the spillage either to a suitable gravity drain or to a
sump equipped with standard dual pumps discharging to the plant drain system.
The Contractor shall automate draining down where appropriate, and shall make
allowance in the treatment stages for return of liquors generated during draining down
and cleaning of the works.
9.18 Standby Requirements

The Contractor shall design the Works such that each stage of the process includes
appropriate standby capacity and bypass arrangements. The works must be designed
such that at Peak Daily Flow any individual unit can be taken out of service for planned
maintenance work without breaching the specified performance requirements. This
requirement includes all process units including biological treatment, settlement tanks
and all sludge treatment facilities.
All mechanical and Electrical rotating equipments shall be arranged in duty/standby
configurations with automated rotation of duty to ensure even wear, and automated
changeover to standby units in the event of plant failure. Standby plant shall be of the
same type and capacity as the duty plant. The following table gives the minimum
standby capacity requirement versus the number of duty plant units.
Table 9.4 – Minimum Standby Requirements

No of duty units Minimum standby (%)
1 100
2 50
3 33
>3 25
9.19 Bypass Requirements

The Contractor shall provide an emergency bypass channel or pipe for the whole of the
Works capable of handling the required Pass Forward Flow (PFF). The emergency
bypass shall lead from a designed emergency overflow at the Inlet Chamber to the
Outfall and include connections from key points like distribution chamber after Grit
removal system, and distribution chamber after Secondary Clarifier in the process such
that in the event of a blockage or complete process failure, partially treated effluent could
continue to be discharged to the creek without overspill and consequent damage to the
Works.
Access points to the bypass (i.e. designed overflow points in the Works) shall include
devices to record overflow events, which shall be logged in the SCADA system.
The Contractor shall not discharge any flows through bypass, except in an emergency
and with the express permission of the Employer for each overflow event.
9.20 Plant Water System
The contractor shall not use any outside water for plant water requirements during
Operation and Maintenance service.The entire plant water requirement shall be taken
from Treated water storage tank and shall be used for multiple applications including but

not limited to all chemical solution preparation, motive water system, thickener dilution
water, general cleaning and flushing needs also for landscaping requirements.
Plant water should meet no detectable Fecal Coliform standards wherever it has
possibility of direct or indirect human contact.
Plant water shall be further treated to meet the specific process water requirements of
WwTF. The plant water system shall be designed to provide adequate water pressure for
all of the selected applications.
The Contractor shall provide a pressurised plant water booster system to supply plant
water to appropriate treatment systems throughout the Works via a pressurised plant
water ring main. The Contractor shall design the plant water booster system to maintain
a minimum pressure of 2.5 bar at the farthest point on the ring main from the booster set
under conditions of maximum plant water in use.
The plant water ring main shall provide hose connection hydrants where required for
cleaning of principal process units and equipment. The Contractor shall identify potential
points of spillage and shall provide hose connection hydrants for washing down within
buildings and areas where sludge or liquor spillage may occur. The hydrants shall be
specially identified as “Non-Drinking Water”:
Any washwater used for cleaning equipment, vehicles or contaminated areas shall be
drained and returned to the main wastewater stream for treatment.
Pressure gauges complete with isolation valves shall be provided and fitted by the
Contractor to all delivery lines and booster set pressure vessels
9.21 Potable Water System
Contractor shall propose the potable water requirement for entire WwTF which also
include water requirement for safety shower.
The Contractor shall provide a separate booster set to supply potable water to a potable
water ring main. This water shall be drawn, via a break tank, from the mains feed to the
Site. The break tank shall be included with the potable water booster set. The potable
water booster system shall be designed to maintain a minimum pressure of 2 bar at the
furthest point on the ring main from the booster set under conditions of maximum water
use.
The Contractor shall provide separate suction pipe work for each booster set pump
complete with isolation valve, non-return valve and strainer.
Pressure gauges complete with isolation valves shall be provided and fitted by the
Contractor to all delivery lines and booster set pressure vessels.
Contractor shall arrange for Site Visit for Employer’s Representative (Along with three
Engineers) for witnessing the performance of existing sizable treatment facilities (India /
Abroad) which are based on new technology proposed by contractor for approval of
designs and drawings as a part of design requirement. Contractor shall consider all cost
towards travelling, lodging & boarding etc for at his own cost.
9.22 Clean Development Mechanism (CDM)

The potential to reduce the emission of Green House Gases (GHGs) and the associated
prospect of Carbon Credits through the CDM encouraged by MCGM to incorporate the
methane capture and power generation components into the design of proposed WwTF.
The WwTF will incorporate facilities for methane capture and gas based power generation
as already explained which is expected to significantly reduce the GHG emissions. The

utilization of bio gas for power production causes reduction in emission of Methane, one of
the GHG, into the Atmosphere. As per the Kyoto Protocol, all the new STPs are eligible for
Carbon Fund under the CDM for the reduction of GHG.
The contractor shall submit documents (on behalf of the Employer) to the Ministry of
Environment and Forests (MOEF), Government of India and obtain Host Country Approval.
Subsequently this CDM project will be under validation. After validation this project has to
be registered with the United Nations Framework Convention on Climate Change
(UNFCCC), the authorized body for issuing Carbon Credit. So it is the contractor’s
responsibility to initiate and continuously follow up with the relevant Authorities and
expedite the approval process at different stages and to ensure timely registration for
availing the benefits of carbon credit from the day the plant put to operation.
9.23 Renewable Energy Certificates

Renewable Energy Certificates (RECs) are a policy mechanism to promote renewable
energy based power generation in India. This project has the potential to be eligible for
RECs. If the project proves to be eligible for RECs, the Contractor shall apply on the
Employer’s behalf for RECs for all of the energy produced on Site and shall assist the
Employer in all aspects of the set-up of the REC mechanism.
The RECs shall be in the name of the Employer. The Employer shall reimburse the
Contractor for 50% of the value of the RECs. However, the Contractor shall not rely on this
as a source of income and this benefit shall not be taken into account by the Contractor in
his calculation of the rates for the operation service (which include energy costs).
9.24 Ventilation and Air Conditioning
The Contractor shall provide control rooms with PLC installation with appropriate air
conditioning systems which maintain the rooms at positive pressure with respect to
process areas.
The electrical/switch rooms shall be provided with proper ventilation.
Any access ways from the process areas to electrical rooms shall be by means of a
double door system which will act as an airlock with positive pressure. The design shall
also prevent surface condensation which may otherwise cause corrosion.
Each blower stage in the ventilation systems shall be supported by a standby, with
automatic starting of the standby unit at failure of a duty machine.
To limit power consumption and minimise the risk of noise nuisance, the velocity of the
air through the ventilation ducting shall not exceed 8 m/s.
The ducting shall be manufactured from suitably corrosion resistant material. Galvanised
steel will not be acceptable.
Mechanical and natural ventilation rates shall take into account any requirements arising
from the conclusions of the Hazardous Areas Classification.
9.25 Room Area Classification
For the purpose of ventilation & air conditioning enclosed spaces shall be divided into
two categories:
• Comfort air-conditioning areas
• Forced mechanical ventilation areas
Comfort air-conditioning areas - Areas such as SCADA, control rooms, ,
administration buildings, etc. require comfortable conditions. These shall be maintained
at a comfortable temperature for operators and shall be supplied with filtered air. For

comfort air-conditioning the temperature will be maintained at 22 ºC ± 2 ºC.

Forced mechanical ventilation areas - In this type of ventilation system the air
movement is produced by mechanical equipment such as fans / blowers and shall
ensure that air pressures are negative. All areas covered under this ventilation system
shall be designed to facilitate the subsequent addition of odour treatment. The following
circulation air changes per hour shall be used as a minimum standard for system design:
Table 9.5 – Air changes
Minimum Air
Areas/System
Changes Per Hour
Inlet Chamber 12
Screen Chamber 12
Grit Removal Chamber 12
Sludge Treatment Buildings 12
Digester blower/pump building 12
Chemical Building 15
Other area as identified by contractor 12
Ventilation design shall provide for the dissipation of heat generated by electrical
equipment.
9.26 Odour Control
The Contractor shall design the Works to ensure that odour release shall minimised to
reduce the risk of odour nuisance or complaints outside the Site. The Contractor’s design
shall avoid cascading flows and the design shall provide for cleaning systems for odour.
The Contractor’s design shall also meet standards as per the latest version of WPCF
MOP-1.
All preliminary units and Sludge Handling Units shall be provided with Odour control
system.
The concentration of H2S and CO in the air inside buildings within the boundary of the
Site may be measured by the Employer at any time using hand-held instruments.
The concentration of CO inside buildings and at the plant boundary must meet the
standards set out in the current version of the National Ambient Air Quality Standards
issued by the Central Pollution Control Board.
The report of the model shall include the assumptions made with respect to the odour
emissions. The odour control unit(s) to be installed at the proposed WwTF may be a
single central unit or a number of units located locally to the odour source.
Contractor shall provide Both the duty and standby odour control units as shall be rated
for 100% of the applied odour loading.
The odour treatment systems shall consist of any one of the following processes;
• Chemical Scrubbers with standby arrangements
• Activated Carbon Polishing Filter Systems
• Bio filters/Bio scrubbers

Contractor shall have sufficient number of field olfactometer to detect odour within WwTF
facilities and at boundary so as any abnormal increase of odour threshold can be
avoided.
9.27 Modular Design Approach

All WwTF components that are not easy to replace or expand in the future, including but
not limited to:
• All Below ground wet wells or other below-ground structures
• All Header pipes
• All interconnecting Channels and Pipes
• All process buildings
• All electrical buildings
• PLC/SCADA rooms
• Admin Buildings
• Laboratory rooms
• Collection and distribution and other common channels and pipes and final outfall
structure
shall be designed and constructed to provide the ultimate build out design capacity in
this contract.
For WwTF components that can be easily expanded in the future, the design and
construction of the initial design capacity under this contract shall be performed such that
future expansion to the ultimate build out capacity can be accomplished easily and in a
modular manner while maintaining the initial capacity fully operational at all times.
Space shall be reserved within the WwTF site boundary for the required future modules,
and the design shall include features (including but not limited to caps or blind flanges for
common header pipes) that will allow easy future extension/expansion with minimal
disturbance to initial components.
The contractor submittals and drawings shall clearly show and describe such features as
well as the space reserved for future expansion.
Further, for all components under this contract, the capacity to be provided shall be
designed and constructed using multiple, suitably sized unit process modules to ensure
reliability, redundancy, and appropriate turndown for optimum capacity utilization and
process efficiency.
As a minimum contractor should follow the below specified methodology for arriving the
minimum number of working process units unless specified otherwise:
• Average flow that shall be limited to each module design shall be of 60MLD.
• All modules shall be hydraulically connected to each other such that when one
module or unit in module takeoff for maintenance then same flow can be diverted to
other working module without effecting the overall performance of the facilities.
• For liquid operation there shall be a minimum of two (2) working process unit for each
module, unless and otherwise specified.
• For sludge operation there shall be a minimum of one (1) working process unit for
each module, unless and otherwise specified.

9.28 Noise Control

Noise evaluation model shall be carried out to demonstrate with supporting calculations
that internal, external and site boundary noise levels shall be complied with as per tender
requirements. All plant items and piping that generate significant noise shall be included
in the model taking into account the following aspects to demonstrate the suitability of
the design:
• Critical combinations for plant operation
• The arrangement and acoustic properties of plant room walls and doorways
• The layout of plant rooms and external plant items within the site
• The effect of the wind temperature and humidity on the predicted noise levels at the
site boundary
Based on model design output and recommendations all mechanical equipments,
buildings and noise generating piping locations shall be provided with acoustic
enclosures or sound deadening arrangements where appropriate to ensure that the
noise level from the plant when operating at its design capacity shall not exceed limits
specified in tender document.

Process Design

10 PROCESS DESIGN
10.1 General
10.1.1 Design Requirements
The Contractor is responsible for the complete design and construction of the Works and
for the subsequent provision of the Operation and Maintenance Services in accordance
with the Contract. The Contractor shall select the type, number, sequence and
configuration of process units needed to achieve the effluent standards. The Contractor's
design of the Works shall be in accordance with these Employer’s Requirements and
shall satisfy the performance requirements contained in Section 18 and all other
requirements of the Contract.
The Works shall be capable of conveying and treating the maximum flows and loads
specified in Appendix B1 to the standards specified.
The Works shall have capacity to convey through the treatment processes to the outfall
structure the Pass Forward Flow (PFF) specified in Appendix B1 without overflow. The
Contractor shall determine the diurnal variation and other variation factors and take
consideration of these in his design.
The Contractor shall not stop or reduce the delivery of flows from the sewerage network
to the wastewater treatment works. The Contractor shall not discharge any flows through
an emergency bypass, except in an emergency and with the express permission of the
Employer’s representative for each overflow event.
The estimated current Dry Weather Flow as given in Volume V- Background Information,
is anticipated to increase during the Operation and Maintanance Service. The
Contractor’s design shall accommodate variations in plant loading during the Operation
and Maintanance Service Period. The Contractor shall make no limiting assumptions in
relation to the timing and rate of any increase in flow and loading and shall not infer any
linear increase in the loading to the Works.
The Employer does not guarantee the wastewater flows and loads which will be
delivered to the WwTF. Flows and loads may be lower than the current estimated flows
and loading. The design of all process units shall be equally distributed in streams
(each of equal capacity) to accommodate variations in plant loading and flows during the
Operation Service Period. Streams shall be operated as per incoming flows. The Works
including each stream, shall be designed by the Contractor to be capable of accepting a
range of incoming flow rates and loads up to and including the Pass Forward Flow (PFF)
and Loads specified in Appendix B1 whilst maintaining the performance requirements
stated in clause 18.
The Contractor shall also allow in his hydraulic and process design for the full treatment
of recirculation flows (and associated loads), including but not limited to the dirty
washwater from the screenings and grit treatment systems, supernatant and filtrate,
centrate and miscellaneous other liquors from the sludge treatment processes in addition
to any other relevant design parameters not specifically identified here whilst maintaining
the performance requirements stated in Section 18.
The Contractor shall minimize as far as possible the use of proprietary equipment or
processes which will require inputs from third parties throughout the Operation and
Maintenance Service Period.
The process units shall be selected based on minimum process design parameters given
in this section. All tenderers shall complete and return the schedule of design parameters
with their tenders – no deviation from the minimum design parameters shall be accepted

without written approval from the Employer.
10.1.2 Influent Characteristics
The characteristics of the wastewater arriving at the works are influenced by

contributions from storm water and tidal water infiltration to the collection system. The
tidal infiltration can create elevated chloride and sulphate concentrations in the
wastewater. The Contractor shall ensure that the process design is appropriate for these
conditions and that materials used in the construction of the Works are resistant to
corrosion resulting from elevated levels of chlorides and sulphates in the influent.
The Contractor shall provide protective coatings in accordance with Section 14.12 to
protect structures and equipment from corrosion due to the presence of hydrogen
sulphide gas, including in open structures.
10.1.3 Design Standards
The Contractor shall ensure that treatment processes provided are based upon
technically proven processes.
The design shall be based on Employer’s Requirement. For any further technical /design
parameter, which is not specified in Employer’s Requirement or other Tender Volumes,
the Tenderer shall follow the latest Indian (CPHEEO) Manual on Sewerage and Sewage
Treatment and latest edition of Wastewater Treatment and Reuse- Metcalf & Eddy.
If any design data which are not covered in any of the above documents, the tenderer
can offer design based on relevant applicable standard or guideline.
10.1.4 Process requirements
The following main treatment processes are envisaged in the Contractor’s design of the
works:
• Distribution Box
• Inlet Chamber;
• Preliminary treatment (screening & grit removal);
• Parshall Flume (If required) or Flow mearsurement
• Primary Settlement (If required)
• Biological treatment
• Secondary Settlement
• Disinfection;
• Tertiary Treatment for Recycle & Reuse
• Outfall channel with flow measurement
• Sludge Thickening
• Sludge Pre-treatment (if required)
• Anaerobic sludge digestion and biogas storage including flare system (If required);
• Energy recovery using digester biogas
• Sludge dewatering;
• All chemical dosing and handling system with storage
• Plant drainage system
• Plant water system
• Potable water system
• Storage of reuse water with facilities as defined

• Odour control units

• Storage and transporation of sludge including safe disposal of all screenings and
grits.
• Bypass arrangements
The provision of Primary Settlement Tanks is as per bidder’s design requirement. The
bidder can consider it to increase biogas production and energy recovery can be
achieved from primary sludge and reduce the biological load in secondary treatment.
The Works at the treatment facility shall also include, but not be limited to, the items
listed below:
a) Wastewater treatment facilities:
• Transfer of flows via open flow channels and underground conduits;
• Flow measurement at locations in accordance with Section 10.123;
• All ancillary mechanical and electrical installations associated with the main
treatment processes;
• Suitable and appropriate lifting equipment for maintenance and operation;
• Potential septicity treatment (if required);
• Facilities for collection of bags, skips and containers, wherever necessary;
• SCADA system, telemetry and alarm equipment;
• Provision of electricity, water and other utilities and services to the Site;
• Cabling, and all electrical installation equipment and materials;
• Process control, monitoring and instrumentation;
• Provision of testing and laboratory facilities;
• Provision of spare parts.
All on-site civil engineering works associated with the wastewater and sludge treatment
facility including:
• Administration buildings;
• Approach and all plant site roads;
• Landscaping and planting of the Site;
• Site drainage, run-off and internal building drainage;
• Security systems including guardhouse, CCTV, boundary wall and access gates.
b) Screening and grit disposal, Treated sludge storage and transportation
• Sludge storage facilities
• Sludge handling facilities;
c) Operation and Maintenance Service
• Operation and maintenance of the constructed Works by the Contractor for a period
of 15 (Fifteen) years.
10.1.5 Site Layout Restrictions
The Contractor’s design shall take account of the following Site restrictions:
Existing WwTF operating units: The area demarcated in Drawing No.TCE.10201A-
CH-2032-GA-20001 (shown hatched) shall not be accessed by the Contractor. The
Contractor shall plan all his activities and Works within the demarcated site area for
WwTF (Refer Drawing No. TCE.10201A-CH-2032-GA-20002). Contractor may obtain the

prior permission from Employer Representative to get access to such area if required.
Proximity to reserved forest area: The proposed Site for Versova is surrounded by
reserved forest. The Contractor shall ensure that all his activities are restricted to the
designated Site and shall not carry out any activities which may be detrimental to the
reserved forest. Any activity outside the Site may require permission from the
appropriate authority in the forest department.
Location of entrance gate and associated guardhouse: The Contractor shall
construct an approach road as shown on the Drawing No. TCE.10201A-CV-3054-SI-
30001 and shall construct an appropriate gate and guardhouse adjacent to the new
Works access.
Location of internal roads: The Contractor shall design his layout to facilitate vehicular
access to all process units, all buildings and all necessary elements of the works.
Tree Authority requirements: It is a requirement of the Contract that the Contractor
obtains consent for removal of any trees and shall follow the instructions of the consent.
The Contractor shall allow an appropriate amount of time in his programme for liaising
with the authority, including organising a Site visit with the authority, and obtaining the
necessary consent. If any trees in the plant premises are to be removed (it should be
minimum) The Contractor shall transplant the same number of trees, or replant Five
times the number of trees cut or as directed by Tree Authority, either on site or
elsewhere as directed by the Tree Authority. If any transplanted trees do not survive, the
Contractor shall be required to replant five times that amount of new trees or directed by
Tree Authority. Newly planted trees which do not survive shall be replaced with equal
numbers of new trees.
The Contractor shall consider the cost of compliances, including finding the suitable land
in case of transplantation, prescribed by the the Tree Authority in their contract price.
10.2 Inlet Chamber

The Contractor shall provide an Inlet Chamber to receive incoming flow and same shall
be designed for Pass Forward Flow (PFF) plus any waste streams (Centrate, wash water,
drain flows etc.) designed to be returned to the head of the Works.
The inlet chamber receives the flows from outlet (Gravity Pipe Diameter 2000 mm) of
new IPS terminated at the boundary of WwTF facilities from where contractor to takes
the flows to Inlet chamber. Provision shall be made for the measurement of received flow
at each inlet chamber.
Total Design Flow : PFF with recycle stream
Shape : Rectangular or tapered
Minimum No of units : 2Nos (One at each stream of lagoons)

10.3 Preliminary Treatment
10.3.1 Screening
The Contractor shall provide mechanically operated screening equipment. suitable for
open channel type flow. Manually operated screening removal system is not allowed.
The Contractor shall provide a sufficient number of appropriately sized units operating in
parallel to meet the Employer’s Requirements for the Flows and Loads specified in
Appendix B1.

The Contractor shall provide a means of isolating each screen with motorized
penstocks (upstream and downstream of each screen) capable of manual operation.
During normal operation, The screens shall be equipped with an automatic cleaning
system to prevent blockage. The Contractor shall ensure that the screen cleaning
system can be operated intermittently and can be controlled by both an adjustable timed
cycle and a pre-set differential head across the screen using ultrasonic level sensors.
The screens shall be designed to achieve a capture rate of at least 90% of particles
greater than 6 mm in 2 dimensions
The Contractor shall ensure screenings removed from the flow are washed, dewatered
and compacted, or equivalent, to achieve a minimum dry solids content of 30%.
The compacted screenings shall be free of faecal matter. In order to minimise odour
nuisance, the Contractor shall store the screenings in suitable enclosed containers. The
capacity of the screenings treatment plant shall be adequate to treat the peak screenings
loads, which may occur during monsoon. The Contractor shall demonstrate that this has
been taken into account in the design of the screenings handling system.
The Contractor shall remove screenings from the Site in sealed bags/containers
designed to ensure no release of odours or liquid to the environment along the route to
the disposal location.
The Contractor shall make provision for storage of empty screenings containers/bags on
the WwTF Site. These containers shall be thoroughly clean and odour free.
The Contractor shall be responsible for the safe transport and disposal of screenings to a
legal, licenced Landfill Site.
Design Flow : PFF with recycle stream
Type of Screen : Mechanical Rake Bar
screen/StepScreen/
Drum Screen/Any other
suitable type
Screening Size : 6 mm for Non Membrane
technology
Max. 2 mm for Membrane
technology
Maximum Head loss at 50% Blocked condition : 300 mm
MOC of screen : SS 316L
Angle of inclination of screen : 70 to 80 Degrees

Maximum velocity through screen opening at PFF flow : 1.2m/s
Minimum upstream straight length of channel : 4 times of width of the

screen channel
Minimum downstream straight length of channel : 2 times of width of the
screen channel
10.3.2 Grit Basins and Grit Washers and Classifiers
The Contractor shall provide grit separators downstream of the screens and no manual
grit removal system is allowed.

The Contractor shall provide a sufficient number of appropriately sized units operating in
parallel to meet the Employer’s Requirements for the Ultimate Flows and Loads specified
in Appendix B1.
The Contractor shall provide a means of isolating each separator with motorised
penstocks (upstream and downstream) capable of manual activation and operation.
The grit separators shall be capable of removing at least 95% of particles with a specific
gravity of less than 2.65 and with a minimum size of diameter of 0.20 mm although 0.10
to 0.15 mm is preffered.
The Contractor shall design the dewatering system to achieve an organic matter content
of less than 10% of the dry solids content (in the cleaned grit) measured on a weight
(w/w) basis.
The Contractor shall return the dirty water from the grit separator to the main inlet flow.
The Contractor shall design the grit separation, grit handling, loading and collection units
to minimise odour nuisance. The Contractor shall be responsible for the storage,
transport and safe disposal of grits and the Contractor shall design the facilities to
prevent release of odour and liquids to the environment.
The Contractor shall make provision for storage of sufficient number of containers on the
WwTF Site. The Contractor shall ensure that these containers are kept thoroughly clean
and odour free when empty. The container design shall be suitable to lift/unload/
transport through refuse vehicle so that screenings/grit shall not spill/fly away.
Design Flow : PFF with recycle/return streams
Type of Grit Removal System : Vortex with Screw classifiers

MOC Grit / Classifier Mechanism : SS 316L
Minimum grit load : 60L/ML
10.4 Primary Treatment
10.4.1 General
Primary settlement tanks are required to collect primary sludge for improving the
effectiveness of sludge digestion and biogas generation and to reduce the biological load
on secondary treatment.
The Contractor shall provide a sufficient number of appropriately sized primary settling
tanks of conventional type with circular central column supported with central drive or
Lamella plate settler type or any other proven primary treatment system.
Primary treatment system shall operate in parallel to meet the Employer’s Requirements
for the Flows and Loads as specified in Appendix B1. The Contractor shall ensure that
the design can adequately manage the full range of flows expected at the treatment
facility, in conjunction with the requirement for individual process units being taken offline
for maintenance in accordance with requirements specified elsewhere in tender
document.

Each Primary treatment system shall be fitted with a scum collection & removal system.
The system shall be designed to minimise the volume of liquid discharged with the scum
whilst providing efficient removal of the scum.
The automatic desludging shall be designed to discharge sludge containing minimum 2
to 3% dry solids concentration.
Each sludge line shall be equipped with magnetic type flow meter with spool piece
arrangement and all flow events shall be recorded and controlled through PLC/SCADA.
The design of the primary settlement tank sludge draw-off pipe work and the location of
the pumps (if required) shall ensure a positive head on the pump suction during normal
operation. The sludge head loss calculations on all sludge pipe work shall take account
of the sludge characteristics including the variations in viscosity arising from changes in
the dry solids content of the sludge (for example, by using the methods described in the
recommendations of “How to Design Sewage Sludge Pumping Systems”, Technical
Report TR185, WRc). The configuration of the sludge draw-off pipe work shall allow for
easy access for clearance of blockages in the event of sludge consolidation occurring.
Design Flow : PFF with Recycle/Return Streams
BOD removal : As per CPHEEO/Metcalf Eddy

TSS removal : As per CPHEEO/Metcalf Eddy
Weir Loading : As per CPHEEO/Metcalf Eddy
Number of Scum pit : Minimum 2 Nos
Primary Scum Pit Volume : 80 M3 Each
10.5 Biological Treatment
10.5.1 General
Biological treatment systems shall observe the design parameters from internationally
recognized references, including the latest CPHEEO Manual.
The biological treatment shall be designed based on the average flow with Recycle/
Return Streams (if any) and with hydraulic considerations for PFF with Recycle/ Return
Streams (if any).
The Contractor is permitted to offer any biological process with proven technology.
Regardless of the biological treatment selected, the minimum design parameters shall be
achieved and the final settlement tank design shall be based on flux theory.
The treatment processes listed below shall not be accepted
• Oxidation pond (facultative/anaerobic/aerobic)
• Aerated Lagoons
• Trickling filters
• Oxidation ditch
• Rotating Biological Contactors (RBC)
• UASB

• Waste Stablisation Pond

The proposed technology shall be supported with detailed process and methodology in
sequences along with permissible design parameters, components, and technical
specifications with other process loading data confirming to standard operating manuals
in consonant with international standards or latest CPHEEO manual meeting project
requirement with specified size of each units with conceptual layouts.
10.5.2 Activated Sludge Process (with Biological Nutrient Removal-BNR)
Activated sludge process with BNR removal shall be, based on a series of rectangular
tanks in parallel with all of the influent wastewater and Return Activated Sludge (RAS)
and Mixed Liquor Recycle (MLR) to each tank.
Each basin shall be physically divided into anaerobic, anoxic, and aerobic zones. The
anaerobic-anoxic and anoxic-aerobic zone interfaces shall be concrete partition walls. All
anaerobic and anoxic zones shall be provided with mechanical submerged
mixers.Individual volumes of each basin shall be as per contractor design based on
parameters outlined in Appendix B, however it shall meet the overall minimum
requirements as specified herein.
The Contractor shall ensure that the design can adequately manage the range of flows
and loads expected including recycle streams, in conjunction with the requirement for
individual process units being taken offline for maintenance.
The Contractor shall design activated sludge systems to maximise the settleability of the
mixed liquor in downstream settlement tanks.
The Contractor shall minimise dead spots within the aeration lanes by providing baffle
walls and fillets to corners of tanks where necessary. The size of any fillets at the base of
walls shall be kept to a minimum in order to maximise the area of horizontal aeration
tank floor available for installation of the aeration system.
The Contractor shall provide suitable arrangements for draining the aeration tanks. The
Contractor shall design the inlet and outlet channels and/or pipe work with isolation gates
to permit any of the individual aeration tanks to be taken out of service.
Design Flow : Average flow including Recycle/Return

Streams (If any) and with hydraulically
catering capacity considerations for
PFF including Recycle/Return Streams
(if any )
Minimum Free Board : 0.6 m
RAS flow ratio : As per CPHEEO/Metcalf eddy

MLR ratio : As per CPHEEO/Metcalf eddy
Anaerobic/Anoxic/Aerobic HRT : As per CPHEEO/Metcalf eddy
Mixing for Anaerobic and Anoxic zone : Submersible mixers with 10W/m3
power output

Aerobic Zone DO : 2.0mg/L

Peak factor for AOTR : 1.2
Type of Aeration : Diffused air, Fine bubble membrane,
tubular or disc, retrievable/fixed
Membrane material : EPDM or silicone elastomer with UV
protection or PU Membrane or
Chlorinated PE”
Max Alpha Factor, α : 0.60
Max Beta Factor, β : 0.95
Max Fouling factor, F : 0.80
Aeration system sizing basis liquid : Max liquid temp.
temperature
Aeration system sizing basis air : Max air temp.
temperature
SOTE per unit diffuser submergence at : As per Guaranteed by the
peak air flow (min to be provided and manufacturer (Bidder to include in his
max to be used as design basis) bid a letter from the manufacturer of
the diffuser, giving reference of this
project, guaranteeing the SOTE of the
proposed diffuser system, the minimum
guaranteed service life of the diffuser
and the head loss during the last year
of diffuser’s service life.)
10.5.3 Secondary settling tanks
The secondary settling tanks shall be circular radial flow tanks or any other proven type .
The mixed liquor discharges from the aeration tanks shall be collected together and
redistributed to the secondary settling tanks using equal non-submerged weirs of
appropriate length.
For circular radial flow tanks the inlet pipe shall discharge within a stilling box or diffusion
mechanism located at the centre of the tank and this shall occupy a minimum liquid
surface area of 5% of the liquid surface area of the tank. Stilling box / baffle to extend to
a minimum of 50% of the tank sidewall depth and extend to a height 300 mm above the
water surface. A submersible pump shall be used to provide a spray bar for flushing in
settling tank.
The design solids retention time in the sludge hopper of secondary clarifier shall be
based on a minimum of 1 hour-storage of average sludge production.
Each secondary settling tank shall be fitted with a scum collection & removal system.
The system shall be designed to minimise the volume of liquid discharged with the scum
whilst providing efficient removal of the scum. All the scum shall be properly screened
separately in accordance with screening requirements specified in tender document and
liquid stream shall be sent directly to the sludge holding tank using an automated
pumped system.
The secondary settlement tanks shall be provided with automatic Return Activated
Sludge (RAS) pumps and Waste Activated Sludge (WAS) systems.

The RAS system shall take account of the following:

• Each RAS pump shall be equipped with magnetic type flow meter and all flow events
shall be recorded and controlled through PLC/SCADA system taking into account
system inputs such as the measured flow & characteristics of influent to the facility
and the level of the settled sludge blanket in each tank
• The contractor shall provide each tank with a dedicated RAS pump with dedicated
standby pumps which shall be directly coupled to the sludge hopper pipe of tank.
• The pumped flow of RAS shall be continuous, intermittent RAS pump operation is not
permitted.
• The RAS pumps shall be capable of returning flows in the range not narrower than
0.5 to 1.0 times the average inlet flow to clarifier.
• A single RAS stream, combining the RAS flows from the individual secondary
settlement tanks, shall transfer RAS to an inlet mixing channel / chamber upstream of
the aeration system. and shall be equipped with magnetic type flow meter and all
flow events shall be recorded and controlled through PLC/SCADA system
• A provision shall be made to transfer the 50% of RAS flow to inlet of aeration tank
and same shall be controlled with eccentric plug valve with magnetic type flow meter
and all flow events shall be recorded and controlled through PLC/SCADA system
The WAS system shall take account of the following:
• WAS flow shall be tapped from the combined RAS stream and transferred to the
sludge holding / blending tank as per design requirements.
• WAS flow shall be tapped and controlled with eccentric plug valve with magnetic type
flow meter and all flow events shall be recorded and controlled through PLC/SCADA
system
• WAS flow shall be sized to waste daily sludge production and shall be operated in
totalizing mode based on influent flow and characteristics
(if any)
Type : Circular Conventional Central column
supported OR any other proven type
Sludge and scum removal : 4-arm spiral sludge scraper - two full-
radius arms and two 1/3rd radius arms.
Center sludge hopper sized per most
rigorous published criteria. Full-radius
scum baffle with beach-type skimmer.
Maximum SOR at average flow : 22 m3/m2/day
condition
Maximum SOR at PFF flow with one : 50 m3/m2/day
unit out of service condition
Maximum SLR at average flow + Recyle : 120kg/m2/day
flow
Maximum SLR at Peak flow + Recyle : 190 kg/m2/day
flow

Minimum SWD : 3.5m

Maximum Weir loading at Average Flow : 185m3/d/m
Conical bottom slope : 1:12
Maximum Velocity in central column : 0.9m/s
Maximum Under Flow sludge : 0.8%
concentration at average flow
10.5.4 Sequencing Batch Reactors
The following design parameters shall be used for Sequencing Batch Reactors (SBR)
design as well as additional design parameters taken from internationally recognized
references, standards or design manuals (for which the Contractor must provide
substantiation):
• The SBR system shall be capable of treating the Design Flows and Loads given in
Appendix B1and meeting the performance requirements stated in Section 18.
• All the fill volume of the basin in cycle shall be decanted during decant phase of the
same cycle
• The sludge age and F:M ratio shall be as per CPHEEO.
• The aerated mixed liquor shall be determined by disregarding the mass of mixed
liquor in the settling and decanting phases at any time.
The hydraulic retention time (HRT) in the SBR basins shall be calculated on the basis of
the depth to which the basins are filled under average flow conditions, not on the basis of
maximum top water level (TWL). The system shall be designed using a Stirred Specific
Sludge Volume Index (SSVI3.5) of not less than120 ml/g.
The inlet to the SBR shall be baffled in a similar manner to that of a “selector”. The
baffled zone shall be hydraulically linked to the main aeration reactor. The Contractor
shall indicate whether the baffled zone is aerated. If the baffled reactor is not aerated
adequate mixing with submersible mixers shall be supplied by the Contractor where the
power input for the mixing shall be a minimum of 10W/m3 (of baffled zone volume).
Each SBR tank shall be fitted with separate scum collection & removal system. The
system shall be designed to minimise the volume of liquid discharged with the scum
whilst providing efficient removal of the scum and shall capable of collecting the scum
with varied water levels of tank. All the scum shall be properly screened separately in
accordance with screening requirements specified in tender document and liquid stream
shall be sent directly to the sludge holding tank using an automated pumped system.
Each SBR basin shall have a separate diffuser grid which should be supplied by a
separate air drop pipe with the air flow controlled by a separate valve and measured by a
separate flow meter.
SBR basins may or may not have internal partitions. Regardless of such internal
partitioning, all SBR designs shall strictly comply with the minimum sizing and all other
requirements specified in the bid documents. Process air blowers as well as air piping
and valves for SBRs shall be configured such that one or more blowers are dedicated to
each SBR basin that is in the aeration phase at any given time. The discharge from any
given blower shall be routed to no more than a single SBR basin at any given time.

The decanting device shall be inclusive of local control boxes with and function buttons,
communication to main PLC.
SBR basin design shall include PFF so no overflow of basins at any time.
The required oxygen shall be provided by fine bubble membrane air diffusers only.
The selected air blower shall be capable of discharging the air flow to SBR tank varied
water levels.
The RAS system requirement for SBR basin:
• Each SBR tank shall be equipped with dedicated working and standby pumps to
pump RAS flow to the inlet of each tank as per design requirements
• The RAS pumps shall be capable of returning flows as per the design of technology
provider.
RAS flow shall be controlled with eccentric plug valve with magnetic type flow meter and
all flow events shall be recorded and controlled through PLC/SCADA system.
The WAS system shall take account of the following for SBR tank sludge wasting:
• Each SBR tank shall be equipped with dedicated working and standby pumps to
pump WAS flow to the sludge holding / blending tank as per design requirements.
• WAS flow shall be controlled with eccentric plug valve with magnetic type flow meter
and all flow events shall be recorded and controlled through PLC/SCADA system
• WAS flow shall be sized to waste daily sludge production and shall be operated in
totalizing mode based on influent flow and characteristics
• The maximum concentration for WAS flow sludge shall be considered 0.8%.
The Contractor shall take account of the fact that a fully nitrifying process may become
established at the specified design loading rates and mixed liquor temperature range for
selected cycle time. The design of the aeration system including tank sizing, blower
capacity, diffuser numbers and configuration shall take account of this.
The aeration requirement for each individual element of the SBR cycle shall be shown
(i.e fill and aerate, aerate, etc.) by the Contractor and the calculation method to calculate
the level of mixed liquor. The calculations shall demonstrate the aeration requirement at
ADWF.
The design MLSS concentration at reactor top water level shall provide the required
settling velocity, taking into account the minimum total settle time (i.e., the combined
duration of the settle and decant phases) and the maximum distance for the mixed liquor
settle (from maximum Top Water Level to the top of the settled sludge blanket at the end
of decant).
If the SBR cycle includes fill during settle, the Contractor shall fully describe the internal
configuration of each basin which ensures that mixed liquor settlement is not adversely
affected and that short circuiting of influent wastewater does not occur.
The effluent decanting arrangement and operation shall be designed to include a proven,
robust and effective manner of decanting top-waters with a proven history of satisfactory
performance on similar sized installations. The design and proposed operation of the
Works shall ensure that foam, scum, oils fats and grease are not discharged with the
effluent from decanter discharge.
The rate and method of decanting shall ensure that no scouring or re-suspension of the
sludge blanket shall occur.The design of the decant mechanism shall permit a visual
inspection of the discharge and the identification of any leakage within the decant
mechanism.

A minimum of two electrically actuated variable speed moving weir decanters shall be
provided in each basin which function under a controlled (but variable) constant lowering
rate. for maximum overflow rate at the Maximum Daily Flow as defined in Appendix B1.
The vertical travel of the decant arms (Decant depth) shall not exceed 2.5m. The
material of construction of the decanters shall be grade 316L stainless steel.
The decanters shall be controlled in such a way as to operate for the full duration of the
decant phase irrespective of the flow to the SBR to maximize total settle time, that is,
settle plus decant durations. The Contractor shall describe the method of decanter
control by which an even distribution of flow is provided between the decanters during
operation.
The decanters shall be designed to prevent solids entering the decanting device during
the aeration phase. Each decanter shall be fitted with a scum retention
mechanism/baffles to prevent surface scum and floatables from exiting with the treated
effluent.
All critical decanter components that may require routine inspection or maintenance shall
be easily accessible from an access platform at basin coping level without taking a basin
out of service or draining or partially draining the basin. It shall be possible to carry out
decanter maintenance activities without interrupting normal operation of the basin while
the decanter is at its parked position during non-decant phases of the process cycle.
Each SBR basin shall be provided with a minimum of two dissolved oxygen probes, in
which their average shall be used to provide a control signal for the automatic control of
the aeration system through PLC/SCADA.
The location of the dissolved oxygen probes within each basin shall provide adequate
control without detrimental effects on the process. Sufficient cabling shall be provided to
enable the position of all dissolved oxygen probes to be easily changed in every plane
during commissioning and operation.
The aeration system shall include for a default air flow to each basin which shall be
maintained in the event of a fault to the control dissolved oxygen probe.
The capacity of the aeration system shall ensure that sufficient energy is provided to lift
and completely mix the settled sludge blanket at the start of aerate. The aeration control
system shall ensure that the blower output is sufficient at this stage of the process cycle
to provide complete and uniform mixing of the process mixed liquor solids.
If the process cycle includes a fill-mix phase without aeration, submersible type mixers
shall be provided, which shall be designed to minimize any disruption to activated sludge
flocs. The submersible mixer shall provide sufficient energy to lift and completely mix the
settled sludge blanket. At least one spare unit shall be provided for standby purposes.
The use of jet aeration systems is not acceptable.
Suitable arrangements shall be provided for draining the basins.
The inlet and outlet channels and/or pipe work shall be provided with gate/valve and
designed to permit any of the individual basins to be taken out of service.
(if any)
Maximum SWD : 6.0m
Minimum Free Board : 0.6m
Minimum total HRT at average flow : As per CPHEEO

Selector Zones : Optional

Anaerobic/Anoxic/Aerobic zone : As per bidder design
Anaerobic Anoxic Zone Mixing : Design As per technology provider

requirements
Mixing requirements in selector zone , if : Design As per technology provider
provided
Type of Aeration : Diffused air, Fine bubble membrane,
tubular or disc, retrievable/fixed
Membrane material : EPDM or silicone elastomer with UV
protection or PU Membrane or
Chlorinated PE
Aeration system sizing basis liquid : Max liquid temp
temperature
Aeration system sizing basis air : Max air temp
temperature
proposed diffuser system, the
minimum guaranteed service life of the
diffuser and the head loss during the
last year of diffuser’s service life.)
10.5.5 Membrane Bio Reactor
For STP with Membrane Bio Reactor (MBR) technology, the Aeration Basin(s) along with
Anaerobic & anoxic tank(s) shall be offered as per requirement for BN removal;whereas
the MBR membrane filtration modules shall be installed in the separate tank(s). The
MBR basins shall be fully covered with solid non-skid GRP cover plates. Due
consideration to be offered for the stoppage of any foreign material like leaves etc. into
the fine screened effluent in MBR Units. The design shall provide for easy isolation of
each MBR basin and shall include all required facilities for complete, fully automated
clean-in-place (CIP) functionality.
The MBR membrane basins shall be fully covered with solid / chequered non-skid GRP
cover plates. The design shall provide for easy isolation of each MBR basin and shall
include all required facilities for complete and automatic clean-in-place (CIP) functionality.
An electric overhead bridge crane or monorail chain pulley block with travelling trolley
shall be provided for easy removal of the membrane modules. The crane or block shall
provide adequate vertical clearance to safely lift the membrane modules above all piping,

equipment, or other items that may be located in the travel path from the module location
in the tank to an adequately-sized adjacent membrane “lay-down” area designated for
membrane maintenance. The crane coverage shall include the entire MBR basin area
plus the lay-down area, if required.
The scope of supply for the MBR system shall consist of, but not limited to the following:
• A complete microporous membrane system with relevant track record in sewage
treatment application and associated pumps and process equipment as
necessary to meet the performance requirements listed subsequently.
• All equipment associated with the backwash system (if the membrane is
backwashable) including pumps, chemical addition systems, air blowers, air
compressors, dryers and receivers as necessary to sustain the permeability of
microporous membranes;
• Chemical storage, handling, injection and mixing systems, pumps, tanks, heaters
and instrumentation associated with the microporous membrane Clean-In-Place
(CIP) system;
• All interconnecting pipe works, fittings and valves,
• All interconnecting wiring (power and control)
• All required process control and monitoring instrumentation, and
• All on-line analysers for performance monitoring and verification.
Membrane volume shall not be considered as a part of aerobic volume for SRT
Calculation. The sludge from MBR basins shall continuously overflow into an adequately-
sized common structure that shall serve as the wet well for RAS pumps.
MBR building shall be provided. This building shall house all MBR-related equipment
such as Scour Air Blowers, Permeate/Back pulse Pumps, and RAS/MLR Pumps as
applicable.In addition, the MBR Equipment building shall house all equipment necessary
for all types/modes of membrane cleaning.
The Process Air Blowers for MBRs may be housed in the MBR building or a separate
building. Separate blower shall be provided for Air scouring. The design parameters for
the MBR based Process are as enlisted:

(if any)
Minimum Free Board : 0.6m
Minimum total HRT for anoxic,anaerobic : As per CPHEEO/Metcalf Eddy
& aeration tank at average flow
MBR (Membrane)Tank : As per bidder design
Mixing requirements in : As per Contractor’s design
Anaerobic/Anoxic zone, if provided

Type of Aeration : Diffused air

temperature
temperature
minimum guaranteed service life of the
diffuser and the head loss during the
last year of diffuser’s service life.)
Screening prior to MBR basin : Maximum 2mm screening and
specifications shall be as specified in
tender document
Membrane MOC : PVDF/PS/PES/Chlorinated PE
Membrane Configuration : As per Bidder design
Flux : As per CPHEEO
Type of cleaning : CIP (cleaning in place)
Maximum MLSS allowed : As per CPHEEO
Minimum Life of Membrane : 10 Years
10.5.6 Moving Bed Bio Reactor
Moving Bed Bio Reactor (MBBR) with Aeration shall be designed to treat the waste
water using free floating/moving cylindrical biomass carriers. The media/carriers shall
be kept in suspension at any time by diffused aeration. MBBR tanks shall be anaerobic,
Anoxic and aerobic stage for BOD, COD removal.
RAS & MLR may be provided depending upon bidder’s design/proposal. The MBBR
bioreactor shall be suitably sized to achieve the desired treated sewage quality.
Reactor Media shall be as per bidder’s design but compatible with other media types
for future operations considering about 20% variation in specific surface area. The
media shall have a specific gravity of equal to or less than that of the waste water and
be suitable of providing axial rotation in all planes as well as ensuring aeration to all
surfaces.
Aeration will be provided through either Coarse or fine bubble diffusers as per bidder’s
design which should be retrieval/fixed type.
Media Trap made from SS 316L or superior material shall be provided to ensure that
media does not escape to the downstream unit. The size of the screens will be
governed by the size of the bio-carriers. The entry and exit of waste water shall be at
opposite ends both in horizontal &vertical plane. The reactor dimensions, media

quantity shall be adequate for providing adequate sufficient surface area for
maintaining the biomass required for degradation and air required as required to
achieve the quality. The aeration system shall be provided for sufficient oxygen supply
for the effective biodegradation in aerobic reactors.
Blowers, piping, valves and other equipment to maintain air flow to the aerobic reactors
must suit the needs of the media circulation and aeration of MBBR system. All systems
and process equipment as necessary to meet the performance requirements will be
provided by the Contractor.
Design Flow : Average flow including
Recycle/Return Streams (If any)
and with hydraulically catering
capacity considerations for PFF
including Recycle/Return Streams
(if any)
Flow Distribution : As per clause 10.13.4
Minimum total HRT at average flow : As per CPHEEO/Metcalf Eddy
(Aerobic process including Anoxic
and Anaerobic
Anoxic/Anaerobic/Aerobic zone : As per CPHEEO/Metcalf Eddy
Mixing requirements in Anaerobic/Anoxic : As per Contractor’s design
zone, if provided
Mixing requirements in Aerobic zone : To keep media in suspension
Type of Aeration : Diffused air
temperature
temperature
peak air flow (min to be provided and max manufacturer (Bidder to include in
to be used as design basis) his bid a letter from the
manufacturer of the diffuser, giving
reference of this project,
guaranteeing the SOTE of the
minimum guaranteed service life of
the diffuser and the head loss
during the last year of diffuser’s
service life.)
MBBR Media : PP/PE/HDPE (Virgin plastic)
Shape : Cylindrical or as per patented
design
Specific Surface Area : 450 to 600 m2/m3 of media

Media Volume in MBBR basin : 30 to 45%
10.5.7 Aeration systems (For all Biological Processes)
For all the biological treatment process proposed under this project shall be designed to
maximise oxygen transfer and to adapt to the changing oxygen demands in biological
treatment systems. For plug flow systems tapered aeration shall be provided. The
Contractor shall state the turndown ratio of blowers and any other proposed aeration
devices.
Surface aerators shall not be permitted for secondary treatment.
Appropriate sized motorised isolation gates shall be provided at the inlet of aeration
basin. Special care shall be taken to ensure that the increase in aerobic zone water
surface elevation caused by diffused aeration at the interface.
The aeration system shall be capable of complete and uniform mixing and suspension of
mixed liquor suspended solids throughout the aerated parts of the process.
The aeration system shall be capable of a 4:1 turndown from the maximum air flow as
described above while maintaining continuous air flow. Intermittent air flow shall not be
permitted over this range of turndown.
Blower discharge piping shall be heavy duty, thick metal design to withstand the
pressure and loads imposed on the piping as well as noise attenuation.
Pressure tappings shall be provided to monitor pressure drop for each air valve.
The design of the aeration system, including the air headers, drop leg pipes to the in-
basin aeration pipe work and the in-basin aeration pipe work itself shall ensure an even
distribution of air throughout the system at all air flow rates. The Contractor shall carry
out a visual pattern test with a minimum of water covering the aeration system to
demonstrate this.
Vertical drop legs shall be SS 316L minimum. The diffuser grid piping below liquid, shall
be SS316L material.
The design of all of the aeration system pipework shall ensure that sufficient flexibility is
provided to allow for movement arising from thermal and other effects to be
accommodated during operation without detriment to performance.
The Contractor shall provide full details on the performance characteristics of proposed
aeration devices. The details required shall include:
• Standard oxygen transfer rates (kg O2/h) at the chosen reactor depth.
• Alpha factor assumed for wastewater at various stages in the process for plug flow or
modular designs
• The overall standard oxygen transfer efficiency (%)
• The standard aeration efficiency (kgO2/kWh)
The Contractor’s design shall be such that it is feasible to carry out performance testing
of the aeration system on a full scale section of the facility.
Retrievable/ Fixed Fine bubble diffused air systems proposed with membrane type
diffusers shall be utilized. Ceramic diffusers shall not be permitted. The Contractor shall
state the following:
• minimum and maximum air flow rate/capacity of the diffusers at the operating liquid
depth or range of depths.
• number of diffusers in aeration zones.

The air flow per diffuser shall not exceed the following limits:
Nm³/Hr/m² for effective perforated area of diffuser membrane
Average oxygen demand Maximum oxygen demand
(“average” conditions) (“maximum” conditions)
Disc diffusers 80 140
Tube diffusers 40 70
Design of the fine bubble flexible membrane system shall take account of the
temperature of the air at the flexible membranes, considering the worst case ambient
temperature, air flow and blower delivery pressure. Blower discharge piping after-cooling
shall be provided if necessary to avoid excessive air temperatures damaging the material
of the flexible membranes and/or upsetting the aeration process performance.
Clean water Standard Oxygen Transfer Efficiency(SOTE) tests shall be performed for
each different diffuser grid geometry/arrangement proposed in the design. These tests
shall be performed by the diffuser Manufacturer at the Manufacturer’s testing facility or
an equivalent facility appropriately equipped with an adequately sized testing tank and
other required appurtenances and also conduct at field conditions. The testing shall be
performed in full compliance with the latest version of the applicable standard testing
protocol. These tests shall be witnessed by Employer’s Representative.
10.5.8 Alum Dosing System
An alum dosing system shall be provided to accomplish backup chemical phosphorus

removal in the event of inadequate biological removal, if required. An alum dosing
system shall be provided to dose fixed rate of 10mg/L of alum to biological process. The
dosing point for alum shall be as per bidder proposal.
Alum dosing rate at average flow : As per Bidder design
condition
Alum solution strength : 10%
Alum solution preparation : Complete atomized alum solution
preparation with 1days storage for
prepared solution
Powder or emulsion alum storage period : 30days
Alum mixer MOC : SS 316L
Velocity Gradient for alum mixing : 600s-1
Alum dispersion rapid mixers : In-channel submersible vacuum
induction type with SS316L or Titanium
MOC and 1500s-1 velocity gradient
However, the Bidder has liberty to choose suitable chemicals for Phosphorus removal
10.6 Tertiary Treatment

If further treatment It is necessary to achieve the effluent standards for discharge to creek,
The Contractor shall use further tertiary treatment units to achieve this. One or more
further treatment steps may be required to achieve the effluent parameters outlined in
Appendix B. Design parameters from internationally recognized references, or the
CPHEEO Manual shall be observed.

The following treatment options may be suitable for further treatment:

• Sand filter (Pressure / Gravity)
• Physical/Chemical Treatment
• Disc Filtration
• Membrane Filteration
• Any other process which shall meet the standards as specified in Appendix B
10.7 Disinfection
Contractor shall propose either Chlorination or UV System for disinfection of treated
effluent received from the Biological treatment. However, dual system shall also be
accepted. The level of disinfection required is dictated by the level of effluent treatment
provided by the contractor at U/S of process stream. Also, contractor shall ensure that the
effectiveness disinfection treatment shall be measured at D/S of the disinfection treatment
and same shall be recorded and controlled through PLC/SCADA.
The contractor shall provide the sufficient justification on selected disinfection technology
and its suitability for the Project.
10.7.1 Chlorination System
Chlorine shall be injected via an inline vacuum educator placed in the filtered effluent pipe
and mixing chamber of the Chlorine Contact Tanks.
The level of disinfection required is dictated by the level of effluent treatment provided by
the contractor. The contractor shall provide justification of his design basis and offer
equipment.
The contractor shall ensure that excess levels of disinfection chemicals are neutralised
prior to discharge to the environment.
An Emergency Chlorine Scrubber and all associated systems and controls shall be
provided to contain and neutralize any chlorine gas leaks.
Facilities shall also include to measure the effectiveness of chlorine disinfection at D/S of
the chlorine contact tank channel and same shall be recorded and controlled through
PLC/SCADA
Design Flow : Average Flow with Recycle/Return
Streams or Maximum instantaneous
flow from Secondary treatment
whichever is higher
Chlorinator Quanity : 1 Working + 1 Standby
Minimum HRT at average flow with : 0.5 Hrs
recycle flows
Minimum effective length to Pass width : As per CPHEEO
ratio
Pass Width to SWD ratio : 1.0 : 2.5
Minimum chlorine dose at average flow : 5.0mg/L
for Chlorination system design
Maximum withdraw rate through each : 6.0kg/h
cylinder
Chlorinator capacity : Shall meet the peak chlorine demand

during PFF condition with recycle flows

Minimum storage period for chlorine : As per CPHEEO
Type of chlorinator : Vacuum type gas feed
Type of chlorine ejector : Inline vacuum induction
10.7.2 Ultra Violet (UV) Disinfection system
The proposed UV system shall be completely automated and controlled through

PLC/SCADA.
UV facilities shall also include to measure the effectiveness of UV disinfection at D/S of
the UV channel and same shall be recorded and controlled through PLC/SCADA
Additionally, UV facilities design shall ensure that all bypass events of plant shall be
disinfected with UV dose before its discharge to creek.
Design Flow : Peak Flow with Recycle/Return

Streams
Type of Installation : Open Channel type
Location : Located within UV Building
Minimum Redundancy : (n-1) at peak flow
Minimum UV dose at average flow : As per Bidder Design
UV dose at Peak flow : Shall meet the peak UV demand during
Peak Flow Condition
Hydraulic Design : Shall meet the Peak Flow Condition
Minimum UV Transmittance : 55% at all flow conditions
10.8 Tertiary Treatment System and Arrangement for Re-Use Effluent
To achieve the effluent standards for reuse as specified in Appendix B1, the Contractor
shall provide tertiary treatment units of capacity 90 MLD in 2 modules of 45 MLD each.
• Both modules shall be constructed under this contract during DB period.
• The contractor shall keep space in the layout for balance flow of 90 MLD
The Design of tertiary treatment system of capacity 180 MLD in 4 module of 45 MLD shall
be submitted with bid.
One or more further treatment steps may be required to achieve the effluent parameters
for reuse as outlined in Appendix B1. Design parameters from internationally recognized
references can be used.
The following treatment options may be suitable for further treatment:

• Activated Carbon filters
• Disc Filters
• Ultra-Filtration
• Any other process which shall meet the reuse standards as specified in Appendix B1.
Treated water which meet the reuse quality as specified in Appendix B1 shall be stored in
closed tank after disinfection. In order to re-use this stored water, suitable type pumping
system (Drywell or Wet well) shall be used to pump. Appropriate facilities with necessary

requirements shall be provided for filling the road tankers. The discharge facilities shall be
designed to rapidly fill up to four road tankers simultaneously. An efficient system for
handing internal traffic, including roads and areas for queuing shall be designed. The
above paragraph shall be supersede regarding type of pumping arrangement for Tertiary
Treatment system.
The design of the facilities shall ensure that fire storage is reserved only for fire fighting.
The Contractor shall ensure that the design can adequately manage the required flows
treated at the reuse treatment facility, in conjunction with the requirement for individual
units being taken offline for maintenance in accordance.
Treatment Scheme : As per bidder choice

Treated Water Storage Tank Details : Closed rectangular tank with two compartment
having
• Capacity –160 KL X 2 Nos
• HRT – 5 min.
• 1.0m clear free board Air vent system
• 4Nos 1200mm Diameter circular manholes
with 600H x 200Thick kerb wall on top.
• Baffle walls in each compartment
• 1500mm wide stair case access to each
compartment
• Drywell pumping arrangement with all
associated facilities as defined to discharge
to road side tankers and other facilities.
The Contractor shall provide Tertiary Treated Water to the capacity required by the
Employer as per the quality defined in the Tender documents at the periphery of the
WwTF (at a mutually agreed location). The Employer reserves the right to draw upon the
tertiary treated water according to their requirement (subject to the ceiling of the maximum
capacity of tertiary treatment) and payment of tertiary treated water shall be based on the
actual tertiary treated water drawn by the Employer.
10.9 Not Used

10.10 Sludge Handling and Treatment
All sludge produced by the Works shall be subjected to thickening/sludge pre-treatment/
anaerobic digestion and dewatering to produce a product which complies with the
performance standards specified in Section 18.
The configuration of the sludge handling pumps and associated valves and pipe work shall
ensure that no backflow is possible through each pump when the pump is not running.
The sludge head loss calculations in all sludge pipe work shall take account of the specific
sludge characteristics for different types of sludge’s including the variations in viscosity
arising from changes in the dry solids content of the sludge (for example, by using the
methods described in the recommendations of “How to Design Sewage Sludge Pumping
Systems”, Technical Report TR185, WRc).
10.10.1 Configuration of Sludge Streams
The Contractor shall provide a sufficient number of appropriately sized sludge thickening
streams (including all associated ancillaries such as pumps and polymer dosing

equipment) operating in parallel to meet the Employer’s Requirements for the Flows and
Loads specified in Appendix B1. The number and capacity of the units shall be based on
a maximum operating period of 16 hours per day. The Contractor shall ensure that the
design can adequately manage the full range of flows expected at the treatment facility,
in conjunction with the requirement for individual process units being taken offline for
maintenance in accordance.
The Contractor shall thicken sludge prior to sludge pretreatment / digestion. WAS co-
thickening with primary sludge is acceptable.
Mechanical systems (such as drum thickeners, Disc Thickener, Screw Thickener and
roofed picket fence thickeners) shall be acceptable for sludge thickening. Contractor
shall propose an in-line pressurized sludge screening/ sludge grinders separately prior to
sludge thickening.
Material of Construction for an in-line pressurized screens and thickeners shall be of SS
316L. All the associated feed pumps shall meet the standby requirements as specified in
tender document.
Contractor shall choose the screening and thickening such that they will work with single
feed pump. Or contractor can propose separate pumping for screening and thickening.
The facility must be capable of fully continuous automatic operation without operator
intervention for any 24 hour period.
A critical fault condition in any component of a duty stream shall raise an alarm and take
the entire duty stream out of use. Each sludge screening and thickening stream and its
ancillary equipment shall start up and shut down automatically when required using a
pre-set controlled sequence. Shut down shall include a wash down phase after the
sludge feed has stopped to leave the clean condition. The Contractor shall provide
automatic systems to monitor filtrate quality from thickener.
Polyelectrolyte solution preparation/storage systems with standby solution preparation
units shall be provided with sufficient capacity for all mechanical devices used for sludge
thickening. The selection of the type of polymer (powder or emulsion) shall be based on
preliminary bench scale testing by different polymer suppliers. Dosing of polymer
solution to condition the WAS prior to thickening shall be linked to the operation of each
thickener and shall be fully automatic. The volumetric polymer solution dosing rate from
each polymer dosing pump shall be manually adjustable.
Sludge screening and thickening systems shall be located in a sludge building or
otherwise enclosed and sealed from the outside atmosphere. Adequate ventilation shall
be provided to eliminate odour nuisance
10.10.2 Sludge Storage
The Contractor shall provide a minimum of 24 hours storage based on maximum design
loads upstream of each of the digestion.
Sludge storage capacity shall be based on providing a steady continuous flow of sludge
through the treatment units during their normal hours of operation.
The sludge storage tank requirements may be summarized as follows based on
contractor design:

Table 10.1 – Sludge storage

Sludge Type(s) Minimum Effective Mixing Covered
Capacity Requirement
Blended thickened 12 hours of average sludge Mechanical Yes,
Primary + Thickened production mixing ventilated
WAS for
digester/sludge pre-
treatment feed
Digested sludge 12 hours of average sludge Mechanical Yes,
(dewatering feed) production mixing ventilated
Sludge cake storage at 12 hours of average sludge No Yes
site production
10.10.3 Sludge Pre-Treatment and/or Anaerobic Digestion and/or Sludge Dryer
Thickened primary and secondary biological sludge shall be blended and mixed in the
sludge holding tank(s) which shall have suitable mixing equipment and shall be covered,
from where the sludge shall be pumped to the Sludge Pre-treatment and/or anaerobic
digesters and/or dryer.
The requirement of sludge pre-Treatment and/or Digestion and/or Dryer is:
• Sludge pre-treatment and/or digestion and/or dryer process shall capable of handling
sludge from Primary Clarifier and Waste Activated Sludge from biological treatment
in combined form.
• The sludge shall be continuously fed to the sludge pre-treatment units and/or
anaerobic digestion and /or Dryer system based on bidder’s proposal.
• All sludge treatment units shall have a highly efficient odor handling unit or system to
meet the environmental compliance as per CPCB / MPCB.
• All sludge treatment syste/units shall comply with relevant international best practice.
• Sludge dryer shall be Paddle type/Belt type/any other type.
• To Increase the dewatering characteristics of the sludge to minimum 25% solid
consistency and above.
• To reduce the sludge quantities to be handled after dewatering the sludge
• Improve the sludge quality for safe reuse as per Class - A EPA standards.
• To avoid the re-growth and reactivation of pathogen in dewatered sludge.
• To produce odor free dewatered sludge.
• Utilization of biogas in the combined heat and power (CHP) units, if bidder
considered biogas generation.
• The dried sludge should strictly meet the Class A EPA bio-solids requirement for
sludge cake as indicated below.
• Hydrolysis process for sludge treatment shall also be considered in sludge pre-
Treatment.

Table 10.2 – Class A EPA Standard

Pathogen or Indicator Standard density limits (Dry Weight)
Salmonella < 3 MPN / 4 g Total Dry Solids
Fecal Coliforms < 1000 MPN/g of total dry solids
Enteric Viruses < 1 PFU / 4 g Total Solids
Viable Helminth Ova < 1 / 4 g Total Solids
Note:
A. The sludge sample must satisfy the above limits by determining the geometric mean
of seven samples of biosolids after treatment.
B. The laboratory equipment for measuring above sludge parameters shall be provided
in the Laboratory.
The Contractor shall provide a sufficient number of appropriately sized sludge pre-
treatment and/or anaerobic digesters and/or Sludge Dryer operating in parallel to meet
the Employer’s Requirements for the Flows and Loads specified in Appendix B1. The
Contractor shall ensure that the design can adequately manage the full range of flows
expected at the treatment facility, in conjunction with the requirement for individual
process units being taken offline for maintenance.
The contractor shall propose single stage high rate anaerobic mesophilic type digester or
thermophilic digester, designed to operate with homogeneous mixing. The shape of the
digester shall be either of:
a) Cylindrical with Fixed Cover
b) Egg Shaped Digester (ESDs)
The selected digester shape shall allow more efficient optimized mixing and also reduce
the footprint and enhance the performance over long run. However, contractor shall
provide sufficient justification on selected shape and its effectiveness over long run
performance.
The digesters shall be equipped with an automatic temperature control system. In each
digester, at least two temperature sensors shall be installed. The average daily
temperature of the sludge in the digesters shall be kept at a constant set point (+/-0.5C)
and not be outside the range 18 to 40°C. The instantaneous temperature shall be
continuously in the range of the set point ±2°C.
Each Digester shall meet the minimum following requirements:
• All necessary pressure and vacuum release valves, instrumentation and control
system alarms and interlocks to prevent excessive positive or negative pressure
within the digester roof space.
• Liquid level control and sludge removal via an overflow system.
• An emergency overflow.
• Scum and foam control measures
• A sludge draw-off pipe and manually operated valve at the bottom centre of the
Digester base.
• Automated to avoid the risk of draining the digester with the consequence of
negative pressures and hence air ingress into the digester through the vacuum
release valve.
• Man way quick release hatches on the roof.
• Contractor shall ensure that all appropriate inspection/maintenance access shall be
provided for digester to ensure inspection during running condition and for 100%

cleaning during digester takeoff for maintenance.

• Quick release sampling hatches on the roof with access tubes well below liquid
surface level.
• View ports with manual internal wiper blades on the roof.
• The design of the anaerobic digestion system shall maximize safety and security of
operation as the result of the presence of biogas in both normal and abnormal
operation.
• The selected location of the digester feeding point or points in each digester shall
minimize the degree of short-circuiting.
• Sludge withdrawal from the digesters shall be by displacement of the tank contents
via a gravity overflow system.
• Digester design shall facilitate reduced potential for grit accumulation at bottom and
less potential for scum accumulation at top.
• All wetted parts MOC of Digester shall be SS316L
• Digesters shall be either heated or cooled based on design to meet the digester
temperature requirement as specified in Section 18.
• The Contractor shall specify the percentage of solids destroyed during digestion
which shall not be less than the amount specified in Section 18.
Alternatively, bidders can also propose suitable arrangement/ equipment system in

Digester as per their design.
10.10.4 Gas Storage
Gas take-off from the digester shall be from the apex of the digester top. A flame arrestor
and an ultrasonic type flow meter shall be provided on the gas line from each digester.
The biogas generated during digestion shall be directed to a gasholder having 25% of
storage capacity based on daily gas production and shall be utilized to heat the sludge
and to generate power in order to reduce the quantity of power required to be imported
at the Works. The gasholder and collection pipes must be sized for minimal headloss
such that if the digester sludge volume changes, biogas (and not air) will be drawn into
the digester and the gas will not be lost by displacement.
The gas storage capacity shall be based on one of the following:
• Double membrane type (a separate structure for a fixed roof digester);
• Rising gas bell (a separate structure for a fixed roof digester);
• Sludge cum biogas storage tank.
If a floating gas holder roof or a separate rising gas bell is provided, all metal parts shall
be coated with approved coatings and the side skirts are to be made of Stainless Steel
316L plate.
Normal gas operating pressure of the digesters, gas piping and storage systems shall be
200 mm WC (water column), with a vacuum protection of minus 50 mm WC.
The biogas generated shall be property of the Employer. The Contractor can use the
biogas for power generation and sludge heating only and any surplus gas shall be
burned through flare system. Contractor shall make provision for gas tap off at a suitable
location (with valve and end cap to properly seal open end). The Employer at a later date
may extend gas line from tap off at his own cost to use surplus gas for any other purpose.
Drainage for condensate shall be provided at all low points in all biogas pipelines and all
ancillaries such as ceramic filters shall be provided to remove contaminants and other

deleterious materials from the biogas. All necessary control and safety devices shall be
provided. All gas pipe work and weld on flanges shall be Stainless Steel 316L.
10.10.5 Energy Generation
The Contractor shall generate electrical energy from the biogas produced by the sludge
digestion process. Contractor shall use combined heat and power (CHP) units in the
process/captive consumption of the STP. The energy to be recovered from the
combined heat and power units shall be in the form of electrical power and heat.
The design and specification of the combined heat and power units shall take into
account the contaminants that will be present in the biogas from the digesters, including
hydrogen sulphide (H2S) and ammonia (NH3), and any harmful effects resulting from
their combustion. The Contractor shall provide a H2S gas scrubbing system which will
provide the outlet H2S concentration of less than 50mg/L to protect and maintain the
engine. The H2S scrubbing system shall be compatible with the CHP.
The removal of siloxanes is not a requirement unless it is necessary to meet the siloxane
limits specified by the CHP unit supplier.
The design of the Works shall be such as to minimize overall external power demand
and maximize the captive power generated from the Works.
In the event of a power failure the CHP units shall be used to assist with running
essential services.
10.10.6 Biogas Burner (Optional)
The Contractor shall provide 2 no. enclosed flame high efficiency waste bio-gas burners
(1duty/1 standby) for complete destruction of all contaminants in the gas. Each burner
shall be sized for at least 150% of the maximum gas production based on flows and
loads specified in Appendix B1. Each burner shall burn the gas at a minimum of 700oC.
Flaring of biogas shall only be permitted if the rate of biogas production exceeds the
biogas consumption of the CHP unit. The pilot burner shall have an electronic ignition
system.
Drainage for condensate shall be provided at all low points in all biogas pipelines and all
ancillaries such as ceramic filters shall be provided to remove contaminants and other
deleterious materials from the biogas. All necessary control and safety devices shall be
provided. All gas pipe work and weld on flanges shall be Stainless Steel 316L.
10.10.7 Sludge Treatment Chemical Handling Systems
The Contractor shall provide polymer dosing solutions to enhance sludge

thickening/dewatering. The polymer make-up system and grade of polymer selected
shall be suitable for the sludge type, specified sludge throughput and the type of
mechanical device proposed for thickening/dewatering.
In order to ensure efficient use of resources the following usage levels for polyelectrolyte
shall used:
Table 10.4 – Polyelectrolyte dosing limits
Method Polyelectrolyte Usage
Mechanical Thickening As per Contractor’s design
Mechanical Dewatering As per Contractor’s design

Each polymer dosing system shall comprise make-up units, transfer pumps operated on
a duty/standby basis, polymer solution storage and polymer dosing pumps.
The solutions shall be prepared and dosed automatically. Adequate mixing and
dispersion of the chemicals in the medium shall be achieved.
Polymer dosing shall be based on the flow of polymer solution prior to mixing with
polymer carrier water. The flow of polymer solution shall be manually adjustable at each
polymer dosing pump and shall be related to the demand in order to minimise
consumption of chemicals. Each polymer dosing pump shall be dedicated to a
thickening/dewatering stream.
The operation of each polymer dosing pump and the corresponding flow of polymer
carrier water shall be automatically controlled and co-ordinated with the start-up and
shut-down sequences of the relevant dedicated thickening/dewatering stream.
Storage capacity for chemicals used at the facility shall be sufficient to enable the facility
to be operated for four weeks at maximum throughput. Solid type polymers shall be
stored on wooden pallets at a designated place. Polymer bags or containers for manual
lifting and emptying shall not exceed 25kg gross weight each.
If liquid polymers are used they shall be stored in small containers of 10 litres to enable
the operator to lift and dump it in the solution preparation tank.
The Contractor shall bund all storage tanks for chemicals and any spillage shall be
diverted to the return liquor stream.
10.10.8 Sludge Dewatering
The sludge dewatering plant shall produce a cake concentration with a minimum dry
solids content as specified in Table 18.4.
The Contractor shall provide a sufficient number of appropriately sized dewatering
streams (including all associated ancillaries such as all pumps and polymer dosing
equipment) operating in parallel to meet the Employer’s Requirements for the Flows and
Loads specified in Appendix B1. The Contractor shall ensure that the design can
adequately manage the full range of flows expected at the treatment facility, in
conjunction with the requirement for individual process units being taken offline for
maintenance in accordance
Sludge Dewatering shall comprise as a minimum the following items of equipment,
including all necessary ancillaries:
• sludge feed pump
• polymer solution dosing pump
• dewatering unit
A critical fault condition in any component of a duty stream shall raise an alarm and take
the entire duty stream out of use.
Each sludge dewatering stream and its ancillary equipment shall start up and shut down
automatically when required using a pre-set controlled sequence. The dewatering unit
shut down shall include a wash down phase after the sludge feed has stopped to leave
the dewatering unit in a clean condition. The Contractor shall also provide automatic
systems to monitor filtrate/centrate quality with provision of tubidity/TSS meter.
Each sludge dewatering stream shall be provided with a dedicated feed pump which
shall be directly coupled to the digested sludge storage tank.
Polyelectrolyte solution preparation/storage systems with standby solution preparation
systems shall be provided with sufficient capacity for all mechanical devices used for

sludge dewatering. The selection of the type of polymer (powder or emulsion) shall be
based on preliminary bench scale testing by different polymer suppliers. Dosing of
polymer solution to condition the digested sludge prior to dewatering shall be linked to
the operation of each dewatering unit and shall be fully automatic. The volumetric
polymer solution dosing rate from each polymer dosing pump shall be manually
adjustable.
Where centrifuges are proposed controls shall be put in place to adjust the differential
speed of the bowl and conveyor.
Complete sludge dewatering systems shall be located in a building. Adequate ventilation
shall be provided to eliminate odour nuisance.
10.10.9 Sludge Storage Facilities
The Contractor shall, from the start of Commissioning, provide sludge storage facilities
for sludge cake at the Works. The Contractor shall consider the following when
calculating sludge storage areas:
• An operational buffer
• An emergency buffer
• Seasonal variations in sludge demand (e.g. during monsoon)
Contractor shall provide surface mounted 50 ton capacity weighbridge for weighment of
sludge at site before transporting it to offsite for disposal.
10.10.10 Sampling and Analysis
Sampling and analysis shall be carried out by the Contractor in accordance with any
regulations that relate to the use of the sludge.
10.10.11 Record Keeping
General - The Contractor shall keep records, including the following, during the Contract
Period:
a) all statutory records required for the use of sludge in agriculture insofar as the sludge
is recycled to agriculture;
b) all sampling and analysis data in relation to sludge and soil collected in complying
with its obligations under this agreement,
c) the location of land used in the disposal;
d) the uses of land used in the disposal;
e) all individual load tickets, and weighbridge tickets for exported sludge.
The Contractor shall on 7 days notice make such records available to the Employer.
Sludge Treatment Records - The Contractor shall keep records of results of the tests to
be carried out pursuant to Section 7 and the following records during the Concession
Period:
a) Digester retention times, temperatures and solids reductions;
b) Metals contents of sludge cake product;
c) Nutrient values of sludge cake product;
d) Faecal coliform and salmonella levels in sludge cake product;
e) Dry solids of sludge cake product;
f) Soils analysis of land to which sludge is applied;

g) Volumes and tonnages of sludge leaving the Works

Software - The Contractor shall keep the records listed using suitable proprietary
software. Users of the software must be adequately trained by the authors of the
software.
Maps - The Contractor shall use maps to record and analyze sludge use. The maps
need not show individual field boundaries. The Contractor shall use the maps in
conjunction with software such as MAPINFO to provide a visual record of sludge re-use.
10.11 Sludge Transport

Safe Transportation of the Class A Sludge from the plant to the designated location for
disposal i.e. Malad WwTF. The transportation cost of the same shall be included within
the O&M costs quoted by the Tenderer. There shall not be any tipping fee involved in the
disposal under this Contract. The vehicle transporting the sludge shall be properly
covered to prevent any spillage, odour etc. and shall comply with the environmental
requirements and shall be GPS enabled so that the same can be tracked.
10.12 Flow Measurement, Sampling and Monitoring
10.12.1 General
The Contractor shall provide sufficient measuring devices and sampling equipment to
comply with the Employer’s Requirements in respect of the proper operation and
maintenance of the facility and to enable the proper monitoring, sampling and analysis to
be carried out.
Flow measurement and sampling facilities shall be provided by the Contractor for the
following purposes:
• determination of the incoming wastewater pollutants load for payment purposes;
• determination of the quality and quantity of flows discharged to the outfall for
compliance and payment purposes;
• determination of operational loads onto particular process units for process control
and operation.
The minimum requirements for flow measurements and sampling during normal
operation are stated in Section 18 of this volume. More detailed sampling and measuring
will be required during the Tests on Completion of Design-Build and Tests Prior to
Contract Completion.
10.12.2 Flow Measurement
Flow measurement devices shall be installed at the following locations (as a minimum) to
measure the flows at not less than 99% accuracy
• Influent flow measurement prior to each inlet chamber;
• Flow measurement between primary settling tanks and aeration tanks;
• Effluent flow measurement after secondary settling tanks / biological process;
• Effluent flow measurement at Inlet and outlet point of tertiary treatment unit
• Effluent flow measurement at discharge point
• Effluent flow measurement at exit to effluent storage
• Flow measurement at all overflow and by-pass locations;

• Sludge measurement for primary Sludge;

• Sludge measurement for Return Activated Sludge;
• Sludge measurement for surplus secondary activated Sludge;
• Sludge measurement at inlet of the primary digesters;
• Sludge measurement at inlet to the sludge dewatering equipment;
• Air flow measurement to each biological process tank
• Chemical feed flow measurement
• Digester Gas measurement – total gas flow;
• Digester Gas measurement – Waste Gas burner;
• Digester Gas measurement – Biogas engine.
• Digester Gas measurement – Boiler or steam generator
• Effluent flow measurement at Inlet and outlet point of Tertiary Treatment unit
For all the above flow measurement points except overflow and by-pass,
electromagnetic or ultrasonic flowmeters (with insertion type transducers only) shall be
used. The Contractor shall ensure that electronic fingerprints are used to enable
calibration to be conducted on Site.
At all the above locations continuous flow measurement is required and flow
measurement devices shall provide instantaneous and totalized flow records. Signals
from flow measurement devices shall be linked to the PLC/SCADA system to allow daily
totalised flow and other flow trends to be analyzed ,recorded and for control.
Spool piece arrangement shall be provided for each size of electromagnetic flow meters
with diameters more than 500 mm such that the instrument can be isolated and removed
for calibration and maintenance without interrupting the flow.
10.12.3 Sampling
The Contractor shall carry out sampling at the stages of the process set out in Section 18.
The exact locations of the sample points shall be agreed between the Contractor and the
For the sampling points which are directly connected to the performance requirements or
payments, refrigerated automatic samplers shall be permanently installed. Influent and
final effluent automatic samplers shall be flow or time proportional. Any automatic
samplers which are utilized for determination of the loads for payment purposes shall be
capable of collecting flow and/or time proportional composite samples.
10.12.4 Process Monitoring
In order that the performance of the Works may be effectively monitored, wastewater,
sludge, and other process parameters are required to be analyzed by on-site
instrumentation.
Contractor shall provide digital display monitors at main admin building and at main
entrance of WwTF facilities to digitally display real time 24/7 basis all the influent and
effluent parameters as indicated below
Sr.No. Parameter Unit
1 Sewage Inflow and outflow M3/hr
2 pH ---

3 BOD Mg/litre
4 TSS Mg/litre
10.13 Hydraulic Design
10.13.1 General
The principal hydraulic design requirements applicable to the Works are:

• all aspects of the design of the hydraulics shall be based on sound principles and
good common engineering practice typical for municipal engineered works;
• the WwTF and all parts thereof shall be capable of passing the required wastewater
flows, including returned and recycled flows;
• the flows shall be evenly distributed between the numbers of streams and process
units in operation for all flow conditions;
• suspended sediment entering the facility shall be kept in suspension and
transported through the facility by the flow as far as the treatment unit where it is to
be removed or separated from the main wastewater flow;
• the hydraulic design shall comply, where applicable with relevant international
standards.
10.13.2 Levels
Published tide data is as follows and is relative to Town Hall Datum (THD).
Highest Water Level at creek 29.34 m relative to THD
The Works shall be designed and constructed so that:
• The lowest invert level of discharge channel at outfall structure shall be 30.40m
• The maximum water level that will be available in incoming rising main at inlet to
receiving chamber is 36.00 m relative to THD.
• FGL - 30.24THD
10.13.3 Design Flows
The hydraulic design flows throughout the facility from inlet to grit removal system shall
take full account of PFF, recycled flows and returned flows and from D/S side of grit
removal system to Outfall channel, shall take full account of PFF, recycled flows and
returned flows unless specified otherwise. The hydraulic design calculations shall
demonstrate the proper functioning of the facility if any one of the process units were to
be out of service for maintenance at the PFF condition and shall satisfy the modular
design approach as per Section 9.277.
The division of flow between the process streams and between individual treatment units
in each process stream shall be achieved by the use of suitable control structures, such
as freely discharging weirs or flumes. These may be sited at the inlet or outlet to each
treatment unit, or at a distribution chamber upstream of the treatment units.
Where the applicable control structures are sited downstream of the chamber or other
location where the division of flows occurs, then the intervening channels, culverts and

pipes shall, as far as practicable, be functionally identical in terms of conduit dimensions,

lengths, bend angles, etc. so as not to impair the even division of flow.
Hydraulic calculations shall be based on the Colebrook-White or Hazen-Williams
formulae for pipe and the Manning equation for open channel flow. The hydraulic design
calculations shall show clearly the methods of calculation and analysis used, including all
assumptions made. The calculations shall include a hydraulic profile and full details of
the depths, velocities, water surface or pressure head elevations, energy (or total head)
elevations and (for open channels or closed conduits flowing partially full) Froude
numbers throughout the WwTF.
The head loss calculations in all sludge pipe work shall take account of the specific
sludge characteristics for different types of sludges including the variations in viscosity
arising from changes in the dry solids content of the sludge (for example, by using the
methods described in the recommendations of “How to Design Sewage Sludge Pumping
Systems”, Technical Report TR185, WRc).
All parts of the Works shall be designed with allowances for the most adverse
combinations of anticipated maximum and minimum settlements or other movements of
the structures concerned. In particular, the minimum freeboard in hydraulic structures
shall include an appropriate allowance for anticipated settlement.
10.13.4 Flow Distribution
The division of flow between the process streams and between individual treatment units
in each process stream, shall be achieved by.
• non-submerged (i.e. with a positive free fall from weir invert to the water surface on
the downstream side) overflow weirs followed by isolation gate,
• non-submerged downward opening overflow weir gates for bypass flows
All gas / air / sludge flow distribution shall be using automatic feedback flow control using
inline flow measurement and modulated flow control valves with electric actuators and
data input and control through PLC/SCADA
10.13.5 Pipelines and Culverts
The hydraulic design calculations for pipes and culverts flowing full shall include profiles
of the static head and total energy elevations in relation to the soffit of the conduit. No
designs shall cause, assume or require the occurrence of sub-atmospheric pressures
within any conduit. All pipe and culvert intakes shall be designed to reduce air vortices.
10.13.6 Channels
The Manning Formula or similar shall be used for the design of open channels and shall,
except where expressly permitted otherwise, be designed for sub-critical flow, with a
Froude number no higher than 0.5.
Channels collecting flows from weirs along one or both sides of the channel shall be
designed and analysed taking account of both friction losses and losses due to mixing of
the incoming flow. The modified ‘Camp’ formulae may be used for headloss calculation
for ‘staged flows’ in effluent launders with weirs.

10.13.7 Control and other Hydraulic Structures
As far as practicable, sharp crested weirs with free discharge shall be used and shall be
designed with standard profiles for which flow characteristics are readily available, so
that their hydraulic performance can be predicted reliably from reputable hydraulic texts.
Sharp-crested weirs shall include adequate provision for maintaining atmospheric
pressures beneath the nappe.
Flumes shall be designed with the appropriate approach distance and the discharge
shall be designed to be free flowing (not drowned) with the appropriate maximum
submergence. Flumes shall be designed to work under all hydraulic flow conditions from
minimum to maximum.
10.13.8 Penstocks
Penstocks in channels shall be designed so that, when fully open, there is no

encroachment on the cross-sectional area of the maximum flow depth.
10.13.9 Hydraulic Gradient
The hydraulic gradient shall be calculated according to the following criteria:

• the roughness coefficient “C” or “K” shall be as per common engineering practice
(pipes and channels), the pipe manufacturer’s guidelines, taking into account
whether the use is for wastewater or surface water.
• a freeboard of at least 100 mm shall be provided to upstream weir crests under
maximum flow conditions when one stream is isolated, and at least 150 mm shall be
provided under full flow with all streams operational.
• The design shall ensure to minimize the turbulence and the release of H2S and other
odorous compounds by providing smooth transitions of flows and limiting the freefall
to maximum of 200mm unless it is essential for the process requirement
• the ADWF hydraulic gradient shall be calculated assuming one stream of process
plant is offline, and weir levels set accordingly.
10.13.10 Slopes
Contractor shall ensure that all pipes and channels shall be provided with proper slope
based on calculation. Also, shall ensure that provided slopes will facilitates draining of
pipes and channels when required during maintenance. At minimum contractor shall
consider following slopes for:
• All biogas lines on suction side shall have minimum slope of 2% and on discharge
side shall have minimum slope of 1.25%
• All pipe lines carrying plant drain and scum shall have minimum slope of 1%
• All channel shall have minimum slope of 1%
• All gravity sludge lines shall have minimum slope of 1.25% on suction side and
minimum slope of 0.5% on discharge side.
• If channels are not constructed in slope, then minimum 50mm thick screeding shall
be considered at lowest discharge point of channel and accordingly slope shall be
provided

10.13.11 Free Board
For all structures containing water or process liquid, the minimum freeboard (distance by
which top of wall / bottom of slab in case of walkway or closed tank is higher than the
maximum water surface level at receiving water under one unit out of service condition
for PFF condition) shall be 0.5 m unless specified otherwise.
10.13.12 Velocities
Following velocity criteria shall be followed by contractor for flows based on PFF with
return streams:
• For liquid lines the minimum pipe flow velocity shall be no less than 0.6 m/s and the
maximum pipe flow velocity shall be no more than 1.2 m/s for pumped suction and no
more than 2.5 m/s for pumped discharge, no more than 1.5 m/s for rising main and
maximum pipe flow velocity shall be no more than 1.2 m/s for gravity flow.
• For sludge lines the minimum pipe flow velocity shall be no less than 0.8 m/s and the
maximum pipe flow velocity shall be no more than 1.2 m/s for pumped suction and no
more than 1.5 m/s for pumped discharge and maximum pipe flow velocity shall be no
more than 1.2 m/s for gravity flow.
• For air piping, the normal velocity shall be not more than 18 m/s
• For biogas piping the normal pipeline velocity shall be no more than 12 m/s on
discharge side, whereas same shall be no more than 4m/s on suction side.
• For channels, the maximum velocity shall be no more than 1.2m/s
• For liquids the maximum velocity through gate opening shall be no more than
0.96m/s
• Self cleaning velocity shall be achieved.

Mechanical Works Design

11 MECHANICAL WORKS DESIGN

11.1 General Arrangement of the Works
The Contractor shall provide and arrange the Works to comply with the following general
guidelines:
• Minimum of 3.0m or more space shall be provided between outer face of items of
Plant and adjacent Plant or fixed structures to permit safe and convenient access for
operation and maintenance.
• For all walkways, platforms, equipment walkways, process tank walkways, etc. the
walking space between the handrails shall be 1.2m clear and shall not be taken up
(or blocked) by such items as piping, valves, actuators etc.,
• Layout of the site structures/equipment should comply with code distances required
between non-hazardous and hazardous structures/plant/equipment, etc.,
• Plant shall be arranged to permit the removal of individual Plant items or packages.
• An area adjacent to all mechanical Plant shall be provided as a maintenance lay
down area.
• Electrically operated cranes, fixed runways, lifting eyes or other means shall be
provided to permit the removal of larger items of Plant that may have to be removed
during the course of their normal operational life for maintenance or replacement
purposes.
• Areas where leakage of water is likely to occur, whether in normal use or during
maintenance, shall be provided with covered drainage channels which shall have
direct the spillage either to a suitable gravity drain or to a sump equipped with
standard dual pumps discharging to the plant drain system
• Where necessary, Plant shall be provided with removable acoustic coverings to limit
the noise produced during normal operation to the limits detailed elsewhere.
• Pipe work shall be designed and installed to prevent blockages and to permit their
clearance without dismantling pipe work or equipment.
• Valve and penstock actuators located outdoors shall not be of the pneumatic type.
• The treatment works shall be designed such that all potential spillages and
overflows resultant from single failures are either contained within structures or
sufficient alarms and controls are incorporated to prevent spillages and overflows
from escaping.
• Interceptor and containment tanks shall be provided for containment of all chemicals,
fuel and thickened sludge on Site, resultant from spillages and overflows.
• The Contractor shall take due regard to the potential of hazardous mixing of
chemicals, particularly as a result of leaks and spillages, and their drainage and
containment.
• Chemical pipe work shall be secured to racks or trays, to walls of tanks and walls of
buildings as necessary. It shall be arranged to facilitate maintenance and removal of
individual runs without dismantling adjacent pipes.
• All chemical pipes shall be colour banded and suitably labelled to enable individual
lines to be identified throughout their length.
• Particular attention shall be paid to the layout of the chemical pipe work, which shall
be functional and neat in appearance. Generally, where pipe work is installed in
trenches, it shall be supported not less than 300mm clear of the trench floor.
• The Contractor shall provide all signage necessary to inform of chemical and
operational hazards and to comply with statutory legislation.
• When selecting materials for pipe work, the Contractor shall give consideration to

the deteriorating effect of the action of ultra-violet light on materials.
11.2 Pumping Systems

The Contractor shall provide pumping systems with isolation valves, non-return valves,
and all necessary pipe work and fittings.
The Contractor shall provide pipe supports, hangers and anchors to support and control
movement of pipes and valves all in accordance with recognized international piping
standards.
All pumps shall operate at high efficiency throughout their duty range and they shall be
capable of continuous operation throughout their required operational range.
Lubrication arrangements shall be designed to avoid any contamination of pumped fluid.
Dry well mounted pumps shall provide effective means for collecting gland/seal leakage
water which shall be piped to a floor drain or sump.
The Contractor shall be responsible for the protection of pumping system pipelines,
including conducting hydraulic surge analyses and providing surge protection, as
necessary.
Main pump sets shall operate at a nominal speed of:

Maximum speed for pump sets
Raw wastewater: no greater than 1,500 rpm;
RAS: no greater than 1,500 rpm;
Treated wastewater: no greater than 1,800 rpm.
11.3 Chemical Storage and Dosing Systems
Bulk chemical storage shall have a minimum storage capacity equivalent to 30 days of
average usage at maximum facility throughput.
The Contractor shall provide flushing lines to dosing pump suction and delivery pipe
work.
The Contractor shall provide chemical dosing systems with calibration tubes and flow
measurement facilities.
For areas of polymer use and worker safety, the Contractor shall lay down corrosion
resistant anti-slip interlocking grid type rubberized flooring mats with raised stub
legs/pegs and surface ports/openings to allow free flowing drainage. The concrete
surfaces of the bunded areas (floors/walls) shall be first treated with an anti-corrosion
protective coating before the lay down of the anti-slip flooring.
11.4 Chemical Safety Facilities
The Contractor shall provide emergency showers in areas where chemicals are present.
The Contractor shall provide facilities to ensure protection from risks of tampering to
chemicals by unauthorised persons.
Portable and permanent firefighting equipment and facilities including, fire extinguishers
and fire blankets etc. shall be provided by the Contractor, as appropriate, in consultation
with the relevant local fire authorities.
A wash-down water facility shall be provided by the Contractor suitable for hosing-down
the chemical delivery areas, storage areas and dosing areas.
Service water chemical make-up, carrier water and wash-down shall be supplied by the

Contractor from a separate system to the Site potable water and emergency shower
supply system.
Hazard warning signs and weather-proof guidance notices shall be provided by the
Contractor to identify the safety precautions and emergency actions for each chemical
handled. These shall be fixed near to the appropriate bulk tank fill line hose connection
points.
All pipes shall be labelled by the Contractor and/or colour coded and identified with the
direction of flow at appropriate intervals.
11.5 Materials of Construction
All materials of construction for tanks, vessels, pipelines, pumps, valves, etc shall be
suitable for long term contact with the liquid or chemical concerned and at the prevailing
concentrations. Equipment shall be coated and protected in accordance with Volume 2A
Section 21 Painting and Protective Coatings, and Volume 2B Section 2.21 Surface
Protection.
All pipe work employed shall comply with the schedule below unless agreed with the
Employer’s Representative. The Employer’s Representative shall be under no obligation
to accept alternative pipeline material. Contractor to ensure compatibility of all pipelines
with fluids or sludge carried and with external and internal loadings and pressures.
Table 11.1 – Pipe materials
Service Size Range Pipe material
Raw water Up to and including DN Ductile Iron (DI) K9 class
including 1100
supernatant
Greater than DN 1100 Carbon Steel with cement mortar
lining and external guniting as per IS
code.
Sewage Up to and including DN Ductile Iron (DI) K9 class
1100
Greater than DN 1100 Carbon Steel with cement mortar
lining and external guniting as per IS
code.)
Sampling All Diameter uPVC/CPVC
ABS
SS 316
Instrumentation All Diameter Copper (Plain/coated)
piping uPVC/CPVC
Nylon
Stainless Steel
Chemical All Diameter uPVC/CPVC
Dosing SS 316L
HDPE
Chlorine Drum All Diameter Cadmium plated 70/30 copper nickel
connections CN 107, BS 2871 : Part 1

Chlorine gas or All Diameter Flanged or carbon steel A 106 Gr B.,

liquid CAF flanged joints
Sludge All diameters Ductile iron K9 below ground
Ductile iron K9 or Stainless steel 304L
above ground/inside buildings
Biogas All diameters Stainless steel 316L (below/above
ground, inside/outside buildings)
Process Air Blower discharge and SS 304L within building (Non wetted
piping common header– All part)
diameters
Transfer to and Stainless steel (316L)
distribution piping around Diffuser air grid – SS 316L
aeration tanks - All
diameters
11.6 Isolation and Drain Down

The Contractor shall provide facilities for isolating and draining down all pipework,
chambers and storage tanks. Wherever duty/standby equipment is provided, it shall be
possible to isolate and drain-down each of the duty or standby items while the other
items are in service as per tender requirements.

Electrical Works Design

12 ELECTRICAL WORKS DESIGN

12.1 General
12.1.1 Scope
This section describes the electrical Plant and services to be provided by the Bidder and
specifies the particular requirements for the Works not covered elsewhere in the
Contract.
The electrical Plant and services to be provided shall comprise all the necessary Works
for the completion of all main and ancillary installations, and shall include but not be
limited to:
• The power supply to the Site to cater for the Works installation, testing,
commissioning, operation and maintenance.
• The power distribution equipment, including power and distribution transformers,
switchgear panels,VFD, distribution boards, electrical protection, metering, earthing,
cabling, and cable support systems for the Works.
• Emergency power supply system , associated auxiliaries and Switch board. Provision
to extend Swithboard to connect the power generated from Bio gas plant.
• The Uninterruptible Power Supply systems , associated battery system and
Distribution board .
• Battery, battery charger and DC Distribution Board
• The electric motors and actuators to operate the mechanical equipment being
installed at the WwTF.
• The electrical starting equipment, isolating equipment, electrical protection, controls
and interlocks for each Plant item at the WwTF.
• The indoor, outdoor and emergency lighting including all poles, brackets, fixings, etc.
for the WwTF.Centralised Solar street/high mast comprising of Solar modules,cabling
and associated auxiliaries.
• The Site electrical services including sockets, space heating, ventilation, etc.
• The fire detection and alarm systems.
• The gas detection and alarm systems.
• The telecommunications systems (EPABX and PA systems).
• The security systems including CCTV system.
• The Earthing,lighting and lightning protection system.
• The construction phase electrical services.
• The Materials and accessories to provide a complete electrical installation.
• The field instrumentation, PLC, SCADA Automation systems.
• Alternator and auxiliaries required for The bio-gas power generation unit
• The equipment and control systems to interface with the power supply utility’s
incoming supply and the power generated through bio-gas generation
Variable frequency drives (VFD) shall be provided for the following equipment :
• RAS pumps,
• Process blowers,
• Thickened sludge scraper pump,
• Centrifuges
• any other as per process requirement

Power supply source of 33 kV, 3 phase, 50 Hz shall be tapped from 33 kV Switchyard

panel in new substation of proposed Influent Pumping Station premises. The distance
between WwTF plant boundary and new substation at IPS is approximately 100m. If that
power supply is not adequate to supply the total load of WwTF, alternative power supply
to be arranged by Contractor. Separate metering for WwTF load monitoring shall be
installed by WwTF Contractor at new substation of proposed IPS.
12.1.2 Electrical Power Supply Design
The Contractor has to take power connection from Substation of the proposed IPS. In
case it is not sufficient the Contractor will be responsible for the supply of power to the
site from an appropriate power supply utility. The Contractor shall discuss with the utility,
at the earliest opportunity, the provision of permanent power supply to the Site, so that
supplies are in place prior to commissioning of the Works. The Contractor shall consult
with the supply authority in advance of each connection, shall make the necessary
application for a new connection. All charges in relation to each connection against
additional supply to the site shall be paid by contractor and same shall be reimbursed by
employer at Actual.
Power source arrangement of 33kV, 3 phase, 50 Hz, 100% capacity dual incoming
supply shall be so that, the outage of one supply feeder will not cause the interruption to
the plant. These incomers shall be obtained from two different feeders from 33 kV
Switchyard panel in new substation of proposed IPS. Motors above 200kW shall be
connected to HT/ LT supply and accordingly appropriate transformers with standby
provision shall be provided for stepping down 33kV to the desired HT/ LT supply.
If treatment technology with power generation from bio-gas is proposed, the Bidder shall
design the system such that the utility power source can be used in conjunction with the
onsite bio-gas source for normal operation of the Works.
The Contrator shall establish the maximum demand for the Site, and in discussion with
the power supply utility, the best method for provision of secure supply. In addition he
shall provide a supply which is capable of running a facility with a demand 20% greater
than that required for the design horizon.
All the recurring charges (monthly energy consumptions bills) towards operation and
maintenance of WwTF shall be borne by the Contractor. Necessary technical support as
well as covering letters required from MCGM shall be provided to the Contractor, as
required.
The Contractor shall ensure that the size of any switchboards, transformers, busbars,
cables and capacitor used in the power supply are adequate for the Work’s requirements
and that they are installed in a manner to provide maximum reliability of supply and
flexibility of operation.
The Contractor shall establish the size and nature of the power supply requirements for
the testing, commissioning and operation of the facility. The Bidder shall provide a
detailed schedule of all electrical loads together with the rated current, power factor,
efficiency and diversity factor of each load sector.
From the above load schedule the Contractor shall establish the Works loading in
kilowatt hours consumption per annum and the peak demand of the wastewater
treatment facility. In addition, the Contractor shall, using the proposed electrical load for
the WwTF, submit detailed applications to the power supply utility for the supply of these
loads, noting the requirements of Section 14.10.
The Contractor shall establish the nature of the power supply and shall ensure that they
are reliable and adequate for the operation of the WwTF without constraints.

The Contractor shall ensure that the necessary cable ducts / hume pipes are provided
for the power supply utility and that power supply cables are properly designed and
installed up to the location of the main switchgear.
• Incoming Supply Conditions - Voltage and variations: 33 kV ± 10%
• Frequency and variations - 50Hz ± 5%
• Combined variation - 10%
• Fault Level at 33 kV - 40kA (Max.) for 1 sec (This shall be confirmed
with electric Supply Co.)
• System Ground - Effective
For any detailed information regarding the existing / new power supply, fault level at
33kV, substation location etc. bidder shall visit the site and collect the required data from
the concerned authority.
12.1.3 Power System Studies and Selective Coordination
The Bidder shall prepare and submit a schedule of the electrical loads for the Works.
This schedule shall show the total connected load in each category, together with the
calculated diversity factor, the probable load and the maximum demand likely to be
experienced.
This information shall be submitted to the Employer’s Representative for review. The
Bidder shall design the electrical power system to suit the ratings and duty cycles of the
plant items and auxiliary systems which are to be installed.
The power distribution shall be designed to suit the voltages at which power is supplied
by the electricity supplier.
The Bidder shall select the necessary voltage and current transformers together with
suitable protection relays to protect the electrical distribution system. This protection
shall include thermal overload, short circuit, ground fault and single phasing as a
minimum.
The electrical protection shall be graded so that indiscriminate tripping is prevented
under fault or surge conditions.
The Bidder shall co-ordinate the electrical protection at the Site with the power supply
utility system protection and shall submit to the Employer’s Representative during the
design a tabulation to demonstrate the protection settings to be employed and the
appropriate discrimination curves for the power system.
12.1.4 Emergency Power Supply
The contractor shall provide two gas fuel trains (Biogas and CNG) to CHP engines as a
permanent and emergency power source to operate it on biogas / CNG as fuel. The
capacity of CHP engines shall be sufficient to operate the facility’s essential services
during a complete power failure of the electricity supplies from power grid.
Cost of any natural gas for running CHP engines during electric power failure will be
borne by the contractor.
The facility shall be capable of safe shut down of non-essential services and of safe
start-up upon restoration of normal power from grid. The contractor shall develop a
procedure and demonstrate how this would be carried out in safe manner.
12.1.5 Uninterruptible Power Supply (UPS)
The Contractor shall supply and install the necessary online, double conversion

uninterruptible power supply (UPS) units for the PLC systems, SCADA operators station,
field instruments, fire detection, smoke detection, gas detection and alarm system,
EPABX and PA system and CCTV system etc. to ensure continuity of supply for a
minimum of 60 minutes duration during mains power failure or “brown out” situations.
The UPS shall be either ‘parallel redundant’ type or ‘hot standby’ type. The Bidder shall
provide a minimum of 2 no. 100% battery charger configuration of appropriate rating with
single set of 100% battery bank. The UPS shall be suitable under normal conditions to
operate continuously at the specified ratings for 24 hours a day, and 365 days a year.
Each system shall be sized for not less than 1.25 times the maximum current demand
that might occur, takinginto account inrush currents and the like; and shall support 1.25
times the maximum continuous load that might occur during a period of 60 minutes. The
continuous load shall include all loads that might occur and de-rating for diversity shall
not be taken.
The UPS shall incorporate a static switch to by-pass the UPS seamlessly and effect a
connection to the mains supply in the event of a UPS failure.
The load supplied by the UPS system shall be supplied from an isolation transformer on
the UPS output. Each load circuit shall be separately protected against over-current, with
sufficient discrimination so that a fault on any circuit will not trip the UPS output supply.
Fault trip times shall be based on a “mains failed” situation, when the internal impedance
of the UPS will be apparent. The UPS shall have Overload capacity of 110% for one
minute.
Start, stop and reset procedures shall be clearly displayed for an operator. The system
shall have features to assist in fault finding. Clear instructions, labeling, shrouding, etc.,
shall be provided so that a technician may undertake maintenance and first line repair as
a minimum.
The degree of protection shall be IP 42 or better.
Tests shall be carried out on the fully assembled unit utilizing the batteries that are to be
supplied with the unit.
The Bidder shall demonstrate the following:-
a) Changeover from full load with mains present to full load on battery supply;
b) Carry out a discharge test on the system at full load and for the specified duty
bridging time period;
c) Carry out recharge test after operation for the specified duty bridging time at full load.
The UPS shall supply the full load during the recharge cycle.
The UPS shall be supplied from an auxiliary switchboard. In the event of failure of the
UPS or if it is taken out for servicing, then an alternative supply of power shall be
provided from an associated motor control centre.
12.1.6 Battery, battery charger and DC Distribution Board
DC Power supply shall be provided for Trip / Closing coils, Indications etc. for HT and LT
Switchgears. The batteries shall be 110V, maintenance free, Ni-Cd type and shall be
complete with battery charger with boost & trickle charging facilities, necessary controls,
indications and DC distribution board.
12.1.7 Power Factor Correction
The Contractor shall design the power system to operate at a minimum power factor of
0.995 lagging at the point of supply of the power supply utility.
Automatic power factor correction systems shall be provided at all MCC’s that feed the

blowers. In addition, an APFC system shall be installed at the PCC to meet the desired
power factor.
Care shall be taken to ensure that harmonic distortions are limited and the Bidder shall
consult the power supply utility concerning the impedance of their supply network at the
frequencies most liable to cause resonance.
12.1.8 Switchgear
High Voltage (HV) switchgear

The High Voltage switchgear shall be designed by the Contractor and shall be indoor
type.
The Bidder shall ensure that the 33kV switchgear is designed to accept the power supply
utility’s power. The Bidder shall distribute the power on the Site, by taking into account
the location of the ‘on-site’ generation if it is proposed and the various power demands
around the Site.
The Bidder shall ensure that the HV switchgear is rated for the fault levels likely to be
encountered on the Site and the system protection installed.
The busbar material of high voltage switchgear shall be copper. The busbars of high
voltage shall be extendable at both ends.
The Bidder shall ensure that circuit breakers on the HV system are interchangeable
where this is possible and logical and that the HV switchgear panels (switchboards) are
suitable for extension at both ends.
An ammeter shall be fitted to each outgoing circuit breaker panel. Readings from these
meters shall be displayed and recorded on the SCADA system.
A digital kilowatt hour meter shall be supplied and installed by the Bidder at the incoming
power supply point and this shall be used to verify the power supply utility power
consumption figures. Energy measured by this kWhr meter shall be displayed and
recorded on the SCADA system.
Low voltage switchgear, Power Control Centre and Motor Control Centre
Low voltage switchgear, Power Control Centre and Motor Control Centre assembly shall
be of the totally enclosed metal clad pattern. PCC and MCC shall be of conventional type.
All single/double front PCC and MCC shall be Totally Type Tested (TTA). Seismic
withstand capacity of the MCC and PCC panels shall be at least for seismic zone 3.
Type of internal separation for PCC/MCC panel shall be as per Form 3B. Lighting board
or small distribution board separation shall be either as per Form 1 or Form 2.
PCC/MCC shall be provided with copper busbars, extendable at both ends.
Each incoming feeder of blower MCC shall be equipped with a Multifunctional Energy
Meter incorporating the functions of a voltmeter, an ammeter, a kilowatt hour meter, a
power factor meter and a frequency meter. The parameters monitored by the energy
meter shall be available for monitoring and recording on the SCADA system.
The Bidder shall select the starter appropriate to each drive motor and shall ensure that
starting sequences are programmed to minimize disruption of the power supply and
maximize Works availability.
When designing the low voltage distribution assemblies the Bidder shall ensure that they
are dimensionally suitable for delivery and installation on Site.
The Bidder shall ensure that provision is included in the low voltage switchgear to
interface with the necessary on-site generators if power generation from bio-gas is
proposed and this provision shall include all the necessary control gear, protection and

interlocking between generator and supply authority to enable the ‘on-site’ generators to
synchronize.The necessary volt free contacts and analogue signals shall be provided by
the Bidder on each panel for interfacing with the SCADA system.
12.1.9 Emergency Stop Equipment and Local Isolation
Local Control Stations

The Bidder shall provide each item of electrically powered rotating machinery with local
start and emergency stop pushbuttons. Where the drives have the capability to run in
forward and reverse, separate “Start Forward” and “Start Reverse” buttons shall be
provided. The pushbuttons shall be housed in the same enclosure, clearly labelled,
adjacent to the relevant access point or machinery.
Where applicable, e.g. screen drive motors, the local control enclosure shall include
pushbuttons for “inch forward” and “inch reverse” control.
“Emergency Stop” buttons shall be of the “Stay Put” type, twist or pull to release, in
accordance with IEC 60947.
The material of Contraction shall be SS 316.
Local Isolation
The Bidder shall provide each item of electrically operated machinery with a local isolator.
Isolators shall be mounted in accessible locations adjacent to the motor, or for
submersible pumps, adjacent to the entrance to the sump.
Local isolators shall have auxiliary contacts to trip and lock out the contactor when the
isolator is open.
Local isolators shall be provided in all cases for valve or penstock actuators.
All local isolators shall be suitable for padlocking in both the “on” and “off” positions and
shall not be provided for use as an emergency stop facility.
12.2 Measurement of Electricity Usage
The Bidder shall be responsible for the provision of electricity meters to permit
assessment of compliance with the Energy Generation requirements and to assess
whether Performance Damages are due.
As a minimum electricity meters shall be installed to measure the electricity provided by
the electricity utility service provider for the Works (this meter can be the service meter
used by the electricity utility service provider for billing purposes provided access can be
gained to the meter to take daily readings). In addition, a meter shall be installed to
measure the energy generated by the Energy Generation System in case, power
generation from bio-gas is proposed.
Each of the above meters shall be read by the Contractor every Day at the same
approximate time. The Contractor shall record and maintain records.
12.3 Cabling and Earthing
12.3.1 General Cabling
This section covers the supply and installation of the necessary cabling and earthing
systems not covered elsewhere in the Employer’s Requirements.
33kV cables, forming part of a dual supply to the WwTF shall be from underground duct
and separated both outside and within the Site by at least 1050 mm to reduce the
possibility of physical damage causing a complete power failure to the Works. For creeky
area underground cable shall be laid through hume pipe.

For the consideration of the Employer’s Representative, the Bidder shall provide detailed
schematic and block diagrams, together with schedules of all cables he proposes to
install for power, control and instrumentation systems. The schedules shall include the
following information:
a) Type of cable;
b) Size of conductors (including circuit protective conductor);
c) Number of cores;
d) Voltage grade;
e) Cable gland;
f) Cable identification reference number;
g) Cable source;
h) Cable destination;
i) Cable length;
j) Installation method;
k) Terminal references.
12.3.2 Types of Cables
Cables shall have a “Fire Retardant and Low Smoke” (FRLS) outer sheath as per
IS 10810 and ASTM D 2863 to restrict release of toxic fumes from the cable in the event
of a fire. XLPE cables shall be as per IS 7098 whereas PVC cables shall be as per
IS 1554.
The following types of cables shall be provided:
a) HT cable power circuits
AL/XLPE/PVC/F/FRLS, 6.6/3.3 kV (UE) grade
AL/XLPE/PVC/F/FRLS, 33 kV (UE) grade
b) LV power circuits
For conductor sizes above 2.5 mm2 AL/XLPE/PVC/W/FRLS, 650/1100V grade
For conductor sizes 2.5 mm2 or less, CU/XLPE/PVC/FRLS, 650/1100V grade,
Unarmoured
c) Auxiliary control and protection circuits

CU/XLPE/PVC/FRLS, 650/1100V grade, Unarmoured, Stranded
d) Control and instrument circuits

All control monitoring and instrumentation shall have individually twisted and
screened pairs, a collective screen, CU/PVC/FRLS, 650/1100Vgrade, Unarmoured,
Stranded
e) Data highway
Optical fiber cables shall be used throughout the data highway interconnecting each
PLC with the SCADA system master-stations.
f) Telecommunications cables
Cables for telephone and data outlets shall be Category 6A Unshielded Twisted Pair
(UTP) type with FRLS sheath.

12.3.3 Cable Sizes
The short time fault current ratings and withstand time of all power cables shall match
the maximum fault ratings of the associated switchgear plant and protection systems.
The Bidder shall determine by site investigation the values of:
• Soil temperatures;
• Soil thermal resistivity.
With the exception of special cables for analogue signal and measuring circuits, the
minimum core size for auxiliary power and control cables shall be 1.5 mm2.
All multicore cables provided for the Works protection, control and monitoring systems
shall incorporate 20% spare cores. All spare cores shall be terminated and identified.
12.3.4 Cabling within Buildings
The all type cable trays for electrical and instrumentation shall be Hot Dip Galvanized
Aluminum (processed at factory) with galvanization thickness of minimum 86 microns for
all areas. The thickness of cable tray shall be minimum 2.5 mm.
The above will supersede any other conflicting provisions in the entire tender document.
For fixing cable trays in trenches, cable galleries, etc. galvanised steel channel inserts
shall be embedded into the concrete, spaced at centres not exceeding 1,500 mm. Civil
structures utilized to support cable tray systems shall be designed to withstand the
additional loading.
Whenever cables pass through walls below ground level, the point of entry shall be
sealed against the ingress of water. This shall be achieved with silicone foam or similar.
12.3.5 External Cabling
External cables shall be contained within underground cable trench unless specifically
agreed with the Employer’s Representative in advance.
Separation between cable systems and all other underground services shall not be less
than 1300 mm in all directions unless otherwise agreed by the Employer’s
Representative.
In ducted section of cable routes the specified segregation between power and control
cables shall be maintained throughout the ducted section and within cable duct
manholes and draw chambers provided by the Contractor for installing cables.
12.3.6 Earthing
The Contractor shall provide and install a complete earthing system in accordance with
the requirements of IS 3043 and IEEE-80 rules.
The Contractor shall design the system to meet the following requirements:
a) Under normal and abnormal operating conditions, there shall be no danger to
persons in any place to which they have access;
b) The maximum current from any point of fault shall be conducted back to the
electricity system neutral without giving rise to dangerous potential gradients either in
the ground or between pieces of apparatus and a person who could be in
simultaneous contact;
c) The passage of fault current shall not result in any thermal or mechanical damage to
the system.

d) Earthing system for electrical, instrumentation control and automation (I&C) and
lightning systems shall be laid separately. Bidder shall be responsible for
interconnection of these grids.
The Contractor shall satisfy the power supply utility that the earthing arrangements on
the electrical installation are compatible with their system requirements.
Earth tape and conductors installed in areas subject to chemical corrosion shall be
sheathed with green/yellow FRLS insulation.
12.3.7 Lightning Protection
The Bidder shall provide and install a lightning protection system where required, in
accordance with IEC 62305: Protection against Lightning. Early streamer emitter type
lightning protection shall not be used.
Selection, installation and maintenance of surge protection devices for protection from
indirect lightning surges and switching surges shall be as per IEC 61643
Earthing for lightning protection system shall be as per IS 3043 or IEC 62561.
The Bidder shall provide the anaerobic digestion complex with lightning protection
including the CHP exhaust stack(s) and the waste gas burner stack(s).
12.4 Building and Site Services
12.4.1 Power Supply
This section describes the building and site services required, and specifies particular
requirements not covered elsewhere in the Contract.
The Contractor shall provide the power supply for all building and site services from the
building services switchboards or otherwise derived from distribution boards which, as
far as practicable, shall form an integral part of the main LV distribution and plant control
switchboards.
The contractor shall maximise use of solar power through centralized solar power
system to provide the power supply for all building and site services with a provision of
auto switch over to normal electric supply in case of emergency/any problem with solar
system
Sub-distribution boards not forming part of LV switchboards shall be complete with
outgoing miniature circuit breakers for connection to the services and other equipment.
Distribution board providing power for lighting shall have provision of Residual Current
Circuit Breakers (RCCB) of 100mA.
At least 3 spare ways for each type and size of circuit breaker in the distribution boards
shall be included.
At least 2 no. 240 V single phase 5/15A outlets shall be provided in each room and in
any case shall be within 15 m of any internal part of a building.
At least 1 no. 415 V three phase socket/ power receptacle shall be provided in each
Plant area for maintenance purposes.
The Contractor shall provide for cooling and ventilation to maintain a temperature of
25OC in PLC-SCADA control rooms and offices.
12.4.2 Lighting Design
The building internal lighting design shall take into consideration:

a) Operating environment;
b) Energy efficiency;
c) Activities to be performed in the areas concerned;
d) Type and style of architectural finish;
e) Access for maintenance;
f) Operating life;
g) Sustainability.
All internal areas shall be provided with LED lighting.
Lux level for each area shall be selected as per IS 3646 & IS 1944.
Lighting circuits shall be supplied from the small power and lighting distribution boards
incorporating manually reset miniature circuit breakers. For large areas or buildings,
separate distribution boards may be located to serve discrete areas.
Switching shall be convenient to doors and entrances, two-way switching being provided
where areas have more than one entrance.
For large areas, lighting shall be contactor controlled. Contactors shall where practical be
incorporated within the respective distribution boards.
The lamps provided shall be of minimum three star rating as designated by Bureau of
Energy efficiency.
In areas housing rotating machinery, lighting shall be arranged on multi-phase circuits to
prevent stroboscopic effects.
The arrangement of circuits shall be such as to provide balanced loading of the phases.
The Contractor shall prepare detailed layout and installation drawings to show the
location of the distribution boards, conduit routes, lighting fixtures, receptacles and other
fittings, etc. for consideration by the Employer’s Representative, together with
illumination level design calculations to support and confirm the proposals.
Except in any building where ceiling or wall finishes permit conduits to be concealed, the
installation shall be carried out in surface run galvanised conduit. All lighting switches,
socket outlets, etc. shall be metal-clad surface mounting type.
12.4.3 Emergency Lighting
The Contractor shall provide emergency lighting for all control rooms, buildings and exit
and escape routes to facilitate the safe evacuation of personnel from all buildings and
structures in the event of power failure and shall be in accordance with BSEN 50172.
The Contractor shall also provide emergency lighting as per direction of Engineer’s
representative.
During the normal operating condition, the emergency lighting shall be connected to the
normal power supply. In the event of mains power failure, the emergency lighting shall
be connected to the emergency power supply.
The emergency luminaries shall be directly connected to the respective area main
lighting circuits, to cover both total power and sub-circuit failures.
Emergency lighting circuits shall incorporate central test unit switches to simulate failure
of the normal supply. These test switches shall be situated in a position within the area
covered by the lighting system to be tested and shall be suitably identified. Switches
situated in positions accessible to unauthorised persons shall be of the tamper-proof, key
operated type. All such switches shall be operated by a common key and the Contractor
shall supply two keys for each switch installed.

12.4.4 Street Lighting
The Bidder shall provide street lighting systems to illuminate all site roadways within the
treatment facility areas and access road. Lux level for outdoor site shall be as per
IS 1944.
The Centralized, On-grid solar lighting system shall also be provided for street lighting.
The Centralised solar lighting systems shall comprise:
1. Solar modules (to be located suitably to cater the street lighting load)
2. LED street light with weatherproof body
3. Galvanized octagonal/ tubular electric poles
4. Batteries
5. Inverter
6. Supply change over switch
7. Required protection and control devices (Short circuit, reverse polarity, battery over
charging, deep discharging etc.) and wiring work.Space required for the solar
modules and suitable location to be proposed by bidder.
Solar module shall convert solar energy into electrical energy and store into the battery.
During the night time stored energy shall be converted to AC using efficient inverter and
shall be supplied to the street lights. The system shall be powered from the normal grid
supply in case of cloudy days or in case of insufficient day light to charge the battery.
The poles shall be sited a minimum of 1m from the road kerb edge with non-extended
brackets to locate the lanterns at the kerb.
The street lighting shall be fed on independent radial buried cable circuits fed and
controlled from a street lighting switchboard. The cables laid for outdoor lighting
application shall be wire armoured.
Each circuit shall be contactor switched, controlled by an astronomical timer and manual-
auto control selector switch. The contactor, time switch and manual control switch for
each area shall be incorporated in the LV road lighting distribution switchboard.
12.4.5 Site Area Lighting
Site area lighting installations shall provide an overall minimum service luminance as per
IS 1944 over the whole of the Site.
All external areas shall be provided with Centralized, On-grid solar LED lighting. The
system of centralized solar lighting shall be designed as described in section 12.4.4.
A minimum of four high mast flood lighting columns shall be provided. Columns shall be
a minimum of 15 m high, or higher if so required by the site layout or building
arrangement. The columns shall be located to suit the proposed layout so as to ensure
no areas are in shadow when all flood lights are energized. The flood lighting shall
provide a minimum horizontal illuminance over the whole of the Site of 5 lux and shall be
designed to provide lighting levels which are uniform and to minimize overspill of lighting
outside the boundary.
Area flood lighting shall be fed from service distribution boards incorporated in the
respective plant or ancillary switchgear buildings. Area lighting shall be capable of
manual control from each respective building and the security control room and shall be
capable of being switched on by a security intruder signal.

12.4.6 Low Voltage (LV) Portable Equipment
For each building the Bidder shall provide one set of low voltage equipment comprising
the following:
240 V, 50 Hz weatherproof, portable, heavy duty floodlight and plug for 240 V centre
tapped earth socket outlet complying with IEC 209 and colour coded.
12.4.7 Fire Detection and Alarm
The Bidder shall provide microprocessor based addressable fire detection and alarm
systems in all plant buildings throughout the Site in accordance with national standards.
The Bidder shall provide a detailed statement for fire protection and emergency
evacuation system with escape route to comply with national standards. The fire alarm
system shall be connected to the SCADA system and emergency services. The FDAS
design shall be governed by NFPA-72 (latest edition) guidelines.
The fire detection and alarm systems shall comply with the following:
a) A fire detection system shall be provided in all electrical buildings, control rooms and
admin building comprising automatic addressable fire detectors and addressable
break glass units.
b) In multiple room or plant area buildings the automatic addressable and manual break
glass units shall be installed in zoned circuits covering each specific room or area.
c) The automatic addressable fire detectors shall operate on rate of temperature rise
and fixed maximum temperature characteristics; the maximum temperature alarm
actuating at 20oC above peak design internal ambient. Each detector shall
incorporate a pilot lamp operation indicator.
d) Automatic heat and smoke detectors shall be ceiling mounting arranged to cover
general building areas and specific plant locations.
e) The manual /addressable break-glass units shall be wall mounted, located at building
entrances, general walkways and corridors and in other areas such that no location
in a building is greater than 30 m from a unit.
f) Sounders shall operate on 24 VDC nominal with sound level of at least 90 dBA ±
2dBA @ 1 meter from the device, with a frequency response of 2000-8000 Hz with a
lower power rating.
g) Alarm/detection installations in ancillary Plant buildings may be installed as zoned
alarm circuits from the fire detection systems of associated adjacent main plant
building.
h) All detector and alarm circuits shall operate on a normally closed fail-safe circuit
principle.
i) Each fire detection system shall operate at 12 V dc or 24 V dc from a single fire
alarm control panel (FACP) which shall be arranged by Bidder,located at a location
subject to the consideration of Employer’s Representative. The FACPs shall be of the
totally enclosed metal clad pattern each complete with integral battery/charger
equipment. The FACPs shall each incorporate alarm and status indicators together
with circuit test facilities to give visual alarm indication of:
i) Actuation of each alarm circuit and zoned protected area
ii) Input power system – healthy/failed
iii) Battery/charger output – healthy/failed
j) Respective cluster LED provided on the FACP shall start blinking for particular zone
area in case of fire detection. Once the fire alarm is acknowledged, the LED shall
glow steady.
k) Operation of any addressable fire detector or addressable break glass unit shall

operate audible alarm(s) located internally and externally on each building. In areas
with high ambient noise the audible alarm shall also incorporate a visual flashing
beacon lamp.
l) Alarm system operation together with the operation of a control panel integral
equipment fault circuit shall also be annunciated on the SCADA system.
m) All component equipment in the fire alarm installations shall comply with a
specification which has been considered by Employer’s Representative. All cable and
wiring systems for the building alarm and detection circuits shall be of pliable fire
resistant type cable, sleeved in stainless steel conduit, to provide mechanical
protection for the cable. All cable terminations for detector and manual break glass
units shall be in stainless steel circular conduit boxes.
n) Alarm circuits between each plant building and the central control panel shall be by
dedicated LSF/SWA/LSF control cables.
o) Interface unit / modules shall be provided for integrating the Public Address system
with the FACPs. In the event of fire, the FACPs shall trigger the PA to generate a
pre-recorded announcement.
p) Lead acid type batteries shall be provided in the FACP panels. The batteries shall
have ample capacity to operate all components of the system, including all alarm
signalling devices for 2 hours in standalone & a minimum period of 30 minutes in
alarm mode upon a normal AC power failure.
q) Interfacing with HVAC shall be provided so that when fire will occur AC will
automatically tripped.
p) The fire alarm panel shall have provision (along with all required hardwares) of third
party interfacing on open protocol so that any third party system can communicate
easily (namely Public Address System). Auto dialling facility shall be provided in FAP
to link to fire brigade station.
12.4.8 Gas Detection System
The Contractor shall incorporate fixed gas detection systems into those areas of the
Works where toxic or explosive atmospheres might occur. These shall include, but not
be limited to, the following areas:
a) Sludge digestion unit;
b) Gas storage units;
In addition to any local annunciation the alarms generated shall be displayed on the
associated PLC/SCADA system which shall initiate an extract purge and detection system.
In addition, a minimum of 2 portable gas monitor based systems units which can detect
CO2, CH4, O2 and H2S, accompanied by the necessary procedures and systems to
ensure their correct application shall be supplied and employed where appropriate by the
Bidder.
12.4.9 Telecommunications and Data Systems
The Contractor shall supply a telecommunications and data system for the wastewater
treatment facility building. Minimum 02 Nos. telephone handsets shall be provided by the
Contractor within Electrical rooms & PLC SCADA control room and admin building rooms
occupied by Client’s senior personnel/ officers to establish voice communication outside
WwTF limits.
Telephone cables for routes external to buildings shall be multi-pair polythene insulated,
0.9 mm dia. copper conductor, petroleum jelly filled, collectively screened with aluminium
tape and copper drain wire, polythene inner sheath, galvanised steel wire armoured and
LSF sheath overall. All cores shall be colour coded. All cable interconnections shall be

made in termination boxes which shall be installed within the buildings. Underground
joint boxes shall not be used. All cables shall incorporate at least 25% spare cores and
all cores including spares shall be terminated.
Telephone distribution cables wholly within buildings to junction boxes and outlet points
shall be similar but unarmoured, and with conductor diameter not less than 0.5 mm.
Each telephone and data outlet shall be wired from a central patch panel in each building,
using Category 6A UTP type telecommunications cable, terminated at a wall outlet point
equipped with a faceplate and wiring terminals. Cable core terminations shall be carried
out in accordance with the manufacturer’s instructions.
Telephone and data cabling within buildings shall be contained in stainless steel conduit.
12.4.10 Security System
The Bidder shall provide a suitable security system for the whole of the Site.
In addition to the general site security system, high risk plant or materials shall be
protected by lockable cabinets, intruder alarms or other devices. Alarm signals shall be
fed to the centralized security control room which shall be located in or adjacent to the
guardhouse.
The general Site security system shall be by Internet Protocol (IP) based colour Closed
Circuit Television (CCTV) systems to detect intruders and raise alarms.
Sufficient cameras(minimum 20 Nos.) shall be deployed to ensure full site coverage.
Output from all cameras shall be fed to a centralized security control room located in or
adjacent to the main guard house which shall include multiple screens to permit live
viewing of camera output. The system shall record the output from all cameras on
Network Video Recorders (NVRs) and save the recordings for a minimum of 60 days on
a First In/First Out (FIFO) basis.
The cameras shall include night vision capability. Principal cameras shall have a
Pan/Tilt/Zoom (PTZ) capability with the facility to be controlled from the centralized
security control room.
All the CCTV products i.e. fixed cameras, PTZ cameras, NVR etc. must be UL approved
or equivalent.
12.4.11 Miscellaneous Materials and Accessories
The Bidder shall be responsible for the supply and installation of all miscellaneous
Materials and accessories necessary to provide a complete electrical installation to
conform to the Employer’s Requirements.
12.4.12 EPABX and PA (Public Address) Systems
The Bidder shall provide an Electronic Private Automatic Branch Exchange (EPABX) and
Public Address (PA) system to satisfy the communication, safety and management
requirements of the Contract and as per relevant Indian/International standard including:
• Institute of Electrical and Electronic Engineer (IEEE) standard 802
Telecommunication Engineering Center (TEC)
• PA system as per EN 60849
• Speaker safety compliance as per EN 60065
• Loudspeakers as per IEC 60849, BS 5839, EN 54-24
• Power handling capacity of loud speakers as per IEC 268-5.
• Minimum 1 No. speaker to cater each room, process/ equipment area in all buildings

• Minimum 1 No. phone/ handset for each room/ equipment area in all buildings

Instrumentation, Control & Automation (ICA) Design

13 INSTRUMENTATION, CONTROL & AUTOMATION (ICA) DESIGN

13.1 Plant and Equipment to be provided
This section describes the ICA System to be provided by the Contractor and specifies
the particular requirements for the Works not covered elsewhere in the Contract.
The Plant to be provided for the Site shall include, but not be limited to, the following:
(a) PLC panels complete with all accessories
(b) flow monitoring equipment for all main process streams including wastewater inflow
and treated wastewater outflow etc.
(c) quality, sampling and monitoring equipment
(d) level monitoring equipment
(e) process control equipment
(f) pressure measuring equipment.
(g) Measurement for gas and power generation
(h) Measurement for sludge management system
In addition, the Contractor shall provide all other monitoring equipment required for the
full functional and safe operation and maintenance of the Works.
All PLCs and four wire monitoring equipment shall operate at 240 VAC,1Phase, 50 Hz.
Two wire monitoring equipment shall operate at 24V DC. All monitoring equipment shall
be supplied from a UPS such that monitoring of all facility conditions is maintained during
a mains power supply failure.
13.2 Drawings and information to be provided
The Contractor shall provide drawings and information which shall include but not be
limited to:
• Functional design specification
• Piping and instrumentation diagram (P&ID)
• PLC/SCADA system architecture
• Input/output (I/O) list
• Instrument list
• Alarm and set points list
• SCADA system mimic screens/menu
• Manufacturers’ catalogues and data sheets.
• Operation and Maintenance Manual
• Cable and Junction box schedule
• Instrument hook up drawings
• Loop schematics and interconnection wiring diagram
• Instrument data sheet, Instrument test and calibration report
• Instrument operation and maintenance manual
• Complete project documentation with operation and control Philosophy
• Final documentation and manuals
• As built drawings.
13.3 Control Room ICA Panels

13.3.1 General
All instrument control panels shall be free-standing, floor-mounted cabinets of the cubicle,
console or desk pattern located within the respective plant buildings or in kiosks housed
in civil structural housings.
Each local plant MCC shall have an associated PLC Panel. It shall include, but not be
limited to, the following equipment and facilities:
a) Local PLC with redundancy to CPU unit;
b) Human Machine Interface (HMI) key-pad (minimum 300mm) and colour display unit
c) Online double conversion type UPS system
d) Relays as required to interpose PLC I/O with plant control equipment.
e) Alarm annunciator panel to give local indication of failures not indicated elsewhere on
the PLC panel or corresponding MCC.
f) Pushbuttons, signal lamps, selector switches and indicating instruments and all other
necessary equipment for the automatic or manual control of the Plant.
g) Monitoring instrumentation as required for the effective operation and maintenance of
the WwTF.
For the pumps, blowers, valves and penstocks the controls, signal lamps, switches and
indicators shall be mounted on the respective panel as a group for each item of Plant.
13.3.2 PLC Panels
PLC panels for the WwTF shall be located within air-conditioned control rooms as free
standing panels They shall comprise, but not be limited to, the following main items of
equipment:
a) PLC system for the control and monitoring of pumps and associated rotating plant
and equipment. By means of an associated PLC keypad an operator shall have the
facility to select a variety of mimics for presentation on the PLC display unit or HMI
unit with the added facility of modifying control set points. These mimics shall include:
i) Simplified displays of plant and auxiliary equipment, with status, set-point, flow
and level indications displays of blowers, pumps and associated plant, with status,
set-point and variable value indication.
ii) A display of the duty for each pump or rotating plant item, with the facility, by use
of the PLC keypad, to manually select duty; or to select auto-duty rotation such
that the duty of each rotating Plant item is automatically changed after a preset
time has elapsed.
b) Alarm annunciator shall include those failure indications not displayed at the local
MCCs, these generally shall include high/low alarm for sump, forebay level,
Motor/Pump winding/bearing temperature, pump pressure, failure of level instrument,
pump trip alarm etc.
c) Process monitoring equipment shall include:
i) Treated wastewater quality monitors
The 4-20mA output from these monitoring and analytical instruments shall be
transmitted to the PLC to provide control and process monitoring on the SCADA
system.
ii) Pitot tube & DP Cells, flow measurement.
Located within the air pipelines the 4-20mA outputs shall be transmitted to the
PLC to provide control functions.
iii) Ultrasonic flow monitoring.
The 4-20mA output from each flow monitor shall be transmitted to the PLC to

provide process monitoring on the SCADA system.

iv) Electromagnetic flow monitoring
The 4-20mA output from each flow monitor shall be transmitted to the PLC to
provide process monitoring on the SCADA system.
v) Pressure monitoring
The 4-20mA output from each pressure sensor shall be transmitted to the PLC to
provide process monitoring on the SCADA system
vi) Temperature monitors.
The 4-20mA outputs from these temperature monitors shall be transmitted to the
PLC to provide plant control and process monitoring on the SCADA system.
vii) Position switches, or linear position transmitters.
The digital, or 4-20mA, outputs from these devices shall be transmitted to the
PLC to provide process monitoring on the SCADA system.
viii) Ultrasonic/radar level monitors located within sumps, chambers and tanks. The
4-20mA output from each level monitor shall be transmitted to the PLC to provide
a control function.
ix) Conductivity Electrodes and float switches
For sumps, chambers and tanks, high level alarm annunciation.
x) Pressure gauges with minimum 100mm dia. gauge size, switches, sensors and
transducers associated with Plant operation and monitoring.
xi) All other instrumentation required for the full and safe functional operation of the
Works.
13.4 MV / LV Substation PLC System
The Contractor shall provide a separate PLC system within a new MV/LV panel room
and substation. The PLC system shall collect all those signals associated with the MV/LV
distribution switchgear, generator and transformer for controlling, monitoring and display
on the associated SCADA system. The PLC system shall operate from a 240V, 50Hz
supply fed from an associated UPS with a secondary supply available from the local
distribution board in the event of a UPS failure.
13.5 Surge Protection Devices for Electronic Equipment
Surge protection devices (SPDs) shall be suitable for withstanding the surge arising from
high energy static discharges and lightning strikes and protect the instruments to which
they are connected. SPDs shall be passive and shall require negligible power for
operation.
SPDs shall be provided to protect devices transmitting and receiving analogue and
digital signals from outdoor field devices.
The surge protection devices shall comply with IEC 61643.
Surge protection devices shall be provided for all field devices, data communication lines
and buried signal cabling.
13.6 Plant Control System
13.6.1 Works to be included
The Works included in this section shall comprise the design, manufacture, supply,
installation, of the Plant Control System.
This section details the main systems and Plant together with the proposed methods of
control of the Plant installations, and shall be read in conjunction with the mechanical
and electrical Plant and measuring equipment sections of the Contract.

In addition to the supply and installation of the Plant Control System, the Contractor shall
also be responsible for testing and commissioning as detailed elsewhere in this Contract.
As an integral part of the commissioning procedure the Contractor shall ensure, and
demonstrate to the Employer’s Representative, that all the monitoring, instrumentation
and control systems are tuned, calibrated, regulated and adjusted to achieve optimum
control of the treatment facility process and Plant operation and that all control systems
are correctly interfaced and operating as a fully integrated system.
The Plant Control System and main items of Plant to be supplied shall include:
a) Supervisory, Control and Data Acquisition (SCADA) system hardware and software
for the wastewater treatment facility
b) Control and indication at the WwTF based on a Programmable Logic Controller (PLC)
c) Online UPS system for each PLC and SCADA system.
All power and control cabling associated with the above Plant shall comply with
Clause 12.3 of this document.
13.6.2 Operating Philosophy
The Plant monitoring and control systems shall provide automatic operation of the
Process Plant and their associated support and subsidiary Plant, with minimum operator
intervention.
13.6.3 Operation and Control
The Contractor shall supervise the wastewater treatment facility by a SCADA system
operator’s terminal located in the plant control room. The SCADA system shall allow ‘real
time’ reporting of critical items within the treatment facility.
Within each WwTF area the individual Plant installations shall be controlled by PLCs
located within their respective local control panels/ MCC panel. These PLCs shall
communicate with each other and the SCADA system operator’s terminal using a
network communications system. The local PLC system shall monitor the operation and
carry out interactive control functions between the Plant and installations within its
sphere of operation. Any process safety or plant critical alarms/trips or controls shall be
hardwired between Plant installations.
Each local PLC system shall incorporate a Human Machine Interface (HMI) minimum
12.7” size unit complete with a key pad for re-setting local parameters and set points, a
visual display unit for viewing Plant status, parameters and set points.
All Plant input/outputs shall be indicated at the local PLC system HMI unit. These signals
shall subsequently be transmitted to the control rooms for processing, display and
storage.
Under abnormal operating conditions, or a control system failure, each Plant installation
shall be capable of being switched to manual control from local control panels and
associated motor control and Plant switchboards.
Automatic control sequences shall continue to operate under automatic control except
when manually selected to “local”, “off” or “remote” on the control panel.
Where a dedicated PLC control system is incorporated in a Plant control panel then the
PLC equipment shall utilise the same protocol/language as the SCADA system. However,
if the Contractor proposes to use individual Plant control systems with a different
protocol/language the valid user certificates for the control panel to SCADA system
protocol conversion shall be submitted to the Employer’s Representative for

consideration.
The facility to adjust the operational parameters on any item of Plant shall be available at
the PLC and remotely at the SCADA system operator’s terminal.
A PLC System shall comprise a PLC, front panel mounted HMI unit necessary for the
control and monitoring of the plant for which that control panel is responsible. The direct
control of plant from the motor control switchboards shall be manual only.
The PLCs shall scan all associated I/O for transmission to the SCADA system operator’s
terminal. Automatic control sequences for the plant shall be carried out within the local
PLC control system; but under abnormal operating conditions, or a control system failure,
the plant shall be switched to manual control from the relevant local control panel(s) or
motor control switchboard.
The local PLC systems shall transmit all the Plant information to the SCADA system
operator’s terminal. The SCADA system operator’s terminal shall have permission to
directly control the complete Plant
Data for the SCADA system, collected from plant, equipment and instrumentation in the
WwTF, shall include the Inputs/Outputs (I/O) indicated in Appendix D – “Typical PLC
Input/Output (I/O) Schedule” of this document, where applicable, for each item of
equipment.
The monitoring data and alarms shall be uploaded automatically onto the dedicated
mimic screens and alarm management pages allocated in the SCADA system. All the
information collected and transmitted from the WwTF shall be available to view at the
WwTF SCADA system operator’s terminal and remotely by the Employer using the
remote viewer software over the broadband connection when required.
A programme development system shall be provided which shall be capable of
amending the system configuration and control database to incorporate future expansion
of the Works and also to take advantage of future technological developments which
may take place in the field of wastewater treatment applications software.
An inverter/battery UPS power system shall be installed in accordance with
Section 12.4.11 of this document, to maintain each PLC system in operation under a
mains failure condition.
13.7 SCADA System
13.7.1 General
The Contractor shall provide a computer based SCADA system at the WwTF to operate
in conjunction with the PLC based control system by providing a human-machine
interface at a central location within the Works which can view and control the PLCs
which run the Works. The Contractor shall supply, install, test, and commission all
necessary hardware, software and associated peripheral devices which will form part of
the SCADA system. The Contractor shall prepare, incorporate mimic screens of Influent
Pumping Station (IPS - by OTHERS) for monitoring IPS equipment/ devices/ plant at
WwTF SCADA. Necessary redundant FO cable between IPS SCADA and WwTF
SCADA shall be laid, terminated, tested and commissioned by WwTF Contractor along
with required communication hardware, signal converters at both communication ends. 1
No. set of redundant Ethernet port with TCP/IP protocol will be available at IPS SCADA
End.
Normal operation of the WwTF will be fully automatic and the SCADA equipment will be
used to carry out functions such as mode control, set point adjustment, data logging and
archiving at the same time as allowing an operator to monitor the system. The SCADA
system functionality shall permit full access to all features for any part of the Site from

the operator workstation.

Data collected by SCADA system shall be capable of being transferred to office personal
computer (PC) networks via Windows Direct Data Exchange (DDE), or other equal
database exchange software. This will enable the latest data to be automatically
uploaded into Microsoft Access or Excel tables, as well as transferring it to other
proprietary software packages.
The SCADA system shall also be capable of web based reporting supporting web
access. In addition the SCADA system shall be openly compatible allowing integration of
other SCADA systems/ third party integration (OPC compatibility).
13.7.2 SCADA System Functions
The SCADA system shall carry out or assist the following actions:
• Indicate status of all main or important motors and drives;
• Indicate status of all actuated valves, bellmouths and actuators;
• Display the status of devices in graphical format (i.e. running, stopped, fault etc.);
• Display all analogue values measured by instruments;
• Annunciate alarms associated with the area of the Plant concerned including details
of the time the alarm occurred;
• Carry out totalisation of flows;
• Provide facilities for the operator to:
o acknowledge alarms;
o view a journal of unacknowledged alarms;
o view a journal of acknowledged alarms;
o display and select the duty drive of duty/standby drive pairs;
o adjust and display process set points.
• Carry out real time and historic trending of analogue values;
• Carry out data archiving of all analogue values;
• Prepare daily, weekly, monthly and annual reports;
• Display a total running hours log of main or important drives.
13.7.3 SCADA System Operator’s Terminal Hardware
The Contractor shall provide the following hardware for the SCADA system operator’s
terminal at the WwTF:
A SCADA system shall be provided as per Control System Architecture Drawing
(10201A-IC-5007-CC- 500001) in Volume 2D.
The computer equipment to be supplied and installed by the Contractor shall comprise:
• Computer having the following minimum specification:
o Latest industry standard PC
o 32” LED colour monitor
o Latest industry standard PC graphics card
o Internal Storage: 2 TB (Raid 5 configuration)
o Latest industry standard DVD/Blue Ray RW disk drive
o Latest industry standard licensed Windows software
o Latest industry standard licensed Microsoft Office software
o Latest licensed anti-virus software
o Keyboard, mouse, etc.

o Ethernet network card

• 1 No. laser printer with A4 and A3 black & white and 1 No. A4 colour capacity and
supplies as necessary.
• The computer hardware and software shall be new and be approved by the
Employer’s Representative before purchase by the Contractor.
• Backing up shall be carried out daily by the Contractor. A copy of the back-up data
shall be provided to the Employer’s Representative.
The hardware and software shall be replaced by up-to-date technology in accordance
with the Contractor’s Maintenance Management Plan.
13.7.4 Deleted
13.7.5 Furniture
The Contractor shall provide desks and furniture to house the computers, printers, UPS
and associated peripherals and equipment and 6 no. operators’ chairs for the control
room.
In addition the Contractor shall provide desks and furniture to house the computers,
printers, UPS and associated peripherals and equipment to house the office purpose PC
and associated equipment and install the furniture.
13.7.6 SCADA System Software
The Contractor shall provide a proprietary software package for the SCADA system
which has a proven track record internationally in the water/wastewater industry and
which is acceptable to the Employer. Using this software the Contractor shall provide a
fully programmed and configured system which shall include the following system
functions:
• Clear language menus for operator interface
• Password access for features on operator’s panel.
• Help facility for functions and alarms etc.
• Alarm annunciation and printing etc.
• Status monitoring of Plant
• Analogue signal monitoring of Plant and instrument parameters
• User programmable software to allow operators to construct programmes for plant
control.
• Integrated control utilising proportional, integral and derivative control techniques
• Auto power up of plant after a power failure.
• Logging of status or value of system points at regular time intervals or change of
state and storing of this information/data
• Data analysis and report preparation utilising proprietary spread sheet packages.
13.8 Deleted
13.9 Instrumentation
The Contractor shall provide instruments to measure all process variables required for
smooth and seamless operation of the entire Works under this contract. Instruments
shall be of an approved & suitable for working in sewage treatment plant environment.
They should be from a reputed manufacturer and be supplied with manufacturers
calibration certificate

Civil Design

14 CIVIL DESIGN
14.1 General
This section of the Employer's Requirements sets out the particular requirements for the
civil engineering and building works and site services at the WwTF Site required by the
Contract unless stated otherwise elsewhere in the Contract. Section 10.1.3 of the
Employer's Requirements also sets out site restrictions which affect the civil design of
the works.
14.1.1 Design Requirements
In designing the Works the Contractor shall comply with the following requirements:
• The Works shall utilise a minimum area, within the Site, consistent with safe and
reliable operation and maintenance;
• Means of access and egress for personnel above and below ground shall comply
with safe and reliable procedures and all Indian regulations;
• ensure the design is consistent with relevant national and local legislation,
guidelines and policies;
• all pipelines, ducts, mains and services shall be provided with flexible joints able to
accommodate the differential movement that may occur between Strutural unit
/buildings and the surrounding soil;
• All pipelines, ducts, mains and services shall be provided with surface access
chambers (including pipeline puddle flanges, dismantling couplings or adapters and
rocker pipes) at all connections including valves and meters;
• Buildings shall be designed in accordance with the current edition of the National
Building Code of India / relevant latest editions of IS codes/ any other latest
standards, codes, IRCs etc.
• All process flow chambers shall have minimum 2m dimension as the smallest
dimension.
• All walkways , stairways and platforms shall have 1.2m clear spacing between the
handrails.
14.2 Site Works
Also refer to Section 2. Site works consists of:
• Demolition of all existing unused structures (above ground & to a depth of 1m below
finished ground level)
• Road works, grading, landscaping, etc. as required to prepare for the new works.
• Provision of temporary roads, grading, etc. as required to construct the new works.
• Provision of final grading, new site road works with under base(s) and asphalt
topping suitable for heavy duty truck load condition.
14.3 Loadings
All buildings shall be designed to withstand loads from; wind loads, earth pressures,
seismic loads, water pressures, surcharges due to temporary or permanent conditions;
dead load and imposed load in combination to comply with the relevant design codes
and standards.
Wind loadings on structures shall be calculated in accordance with IS: 875 (Part 3).
The effects of air temperatures and fluctuations in air temperature shall be taken into
account in the designs.

Earth and water pressures shall be determined by the Contractor and shall take into
account the prevailing site conditions and the proposed construction methods.
The Contractor’s attention is drawn to the fact that the ground water table has been
recorded in close proximity to the existing ground levels. Geotechnical investigations
may not reflect this fact as they may have been carried out in dry weather. Water
retaining structures shall be designed and constructed for uplift based on the external
ground water table at ground level and the structure empty. Uplift shall be resisted by
dead weight with a factor of safety of 1.2. Ground anchors and pressure relief valves as
a means of dealing with uplift are not permissible. Structures shall also be designed to
resist full internal water pressure with no external water pressure or earth pressure.
The possibility and consequences of explosions shall be investigated during HAZOP
studies and the design shall take account of this risk.
Surcharge loads adjacent to basement walls of not less than 10 kN/m2 shall be allowed
for in addition to fill loads. The Contractor shall further design for any surcharges
exceeding this figure occasioned by his proposed method of construction or operation.
Dead loads shall be assessed by the Contractor using the proposed sizes and material
densities.
Loads from overhead cranes comprise dead loads from crane bridges, gantry beams
and hoists, live loads based on crane safe working loads and an allowance for dynamic
effects. These loads shall be factored using the appropriate load factors.
Similarly plant dead and live loads shall be assessed including an allowance for pipe
thrusts and dynamic effects in the design of base slabs and roof slabs. Plant loading
shall not be taken into account in determining the factor of safety against flotation.
All loads used in the design, including those of mechanical and electrical plant shall be
clearly indicated in the design calculations, which are to be included within the
Contractor’s Documents.
14.4 Earthworks, Ground Improvements and Foundations
The new works is to be constructed within the site of existing lagoons and a redundant
section of outfall channel.
Geotechnical information relating to the ground conditions in the lagoons and outfall
channel is included in the Background Information.
In summary, the lagoons and outfall channel are situated over a layer of some 7.0 m to
9.0 m of soft to stiff clay which is of poor bearing capacity and will settle significantly
when loaded. The soft to stiff clay overlies grey fractured basalt. As a consequence it is
considered that the probable optimum solution for foundations for the works built on the
lagoons and outfall channel area will be as follows:
• Prior to any construction work being carried out the lagoons and outfall channel will
have to be drained and sludge will have to be removed and disposed off. Sludge will
have to be dewatered prior to disposal off-site. Prior to draining the outfall channel
the redundant section will have to be isolated from the remaining section which will
continue to receive effluent from the two active lagoons;
• The structures which need to be piled will have to be piled with the pile length
sufficient to bear upon the underlying weathered rock as a minimum. Depending on
loading the piles may have to be extended to bear upon un-weathered rock;
The probable construction sequence is as follows:
1. Empty lagoons of sewage water by pumping into the operating lagoons (discharge
point, rate of flow, pre-treatment requirements to be agreed in advance with MCGM).

2. Dam off the live section of outfall channel and dewater the redundant section by
pumping into the operating lagoons (discharge point, rate of flow, pre-treatment
requirements to be agreed in advance with MCGM).
3. Remove sludge layer from base of lagoons and outfall channel to the original base level.
4. Removed sludge to be dewatered and taken off-site for disposal at an approved
location. Centrate from dewatering to be discharged into the existing lagoons
(discharge point, rate of flow, pre-treatment requirements to be agreed in advance
with MCGM).
5. Layer of graded compacted stone (say 300mm – 500mm thickness) to be placed in
the base of the lagoons to give a working platform/surface for piling rigs.
6. To carry out work in a reasonable time several rigs will be required.
7. Piling installation could commence as soon as access is possible for piling rigs. All
structures shall be on piled foundations.
8. Construction of piled structures could commence as soon as pile installation is
complete.
9. All service connections to structures (pipes, cables, ducts) will have to allow for any
projected differential settlement.
The above is indicative of one possible approach to the Works.
The Contractor is wholly responsible for developing his approach to constructing the
foundations for structures, filling the lagoons and outfall channel to FGL, and dealing with
any related issues such as differential settlement. The Contractor remains fully liable for
the selection, design, construction and performance of the ground improvement
measures he adopts.
Prior to commencing earthworks and foundation works whether as described above or
using different techniques, the Contractor shall submit the geotechnical interpretive
report, calculations for earthworks and foundations as required by Clause 4.4.2 and a
detailed construction method statement and programme relating to this work as required
by Clause 4.5.
14.5 Wastewater Treatment Structures
All wastewater treatment structures (process tanks, channels, chambers, etc.) and
foundations are to be constructed of cast-in-place reinforced concrete.
All interior faces of walls, exposed roofs of structures of above and below grade and
exterior surfaces above finished grade shall have a smooth form finish in accordance
with ACI 301 Surface Finish 3.0 (SF-3):
1. Patch voids larger than 3/4 inch wide or 1/2 inch deep.
2. Remove projections larger than 1/8 inch.
3. Patch tie holes.
4. Provide surface tolerance Class A in accordance with ACI 117.
All exterior walls below FGL and other surfaces shall have an unworked finish with epoxy
coal tar coating, free from substantial voids, honeycombing or other large blemishes,
unless otherwise specified.
The external visible surfaces shall be plastered and painted.
All wastewater treatment structures (process tanks, channels, chambers, etc.) are to be
water tight without leaks.
The cement and chemical materials to be utilized in the concrete make-up are to be
suitable for final use with wastewater and its potential aggressive conditions.
All wastewater retaining structure wall and slab thicknesses are to be designed to suit

the load conditions, geographical conditions, geotechnical conditions and thickness

should be in line with the Table 14.3 Minimum Section thickness.
Where a wastewater process tank is an integral part of an adjoining dry structure, the
interior of the dry structure must be protected by water proofing. The waterproofing shall
be as specified in Vol. 2A, Section 21.2.2 (v) for Service Condition D.
14.6 Administration Facilities
This section of the Employer’s Requirements sets out the minimum requirements for
administration facilities to be provided in the administration building at the WwTF Site by
the Contractor.
The clear height of the rooms under this clause shall be minimum of 3.0m.
The Contractor shall be wholly responsible for the operation and maintenance of all of
these facilities including those provided for the Employer’s sole use and the Shared
facilities throughout the Contract period.
At the end of the Contract, all the above areas (including those identified for sole use by
the Contractor) shall be handed over to the Employer without any costs.
14.6.1 Office Facilities
The clear height of the rooms under this clause shall be minimum of 3.6m. In designing
the Works the Contractor shall provide the following minimum facilities in the
administration building:
Shared Facilities
i) Admin building structure shall be ground + one storeyed
ii) Lobby area ≥30m2 (suitable for a lobby area and receptionist desk);
iii) Laboratory/sample storage room: ≥100m2 equipped with work countertop surfaces,
sample fridge, lab-oven (& exhaust fan), cupboards (high & low), sinks, sample
storage area, etc. The Employer’s Representative will specify the fit-out of this room
during the Design-Build Period
iv) Deleted
v) Meeting/Presentation room ≥ 30m2. The Employer’s Representative will specify the
fit-out of this room during the Design-Build Period;
vi) Mess/Amenity/Canteen room ≥70m2 equipped with sink, countertop surfaces, and
eating area including tables and chairs for 20 persons;
vii) Shower/toilet/changing/locker facilities for male at≥ 25m2 and female at ≥ 12m2.
viii) Office Area ≥100m2
ix) Separate Executive Room with toilet ≥20m2
x) Control/SCADA Room≥100m2.
xi) Additional Washroom/ Toilet Block facility shall be provided in another building on the
opposite side of the site at ≥ 15m2.
For the sole use of the Contractor:
i) Office No.1 > 20m2 for the Operation Service Period of the Contract
For the sole use of the Employer or Employer’s support staff:
i) Office No.2: Two offices shall be constructed of size > 20m2 each for the Operation

Service Period of the Contract, equipped with PC and the office equipment specified
for operational phase of Works;
ii) Office No.3: Two offices shall be constructed of size > 30m2 each for the Operation
Service Period of the Contract, equipped with PC and the office equipment specified
for operational phase of Works;
All areas mentioned above refers to carpet area required (excluding internal walls).
14.6.2 Residential Facility
This section of the Employer’s Requirements sets out the minimum requirements for
residential facilities to be provided at the WwTF Site by the Contractor.
The Contractor shall be wholly responsible for the operation and maintenance of all of
these facilities including those provided for the Employer’s sole use and the Shared
facilities throughout the Contract period.
In designing the Works, the Contractor shall provide the following minimum facilities in
the administration building.
For exclusive use of the Employer’s staff :
Residential facility admeasuring for employer 4000 sq.ft as per requirement of Employer.
For use of the Contractor’s O&M staff :
The Contractor may construct additional residential facilities as follows; for the use of its
staff during the O&M Period, subject to the limits indicated below:
1. One Residential accommodation (1 BHK) admeasuring 500 square feet carpet area
for the Contractor's Plant Supervisor
2. One Dormitory accommodation with 10 numbers beds facility to cover rest area for
its staff in one shift to be used under emergency circumstances.
At the end of the Contract, all the above areas shall be handed over to the Employer
without any costs.
All areas mentioned above refers to carpet area required (excluding internal walls)
14.6.3 Information and Interpetation Center
The Information and Interpetation center shall be of RCC construction and shall have
minimum 500 sq. m. carpet area. The objective of the this center shall be to propagate
informed awareness to students and visiting citizens about the activities and efforts of
Municipal Corporation in the areas of Wastewater management, Storm water
management, Solid waste management, water supply and in general the environment for
the city. The propagation of awareness shall be done through working models of the
treatment plants, museum, documentary films, books, Leaflets etc. There shall be
training cum screening room to accommodate 50 audiences. The facility shall be
complete with projector, screen, chairs etc.
This facility shall be separate building.
All areas mentioned above refers to carpet area required (excluding internal walls)

14.7 Building works and Finishes
14.7.1Architectural Design
Externally the buildings shall be visually aesthetically pleasing demonstrating a high

quality and sensitivity to the local setting. However the design shall also be up-to-date
and comply with the current international philosophy of design, and maintain clean and
simple lines. The Contractor’s attention is drawn to the architectural renderings provided
in the volume entitled Background Information. The Contractor shall ensure that a similar
high standard of architectural and landscaping is provided in his design.
The design approach for buildings and structures shall be to achieve a safe, functional
and durable facility. Materials and their colours for external surfaces shall be selected for
their visual qualities and proven durability to withstand all the local climatic conditions
likely to be experienced, ease of maintenance and reasonable cost. The civil engineering
and building works design shall provide working conditions and facilities entirely suitable
for the Works, that are conducive to its efficient operation and to ensure that
maintenance during the life of the Works is minimised.
Local materials shall be used when possible with regards to quality and reasonable cost.
Effective methods of rainwater disposal shall be provided so that no roof or overhang
water is left to run down the face of the building. Effective drip stops shall be
incorporated in all overhanging elements.
The Contractor shall allow in his design for the climatic conditions and the high humidity
in some of the processes involved. In this respect, the Contractor shall endeavour
through his design to minimise energy consumption by improving system efficiencies,
insulation, draught stripping, humidity control, heat recovery and controls.
14.7.2 Materials
The design and selection of Materials for all buildings shall be guided by the need to
ensure that various elements have long, trouble free operational lives and that the
requirements for building maintenance are reduced to a minimum.
Steelwork: Internal steelwork shall have a protection system in line with the
requirements of ISO 12944. The protection system shall be suitable for a frequently
damp and wet interior and shall have a life to first maintenance of 15 years or more.
External steelwork shall be either stainless steel, aluminium or have a protection system
with a life to first maintenance of 10 years or more.
All galvanising shall be undertaken after the manufacture of the steelwork.
Tanks: Material of tanks shall be suitable as per atmosphere and application.
Windows: Where provided windows shall be consistent with ensuring maximum security.
Floors: Floor slabs shall be designed to cater for plant loading, together with basic floor
live loading.
Suspended floor slabs shall, in addition to the above, be designed to carry all dead loads,
including the ceiling loads, floor finishes etc as applicable.
Ground slabs shall be cast in situ concrete with a minimum thickness as per Table 14.3
of Employer’s Requirement.
Doors: All external personnel doors shall be heavy duty and security duty.
Roller shutter and roller panel doors shall be manually operated with suitable gear
arrangement to reduce man efforts and of aluminium construction with plastic / protective

coating.
14.7.3Internal Finishes
Internally the buildings shall be functional but smart in appearance and based on a
colour co-ordinated design to include all Plant and Materials.
The Contractor shall ensure that all areas of walls, floors and ceilings are provided with
protective finishes suitable for normal operating conditions with a minimum durability of
15 years to first maintenance unless otherwise stated. When selecting Materials the
Contractor shall consider the environment in which it is to be used, the substances to
which it is to be exposed and the need to protect any equipment installed in the vicinity.
The Contractor shall ensure that the Materials selected provide a safe working
environment for the operations staff and are in accordance with all relevant health and
safety regulations.
In all areas where any liquid or sludge spillage may occur the Contractor shall ensure
that the floor is screeded and finished to provide drainage into the nearest suitable Site
drainage collection system. The Contractor shall also seal the screed to prevent liquids
percolating through to the structural concrete beneath. The Contractor shall ensure that
the Materials provide a non-slip surface under all conditions.
Areas subject to washdown or splashing shall be protected to a suitable height with
ceramic tiles or proprietary epoxy coating and be designed to prevent water retention in
the building fabric.
Detailing shall allow for ease of replacement of panels that might become damaged and
hidden structural panels shall be adequately protected.
14.7.4General requirements for Areas to be Finished
The following are the minimum standards for finishes:

Table 14.1 – Schedule of Internal Finishes
Skirtings
Location Walls Floor Ceiling
/Architraves
Mess / amenity Plaster with wipe Glazed non slip Wipe down paint Ceramic tile
area down finish floor tiles finish or wipe skirting
down suspended
ceilings
Offices/ reception Masonry wall with Vitrified glazed wipe down Vitrified glazed
tiles
area /control cement mortar suspended tile skirting
rooms plaster,
gypsum plaster ceilings
over
plastered surface
for
smooth finish with
wipe
down paint finish
Store rooms/ Masonry with Power floated Wipe down paint None required
Switch cement
room/ Workshop mortar plaster concrete or finish or wipe
with wipe
building down paint finish granolithic screed down

Skirtings
Location Walls Floor Ceiling
/Architraves
with anti dusting suspended

hardener/ sealant ceilings
General process Fair faced Steel float finish Self finished Ceramic tiles to
masonry wall
areas with fair worked laid to falls as profiled metal one metre
concrete finish or appropriate with lining sheets above the top
glazed
tiles to one metre anti-dusting of all process
above surface
water level in hardener/ sealant units in splash
proximity
to process units zones
Special Two part epoxy Two part epoxy

process resin with non resin with non
areas, slip aggregate slip aggregate (3
chemical (3 mm in mm in thickness)
handling thickness) up to
areas, 300mm height
sludge from floor level.
handling areas
and
process areas
subject to
corrosive attack
Toilets Masonry wall Ceramic Suspended Ceramic tile

/sinks / with ceramic tiles, ceiling to
showers tiles Antiskid incorporate wipe skirting
down finish
Vehicle Sealed
access screed to
areas protect
structural
integrity of
floors,
slabs to
be
protected
in the
event of
oil, petrol
or
chemical
spillages
Note: General Process Areas and Special process areas indicated in the table refers to
areas where human access is allowed on a routine basis within process buildings.

14.7.5External Finishes of Buildings
The external finishes of the administration, pumping stations and other buildings shall
have as a minimum either:
• aluminium curtain walling; or
• plastered/rendered finish which shall be painted.
For external and internal (except water retaining structures) surfaces of all bulidings,
colour shade shall be white
14.8 External Works
Roads and footpaths shall be suitable for their intended use and shall have at least the
design standards set out in the general technical specifications and the following
requirements. The requirements of this Section shall override those of the general
technical specifications in the event of a conflict.
14.8.1Treatment Facility Roads and Hard standing Areas
Geometric design of roads, junctions, turning circles etc. shall be in accordance with the
national guidelines. They shall be designed to provide an adequate number of lay-bys,
turning areas, parking spaces, etc. to enable sludge tankers, sludge cake lorries,
chemical delivery wagons and other vehicles to discharge or pick up without causing
obstructions to others. Hardstanding areas for skips shall be of concrete construction.
Junction radii shall be a minimum of 10m.
Carriageway widths shall be adequate to accommodate all vehicles required to operate
and maintain the Works and shall provide adequate maneuverability in accordance with
accepted guidelines. Generally this shall be a minimum of 5m width, but shall be 6m
width roads utilised by sludge vehicles, chemical delivery trucks etc. All internal roads
shall have adequate turning circles at bends and junctions so as to allow easy vehicular
movement of the type and size of vehicles and loads anticipated to use the site.
Road drainage shall be provided. The roads shall be laid to falls and have adequate
capacity to be free draining. Roads shall be sealed and paved in order to prevent soil
loss.
Off road parking shall be provided for operational staff cars, maintenance vehicles etc.
as determined by the Contractor but with a minimum space for at least 6 vehicles at the
treatment facility. The Contractor shall also provide parking and turning capability for one
coach and for 6 visitor’s cars at the treatment facility.
Footpaths of minimum 1.5m width shall be provided around all buildings, tanks and
chambers and to all areas where equipment is provided.
Pathways of width 1.5m to shall be provided to connect the STP units and the approach
road.
14.8.2Gates and Boundary
Permanent boundary and gates to the Site shall be provided to the areas as shown on
Drawing No. TCE.10201A-CV-3051-SI-30001
The Contractor shall construct an appropriate new guardhouse and access gate with
appropriate facilities for two guardsmen.
14.9 Site Drainage

Landscape and unpaved areas shall be finished and graded such that there are no
undrained low spots or areas liable to ponding. Surface water will be directed to a
drainage system, not to the waste water stream.
Surface water from the access road and treatment facility area shall be drained to a
drainage system and not to the wastewater stream. The Contractor shall ensure that only
uncontaminated surface water can drain to the surface water system. Surface water pipe
work shall be designed by the Contractor using a rainfall intensity of 100mm/hr with no
surcharging of any pipe work. The Contractor shall obtain consent from the Storm Water
and Drain Department for the discharge of the storm water.
All road and hard standing areas with potential for contamination, wash waters and
works drainage, shall be contained and returned upstream of the preliminary treatment
works and downstream of the inlet flow measurement.
14.10 Services to the Site
14.10.1 General
The Contractor shall be responsible for provision of all services necessary for the Design
Build and Operation Service of the Works. For clarity, the Contractor shall be responsible
for the connection and continued provision of all necessary services (electricity, water,
telecommunications, etc.) to the Site for the Design-Build Period, including
commissioning, and for the provision of the Operation Service. The Contractor shall be
responsible for the payment of all such service providers for such services for the entire
Contract Period. The Contractor shall not assume that any connection can be made from
the existing services being provided to the site.
The Contractor shall advise the Employer’s Representative in writing of all arrangements
made with the public or private utilities and provide copies of all correspondence
between themselves. The Contractor shall give the Employer’s Representative adequate
notice of all meetings with the utility representatives so that the Employer’s
Representative may attend. The Contractor shall minute all such meetings and provide
the Employer’s Representative with copies.
Procedures shall be developed to cater for planned maintenance and for emergency
failure of services, such that the performance standards are still met even in the event of
such outages.
The Contractor shall determine on Site the exact position of all existing services that may
affect or be affected by the Works prior to carrying out his design. He shall submit all
details gathered to the Employer’s Representative.
14.10.2 Electricity Supply Cable Ducts
The Contractor shall provide the electricity supply to the treatment facility Site, which
shall follow the route of the main entrance to the Site and shall be underground in
suitably sized ducts. Any new supply shall be underground within the Site and shall be in
suitably sized ducts. The route of the electricity supply shall be agreed between the
supply authority, planning authority, and Contractor. Where a looped supply or two
supplies are proposed they shall be kept separated by a minimum 1050 mm.
The Contractor shall provide a means to connect an emergency source of power
sufficient to operate the facility's essential service during a complete power failure of the
electricity supplies and shall also facilitate the use of the power generated from bio-
gas(optional) to be utilised. The Contractor designs must demonstrate how this is to be
achieved. The facility shall be capable of safe shut down of all non-essential services
and of safe start-up upon restoration of power. The Contractor shall develop procedures

and demonstrate how these would be carried out in a safe manner.

The Contractor shall research the reliability of the power supplies and the plant through
which it is supplied to the Works and demonstrate that the emergency power source will
work for the duration of a power supply shutdown such that all of the water quality
standards are met.
The Contractor will meet all of the supply authority charges relating to the Site from the
Commencement Date.
Supply to the Employers staff quarters shall be maintained at all times whether the
supply runs through the Contractors work site or common/shared access.
14.10.3 Potable Water
The Contractor shall provide a potable water supply to the Site. Wherever possible, the
supply to the WwTF Site shall be brought along the verge of the access road or
entranceway to the Site. The pipe shall be sized for the flow required.
The Contractor shall be billed at Industrial water rates. The Contractor is encouraged to
minimise clean water usage at the facility.
14.10.4 Telephone Supply
The Contractor shall provide a suitable number and specification of telephone cables.
The route of the telephone cables shall follow the line of the access road.
14.10.5 Spare Ducting
The Contractor shall provide two spare of minimum150 mm dia ducts along the route of the
access road to the Site, with draw pits suitably spaced for the drawing of control cables in the
future.
14.10.6 Fire Fighting System
The Contractor shall supply suitable fire fighting facilities to meet the requirements of the
Chief Fire Officer, MCGM. The facilities shall use Treated Effluent/Potable Water from a
fire water storage tank and comprise:
• at least one electrical and one diesel and one jockey pump set,
• a pressurised ring main,
• hydrants,
• hoses,
• nozzles.
14.11 Reinforced Concrete
Reinforced concrete shall comply with Section 17 of Volume 2A, General Civil
Specification.
Due to the severity of exposure of the site (sea water, high chlorides, high sulphates),
the Contractor shall design suitable concrete mixes for the exposures anticipated.
However, the Contractor’s mix designs shall meet. the following minimum concrete
specification for all liquid retaining structures, structures in contact with water (including
groundwater), superstructures of all buildings and tanks, load bearing members and
foundations:

Table 14.2 – Minimum concrete requirements

No. Structures Requirements
1
All liquid retaining structures Grade of concrete : M50 as per IS 456
All underground structures Cementitious materials : Ordinary Portland
All structures having direct/indirect Cement with GGBS (GGBS shall be between
contact with water (including ground a minimum of 25% and a maximum of 30% of
water/ sewage) the cement content) as per IS12269 and
IS456.
Minimum cementitious content per m³ : 400
kg
Maximum cementitious content per m³ :
550 kg
Maximum water cement ratio : 0.35
Maximum Shrinkage rate:0.04%
2
Pipe encasement Grade of concrete : M35 as per IS 456
Other structural components at Cementitious materials : Ordinary Portland
superstructure (not having any contact Cement with GGBS (GGBS shall be between
with water or sewage for a minimum of 25% and a maximum of 30% of
superstructure) the cement content) as per IS12269 and
IS456.
kg
380 kg
3
Walkways, stairways and platforms Grade of concrete : M25 as per IS 456
outside and around the building/ unit Cementitious materials: Portland
Pozzolana Cement / Ordinary Portland
Cement
kg
340 kg
Super Plasticiser shall be provided where necessary to ensure necessary workability and
wet curing is required.

The following are the minimum grades of concrete which may be used for particular non-
structural application:
• M – 40: Pavements (Carriage way) & M-20 (Foot path)
M20 • M – 15: Plinth protection work, Mud mat below foundations, plinth beams, drains,
trenches, pits etc.
Reinforcing bars shall be of minimum grade Fe 500 with Corrosion resistance steel
conform to IS 1786.
The design of RCC structures shall be carried out by the limit state method as per the
provisions of IS 456. Concrete exposure shall be considered as severe for the purposes
of the depth of cover to reinforcement.
Concrete tanks and other liquid retaining structures shall be designed either as un-
cracked sections in accordance with the recommendation of IS 3370 or using limit state
design for reinforced concrete in accordance with IS 3370 with a design crack width of
0.1mm. The design must also take into account cracking due to shrinkage, the amount,
size and spacing of reinforcement must be adequate for strength and serviceability for
shrinkage effects.
The minimum cover to the main reinforcing bars for different members of structures shall
be as specified in following Table:
Minmum Cover to main reinforcing bars
Buildings Cover
Slab (Floor, Roof, Canopy, and
45 mm
Staircase)
Beams (Sides, Bottom & Top) 45 mm
Columns 50 mm
Pedestals (in contact with earth) 50 mm
Basement wall, retaining walls
Face in contact with earth 45 mm
Interior face 45 mm
Foundations 50 mm
Piles 75mm
Pile cap 50mm
Water retaining structures
Base slab, 50mm
Wall 50mm
Wall foundation 50mm
RCC walls shall include reinforcement on both faces for sections of 200mm or more,
even if not required from a structural design consideration.
All concrete in liquid retaining structures shall include cement additives conforming to
IS: 9103 to ensure a dense and watertight finished structure.
The following minimum structural thicknesses shall be used:
Table 14.3 – Minimum section thicknesses
Elements Minimum Thickness
Suspended RCC floors / slabs 200 mm
walkways 175 mm
Ground slab-on-grade 200 mm
Water retaining slabs/ walls 250 mm
Cable/ pipe trenches/ underground pits and base slabs 100 mm

All footings and raft foundations 300 mm

Parapets 150 mm
Sunshades 75 mm (at edge)
Pre-cast louvers 50 mm
Pre-cast trench cover slabs / floor slabs 75 mm
Paving 150 mm
Basement walls and base slab 250 mm
From the fire resistance perspective, the minimum thickness of reinforced concrete
members will be as per Figure 1 or Table 16A of IS 456 for at least 2 hour of fire
resistance.
Note that these are the general minimum thicknesses employed. Structural elements
shall be designed in accordance with the loads to be imposed.
All steel shall be procured from “original producers” who manufacture billets from iron
ores and rolled the billets to produce steel confirming to IS 1786. No re-rolled material
shall be accepted. If instructed by the Employer’s Representative, the Contractor shall
submit the manufacturer’s test certificates for the steel. Random tests on steel supplied
by the Contractor may be performed by the Employer as per relevant Indian Standards.
Each steel bar shall be identified by the number duly moulded on the bar itself.
14.12 Liners to Concrete Material
Due to the potential for H2S corrosion in the wastewater containing structures, all
concrete surfaces in the following structures shall be completey lined inside with Coal
Tar Epoxy / Resin based epoxy / Polyurea when formed:
• All covered manholes / chambers
• Inlet Chamber
• Preliminary treatment processes
• Primary settlement tanks
• Anoxic zone of aeration tanks
• Sludge storage tanks
• Primary Digesters
• Mixing chambers where possible chemical use might include any of the ferric/ferrous
iron salts.
14.13 Design Requirement of Concrete
The following are the design requirements for all reinforced or plain concrete structures:
All blinding and levelling concrete shall be a minimum 100 mm thick in concrete grade
M15
All physical and chemical properties of this Fe 500 grade steel shall conform to IS: 1786-
2008. Welded wire fabric shall conform to IS: 1566 as shown or specified on the drawing.
The CRS (corrosion resistant steel) index shall be at least 1.35 when tested for Salt
Spray test as per “ASTM B 117 – 2009 test procedure for 120 hours when compared
with the Fe 500 normal reinforcement bars and with same bar diameter. All test results
(including physical and chemical properties and salt spray tests) have to be produced for
the respective bar diameter for each consignment of steel delivered at site and at a
frequency of every 20 Metric Tons.
14.14 Design Philosophy
Following are the details are to be included in the general design philosophy;

• Design philosophy for Liquid Retaining Structures with various boundary conditions
as applicable
• Design philosophy for buildings
• Design philosophy for all structures
Design philosophy shall include material properties (grade, strength, unit weight etc.),
development lengths, lap/splice lengths, Anchorage lengths under tension and
compression, clear cover, water proofing specifications, legend used etc.
Reinforcement detail showing the development length at Column/Footing intersection,
Column and Roof beam intersections, Walls and Base slab intersections; Walls and
cover slab intersections
Detailing of the reinforcement for columns, beams, beam/column intersection,
footing/column intersection, and Slabs as per relevant code provisions/requirements
depending upon the assumptions made in the design as applicable.
Reinforcement detail for cut-outs in slabs and walls with maximum size of cut-outs
Reinforcement detail at top of RCC trench walls showing edge/seating angles
Pouring sequence of concrete and standard details for construction joints, expansion
joints, contraction joints, etc.
Details of Manholes to be placed in the tank
Design Loadings
All buildings and structures shall be designed to resist the worst combination of the
following loads/stresses under test and working conditions; these include dead load, live
load, wind load, seismic load, stresses due to temperature changes, shrinkage and
creep in materials, and dynamic loads:
Dead Load
This shall comprise all permanent construction including walls, floors, roofs, partitions,
stairways, fixed service equipment and other items of machinery. In estimating the loads
of process equipment all fixtures and attached piping shall be included, but excluding
contents, shall be considered.
Dead loads shall be in general as per I.S. 875 Part (I). However, the following minimum
loads shall be considered in design of structures:
Table 14.4 – Material densities
(i) Weight of water : 10 kN/m3
Weight of soil (irrespective of strata
available at site and type of soil used for
(ii) filling etc). However, for checking stability : 20.00 kN/m3
against uplift, actual weight of soil as
determined by field test shall be considered
(iii) Weight of concrete : 24.00 kN/m3
(iv) Weight of reinforced concrete : 25.00 kN/m3
20.00 N/m2 per mm thickness of
(v) Weight of Brickwork(exclusive of plaster) :
brickwork
Weight of Solid Concrete Block work
(vi) : 17.65 kN/m3
(exclusive of plaster)
(vii) Weight of plaster to masonry surface : 18.00 N/m2 per mm thickness
(viii) Weight of granolithic terrazzo finish or : 24.00 N/m2 per mm thickness

rendering screed, etc.

78.5 N/m2 per mm thickness of
(ix) Weight of MS chequered plates :
plates
Live Load
Live Load (LL) shall include the superimposed loads due to the use/occupancy of the
structure/building not including dead, wind or earthquake load. Live loads shall be in
general as per I.S. 875 – 1987 Part (II). However, the following minimum live loads shall
be considered in the design of structures:
i) Live load on roofs: 1.50 kN/m2
ii) Live load on floors supporting Equipment such as pumps, valves, Blowers,
Compressors etc.: 10.00 kN/m2
iii) Live load on all other floors walkways, stairways and platforms: 5.00 kN/m2 (iv) Live
load on Toilet areas: 2.00 kN/m2
iv) Live load Surcharge for Structures (Retaining walls): 10kN/ m2.
In the absence of any suitable provisions for live loads in BIS Codes or as given above
for any particular type of floor or structure, assumptions made must receive the approval
of the Engineer prior to starting the design work. Apart from the specified live loads or
any other load due to material stored, any other equipment load or possible overloading
during maintenance or erection/construction shall be considered and shall be partial or
full whichever causes the most critical condition.
Wind Load
Wind loads shall be as per I.S. 875 - 2015 Part (III).
Earthquake Load
Seismic forces shall be as per I.S. 1893 - 2002.
Dynamic Load
Dynamic loads due to working of plant items such as pumps, blowers, compressors,
switch gears, travelling cranes, etc. shall be considered in the design of structures.
Vehicular Wheel Load
For any structure or pipeline below the roads, Class A loading of IRC 6 shall be
considered.
Joints
Construction joints shall be provided at right angles to the general direction of the
member. The locations of construction joints shall be decided on convenience of
construction. To avoid segregation of concrete in walls, horizontal construction joints are
normally to be provided at every 2 m height. PVC water stops of 150 mm width shall be
used for walls and 230 mm width for base slabs.
14.15 Detailed Design Calculations & Submission
Complete detailed design calculations of foundations and superstructure together with
general arrangement drawings and explanatory sketches shall be submitted by the
Contractor to the Engineer. Separate design calculations for foundations or
superstructures submitted independent of each other shall be deemed to be incomplete
and will not be accepted by the Engineer.
• One (1) Copy of a Compact Disc (CD) containing electronic files relevant to the
structure’s modelling, analysis and design calculations (Microsoft Excel, Staad Pro,
etc.). Files submitted shall be in editable format.

• Print copy (6 Copies) of the contents as submitted in the Compact Disc.

• Good for Construction Drawings
• One (1) Copy of a Compact Disc (CD) containing AutoCAD files (Civil General
Arrangement, Structural Dimensions and Reinforcement Details) pertaining to the
structure. Files submitted shall be in editable format.
• Print copy (6 Copies) of the contents as submitted in the Compact Disc. Prints to be
submitted on A1 Size Sheet as a minimum or A0 Size Sheet when required by the
employer.
• Bar-bending schedule indicating the number, shape and size of the rebars shall be
submitted as part of the Reinforcement Details
• Detailed drawing showing the location, number and depth of inserts shall be
included for any structural steel inserts/Metal inserts in the structure such as rungs,
bolted connections for ladders/railings, etc.
• Location of Construction Joints and pour sequence shall be included on the drawing
for base slabs, walls and top slabs.
• Revised drawings shall be submitted by clouding at the location with the latest
revision number and also show the history of revisions in a table format just above
the title block.
• The design considerations described hereunder establish the minimum basic
requirements of plain and reinforced concrete structures, masonry structures and
structural steel works. However, any particular structure shall be designed for the
satisfactory performance of the functions for which the same is being constructed.
The Contractor shall also take care to check the stability of partly completed
structures.
14.16 Design Criteria for Underground Liquid Retaining Structures
All underground or partly underground liquid containing structures shall be designed for
the following conditions:
• Liquid depth up to full height of wall: no relief due to soil pressure from outside to be
considered
• Structure empty (i.e., empty of liquid, any material, etc.): full earth pressure and
surcharge pressure wherever applicable, to be considered
• If water table exists, earth pressure to be considered for submerged soil conditions
with reference to the geotechnical recommendation
• Partition wall between dry sump and wet sump: to be designed for full liquid depth
up to full height of wall
• Partition wall between two compartments: to be designed as one compartment
empty and other full
Walls and bases shall be designed under operating conditions to resist earthquake
forces from earth pressure mobilization and dynamic water loads (Hydrodynamic
Impulsive Pressure and Hydrodynamic Convective Pressure)
For general retaining walls and large sized tanks where the walls are designed as
retaining walls, sliding check shall also be performed along with over turning checks
Overturning: The stability of a structure as a whole against overturning shall be ensured
so that the restoring moment shall be not less than the sum of 1.2 times the maximum
overturning moment due to the characteristic dead load and 1.4 times the maximum
overturning moment due to the characteristic imposed loads. In cases where dead load
provides the restoring moment, only 0.9 times the characteristic dead load shall be
considered. Restoring moment due to imposed loads shall be ignored.
Sliding: The structure shall have a factor against sliding of not less than 1.4 under the

most adverse combination of the applied characteristic forces. In this case only 0.9 times
the characteristic dead load shall be taken into account.
As a design consideration to control crack, though general requirements of IS 3370 :
2009 & (Annexure F) IS: 456- 2000 shall be followed, All liquid retaining structures shall
be designed based on the serviceability crack width limit state (i.e. 0.1 mm crack width)
and other limit state requirements also to ensure an adequate degree of safety and
serviceability.
In case of Large and Deep Underground Tanks such as Wet Wells, the analysis can be
carried by Finite Element Method using STAAD.Pro V8i or any other equivalent software
predominantly used and accepted in the industry.
14.17 Foundations
The minimum depth of foundations for all structures, equipment, buildings and frame
foundations and load bearing walls shall be as per IS 1904 but in any case this shall not
be less than 1.5 meter in the original soil.
Maximum safe bearing capacity of soil strata shall be taken as determined by the
Contractor through his own independent investigations. Geotechnical reports of
proposed STP sites covered under the contract are provided with the Bid Documents. It
may be used by Contractor as part of, in addition to, or in lieu of such investigations at
his own risk.
Care shall be taken to avoid the foundations of adjacent buildings or structure
foundations, either existing or not within the scope of this Contract. Suitable adjustments
in depth, location and sizes may have to be made depending on site conditions. No extra
claims for such adjustments shall be accepted by the Employer.
Special attention is drawn to danger of uplift being caused by the ground water table. All
underground structural slabs shall be designed for uplift forces due to ground water
pressure.
EGL (Existing ground level) and FGL (Finished ground level) shall be marked on all
drawings showing foundation/sub-structure details and related design documents.
Machine/static equipment foundations shall be separated from adjoining parts of
buildings, other foundations and floor/pavement slabs. Joints at floor/pavement slabs
shall be suitably sealed.
Foundations and structures for machines subject to vibrations shall be so proportioned
that the amplitude and frequency of the foundation/structure are within the permissible
limits as per relevant BIS codes (or as required by the machine vendor).
Machine foundations shall be designed and detailed as per IS: 2974. All appendages to
such foundations shall be reinforced suitably to ensure integral action.
Foundations for plant structures in Swampy/Waterlogged areas, for lightly & medium
loaded structures and relevant Ground Improvements shall be considered in compliance
with the relevant Geotechnical Investigation Report recommendations as applicable.
Also to enlist the services of an experienced & specialized agency for all related design
aspects considerations, equipment specifications, and implementation methodology, etc.,
as an advice for the same.
14.18 Design Requirements
Reinforcement bars and structural steel to be procured only from Primary steel
producers with Integrated Steel such as TATA/SAIL/RINL/JSW. No Re-rolled
material/secondary steel will be accepted or allowed for any structural works.
Only those firms are eligible who are primary steel producer and should have integrated

steel plant in single premises.

Certificate issued by ministry of steel of primary steel producer and integrated steel plant
having infrastructure in single premises for producing sponge iron, billet and TMT
reinforcement bars using iron ore as base material shall be produced.
The steel manufacturing company should have latest ISO accreditation for Quality
Management System.
The minimum amount of reinforcement in each of the two directions at right angles within
each surface zone should be provided as per clause 8.1 of IS 3370 (Part 2):2009.
Definition of surface zones is clearly shown in Figure 1 and Figure 2 of IS 3370 (Part 2):
2009. For slabs, minimum of 10 mm dia bars shall be used to avoid any deformation of
lesser diameter bars under loads prior to construction.
All buildings shall have a minimum 1 meter wide, 100 mm thick plinth protection paving
in M15 grade concrete or stone slabs/tiles. All plinth protection shall be supported on well
compacted strata.
All pipes and ducts laid below the structural plinth and road works shall be surrounded
with concrete of grade M15 having minimum 150 mm thick concrete or D/4 (D = outer dia.
of pipe) thickness whichever is more.
Use of pressure relief valves to reduce uplift pressure due to ground water table shall not
be allowed.
Detailing of the reinforcement shall be considered as per latest Indian code of practices
and special publications as applicable.
Water tightness testing of water retaining structures shall be done in accordance with IS:
3370, (Part I) - 2009. It is described in Clause 10.22 of this document. The depth of
water for testing shall be up to the soffit of the covering slab.
Standards
Materials and workmanship shall comply with the relevant Indian Standards (with
amendments) current on the date of submission of the tender.
Where the relevant standard provides for the furnishing of a certificate to the Engineer, at
his request, stating that the materials supplied comply in all respects with the standard,
the Contractor shall obtain the certificate and forward it to the Engineer.
General Arrangement of Plant
The following general guidelines shall be followed in the preparation of general
arrangement of Plant:
Sufficient room shall be allowed between items of plant and adjacent Plant or fixed
structures to permit safe and convenient access for operation and maintenance
An area adjacent to all mechanical Plant shall be provided as maintenance lay down
area fixed runways, lifting eyes or other means shall be provided to permit the removal of
Plant that may be required to be removed during the course of its normal operational life
for maintenance or any other purpose; areas where leakage is likely to occur whether in
normal use or during maintenance shall be provided with covered drainage channels
which shall direct spillage either to a suitable plant drain or to a sump from where it can
be pumped to plant drain
Orientation
The works shall be laid out within the confines of the Site in order to interface to the
existing infrastructure of roadways and inlet and outlet pipe work. Underground services
requiring to be relocated in order to accommodate the proposed site layout shall, with the
approval of the Employer’s Representative, be relocated by the Contractor.

14.19 Buildings and Structures

All the building and structure works shall generally comply with the following Employer’s
Requirements unless otherwise specified elsewhere:
All external walls shall be in Bricks with fly ash having crushing strength 7.5 MPA and
shall be 200 mm thick.
All internal partition walls shall be in Bricks with fly ash having crushing strength 7.5 MPA.
All internal walls shall be 200mm thick except for toilets. Toilet partition walls shall be in
100 mm thick solid concrete block/bricks with fly ash.
Finishes to concrete liquid retaining structures shall be:
F1 - External surfaces, buried
F2 - External surfaces exposed and up to 300 mm below ground level
F2 - Internal surfaces
Finishes to other concrete structures shall be:
F1 - Buried
F1 - Exposed, where plastering is specified
F2 - Exposed
All internal masonry and ceiling surfaces finish shall have 12 mm thick plain faced
cement plaster in cement mortar (1:4) with neat cement finish on top. The plastered
surface shall made smooth by using cement based putty or gypsum for better
architectural finish. Over this, one coat of primer and two coats of plastic emulsion paint
of approved quality and shade shall be provided.
All external masonry and concrete with rough board finish shall have 20 mm thick sand
faced cement plaster in two coats, base coat 12 mm thick in cement mortar 1:4 and
finishing coat 8 mm thick in cement mortar 1:4. Waterproofing compound of approved
make and quality shall be added to the cement mortar in proportions as specified by the
manufacturer.
All external surfaces exposed and up to 300mm below ground level have one coat of
primer and two coats of waterproof cement based paint of approved quality and shade. A
coat of silicone water repellent paint shall also be applied thereon.
All staircases shall have 25 mm thick kota stone of approved quality and 150mm high
skirting set in cement mortar in 1:4 to give an overall thickness of 50 mm.
Stairways shall be provided to permit access between different levels within buildings.
Staircase shall be minimum 1500 mm wide, minimum Tread = 250 mm, maximum Riser
= 175 mm and maximum 15 number of steps per flight unless specified otherwise.
Staircases in general shall not be steeper than 40°. Staircases having space constraints
may be steeper than 400. The maximum vertical run for a single flight of stairs shall be
3.0 M.
All roof tops and overhead tanks shall be made accessible with RCC Staircase provision.
Vertical step ladders fitted with landing point extensions will be permitted where
considered appropriate by the Engineer to access areas not frequently visited.
Steel staircases shall be constructed of standard channel stringers with M.S. grating
treads 25mm thick with non skid nosing. Steel Ladders shall be minimum 600mm wide
and shall not exceed 6m of straight run. The ladders shall be painted with epoxy paint.
All hand railing shall be provided with MOC Stainless steel SS316L with vertical post

pipe OD 38 mm (schedule 10) and horizontal rail pipe diameter OD 33.4 mm (schedule
10). The minimum height of hand railing shall be 1.2m and maximum spacing of verticals
shall be 1.2 m. Number of horizontal rails shall be 3 (1 top, 1 intermediate and 1 bottom)
with a 100 x 6 toe plate at the bottom.
Building plinth shall be minimum 450 mm above average finished ground level around
building or high flood level whichever is more.
All concrete channels and ducts used for conveying liquid shall have inside finish of type
F2. The width of concrete channels shall not be less than 500 mm. All open channels
shall be provided with hand railings (3-rail) or concrete walls to a minimum height of 1.2
m from the access surface elevation. All concrete surfaces of structures conveying raw
sewage or primary effluent upstream of the aeration tanks shall be protected from
corrosion Coal Tar Epoxy / Resin based Epoxy / Polyurea lining. In addition, the
external surface of the underground water retaining structures that will be buried
under soil also need to be coated with Coal Tar Epoxy /Polyurea lining.
Kerbs to be provided below the hand railing on the catwalks/pathways should be as per
relevant sections of Factory Act. It shall not be less than 150mm.
All exposed surfaces of inserts embedded in concrete shall be painted with two coats of
enamel paint over one coat of red oxide zinc chrome primer. Surfaces in contact with
concrete shall not be painted.
All structural steel members shall be painted as specified in Volume 2A-General Civil
Specifications.
All rooms in the treatment plant buildings shall be provided with appropriate sign boards
indicating the function of the rooms involved written in Marathi, Hindi and English
Languages.
The design of buildings shall reflect the climatic conditions existing on site. Process
buildings shall as far as is possible permit the entry of natural light, and the use of glazed
paneling shall be kept to a minimum and preference given to wall openings protected by
weather canopies.
Emergency exit doorways shall be provided from all buildings in order to comply with
local and international regulations .Stairways and paved areas shall be provided at the
exit points.
All concrete structures in contact with sewage and/or sludge shall be provided with full
interior corrosion protection linings and/or coatings of appropriate material and thickness
to be approved by MCGM.
F1 Finish
Formwork for Class F1 finish shall be constructed of timber, sheet metal or any suitable
materials which will prevent loss of grout when the concrete is vibrated. Surfaces
subsequently to be rendered, plastered or tiled shall be adequately scabbled or
roughened as soon as the formwork is removed to reduce the irregularities to not more
than half the thickness of such rendering, plastering or bedding for tiles and to provide a
satisfactory key.
F2 Finish

Formwork for Class F2 finish shall be faced with wrought tongued and grooved boards or
plywood or metal panels arranged in a uniform approved pattern free from defects likely
to detract from the appearance of the surface.
F3 Finish
Formwork for class F3 finish shall be lined with panels of non-staining material with a
smooth unblemished surface such as sanded plywood or hard compressed fibre board.
The panels shall be as large as possible and shall be arranged in a uniform approved
pattern and fixed to back formwork by oval nails. Unfaced wrought boarding or standard
steel panels will not be permitted. Ribbed finishes shall be formed by a backing of
sanded plywood or hard compressed fibre board, as described for a Class F3 finish,
against which timber battens are fixed. Battens shall have clean, sharp arises at base
and be stopped with a waterproof filler and sanded to give a smooth surface. Battens
shall be securely fixed to the backing by adhesive and screws to prevent the penetration
of grout behind them.

Construction Activities

15 CONSTRUCTION ACTIVITIES
15.1 The Site
The existing treatment facility boundary, the Site boundaries, and other relevant
structures or areas are shown on the Contract drawings in Volume 2D.
The Contractor shall take possession of the Site on the Commencement Date and shall
be responsible for the Site.
The Site consists of an area of the existing Lagoons .The Site also includes a approach
road which shall be constructed / improved by the Contractor as shown on drawing no.
TCE.10201A-CV-3054-SI-30001. A Cableduct of 300mm dia. at both side of road shall
be provided. The existing preliminary treatment works and associated buildings, control
rooms, etc. are within the Site being provided to the Contractor and the area, outside the
site boundary shall not be available for the Contractor’s use.
15.2 Possession of the Site
A condition survey of the Site and its environs shall be carried out by the Contractor prior
to commencement of any works. This shall include the condition of roads, structures,
facilities, lands, plants and trees that may be affected by the Works including the
structure and grounds of existing treatment infrastructure and associated manholes and
chambers. The surveys shall include the taking of record colour photographs covering all
the areas at the Site.
Before bringing any equipment on to the Site the Contractor shall submit to the
Employer’s Representative one set of prints (minimum size 150 x 100mm) from the
record photographs and a written record of the pre-commencement survey. Each
photograph shall be uniquely numbered and the area covered by each photograph
identified on plans or by written narrative. The Contractor shall confirm in writing to the
Employer’s Representative that the survey is a true and accurate record of the condition
of the inspected areas.
The Contractor shall not use the Site for any purpose other than carrying out the work
required under this Contract. A temporary labour camp shall be permitted subject to
availability of land, solely for labour carrying out the work required under this contract for
DB period only. Any such labour camp shall be suitably configured, located and
managed to ensure the highest standards of welfare and safety. The contractor shall
submit all details/drawings of his proposed labour camp to Employer for his approval.
The Employer may revoke the permission at his discretion. All the necessary consents/
permissions from statutory authority shall be obtained by the contractor. No animals shall
be allowed on the Site. A concrete batching plant shall be permitted on the Site, subject
to availability of land and approval of the Employer. The batching plant shall supply
concrete only for use on the Site. The batching plant and staff/labour quarters/huts shall
be dismantled and removed from site within 30 and 60 days respectively after completion
of construction of the plant. This will be precondition for issuance of Commissioning
Certificate.
15.3 Access to the Site
Access to the Site will only be permitted through the existing access road shown on
Drawing No. TCE.10201A-CV-3054-SI-30001 in Volume 2D.

15.4 Environmental Mitigation during Construction
15.4.1 Protection of Environment
The Contractor shall take all reasonable steps to protect the environment on and off the
Site and to avoid damage or nuisance to persons or to property of the public or others
resulting from pollution, noise or other causes arising as a consequence of his methods
of construction, operation and for demolishing existing structures.
During the contract, the Contractor and his Subcontractors shall abide at all times by all
existing enactments on environmental protection and rules made there under,
regulations, notifications and bye-Laws of the state or central government, and any other
Law, bye-Law, regulations that may be passed or notification that may be issued in this
respect in future by the state or central government.
Principal environmental regulations include but are not limited to:
Table 15.1 – Environmental regulations
Year Environmental Regulations
1974 The Water (Prevention & Control of Pollution Act) Amendments, 1988
1975 The Water (Prevention & Control of Pollution) Rules
1977 The Water (Prevention & Control of Pollution) Cess Act, Amendment 1992
1978 The Water (Prevention & Control of Pollution) Cess Rules
1981 The Air (Prevention & Control of Pollution) Act, Amendments, 1987
1982/1983 The Air (Prevention & Control of Pollution) Rules
1986 The Environment (Protection) Act, Amendments
(1989, 1990, 1993, 1996, 1997, 1998, 1999, 2000, 2001)
The Environment (Protection) fourth Amendment Rules 2008
1986 The Environmental (Protection) Rules
1992 E (P) Act Notification – “Environment Statement”
1994 E (P) Act Notification – “Environmental Clearance” EIA Notification 2009
1997 Amendments in the Environment Clearance, EIA Notification – “Public
Hearing” made mandatory
1989 The Hazardous Wastes (Management and Handling) Rules, Amendments,
2000 and 2003
1989 Manufacture, Storage and Import of Hazardous Chemical Rules,
Amendments, 1989, 2000
1991 The Public Liability Insurance Act, 1991
1995 The National Environment Tribunal Act
1997 Prohibition on the Handling of Azodyes
1997 The National Environment Appellate Authority Act
1998 The Bio-Medical Waste (Management &Handling), Rules
1999 Notification for making 100% Utilization of Fly-ash made mandatory,
Amendments 2003
2000 Municipal Solid Waste (Management &Handling) Rules

Year Environmental Regulations

2000 Ozone Depleting Substance (Regulation &Control) Rules
1999 Regulation on recycling of Waste Oil and Non-ferrous scrape
2000 The Noise Pollution Regulations and Control Rules
2001 Batteries (Management &Handling) Rules
15.4.2 Removal of Waste
All material shall be disposed of in accordance with national regulations. Burning of

debris is not permitted on the Site.
15.4.3 Working Hours
The Site normal working hours shall be as stated in the Contract Data. Working on Site
by personnel outside these hours in special circumstances may be permitted by the
Employer’s Representative but this shall be at his discretion and he shall have no
obligation to allow it.
Irrespective of working hours, piling operations, drilling and percussive activities and any
other such activities shall not be permitted between 18:00 hours and 09:00 hours.
Irrespective of working hours, there shall be no movement of traffic to and from the Site
(except for cars and light vans) between 19:00hrs and 07:00hrs.
15.4.4 Noise and Vibration
The Contractor shall carry out his operations in such a manner as to minimise noise and
vibration nuisance.
The Contractor shall comply with the requirements of The Noise Pollution (Regulation
and Control) Rules 2000 and all latest amendments.
The Contractor shall ensure that all his equipment used in the Contract shall be designed
to be reasonably quiet in operation and shall check the measures taken by the
manufacturers to minimise noise during operation of the equipment. The Contractor shall
ensure that all his equipment and associated platforms and connections are properly
maintained to be in efficient working order and reasonably quiet in operation for the full
duration of the Works. The Contractor shall fit effective silencers to machine exhausts
and adopt such other means as may be necessary to reduce noise to acceptable levels.
Machines in intermittent use shall be shut down when not in use, or throttled back to a
minimum. The Contractor shall remove from the Site any items of Contractor’s
equipment which are, in the opinion of the Employer’s Representative ineffectively
silenced.
All compressors, pumps and mechanical static plant shall be low noise models fitted with
properly designed acoustic covers, or screens, to reduce noise to acceptable levels.
These covers shall be kept closed whenever the machines are in use. All ancillary
pneumatic percussion tools shall be fitted with mufflers or silencers of the type
recommended by the manufacturer.
The Contractor shall organise his operations with regard to the positioning of plant and
the location of haul routes, etc. to minimise construction noise to adjacent properties.
The Contractor shall also maintain vegetation at construction sites to reduce air pollution
and noise levels.
He shall further employ the best practical means to minimise noise produced by his

activities.
The Contractor shall ensure that the sound levels arising from his activities during
construction do not exceed the following values when measured at the Site boundary:
Table 15.2 – Noise limits
dB(A) Leq dB(A) Leq dB(A) Leq
Period Hours
(1 hr) (15 min ) (Peak)
All days of week 08.00-20.00 75 80 85
At all other times* 70 75
* When the existing ambient noise levels are higher than the limits shown in the table,
the ambient noise levels may be exceeded by 5 dB(A).
If so ordered by the Employer’s Representative, the Contractor shall take measurements
of background noise and noise attributable to his operations. Measurements and
analyses shall be carried out in accordance with ISO 1996, Acoustics – Description and
Measurement of Environmental Noise.
In addition, noise emitted between 18.00hrs and 09.00hrs shall be free from tonal or
impulse qualities and pile driving or drilling shall not be permitted during these hours.
The Contractor shall carry out the Works in such a manner as to limit vibration at
adjacent properties and at the works, due to his construction activities, to an acceptable
level.
If required by the Employer’s Representative the Contractor shall carry out vibration
monitoring at adjacent properties.
Vibration caused by construction plant to be limited to the recommended values.
Table 15.3 – Vibration limits
Allowable vibration (in terms of peak particle velocity) at the closest part of any
sensitive property to the source of vibration, at a frequency of
Less than 10 Hz 10 to 50 Hz 50 to 100 Hz (and above)
3 mm/s 3 to 8 mm/s 8 to 10 mm/s
15.4.5 Transport of Plant and Materials
The Contractor shall abide by all national regulations and Laws governing the transport
of goods and materials including the classification, packaging and labelling regulations,
whether transport is by land or by sea.
Where lightweight material is transported the Contractor shall ensure vehicles are
adequately covered and loads trimmed if necessary to prevent spillage on to the public
highway.
15.4.6 Traffic Management
The Contractor shall develop and agree a traffic management plan with the Employer’s
Representative and the police to mitigate the effects of construction traffic on traffic in the
locality of the Site.
Where traffic flows on public roads will be affected the Contractor shall provide sufficient
advance warning to the Employer and the police so that advertisements and signage can
be implemented.

The Contractor shall plan his transportation requirements such that rush hour traffic is
not affected.
The Contractor shall provide, erect, and maintain suitable advance warning signs
advising of construction traffic ahead.
The Contractor shall, through regular inspection and maintenance, keep clean and
legible at all times all traffic signs lamps, barriers, cones and traffic control signals and he
shall position, reposition, cover or remove them as necessitated by the progress of the
Works, or as directed by the Employer’s Representative.
15.4.7 Disposal of Spoil and Waste
The Contractor shall give due consideration to the environmental benefits of re-using
excavated material.
The Contractor shall be fully responsible for removal and disposal off Site of any
excavated material that is not re-used on Site. He shall be responsible for obtaining the
necessary permits, licences or other permissions required for its safe disposal in
accordance with any relevant legislation and shall produce such documentation on
request by the Employer’s Representative. The disposal site shall be subject to the
approval of the Employer’s Representative. The Contractor shall ensure that vehicles are
suitably loaded, or covered if necessary, to ensure material is not lost during transport.
15.4.8 Site Drainage and Erosion Control
Drainage of fluids from the Site including pumping from excavations and surface run off
shall be limited as far as possible by the adequate planning of construction sequences
and bunding of the working areas and the use of silt curtains and temporary ditch
soakaways. Washing down of concrete trucks, etc. shall be to designated bins for
containment and removal off Site or treatment on Site.
The discharge from dewatering pumps and surface run-off shall be disposed of in such a
manner as to avoid pollution of waters. Disposal of such discharges shall not cause
damage to roads, sewers, public or private property, work completed or in progress and
it shall not cause unnecessary interference with the use of the roadway by the public, nor
shall it constitute a health hazard.
Soil erosion shall be minimised by the re-vegetation of working areas with grass and
native species as soon as practical. The Contractor shall achieve stabilization of debris
overburden using the following methods:
• Consolidation of the excavated debris and immediate transport to disposal site
• Planting trees, grasses and shrubs
• Provision to channelize rain water down the slope to minimise surface runoff
• Slope stabilization of dumped material
15.4.9 Contaminated Materials
The Contractor shall take samples of material arising on the Site at suitable locations
and frequencies to determine whether the material is harmful to construction workers,
whether it is suitable for re-use on the Site and whether, if it is to be disposed of off-Site,
it requires special permits or licences for disposal. Adequate time shall be allowed for
analysis and interpretation of the results in advance of relevant work. Samples shall be
analysed at an accredited laboratory and the results provided to the Employer’s
Representative.

15.4.10 Dust/ Air Pollution
The Contractor shall comply with the requirements of The Air (Prevention and Control of
Pollution) Act 1981 and all associated Rules and Notifications.
The Contractor shall take adequate measures to control the emission of dust from the
Site. Such measures shall include sprinkling of surfaces, re-vegetation and delayed
stripping of vegetative cover where practical.
The Contractor shall cover or water stockpiles and storage areas to prevent dust
pollution. The Contractor shall also cover trucks transporting construction materials to
minimise spills and shall not overload vehicles.
The Contractor shall not cause any dust nuisance to third parties or to the Employer’s
Representative’s offices.
The Contractor shall tune and service regularly all construction and transportation
equipment in order to prevent air pollution.
15.4.11 Tidiness of the Site and Local Roads
The Contractor shall maintain the Site in tidy condition throughout the duration of the
Contract.
The Contractor shall ensure that any public or private roads used by construction traffic
are not contaminated with material from the Site, by the installation and operation of a
wheel-wash facility or similar, if necessary. The Contractor shall bear the cost of keeping
clean any roads contaminated by material from the Site, and of any consequential effects
of dust arising from materials deposited on roads outside the Site.
15.4.12 Temporary Lighting
The Contractor shall install temporary lighting to assist security and safety of the Site and
its environs.
The impact of the temporary lighting on the local population shall be reduced by the use
of lanterns which prevent glare and the spread of light beyond the Site.
15.4.13 Preservation of Trees, Flora, Fauna and Artefacts
The Contractor shall protect existing trees, flora, fauna and artefacts wherever
practicable to reduce impact on the Site to a minimum.
Trees shall be retained in accordance with the Contract and any that are to be retained
shall be adequately protected to prevent damage.
15.4.14 Pollution
The Contractor shall carry out his activities to prevent nuisance or pollution of any type.
The Employer’s Representative and the Maharashtra Pollution Control Board (MPCB)
shall be notified by the Contractor as soon as possible, in the event of a pollution incident
or of suspected pollution.
15.5 Public Liaison & Communication
The Employer intends to develop a pro-active approach with regard to liaison with the
public throughout the Design-Build Period.
The Contractor shall participate with the Employer in its endeavours to promote this
public liaison objective. During all working hours the Contractor shall have at least one

designated person on site who is conversant in English, Hindi and Marathi.

15.6 Parking for Construction Vehicles
All construction traffic, including personal cars and vans shall park on the Site or on other
areas of land secured by the Contractor and shall be subject to approval by the
Employer’s Representative. No parking shall be allowed to create nuisance or hazard on
the public roads.
15.7 Contractor’s Temporary and Working Areas

No land outside the Site has been made available to the Contractor by the Employer.
15.8 Site Security
A temporary security fence and gates shall be erected by the Contractor to enclose the
Site, prior to the commencement of his construction activities. The security fences and
gates on the Site shall be at least 2m high and of an anti-intruder type and stock-proof.
The Contractor shall undertake special precautions to:
(i) Prevent exposure of members of the public to danger due to rough ground terrain,
excavations or stacked materials;
(ii) Prevent tampering with construction materials, site plant, machinery, site utilities, or
hazardous chemicals utilised or stored on the Site. Additional fencing shall be
required where materials or plant for incorporation into the works are being stored.
These shall be located so that they are not visible to persons outside the Site;
(iii) Prevent access to scaffoldings;
(iv) Provide security personnel at all times;
(v) Not permit any person not engaged on the site to enter the Site.
15.9 Storage of Plant and Materials
The Contractor shall ensure Plant and Materials for incorporation into the Works are
stored in accordance with manufacturer’s recommendations and protected from the
weather.
The Contractor shall be responsible for a proper inventory of plant and materials together
with receipts and issues and identification of same.
The Contractor shall not store or deposit any of his equipment on the Site without the
consent of the Employer’s Representative.
The Contractor shall ensure that no fuel or oil spillages discharge to the environment.
Temporary fuel and oil storage tanks in the Contractor’s compound shall be protected by
an impervious containment bund. The Contractor shall carry out daily inspections for
spillage of fuels/oils at the Site.
Stacked equipment and materials shall be protected from damage by spacers on load
distributing supports and shall be safely arranged. No metalwork shall be stored directly
on the ground.
Small items shall be held in suitable bins, boxes or racks and be clearly labelled.
Equipment and materials shall be handled and stored so that they are not subjected to
excessive stresses and so that protective coatings are not damaged.
The Contractor shall comply with the manufacturers’ package and equipment markings
concerning the use and location of lifting slings, chains and hooks.
Equipment and materials shall be stored in a manner that minimises risks to the
environment and will be located away from sensitive receptors such as watercourses

and drains, where there is risk of harm through spillage, leakage or leaching of harmful
materials.
15.10 Protection against Damage
The Contractor shall take all necessary precautions to avoid causing any damage to
buildings, structures, roads, lands, properties, trees and other features and, during the
currency of the Contract, shall deal promptly with any complaints by owners or occupiers.
Any damage done to road surfaces outside the Site shall be restored to the Employer’s
Representative’s satisfaction at the Contractor’s expense.
Where any portion of the Works is close to, across, or under any existing apparatus of
public utilities or other parties, the Contractor shall temporarily support and work around,
under or adjacent to all apparatus to avoid damage, leakage or danger and to ensure
uninterrupted operation.
15.11 Utilities and Other Services
Any information concerning existing services within the Site that has been notified to or
obtained by the Employer is contained in the Background Information. The positions are
approximate. The Contractor shall make all contact with the relevant public utilities,
service owners, land owners and other parties before commencing any excavations and
shall satisfy himself as to the exact position of existing services which may affect or be
affected by the construction of the Works.
If any information concerning the position, existence, non-existence or type of service is
found to disagree with information provided by the Employer or the relevant authority
then the Contractor shall notify the Employer’s Representative in writing.
The Contractor shall liaise with the relevant utility or owner of the service to determine
whether the apparatus is to be diverted, removed, or left unaffected. All work carried out
in the vicinity of services shall be such as to avoid drainage, leakage or danger and in
the case of public utilities be in accordance with their procedures and codes of practice,
copies of which can be obtained from the utility.
The Contractor shall allow for extended consultations with public utility authorities.
15.12 Archaeology
Any finds of archaeological interest such as relics of antiquity, coins, fossils or other
articles of value shall be immediately brought to the attention of the Employer’s
Representative for appropriate further course of action.
15.13 Setting out, Datum and Surveys
The Contractor shall be responsible for the accurate location of the Works.
Elevation and levels used for the project are linked to the Town Hall Datum (THD). The
Temporary benchmark for the project is as shown on Drawing No. TCE.10201A-CV-
3005-TR-30001.
The Contractor shall satisfy himself as to the accuracy of the survey details and levels
provided on the drawings in Volume 2D and shall carry out additional surveys to verify
the same. The results shall be provided to the Employer’s Representative prior to work
commencing on Site.
The Contractor shall provide at the commencement of work on the Site, substantial
master temporary benchmarks at convenient positions over the Site, suitably protected
for the duration of the Contract and agree the levels of such works with the Employer’s
Representative. Temporary benchmarks at intermediate locations shall be provided by
the Contractor as required and agreed with the Employer’s Representative.

The Contractor shall establish a permanent master survey station and benchmark at a
convenient point near the Site. All levels shall be referenced to Town Hall Datum.
The Contractor shall set out the Works in accordance with the dimensions, lines and
levels shown on his construction drawings.
The contractor shall give the Employer’s Representative not less than 48 hours’ notice of
his intention to set out or give levels of any part of work so that timely arrangements may
be made for checking or issuing instructions.
15.14 Project Signs

The Contractor shall provide, erect, and maintain, until the Works are taken over, 2 sets
of project signs with information about the project near the Site at locations which shall
be subject to approval by the Employer’s Representative. The details of the signs shall
be provided by the Employer’s Representative and a provisional sum is included for this
item.
The Contractor shall not undertake or allow billposting or advertising of any kind upon
the Site or on the project signs without the written consent of the Employer’s
Representative.
15.15 Staff and Materials to Assist the Employer’s Representative
The Contractor shall place at the disposal of the Employer’s Representative, competent
general staff and chainmen at any or all times when and where required to assist in
checking the setting out, levelling or measuring of the Works or for any other purpose
during the progress of the Works together with all necessary pins, ranging rods and other
materials and apparatus. Generally the services of not more than two men will be
required at any one time to assist the Employer’s Representative.
15.16 Meetings
Every Fortnight progress review meetings shall be held at the Site or client office. These
shall be held at the Employer’s Representative’s office until the Site facilities are
available. These shall be chaired by the Employer’s Representative and attended by the
Contractor and any Subcontractor or supplier deemed necessary by the Employer’s
Representative. The dates for the meetings shall be determined by the Employer’s
Representative. Minutes shall be recorded by the Employer’s Representative and
endorsed by the Contractor. They shall be issued to all attendees.
Design meetings shall be held Every Fortnight until issue of the final Contractor’s design
report as per the Contractor’s Documents, and at least once every two months thereafter
or as required by the Employer’s Representative. They shall be held at the Site or client
office and attended by the Contractor and his design representatives. Minutes shall be
recorded by the Contractor and endorsed by the Employer’s Representative. They shall
be circulated to all attendees. A schedule of convenient dates shall be agreed in
advance.
15.17 Method Statements
The Contractor shall submit general and detailed method statements.
A general method statement shall be provided 28 days prior to commencement on Site
which shall outline the procedure that the Contractor intends to employ for each element
of the construction, including a comprehensive list of plant that will be used. It shall
include the relevant sections of his environmental management programme, indicating
what measures will be employed to mitigate against environmental impact during
construction.

Detailed method statements shall be provided for each element of the Works. These
shall comprise a step by step schedule of specific operations or activities with
descriptions, dates, times and duration of each step, supported by sketches or other
detail to aid their understanding. They shall include reference to relevant legislation, and
permits and licences that have been or are required to be obtained.
15.18 Supply of Materials and Services
The Contractor shall be fully responsible for providing all Materials and services required
for the carrying out of the Works.
The Contractor shall supply/install a temporary Site electrical distribution system
including wiring. Cabling and distribution boards for power services, lighting etc. are to
be provided in a safe and efficient manner as required for his construction, Site storage
and the office areas.
Electrical welding equipment shall not be connected to the Site electricity supply and the
Contractor shall provide all necessary portable generating equipment.
The Contractor shall employ competent personnel experienced with similar equipment
and maintain the electricity supply and distribution system. An inspection certificate shall
be supplied to the Employer’s Representative on completion of the temporary installation.
It shall be tested and inspected at intervals of not more than 3 months and the inspection
certificates supplied to the Employer’s Representative.
The Contractor shall ascertain from the supplier any restrictions of supply which are
likely to impose limitations on his programme of work, such as supply of water for testing
purposes.
Where a supply of water, electricity or gas is required, the Contractor may make use of
the permanent supplies once they are installed subject to the requirements of the
supplying authority but the Contractor shall be liable for all charges for the service. The
Contractor shall also be responsible for any additional facility, over and above those
specifically required for the Permanent Works that he installed to provide for his use
during construction, and any costs arising from their use by him.
All such facilities shall be removed by the Contractor on completion of construction. All
installations shall be agreed in advance with the Employer’s Representative.
15.19 Temporary Works
The Contractor shall submit to the Employer’s Representative for review, drawings of
Temporary Works, including staging, fencing, formwork, piling etc. and plant at least 4
weeks prior to those items being delivered to Site. This shall include details and
calculations of any loading imposed on the Permanent Works by their use.
The Contractor shall be solely responsible for the sufficiency, safety, adequacy and
maintenance of all Temporary Works. No review by the Employer’s Representative shall
relieve the Contractor of any of his responsibilities.
15.20 Construction Plant and Equipment
The Contractor shall be responsible for making his own arrangements for all necessary
construction plant and equipment including the supply, storage and maintenance. All
items shall be in full working order and conform to all relevant health and safety
requirements.
When requested by the Employer’s Representative, the Contractor shall supply
information and details of the plant and equipment including its specification, history and
certification.
No review by the Employer’s Representative shall relieve the Contractor of any of his

responsibilities for the adequacy, safety or efficiency of his construction plant and
equipment.
15.21 Smoking
Smoking shall only be permitted in designated, signed, areas.
15.22 Blasting and the use of Explosives
The Contractor shall not carry out any blasting activities on site. The Contractor shall not
be permitted to use explosives.
15.23 Contractor’s Accommodation and Facilities
15.23.1 Location
The Contractor’s temporary site offices, site huts, stores and parking areas shall be
located within the Site, consistent with the requirement for him to minimise the
environmental impact on the Site.
Immediately upon removal of the accommodation and related facilities the Contractor
shall complete landscaping and rehabilitation of the areas occupied in accordance with
the Contract.
15.23.2 Contractor’s Office
The Contractor shall, before commencing work, erect an office for his own use in a
position and to a standard and layout to be agreed by the Employer’s Representative.
The office shall be substantially built, weather-proof, well-lit and suitably furnished. It
shall be properly secure to keep safe the papers, documents and drawings handed to
the Contractor by the Employer’s Representative for use in carrying out the Works. The
office shall contain a letter box for the secure receipt of instructions, messages and mail
from the Employer’s Representative and others. The Contractor shall obtain the correct
postal address and code for the office and notify the Employer’s Representative
accordingly. Messages or instructions left at or sent by post to this office shall be
deemed to have been served on the Contractor. The Contractor’s office shall not be
removed from the Site until the Employer’s Representative, by notice in writing, calls
upon the Contractor to do so.
The Contractor shall provide, erect, construct, maintain and subsequently remove all
temporary messing and sanitary arrangements, stores, workshops, compounds, parking
areas, drainage, lighting and the like, necessary for the completion of the Works for the
use of his own staff and work force plus those of his Subcontractors in accordance with
the latest legislation.
15.23.3 Contractor’s Telephone
The Contractor shall arrange for the installation of a telephone and facsimile system
connected to the terrestrial public telephone system for the use of his own staff and for
those of his Subcontractors. These services shall be located in the Contractor’s offices at
the WwTF Site. The Contractor shall be responsible for the task of establishing, using,
maintaining and removing the system. The Contractor’s Representative shall be provided
with a mobile telephone by the Contractor.
15.23.4 Sanitary Arrangements
Throughout the period of construction of the Works the Contractor shall provide, maintain
and keep clean suitable and sufficient latrines for use by his employees; he shall ensure

that his employees do not foul the Site, and shall be instructed in the proper use of the
latrines.
The Contractor shall connect the latrines to sealed units suitable for disposal or to the
influent stream upstream of all treatment processes subject to agreement from the
15.24 Accommodation for the Employer’s Representative
The Contractor shall provide and maintain offices, fixtures and equipment services as
specified in Appendix C throughout the Design-Build Period and for a further 6 months
after issue of the Commissioning Certificate, for the exclusive use of the Employer’s
Representative and his staff.
All items provided shall be to the satisfaction of the Employer’s Representative and shall
become the property of the Contractor at the end of the Design-Build Period unless
specified otherwise.
The Employer’s Representative’s main office shall be established on the same Site as
the Contractor’s Representative’s main office. The accommodation shall be separate
from, and located adjacent to the Contractor’s accommodation and shall be clearly
marked “Employer’s Representative”. The accommodation shall be in a single storey,
single, weather-proof building which shall be of good quality and of substantial build.
The accommodation area shall be covered by hardstanding surface with macadam, and
properly drained and fenced off. A parking area shall be indicated within this area with
space for 5 cars. The parking area shall be clearly signposted.
Rooms within the office shall be divided by full height partitions, suitably insulated. Walls
and ceilings shall be lined in approved colours and the external walls shall be in an
approved colour.
Floors shall be close boarded and carpeted with industrial quality carpets, with the
exception of the messing areas where the floors shall be linoleum covered.
All doors shall be secure and lockable and 2.sets of keys provided. A doormat and boot
scraper shall be provided at each external door together with boot cleaning facilities.
There shall be adequate natural and artificial lighting and ventilation and windows shall
be fitted with blinds. Air conditioning units shall be integrally fitted and adequate power
points provided in each room.
Emergency exits and emergency lighting shall be provided. Suitable fire extinguishers
shall be provided.
An adequate and reliable electricity supply shall be provided to each office and a potable
water supply and sanitation facilities provided to the kitchen messing area and toilets.
Rooms shall be clean and freshly decorated at the start of the Contract and the
Contractor shall clean the floors, kitchen, basins and toilets daily and windows weekly.
The Contractor shall be responsible for providing and removing the electrical, water,
telephone and sanitation services. He shall be responsible for the cost of all bills and
user charges relating to their use or consumption, with the exception of the unit costs of
telephone calls made by the Employer’s Representative and his staff, which shall be
refunded to the Contractor from the Provisional Sum in the Schedule of Payments in
Volume 3.
15.25 Vehicles for the Employer’s Representative
The Contractor shall provide and maintain one no. vehicle (including fuel, drivers, toll and
parking) for use by the Employer’s Representative during the Design-Build Period. The
vehicles shall be good latest model (6 Seats) as approved by the Employer’s

Representative and shall have air conditioning. The vehicles shall have Tourist permits
and shall be available to the Employer’s Representative at any time, 7 days per week on
a two shifts per day basis. The Contractor shall be responsible for the running and
upkeep of the vehicles including payment of taxes, insurance, licences, permits, fuel, oil,
lubricants, repairs and maintenance and shall also provide competent drivers with each
vehicle. The Contractor shall note that there shall be a requirement of Vehicle at any
time. Failure to provide the same shall result in penalties of Rs. 2,000/day/car.
15.26 Returns of Labour and Plant Reports
The Employer’s Representative will require a weekly report from the Contractor detailing
the labour and plant utilised on the works during the previous week. This report shall be
delivered to the Employer’s Representative at the start of each week.
The weekly report on plant shall detail the number and type of the various machines and
equipment utilised.
The weekly report on labour shall include all skilled and unskilled labour employed in the
construction of the Works and the name and grade of each operative shall be identified,
together with the normal and overtime hours worked.
15.27 Staff Welfare Management
The Contractor shall construct and maintain welfare facilities for his staff and operatives.
The Contractor shall be responsible for and provide all services to the welfare facilities
and shall ensure that all sanitation Laws, labour laws and other Laws and regulations in
force in the area are complied with. The Contractor shall be responsible for providing all
necessary fencing and security to these areas.
15.28 Site and Laboratory Testing
The Contractor shall be responsible for testing of materials at a local national or
internationally accredited laboratory and supplying the results to the Employer’s
Representative, who shall be afforded access to the testing facilities during normal
working hours.
All testing shall be in accordance with the Contractor’s quality procedures.
In addition of above, Contractor shall be responsible for Testing of materials at MCGM’s
Lab, as per requirement of Employer’s Requirement
15.29 Daily Records
A daily record of the day’s activities shall be completed by the Contractor and handed to
and certified by the Employer’s Representative at the end of each working day. The
report shall include, as a minimum, for: work done, all labour utilised, all plant and
equipment (used/standing), weather temperature/conditions, deliveries, visitors, etc.
15.30 Inspections and Testing (except Tests on Completion of Design-Build)
15.30.1 General
This section covers the procedures, inspection, testing and recording of Plant and
Materials up to the start of Tests on Completion of Design-Build. The Employer’s
Requirements for Tests on Completion of Design-Build are covered in Section 17.
The Contractor shall provide a programme of tests ensuring co-ordination between tests
to minimise attendance time.
The Contractor shall provide all labour, materials, service charges and consumables as
may be required. A Provisional Sum for the Employer’s Representative expenses for
attendance at and during works tests and inspections at the Contractor’s or

manufacturer’s premises has been allowed in the Schedule of Payments.

The Contractor shall submit to the Employer’s Representative at least 21 days in
advance of the tests full details of the tests to be carried out (including the time and date
of the tests) to ensure that all requirements of the Contract including the functional
design specification requirements, have been met.
No inspection, acceptance or agreement by the Employer’s Representative of the Works
shall prejudice the right of the Employer’s Representative to reject any Plant or Material if
it subsequently fails to comply with the Contract.
15.30.2 Factory Inspection and Testing
Where practicable and unless “Type Test” certificates are specified, the Contractor shall
carry out works tests on all Plant before dispatch to Site or to store at the manufacturer’s
premises. The Contractor shall arrange for third party inspection and certification and a
provisional sum has been provided for this purpose. The third party agency shall be an
internationally reputable independent firm and shall be subject to the approval of the
Employer’s Representative. The Employer’s Representative shall be given the
opportunity to witness the tests which shall be arranged to represent the working
conditions where possible. Witness tests shall be required for all major items of Plant,
except those of a standard nature, and for other Plant and Materials as required by the
The Contractor shall carry out works tests and inspections on the all major materials
being fabricated or processes on or off Site and shall ensure that they comply with the
drawings and Employer’s Requirements. The Contractor shall ensure that the
manufacturer’s quality assurance procedures are being followed and that the programme
is being adhered to.
The Contractor shall carry out routine and functional works tests to ensure that the item
being tested functions correctly and to demonstrate conformity with the specification. No
item of plant or materials shall be delivered to the Site without inspection and testing
having been carried out or waived in writing by the Employer’s Representative prior to
carrying out of any tests.
Type test certificates shall be provided to the Employer’s Representative before dispatch
to Site. Where such certificates are not available a letter of intent from the testing
authority shall be provided. Where no testing or inspection requirements are detailed in
the Employer’s Requirements or the relevant standard, a recognised trade association
standard or the manufacturer’s test procedure shall be applied.
Calibration certificates for instruments used for such tests shall be provided and, if
necessary, instruments shall be recalibrated before commencement of the tests.
Hardware and software testing for SCADA and PLCs at the software writer’s premises
and at the control panel manufacturer’s premises shall also be in accordance with the
details in Clause 13.10.
Other tests are detailed in the relevant sections of Employer’s Requirements.
For unusual bespoke or critical elements of the civil works being fabricated, painted or
tested off Site the Contractor shall provide suitably licensed and qualified inspectors to
be in full time attendance or carry out a regular visiting regime, depending on the
industry best practice.
15.30.3 Inspection and Testing during Construction of the Works
All water retaining structures shall be tested for water tightness in accordance with the
requirements of Vol 2A – General Civil Specification – Clause 17.18.5.

All pipelines shall be tested in accordance with Vol 2A – General Civil Specification –
Clause 23.10.
The Contractor shall provide all the necessary labour, materials and equipment to test
water retaining structures, and pressure and non-pressure pipelines. Water testing of
structures and pipelines shall be carried out using potable water.
Construction materials such as concrete and its constituents, structural steelwork, piles,
bitumen macadam, masonry, timber, steel grouts, sealants and all protective coatings
shall be tested in accordance with the Employer’s Requirements.
All Materials supplied to or as part of the Works shall be new and subject to quality
assurance inspection certification and testing to demonstrate their fitness for the purpose
intended.
Where quality assured materials are not readily available or whether compliance with
national standards or equivalent is required then the Contractor shall supply test
certificates demonstrating their compliance with the relevant specification.
15.30.4 Pre-installation Inspection
The Employer’s Representative shall be given the opportunity to visually inspect all items
of Plant prior to installation to ensure that no damage has occurred during storage or
transit.
15.30.5 Safety Inspection
Prior to commencement of the Tests on Completion of Design-Build the Employer’s

Representative will arrange for an inspection to check that the Works comply with health
and safety regulations. This inspection will in no way relieve the Contractor of any of his
contractual responsibilities or liabilities.
15.30.6 Record Keeping
The Contractor shall keep a record of all tests and inspections including failed tests and
shall pass these records to the Employer’s Representative following each set of tests or
inspection.
If specialist test equipment is used the Contractor shall supply associated test sheets.
Where the Contractor employs a specialist inspector the inspector’s reports shall be
provided to the Employer’s Representative on successful completion of manufacture or
construction. Should the inspection period be in excess of one week, interim inspection
reports shall be provided on a weekly basis.

Training of Employer’s Operatives by the Contractor

16 TRAINING OF EMPLOYER’S OPERATIVES BY THE CONTRACTOR

16.1 General
The Contractor shall provide comprehensive training for the different categories of the
Employers staff during operation and maintenance period. Training shall fall into two
main types which are ‘off the job’ and ‘on the job’. Off the job training shall take place in
the class room and on the job training shall be carried out on the running plant(s).
16.2 Off The Job Training
The Contractor shall prepare formal training documentation for distribution to the trainees.
Visual aids shall be used to illustrate the points being made and to make the training
programme interesting and enjoyable for the participants.
The off the job training shall comprise the following:
1. Off the Job Training Programme for all Trainees to provide training:
• on the simple physical-chemical and biological process principles involved in the
operation of the Works;
• regarding basic features of the electro-mechanical and instrumentation
equipment to be installed
• health and safety;
• plant safety procedures;
• on the use of the local and central HMIs and SCADA.
• Monitoring devices;
• Operational performance index.
2. Off the Job Process Training Programme for Operators to provide training:
• on the operation of individual items of plant and sections of the Works including
automatic operation and manual operation;
• on the day to day operation of the Works and procedures;
• on a comprehensive list of ‘what if’ scenarios dealing with the actions to be taken
in the event of potential process problems, alarms, plant failures, overflows,
power failures etc.;
• on first line mechanical maintenance;
• safe work practices;
• on safety procedures to be followed in operating, maintaining, and cleaning the
plant;
• special procedures to be followed in the event of chlorine leak.
• Creation of O/M forms;
• Troubleshooting.
3. Off the Job Training Programme for Electrical Maintenance Staff to provide training:
• on the configuration, construction and operation of the electrical Plant;
• on the electrical maintenance requirements of the Works;
• on the switching and safety procedures to be followed;

• safe methods of working;

• on fault finding and repair procedures.
4. Off the Job Training Programme for Mechanical Maintenance Staff To provide
training on:
• On the routine mechanical maintenance requirements of the Works;
• On lubrication requirements of the Works;
• On fault finding, repair and overhaul procedures;
• Cleaning & maintenance method ;
• Safe methods of working
• Creation of O&M forms;
5. Off the Job Training Programme for WwTF Management Staff to provide training on:
• WwTF process management techniques;
• WwTF cost management;
• WwTF laboratory management;
• Safe methods of work general;
• On safety procedures to be followed in operating, maintaining and cleaning the
plant;
• Creation of O&M management Index;
• Creation of Asset/Property ledger and Management method;
6. Off the Job Training Programme for Pumping Station Staff to provide training on:
• Process management techniques;
• Plant cost management;
• Safe methods of work general;
• On safety procedures to be followed in operating, maintaining and cleaning the
plant
• Cleaning & Maintenance method ;
16.3 On The Job Training

The Contractor shall utilise the Operation and Maintenance Manuals as the primary
training aid in carrying out the on the job training. Shortcomings, omissions and errors
identified in the O & M Manuals during the training shall be rectified prior to final
acceptance of the O & M Manuals.
1. On the Job Training Programme for all Trainees to provide training on:
• Plant familiarization tour;

• On the use of the local and central HMI/SCADA;

• Health and safety;
• Identify areas where special safety precautions are necessary.
2. On the Job Process Training Programme for Operators to provide training on:
• under operational conditions on the operation of individual items of plant and
sections of the Works including automatic operation and manual operation;
• illustrate by example the day to day operation of the Works and procedures;
• illustrate by example the actions to be taken in the event of potential process
problems, alarms, plant failures overflows, power failures etc. (as identified in the
‘what if’ scenario off the job training);
• illustrate by example the first line mechanical maintenance;
• illustrate by example safety procedures to be followed in operation, maintenance
and cleaning of the Works;
• Operation at the time of change of inflow load;
• Measure against sludge bulking at settling basins and Biological treatment
basins;
• Proper management method of a sludge treatment facilities;
• Evaluation of Process Monitoring;
• Water quality testing;
• Entry and evaluation of everyday performance data ;
• Creation of various types of a report of a day, monthly, and a fiscal year using PC.
3. On the Job Training Programme for Electrical Maintenance Staff to provide training
on:
• Carry out detail tour of the electrical plant;
• Illustrate by example the operation of the electrical plant;
• Illustrate by example the electrical isolation and maintenance procedures;
• Illustrate by example fault finding and repair procedures;
• Illustrate by example switching and safety procedures to be followed;
• Illustrate by example safe systems of work;
• Entry and evaluation of everyday performance data;
• Creation of various types of a report of a day, the monthly, and a fiscal year.
4. On the Job Training Programme for Mechanical Maintenance Staff to provide training
on:
• Illustrate by example the routine mechanical maintenance requirements of the
Works;
• Illustrate by example lubrication procedures;
• Illustrate by example fault finding, repair and overhaul procedures.
• Illustrate by example safe systems of work;
• Entry and evaluation of everyday performance data;

• Creation of various types of a report of a day, the monthly, and a fiscal year.
16.4 Training Programme

Off the job training shall be carried out prior to Taking Over of the Works or any section
of the Works.
Off the Job training shall be carried out prior to On the Job training. On the Job training
shall be completed as a condition for acceptance of the Works following completion of
the Tests after Completion.
The Contractor shall provide a training plan for each category of staff. The training plan
shall detail the content and duration of each course. The training plan shall be submitted
for the approval of the Engineer at least 90 days prior to the commencement of the Tests
on Completion. The duration of training offered for each category of staff shall not be
less than that detailed in the following table.
Category of Staff Off the Job On the Job

(minimum days duration (minimum days duration for
for each course) each course)
All staff 1 1
Operator 3 5
Electrical 2 2
technician/electrician
Control/instrument technician 10 5
Mechanical technician/fitter 2 2
WwTF management 3 (see note)
Note: It is assumed that WwTF managers on the job training will be continuous
throughout 12 months in a calendar year when the plant(s) is operated by the Contractor.
The training day shall be assumed to be not less than 8 (eight) hours split into two
sessions. The Contractor shall provide facilities for training which shall include inter alia
the training rooms/locations, tables and chairs, projectors, white/black boards, training
aids, training manuals etc.
Where trainees of a given category can all be released from their Works operational
duties simultaneously they may be trained together. Where this is not possible the
Contractor shall repeat the complete course for those who could not attend.
16.5 Training Personnel

The Contractor shall provide suitably qualified trainers to carry out the off the job and on
the job training.
The trainers are to be experienced in WwTF facilities, operation and maintenance in their
relevant discipline and in the training of skilled and unskilled staff.
The Contractor shall submit the curriculum vitae of the trainer nominee's to the Engineer
for approval 90 days prior to the commencement of the Tests on Completion. The
training expert shall be fluent in English, Hindi and Marathi Languages or the Contractor
shall provide the services of an interpreter during the training periods.

16.6 Instrumentation, Control & Automation Training requirements

The Contractor/ system supplier shall conduct training courses for personnel selected by
MCGM. Training shall be conducted by personnel employed by the Contractor/ system
supplier familiar with the system supplied and who have experience and training in
developing and implementing instructional courses.
The contractor shall arrange training for the MCGM personnel for 5 days before the
conduction of FAT. This training shall be separate from the training for MCGM (2
sessions of 5 days each) which shall be conducted during SAT.
The entire cost of the complete training programme, including reasonable per diem
expenses to cover meals, lodging, transport and similar expenses for all MCGM
personnel and the consultants attending the training program, shall be the responsibility
of the Contractor/ system supplier and shall be part of contract.
The Contractor/ system supplier shall submit information on the training programme for
approval, prior to shipment of the equipment. This submittal shall include a course
outline; time required, course schedule, sample workbook and instructor qualification
information for each level.
The Contractor/ system supplier shall make a workbook on each course available to
every person taking the courses listed herein. The workbook shall be of sufficient detail
so that, at a later date, a trainee could review in detail the major topics of the course.
The training times shall be scheduled by the MCGM in advance with the Contractor/
system supplier so as not to disrupt the MCGM’s ability to operate the plant.
16.7 Operations and Maintenance Training

Training shall be provided for Fifteen (15) of the MCGM personnel at the Contractor/
system supplier facility on operations and maintenance of all system components. The
training program shall be divided into two segments and shall consist of at least 5 (five)
working days, each of 8 (eight) hours duration.
The maintenance training program shall be developed for personnel that have
electronics maintenance and repair experience and a general knowledge of computer
systems, but shall not assume any familiarity with the specific hardware furnished. As a
minimum, the following subjects shall be covered:
• System Architecture and Layout
• Hardware Components
• Module Switch Settings (Configuration Switches)
• I/O Modules
• Power Supplies
• Data Highway:
• Programmer connection
• IOP programming and diagnostic techniques
• Battery replacement and recharging
• PC and workstation familiarization and maintenance:
• Troubleshooting

• Disassembly
• Cleaning
• Component Replacement
• Re-assembly
The operation training programme shall include the following topics:

• Power-up, bootstrapping and shutdown of all hardware devices
• Interpretation of all standard displays
• Appropriate actions for software and hardware error occurrences
• Use of operator interface displays and keyboards
• Use of printer including replenishment of supplies
• Manual data entries
• Creation and editing of graphic operator display screens.
• Loading of any required software into the system
• Data base creation and editing.
16.8 Training Assessment

At the conclusion of off-job and on-job training, all the trainees shall be asked to undergo
a simple assessment / test to examine the level of understanding of the working of
WwTF and the effectiveness of the training program. The feedback gathered from the
assessment / test shall be used by the Managers to make a decision whether some of
the trainees need to be re-trained.
The managers who will be at continuous training for 12 month period will have to be
assessed/ tested after completion of the 12 month period.

Tests on Completion of Design-Build

17 TESTS ON COMPLETION OF DESIGN-BUILD

17.1 Definitions
For the purposes of this Section 17 (Tests on Completion of Design-Build) of the
Employer’s Requirements, the following terms shall have the meanings set forth herein:
"Activated Sludge" means a rich broth of bacteria and protozoa used in the Biological
Process;
"Biological Process" means a process for treating Influent primarily utilizing biological
organisms;
"Business Day" means any Day excluding:
• Sunday;
• a Day on which MCGM is closed;
• any Day which is a legal holiday in the state of Maharashtra, India; or
• a Day on which financial institutions in the state of Maharashtra, India are authorized
or required by law or other action of any Governmental Instrumentality to be closed;
"Day" means a calendar day;
"Effluent" means wastewater that has been treated by or has otherwise passed through
the Works;
“Effluent Specifications” as specified in Section 18;
"Eligible Day" means any Day during the Plant Proving Period on which both (i) the
quality of the Influent is within the applicable load parameters specified in Appendix B1
and (ii) the Influent flow does not exceed the quantity specified in Appendix B1;
"Equipment Validation" means the tests to be performed in accordance with the
provisions of this Section of the Employer’s Requirements;
“Hydraulic Validation Test” means a test designed to demonstrate that the Works is
capable of passing the PFF in accordance with the hydraulic design of the Works;
"Influent" means all wastewater (including inflow and infiltration) that is conveyed by the
wastewater system to the Works;
"Instantaneous Flow" means the flow through a specific point at any given moment in
time typically measured in m3/s;
"Interruption" means, in the case of the Plant Proving Period, an interruption of the
treatment process;
"Liquid Proving Period" means the period consisting of 30 consecutive Eligible Days
during which tests to be performed are undertaken in accordance with the provisions of
this Section of the Employer’s Requirements;
"Liquid Proving Period Commencement Date "means the Day which is 30 (thirty) days
after the Contractor has submitted the Liquid Proving Period Plan, all activities required
to be completed prior to completion of Commissioning have been so completed, the
Works has been successfully Commissioned and the Commissioning report submitted by
the Contractor is accepted by the Employer’s Representative;
"Mechanical Dewatering" means dewatering (reducing water content) of Sludge using
filter belt processes or centrifuges;
"Minimum Influent Quantity" means a certain minimum Influent Quantity per Day
(i) contemplated by the Test Requirements and Procedures and (ii) used for the
purposes of confirming that the Works performs in accordance with the performance

requirements;
"Plant Proving Period" means both (i) the Liquid Proving Period and (ii) the Sludge
Proving Period;
"Process Commissioning" means the tests to be performed in accordance with the
provisions of this Section of the Employer’s Requirements including without limitation
(i) process testing of equipment and ancillary systems under actual operating conditions
with at least the Minimum Influent Quantity and (ii) development and testing of a stable
Biological Process with available Influent to produce Compliant Effluent;
“Sludge” means a mixture of solids and water produced during the collection and
treatment of Influent;
"Sludge Proving Period" means the period consisting of 20 consecutive Eligible Days
during which the Sludge produced by the Works is tested and analysed in accordance
with the provisions of this Section of the Employer’s Requirements;
"Sludge Proving Period Commencement Date" means the Day advised by the Contractor
on which sufficient Sludge is being continuously produced and is available for dewatering
for the purposes of the Sludge Proving Period;
"Sludge Specifications" are specified in Section 18;
"SOTR Test" means the Standard Oxygen Transfer Rate Test as carried out on-site in
the actual bioreactor generally in accordance with the American Society for Civil
Engineers "Standard Measurement for Oxygen Transfer to Clean Water" Second Edition
June 1992 or other equivalent European or internationally recognised standard;
"Test Requirements and Procedures" means the detailed test procedures and
requirements prepared by the Contractor and approved by the Employer prior to
commencement of testing.
“Testing Plan” means the plan prepared by the Contractor in accordance with this
Section of the Employer’s Requirements setting out all tests to be carried out, the
methodology for testing, and incorporating the Employer’s comments.
“Testing Programme” means the testing programme developed by the Contractor in
accordance with this Section of the Employer’s Requirements setting out a schedule for
all tests and incorporating the Employer’s comments.
17.2 General
17.2.1 Introduction
The Contractor shall be responsible for developing and implementing testing procedures
for the construction inspection, dry and wet testing, and performance and reliability
testing and capacity demonstration of the Works in accordance with this Section of the
Employer’s Requirements. The Contractor shall be responsible for providing all supplies
required for carrying out such tests, except for Influent for Commissioning and testing
purposes which shall be supplied by the Employer.
All tests shall be conducted in accordance with internationally recognized standards and
procedures agreed between the Parties as part of the Test Requirements and
Procedures.
The performance of the tests shall include inspection and performance tests of all
structures, pipelines, equipment, systems and processes under actual operating
conditions, including operation of all equipment, systems and processes in both manual
and automated modes.
During the performance of the tests the Contractor shall have suitably qualified and

experienced technicians as required to ensure that all requirements are fulfilled.
17.2.2 Testing Plan & Programme
At least 30 (thirty) Days prior to the proposed commencement of any testing required by
the Contract, the Contractor shall submit to the Employer, in writing a Testing Plan
including all relevant Test Requirements and Procedures relating to the Works and a
proposed Testing Programme.
The Employer shall have a period of 15 (Fifteen) Days after receipt of the Testing Plan
and Programme to submit any comments including requesting that the Contractor
conduct additional tests which in the opinion of the Employer should be carried out to
prove that the Works has been designed and constructed and is capable of being
operated according to the design, performance and operation requirements specified
and is capable of attaining the requirements of this Section of the Employer’s
Requirements. The Contractor shall accommodate any such comments into the Testing
Plan and Programme.
The Testing Plan and Programme shall include as a minimum test requirements,
procedures and a detailed schedule relating to:
a) Testing of pipelines;
b) Testing of water retaining structures;
c) Factory inspections and testing;
d) Equipment Validation;
e) SOTR test;
f) Process Commissioning;
g) Hydraulic Validation test; and
h) Plant Proving Period.
Upon successful completion of the testing of the Works contemplated by this Section of
the Employer’s Requirements, the Contractor shall be permitted to submit to the
Employer, for the Employer’s approval, the Commissioning Certificate for the Works.
17.2.3 Influent for Commissioning and Plant Proving Period
Influent (ADWF or Peak flow as the case may be) shall be available for Commissioning
and for the Plant Proving Period.The Employer shall have a period of 20 (twenty)
Business Days to submit any comments on such proposals and the Contractor shall
comply with all such comments.
17.2.4 Disposal of Non-Compliant Effluent
During Testing and Commissioning it may be necessary to discharge partially treated

effluent to the outfall. The Contractor shall make reasonable endeavours to minimize the
quantity of effluent so discharged.
17.2.5 Test Schedule and Right to Witness Inspections and Tests
In connection with the Test Requirements and Procedures, the Contractor shall
periodically update the detailed testing and inspection programme. The Contractor shall
promptly, and, in any event, at least 10 (ten) Business Days prior to the commencement
of any applicable testing provide the Employer with a copy of such programme and any
updates issued with respect thereto.
The Employer and/or its Representative shall have the right to have representatives
present during inspections and tests of major equipment and systems of the Works in the

factory and on-site during construction. The presence of the Employer during any
inspection or test shall not relieve the Contractor of its responsibility for supplying the
equipment or systems in accordance with the Contractor’s Programme.
17.2.6 Factory Tests/Inspections
Selected items of equipment identified jointly by the Contractor and the Employer,
including major pumps, aeration blowers, dewatering units, switchboards and items of
critical plant must be tested or inspected at the manufacturer's factory before dispatch to
Site. The Employer’s Representative (if it elects to participate) will travel to the
manufacturer's factory where such identified equipment will be run on a test rig set up to
simulate the defined operating parameters for the equipment under test. The tests will be
witnessed by the Employer’s Representative (if it elects to participate).
17.3 Equipment Validation
17.3.1 General
Equipment Validation shall be for the purpose of proving the operational performance
and reliability of key pieces of equipment and ancillary systems that comprise the Plant
identified by the Contractor in the Test Requirements and Procedures. The Equipment
Validation includes as described in more detail below (i) pre-commissioning (on-site)
testing and (ii) hydrostatic validation, in each case, for the pieces of equipment identified
in the Test Procedures and Requirements. Such testing shall be undertaken, in
accordance with this Section of the Employer’s Requirements, upon delivery and
installation of each such piece of equipment to ascertain the mechanical, electrical,
electronic and structural fitness and reliability, as appropriate. The tests shall, as
appropriate, include hydraulic leakage testing of the equipment prior to installation,
confirmation that installation of such equipment is in accordance with manufacturers'
recommendations, pressurized testing of the system pipelines and a visual inspection of
all installed equipment.
During the Works Equipment Validation tests the Contractor shall demonstrate that each
applicable piece of equipment and related system achieves the applicable Technical
Specifications.
17.3.2 Pre-Commissioning (On-Site) Testing
Immediately upon arrival at the Site, all equipment shall be inspected by the Contractor
and the Employer's Representative (if it elects to participate) in order to determine
whether any part of the equipment may have been damaged during transit. The
equipment shall be installed by the Contractor without delay whenever possible. If the
equipment cannot be installed immediately, it must be stored by the Contractor under
appropriate conditions.
Upon installation, all equipment shall be subjected to the pre-commissioning testing

established in the Test Procedures and Requirements.
17.3.3 Test Reports for Equipment Validation
Within 21 (Twenty one) Days after the completion of any particular Equipment Validation
test, the Contractor shall compile and provide to the Employer’s Representative a final
test report summarizing the results of such test, including all information reasonably
necessary to evaluate the applicable results. The Employer’s Representative shall
indicate in writing within 15 (fifteen) Business Days after receiving from the Contractor
each such test report whether it accepts or disputes that such test results are accurate.

In the event the Employer’s Representative disputes the results submitted by the
Contractor, the Employer’s Representative may request that the Contractor repeats the
relevant test as soon as practicable thereafter.
17.4 Process Commissioning
17.4.1 General
Following the successful completion of all Equipment Validation the Process

Commissioning of the Works shall commence. The Process Commissioning shall be for
the purpose of proving the operational performance and reliability of the Works under
normal operating conditions in accordance with the Test Requirements and Procedures.
Such testing shall be undertaken in accordance with this Section of the Employer’s
Requirements.
17.4.2 Process Commissioning
During the Process Commissioning of the Works, Influent shall first be introduced so that
the Activated Sludge can be developed and brought into a stable state.
During the Process Commissioning all elements of the Works shall be operational.
During this period, it is anticipated that the Activated Sludge will take several Days to
develop into a stable steady state and that the quality of the Effluent produced at the
Works will improve gradually. Once the Effluent produced at the Works begins to achieve
the effluent specifications included in Appendix B2, the Process Commissioning will
require a further period in order for the Activated Sludge to fully stabilize. The Process
Commissioning shall be completed once the Activated Sludge has been fully stabilized.
During the Process Commissioning, the Contractor shall monitor and check all
equipment at regular intervals in accordance with the check lists established in the
Testing Plan. Process Commissioning will be successfully achieved when the Works
achieves the performance requirements set forth in Appendix B2 including, without
limitation, achievement of the Effluent Specifications under a full range of anticipated
flow conditions for Influent which is compliant with the quality and quantity parameters
specified in Appendix B1.
During the Process Commissioning, the hydraulic operational performance and reliability
of individual equipment and ancillary systems within the Works as a whole under the
specified hydraulic load will be proven. The hydraulic validation tests shall be carried out
for specific equipment and ancillary systems within the Works and for the Works in
totality (as far as practicable) as specified in the Testing Plan.
During the Process Commissioning, equipment may be stopped to make adjustments
but it should not be necessary to take the whole Works off-line. The control systems at
the Works shall be tested thoroughly under normal operating conditions with adjustments
made to simulate process faults and equipment failures.
17.4.3 Test Reports for Process Commissioning
Within 10 (ten) Days after completion of the Process Commissioning for the Works, the
Contractor shall compile and submit to the Employer’s Representative the final test
report on the Process Commissioning including all information reasonably necessary to
evaluate the results. The Employer’s Representative shall indicate in writing within 5 (five)
Business Days after receiving the test report on the Process Commissioning from the
Contractor whether it accepts or disputes that such test results are accurate.

17.4.4 Hydraulic Validation Test
During the Process Commissioning or prior to issue of the Commissioning Certificate the
Contractor shall demonstrate that the whole of the Works is capable of passing the
instantaneous pass forward flow (PFF) that it has been designed and constructed to deal
with, without overflow or spillage or exceedance of the levels shown in the final approved
hydraulic profile of the Works. During the Hydraulic Validation Test any section of the
Works under test shall be subject to the return and recycle flows it would be subject to
under normal operation in addition to the test flow rate of the PFF. Since the Influent is
unlikely to be available at this rate during the Commissioning or Plant Proving Period the
Contractor shall propose a method for simulating the PFF. This could include:
• If the works has multiple process trains by passing the appropriate proportion of the
PFF through 1 module;
• Accumulating flow in all sumps so that pump run times can be extended beyond
what would be required by the incoming flow;
• Using available storage to temporarily store incoming flow and then discharge at an
accelerated rate;
• Using temporary pumps to recycle flows to increase flow rates in the portion of the
works subject to recycling.
The Contractor’s proposals for the Hydraulic Validation Test shall be included in the
Testing Plan.
17.4.5 SOTR Test
The clean water non-steady state method shall be used to test the manufacturer’s claims
on diffuser performance and to evaluate the electricity consumption of the process under
clean water conditions. This will involve measuring the rate of increase in concentration
of dissolved oxygen in water, which has been deoxygenated. The test shall be carried
out in accordance with the American Society of Civil Engineers Standard “Measurement
of Oxygen Transfer in Clean Water” ANSI/ASCE 2-91, June 1992 or other equivalent
European or internationally recognised standard procedure.
The SOTR test shall be carried out on a section of the Works which has been isolated
and configured such that it is possible to deduce the capacity of the entire Works from
the performance of the section.
The required quantity and quality of water, shall be arranged by contractor.
17.5 Plant Proving Period
17.5.1 Proving Tests
After completion of the Process Commissioning of the Works in accordance with this
Section of the Employer’s Requirements, the Contractor shall be entitled to prepare the
Works for its Plant Proving Period. The purpose of the Plant Proving Period is (i) to
demonstrate the operational integrity of the Works and (ii) to establish that the
Commissioning Certificate for the Works can be issued. During the Plant Proving Period,
the Works must also demonstrate its ability to accept and treat to the Effluent
Specifications and Sludge Specifications the Minimum Influent Quantity.
The Plant Proving Period for the Works shall be conducted in two parts which may be in
parallel, the Liquid Proving Period and the Sludge Proving Period. During these periods,
the Works and related equipment and systems shall be operated continuously and in
accordance with the prevailing Influent and flow conditions. During the Liquid Proving
Period the Works shall be operated to produce Effluent to within the Effluent

Specifications. During the Sludge Proving Period the Works shall be operated to produce
Sludge to within the Sludge Specifications.
During the Plant Proving Period, the Works shall be operated in accordance with the
requirements of Good Industry Practice.
17.5.2 Liquid Proving Period
The Plant Proving Period shall commence with the 30 day Liquid Proving Period. The
Contractor shall notify the Employer’s Representative when the Works is ready for the
Liquid Proving Period and shall submit to the Employer’s Representative its plan for the
Liquid Proving Period for the Works, including a sampling and testing plan and method,
at least 30 (thirty) Days prior to the proposed commencement of the Liquid Proving
Period. The Employer’s Representative shall have a period of 15 (fifteen) Business Days
to submit any comments on such plan and method and the Contractor shall accept all
such reasonable requests.
During the Liquid Proving Period, the instantaneous flow and the total daily flow for
Influent and Effluent shall be continuously monitored by and recorded by permanent flow
meters. Samples of Influent and Effluent shall be taken and tested in accordance with
Appendix B1 & B2 and section 18 of the Employer’s Requirements.
The minimum requirements for achieving successful completion of the Liquid Proving
Period for the Works are set out in Appendix B1 & B2 and section 18 of this volume,
provided that the daily quantity of Influent is not less than the applicable Minimum
Influent Quantity.
17.5.3 Sludge Proving Period
The 20 day Sludge Proving Period for the Works will commence on the Sludge Proving
Period Commencement Date. The Contractor shall submit to the Employer’s
Representative its plan for the Sludge Proving Period, including a sampling and testing
plan and method, at least 30 (thirty) Days prior to the Sludge Proving Period
Commencement Date. The Employer’s Representative shall have a period of 15 (fifteen)
Business Days to submit any comments on such plan and method and the Contractor
shall accept all reasonable requests.
The minimum requirements for achieving successful completion of the Sludge Proving
Period for the Works are set out in Appendix B1 & B2 and section 18 of this volume,
provided that the daily quantity of Influent is not less than the applicable Minimum
Influent Quantity.
17.5.4 Plant Proving Period Reports
During the Liquid Proving Period, the Contractor shall collect all relevant data relating to
the Effluent Specifications, the quality parameters, details of any failures and other
relevant information. At the end of the Liquid Proving Period, the Contractor shall submit
to the Employer a draft written report within 10 (ten) Days or as directed otherwise by the
Employer. The Employer shall have a period of 5 (five) Business Days to review such
report and either accept or reject it. If the report is not acceptable it shall be returned to
the Contractor for verification or amendments and resubmission.
During the Sludge Proving Period, the Contractor shall report daily on the volume of
Sludge processed, the quality parameters, details of any failures and other relevant
information. At the end of the Sludge Proving Period, the Contractor shall submit to the
Employer a written report within 10 (ten) Days or as directed otherwise by the Employer.
The Employer shall have a period of 5 (five) Business Days to review such report and
either accept or reject it. If the report is not acceptable it shall be returned to the

Contractor for verification or amendments and resubmission.

If the Employer disputes the results from the Plant Proving Period submitted by the
Contractor, the Employer may request that the Contractor repeat the applicable Proving
Period as soon as practicable thereafter.
The Contractor shall submit two bound copies of the final reports prepared with respect
to the Liquid Proving Period and the Sludge Proving Period within 60 (sixty) Days of the
acceptance of the draft report by the Employer.

Operation Service Performance Requirements

18 OPERATION SERVICE PERFORMANCE REQUIREMENTS

18.1 General
In this section, the required performance of the Works during the Operation Service is
described.
The Contractor shall be obliged to receive and accept all wastewater delivered to the
WwTF during the Contract Period. The Contractor shall not stop or reduce the delivery of
flows from the sewerage network to the wastewater treatment works. The Contractor
shall not discharge any flows through an emergency bypass, except in an emergency
and with the express permission of the Employer for each overflow event.
18.2 Measurement of Qualitative and Quantitative Performance
The minimum requirements for monitoring, sampling and analysis during normal
operation are specified in Appendix B3.
The main monitoring and measurement requirements for the purposes of compliance
and payment during the Operation Service Period are set out in Tables B3.2 and B3.3 of
Appendix B3, however additional measurement points may be required to comply with
the Contract. Any additional measurement points shall be installed by the Contractor at
his cost.
18.3 Performance Standards
18.3.1 Treated Effluent Standards
The Contractor shall ensure that the Works produce treated effluent meeting the
standards specified in Appendix B1.
Treated Effluent COD performance requirements may be relaxed subject to the
Contractor proving the presence of non-biodegradable COD corresponding to the
influent quality to which cannot be treated using the processes provided at the Works.
Compliance with the above standards shall be assessed on a quarterly basis in
conjunction with the quarterly payments (including performance damages) and in
accordance with the programme of analyses for compliance purposes specified in
Appendix B3.2, and on the basis of the actual number of samples taken in the quarter.
The Employer’s Representative may instruct additional sampling over and above that
specified in Appendix B3.2 and the Contractor shall allow for 10% over and above that
specified in Appendix B3.2 in his rates.
The sampling specified in Appendix B and additional sampling instructed by the
Employer’s Representative shall be included in the assessment of compliance and the
associated application of performance damages
Treated Sludge Standards
The sludge at the time of its transportation off the Site, shall meet the specific quality
standards shown in Table 18.2. These are consistent with the quality requirements for a
“Class A Bio-solids” product as defined in the US EPA Regulations Part 503.
Table 18.2 – Sludge Product Quality Requirements
Parameter Quality Criteria Compliance Criteria
Salmonella < 3 MPN / 4 g Total Dry Solids Continuously less than
Faecal Coliforms < 1000 MPN/g of total dry solids the criteria
Enteric Viruses < 1 PFU / 4 g Total Solids
Viable Helminth Ova < 1 / 4 g Total Solids

Minimum dry solids 25% Dry Solids Greater than the

concentration criteria
18.3.2 Odour Standards
The works shall be so designed and operated by the Contractor, as far as is practically
possible, to ensure that the air quality in the environs of the Site shall not give rise to
complaints from third parties.
18.3.3 Noise Standards
The Works shall be designed and operated and maintained by the Contractor to ensure
that the noise emanating from the Works does not exceed the limits set out in Table 18.3
below during operation, when measured at any position on the Site boundary.
Table 18.3 – Noise Performance Levels Outside of the Site
Time Standard (15 minute Leq)
06:00 – 22:00 55 dB(A)
22:00 – 06:00 45 dB(A)
The noise level 1 m in a perpendicular direction from any point on any item of equipment
(if unprotected) or the shell of a building or enclosure shall be continuously less than 80
dB(A).
The Noise measurements shall be carried out as per MPCB / Indian Standard.
Noise measurements shall be carried out whenever there is a complaint and in any event
shall be monitored following any change in the plant design or operation of the Works
affecting noise levels.
Noise levels shall be measured using a calibrated sound level meter complying with BS
EN 60651. Sound levels shall be monitored in accordance with ISO Recommendations
R1996, ‘Assessment of Noise with Respect to Community Response’ as amended by
ISO Recommendations, R1996/1, 2 and 3 ‘Description and Measurement of
Environmental Noise’ as appropriate.
18.3.4 General Performance Requirements and Standards
In addition to the performance requirements and standards specified in Appendix

B1,18.2 and 18.3, the Works shall also comply with the performance requirements
specified in Table 18.4.
Table 18.4 – General Performance Requirements for the Works
Description Parameter Value
Screens and Dry solids content of screenings ≥ 30% DS (w/w)
screenings
Organic solids content of screenings <10% of DS
system
Reliability (downtime) <4%
Grit separation Particles removal > 95%
and grit Handling Organic solids content of cleaned grit < 10% of DS
Reliability (downtime) <4%
Primary Reliability (downtime) ≤ 2%
settlement
BOD Removal >30%

Description Parameter Value

TSS Removal >60%
Aeration plant Ability of aeration system to ≥ 2 mg/l
continuously maintain the DO
concentration
Reliability (downtime) of aeration system ≤ 2%
Secondary Reliability (downtime) ≤ 2%
Clarifier
Outlet TSS ≤ 20mg/l
Primary sludge Dry solids content of thickened sludge ≥ 5% DS (w/w)
thickening
Reliability (downtime) ≤ 2%
Secondary Thickened dry solids content ≥ 5% DS (w/w)
sludge
Reliability (downtime) ≤4%
thickening
Sludge digestion Temperature of the sludge in the The average daily set
digesters point temperature of the
sludge in the digesters
shall be between 18 to
40° C, but not be outside
the set point by a range
±2.0°C.
Retention time in the digesters (based As per CPHEEO
on ADWF x 1.3)
VSS destruction >50 %
Mixing Homogeneous
Sludge Dewatered Cake ≥ 25% DS (w/w)
dewatering
Sludge storage Blended Primary & WAS sludge 24 hours
Digested sludge 12 hours
Dewatered sludge 24 hours
Hydraulic Pass Forward Flow As stated in Appendix
capacity of the B1
Works (excl.
liquors)
18.4 Monitoring, Sampling and Analysis
18.4.1 General
Prior to the commencement of the Operation Service Period, the Contractor shall submit
to the Employer’s Representative for approval a schedule of tests and procedures that
will allow the Contractor to:
• demonstrate effective Works operation;
• demonstrate compliance with the Employer’s Requirements;
• provide a basis for determination of payment.
The required minimum frequencies for sampling and measurement for normal operation

and reporting purposes, for compliance with performance standards and for payment
purposes are set out in separate tables in Appendix B3.
The Contractor shall arrange sampling to be undertaken by suitably trained personnel.
Sample lines shall be continuously purged.
Analyses shall be carried out in accordance with;
• The latest edition of “Standard Methods for the Examination of Water and
Wastewater” (APHA, AWWA, WEF)
• IS 2488: Methods of Sampling and Testing For Industrial Effluents
• The standard SCA Blue Book Analytical Methods (Methods for Examination of
Waters and Associated Materials – HMSO, UK)
• Other equivalent methods agreed with the Employer’s Representative may also be
used.
• Noise levels shall be measured using a calibrated sound level meter complying with
BSEN 60651.
The Contractor shall provide all the equipment necessary, and shall undertake all
sampling, and shall pay for all the testing and analysis unless expressly stated otherwise.
The monitoring facilities shall be linked into the central control and monitoring system for
the Works.
The Contractor shall take all samples necessary to demonstrate compliance with the
Employer’s Requirements, including those required for payment purposes. The
Contractor shall deliver all such samples to be tested/analysed to a laboratory jointly
agreed between the Employer and the Contractor, which may be on Site if appropriate.
In the case of breakdown of the automatic sampling equipment, sampling shall be
undertaken manually at three-hourly intervals and the results will be weighted according
to flow in order to establish the equivalent daily total load.
Sampling and monitoring points for all the sampling and monitoring required during the
Contract shall be proposed by the Contractor, and shall be submitted to the Employer’s
Representative for approval. They shall be suitable for the sampling regimes required
under this Section 18 and also in Appendix B2 &B3. Where appropriate samples shall be
representative of the wastewater, liquor or sludge that has passed through that point
over the period since the last sample was taken.
The Contractor shall adjust and expand on the testing and monitoring procedures,
described here and in Appendix B3, to suit his proposed process design arrangement, if
necessary. In the course of the Operation Service, the Contractor shall update the tests
and procedures according to the operational experience and any alterations to the
treatment process.
Figure B3.1 and Tables B3.1, B3.2, and B3.3 in Appendix B3 present the minimum
requirements for flow monitoring, sampling and recording facilities, and identify the
measurement points to be used for monitoring and measurement for compliance and for
payment.
The instrumentation associated with the flow measurement for the main process streams
shall record the flow rates in terms of both daily and 15-minute averages.
Flow meters and other in-line meters shall be calibrated by the Contractor on a regular
basis, in accordance with the manufacturer’s recommendations. The accuracy of the flow
measuring devices used for determination of payments shall be checked by the
Contractor at a frequency agreed with the Employer’s Representative. The Contractor
shall submit a detailed methodology of this calibration to the Employer’s Representative
for approval.

The Contractor’s information system shall be capable of displaying a minimum of two

years’ historical data. The system shall be capable of data handling and management
reporting as agreed with the Employer’s Representative. The system shall also be
compatible with the data recording systems used by the Employer to record parameters
at other wastewater treatment facilities and allow export of data from the Contractor’s
information system to the Employer’s data recording systems.
Influent at the Inlet Chamber shall be sampled and analysed daily in accordance with the
testing requirements set out in Appendix B. The sampling point shall be upstream of any
returned wastewater or other streams arising from the operation of the Works.
Effluent from the secondary settlement tanks (treated effluent) shall be sampled,
analysed and in accordance with the testing requirements set out in Appendix B and
checked for compliance with standards, as defined in Appendix B.
In both of the above cases permanently installed automatic flow-proportional refrigerated
samplers shall be used and the 24-hour composite samples shall be collected daily and
analysed at the frequency stated in Appendix B3. In addition a reserve sample shall be
kept refrigerated for 7 days in order that the Employer’s Representative may order
further analysis if he so requires. At all times, the samples shall be stored in the dark and
at a temperature of 1°C to 4°C. The samples shall not be allowed to freeze.
Analysis for such determinants as BOD, COD and SS of sewage and treated effluent
shall be commenced as soon as it is possible, and in any case within a maximum of 24
hours from the end of the sampling period, and completed without delay.
Where sampling is to be undertaken on a weekly basis (e.g. once per week or twice per
week) the sample shall be taken over a 24 hour period. The day of the week selected
shall be determined between the Employer’s Representative and the Contractor to
ensure representative results. The day(s) selected shall vary each week unless agreed
otherwise.
Samples of liquid sludge or sludge cake, shall be composite samples comprising at least
three spot sub-samples, each of equal volume. The sub-samples shall be collected
manually at 30-minute intervals over at least one hour or, in case of intermittent
processes, over the period of sludge flow. In the case of assessment of polyelectrolyte
consumption, the sludge samples shall be collected over a two-hour period at 30-minute
intervals. The analysis of dry solids content shall commence within a maximum of 24
hours from the end of the sampling period.
Sludge samples shall be taken at the outlet to the process unit (thickener/dewaterer etc).
Sludge samples which are to be analysed for the concentration of faecal coliform shall
be placed in sterilised containers. Samples containers shall be polyethylene,
polypropylene, Teflon, non-etched Pyrex glass or equivalent or stainless steel.
The three samples of final sludge product taken on any particular sampling day shall be
analysed separately for faecal coliforms. The geometric mean shall be used for
assessment of the compliance with the standard. The three samples shall also be used
to determine the dry solids content. Analysis for faecal coliform concentration shall be
commenced within six hours of collection of the last sample.
All samples taken by the Contractor that are required to be analysed to demonstrate
compliance with the performance criteria and for payment purposes shall be split into two
equal parts. The samples shall be labeled with the name of the sampling point and date
and time of collection. The Contractor shall analyse the first sample and store the second
sample in accordance with industry best practice to preserve its status for further
analysis for a minimum of 7 days.
The Employer may, at his discretion, have the second sample analysed at an
independent laboratory. Where such analyses demonstrate non-compliance with the

Employer’s Requirements the laboratory and transportation costs will be paid by the
Contractor.
All analysis by the Contractor and the Employer’s Representative shall be carried out at
a laboratory or service accredited for that purpose. Samples that require immediate
analysis shall be analysed by the Contractor immediately and witnessed by the
The Employer or the Employer's Representative reserves the right to enter the Works, to
take samples or undertake tests at any location and at any time without the requirement
to give prior notice to the Contractor. However, the Employer shall notify the Contractor
immediately prior to entering the Site to comply with health and safety requirements. If
the results of these tests indicate a discrepancy with Contractor’s records, further
investigation shall be agreed between the parties to ensure that the Contractor’s
monitoring procedures meet the requirements of the Contract.
The Contractor shall undertake sampling, testing and analyse procedures for all process
stages to provide reliable data for quality control and for use in interpreting the
performance of the Works.
18.4.2 On Site Analysis
In addition to the services provided by a Nominated Laboratory, the Contractor shall

provide on-site analytical services to allow for routine and non-routine monitoring,
analysis and control of the treatment facility processes in respect of all wastes, whether
liquid, solid or gas. The scope of measurements conducted in the on-site laboratory shall
include but not be limited to:
a) temperature of air, sewage and sludge ;
b) pH;
c) Chemical Oxygen Demand (COD);
d) Biochemical Oxygen Demand (BOD);
e) Suspended Solids (SS) concentration;
f) Dry solids content in sludge (total dry solids);
g) Stirred Sludge Volume Index (SSVI);
h) Microscopic examination of the biomass in the aeration tank;
i) Dissolved oxygen (DO) concentration.
j) Nitrogen and Phosphorus
k) Residual Chlorine
The results from the above analyses made on Site shall not be used for determining
compliance or for payment purposes, unless made at a laboratory where it has been
agreed to be the Nominated Laboratory.
The on-site laboratory shall be provided in accordance with:
• the design references as noted in Section 10
• the references as noted in Section 18.4.1
18.4.3 Compliance with Environmental Standards
Compliance with all relevant legislation shall be the responsibility of the Contractor.
Appendix B3 indicates which of the routine measurements will be utilised to assess
compliance with the environmental standards.

18.5 Failure to Meet Performance Requirements
18.5.1 General
If it is determined by the Contractor that the Works are failing to meet the performance
requirements specified in this Volume for any reason, the Contractor shall take
immediate remedial action and advise the Employer’s Representative in writing of the
specific cause for the failure and report the actions taken or the proposal to correct the
deficiency.
If it is determined by the Employer’s Representative that the Works are failing to meet
the performance requirements specified in this Volume for any reason, the Employer’s
Representative will advise the Contractor in writing and the Contractor shall determine
the specific cause for the failure and report to the Employer’s Representative within 7
days on actions to correct the deficiency.
Where the Contractor is unable to meet the specified contractual performance standards
for whatever reason, and irrespective of whether the penalties described in the Schedule
of Payments are applied, the Contractor shall use his best endeavours to maintain the
performance standards as close to the specified levels as possible, at all times. Failure
to do so will be deemed to be a failure of his contractual obligations.
Unless the following conflicts with more specific requirements relating to specific Failure
Event types set out below, on the occurrence of a Failure Event, the Contractor shall:
• as soon as possible and not more than 24 hours after the Failure Event is apparent
notify the Employer of the location and extent of the Failure Event;
• within 3 days of the Failure Event submit a report to the Employer identifying and
explaining the cause of the Failure Event and the Contractor’s plans for preventing a
recurrence of the Failure Event;
• implement the Contractor’s plans for preventing recurrence of the Failure Event; and
• report monthly on progress of implementation of the Contractor’s plans for
preventing recurrence of the Failure Event measured against the Contractor’s plans
until the Contractor’s plans have been effected.
18.5.2 Failure Events
In the event of a failure where an allowable exception cannot be identified, payment to

the Contractor will be adjusted in accordance with the terms of the Schedule of
Payments for the Operation Service.
Table 18.5 – Failure Events and Allowable Exceptions
Failure Monitoring
Failure Event Description Allowable Exception
Event Aspect
1 Treated Treated Effluent exceedances Catchment Pollution Incident
effluent are greater than the allowable Or
number set out in Appendix B1.
Influent parameters greater
than Flows or Loads
specified in Appendix B1

Failure Monitoring
Failure Event Description Allowable Exception
Event Aspect
2 Sludge Dry solids content in any Catchment Pollution Incident
product – composite sample less than the Or
solids value specified in Table 18.4.
content
than Flows or Loads
3 Sludge For each day on which the Catchment Pollution Incident
process – digester temperature (at any Or
digester moment in time measured
temperature continuously) ranges outside
than Flows or Loads
the limits specified in Table
18.4.
4 Noise levels Noise levels exceed None
performance requirements or
complaints are received
In the event that the measurement and monitoring of the Works indicates persistent
problems as evidenced by frequent failures in terms of the Failure Events identified, the
Contractor shall promptly submit to the Employer’s Representative detailed proposals for
remedying the problems. Once the Employer’s Representative has approved such
proposals, the Contractor shall proceed to implement the proposed modifications, at his
own cost.
18.5.3 Catchment Pollution Incident
A Catchment Pollution Incident is defined as a situation in which the threshold values or

concentrations (relevant to the failure) set out in Table 18.6 are exceeded, when
measured in the Works influent at measurement point 1. Where the Contractor can
demonstrate, to the satisfaction of the Employer’s Representative, that the relevant
influent values or concentrations stated in Table 18.6 were exceeded during the period
for which a failure was recorded:
a) the Contractor shall not be liable for the costs arising from the Catchment Pollution
Incident;
b) the relevant deductions from payments as stated in Schedule of Payments for the
Operation Service will not be applied in the event of a Catchment Pollution Incident;
c) the Contractor will be given a reasonable time to recover the Works to its normal
operation following a Catchment Pollution Incident, save always that the Contractor
takes all practicable steps to limit the time taken to recover the plant; and
d) the Employer will not reimburse the Contractor for the any costs reasonably incurred
in returning the Works to its normal operational mode following a Catchment Pollution
Incident, save always that the Contractor takes all practicable steps to limit the costs
incurred in recovering the Works to normality.
Table 18.6 – Catchment Pollution Incident Influent Characteristics
Threshold Value or
Parameter Sample or Definition Unit
Concentration
< 6.0 or
pH Daily composite
>9.0
Temperature Daily average °C >35

Threshold Value or
Parameter Sample or Definition Unit
Concentration
CN – (unassociated >0.5
Daily composite Spot mg/L
soluble)
Phenols Daily composite mg/L >5.0
>0.1
As (soluble) Daily composite Spot mg/L
>0.2
>0.5
Cd (soluble) Daily composite Spot mg/L
>0.1
>2.0
Cr3+ (soluble) Daily composite Spot mg/L
>4.0
>1.0
Cr6+ (soluble) Daily composite Spot mg/L
>2.0
>1.0
Cu (soluble) Daily composite Spot mg/L
>2.0
>0.1
Hg (soluble) Daily composite Spot mg/L
>0.1
>0.5
Ni (soluble) Daily composite Spot mg/L
>1.0
>0.5
Pb (soluble) Daily composite Spot mg/L
>1.0
>2.0
Zn (soluble) Daily composite Spot mg/L
>4.0
Cr6+ + Cu + Ni + Pb + >4.0
Daily composite Spot mg/L
Zn (all soluble) >5.0
Concentration of a substance or
combination of substances is
greater than a level which is
capable, as clearly
The presence in a
demonstrated by reference to
sample of any
scientific literature, of causing a
substance or
reduction of at least 10% of the
combination of
Daily composite N/A average biological reaction rate
substances which are
(calculated by reference to the
known to cause
biological reaction rate of the
inhibition of the
wastewater treatment facility
biological reaction rate
under the same or similar loads)
on days where the
environmental standards are
met.

Operation Management Requirements

19 OPERATION MANAGEMENT REQUIREMENTS

19.1 General
The Contractor shall operate and maintain the Works in accordance with the Contract
until the end of the Operation Service Period and during this period shall be responsible
for all aspects of the wastewater treatment and sludge treatment and safe disposal of all
screenings, grit, and sludge. The Contractor shall ensure that the wastewater treatment
facility achieves the required treated effluent quality. The treatment, transportation, and
safe disposal of sludge & screening/grit material to the Designated Landfill Site shall be
carried out by the Contractor in an efficient and cost- effective manner in compliance with
statutory requirements.
The Contractor shall be responsible for transporting all the screenings, grit and sludge
arising from the Works to designated site specified by Employer.
19.2 Employer’s Communication

The Operation Service requirements shall apply to the whole of the Works.
The Employer shall keep the Contractor informed of proposed alterations to major
infrastructure which may in the Employer’s opinion have a material impact on the WwTF.
The Employer shall, except in the case of emergency, inform the Contractor where it
intends to carry out any repair, maintenance or upgrading of any part of the any of the
collection system which could have a material impact on the Contractor’s ability to deliver
the services.
The Employer shall also advise of any proposed discharges to the collection system
which may in the Employer’s opinion have a material impact on the WwTF.
19.3 The Site
The Site is shown on the drawings Volume 2D. Access to the Site shall be via the access
road as shown on the drawings Volume 2D.
19.4 General Requirements
During the Operation Service Period, the Contractor shall take total responsibility for the
operation and maintenance of the Works. As part of these general obligations, the
Contractor shall undertake the following tasks.
a) Provide all the staff for the managerial, technical, supervisory and administrative
responsibilities and labour necessary to operate and maintain the Works, safely and
efficiently.
b) Develop and implement the necessary procedures and information systems required
for the Operation Service.
c) Carry out all flow measurement, sampling and laboratory analyses for the wastewater
treatment and sludge treatment and disposal throughout the Operation Service
Period.
d) Operate and maintain the Works and ensure that all the Plant is able to operate at all
times to its maximum installed capacity. The Operation Service shall achieve the
performance criteria specified in these documents. The Contractor shall satisfy all
legal and environmental requirements for supply of water and disposal of sludge and
other waste products for each day of the Operation Service Period.
e) Provide (including payment of all supply authority charges) all necessary services to
the site including electricity, water, gas, telecommunications and any other services
necessary for the provision of the Operation Service.

f) Utilise information gathered as a result of monitoring to determine what

improvements can be made to optimise the operation of the treatment facility.
g) Implement all systems required and record and make available to the Employer’s
Representative all necessary operation and maintenance information.
h) Keep and update the Operational Cost Model for the Operation Service.
i) Transport all waste by-products and sludge arising at the Site .
j) Operate the Works in the most economic manner with respect to the consumption of
energy and other resources.
k) Carry out the Tests Prior to Contract Completion.
l) Maintain the Works such that they remain in a visually and aesthetically pleasing
condition at all times.
m) Monitor all changes in legislation, codes or standards and bring these to the attention
of the Employer’s Representative.
n) Operate the Works to minimize the total long term life cycle cost of the facility,
supported by establishing the optimal timing and strategy to replace assets based on
the historical operating and maintenance records.
19.5 Management, Operation and Maintenance Personnel
The Contractor shall provide suitably qualified personnel for the management, operation
and maintenance of the works. The personnel shall have skills in the areas of, but not
confined to:
• Operations management;
• Maintenance management;
• Asset Management;
• Treatment process operation and management;
• Analytical chemistry and laboratory procedure management;
• Mechanical and electrical plant and equipment operation and maintenance;
• ICA operation and maintenance;
• Software, communications and IT systems programming and configuration;
• Facilities operation and maintenance;
• Administration;
• Quality Management Systems planning, implementation, management and auditing;
• Health and safety planning, implementation, management and auditing.
All personnel employed by the Contractor shall be suitably qualified and have an
appropriate level of training and experience in the area to which they are allocated. Prior
to the commencement date, the Contractor shall submit details of the key personnel he
proposes in each of the above areas to the Employer's Representative for approval.
The Contractor shall develop and maintain the competencies of personnel through yearly
evaluations and encourage employee development and reward throughout the Operation
Service Period.
All key personnel employed by the Contractor in the delivery of the service shall remain
at all times the employees of the Contractor. The Contractor shall not subcontract or
assign any part of this obligation without the prior written consent of the Employer's
Representative, which shall not be unreasonably withheld.
Should the Employer or the Employer's Representative be reasonably dissatisfied with
the performance of any of the Contractor’s personnel, the Contractor shall, at the
Employer's Representative’s written request, remove the said person(s) from the service.
Any such personnel shall be immediately replaced by staff of equivalent or greater
qualification and experience, and this shall be subject to review by the Employer’s

Representative.
The Contractor shall ensure that there is a suitable level of continuity of key personnel.
Should the Contractor wish to change any personnel engaged directly in the
management and operation of the service, then the Employer's Representative shall be
informed at least two months in advance, wherever practical.
The names, status, qualifications, years of experience and record of training of all
personnel engaged in the operation service shall be provided as part of the Operation
and Maintenance Plan (refer to Section 20 of the Employer’s Requirements). This shall
include details of individual ongoing staff-training programmes. These programmes shall
be updated and maintained regularly by the Contractor. Updates shall show evidence of
the training carried out each year and training proposed for the following year.
Any new personnel or personnel reallocated to different duties shall be supervised by
experienced staff until they are properly trained and have a level of experience deemed
necessary for the service tasks being undertaken. This shall be deemed to be for a
minimum of two months. The Contractor shall provide details, as part of the Operation
and Maintenance Plan, of the measures to be taken to cater for these changes.
19.6 Health and Safety Requirements during Operation Service
The Contractor shall be responsible for all aspects of health and safety during the
Operation Service Period and shall comply with all national and regional legislation and
regulations. The Contractor shall also refer to Section 5 of the Employer’s Requirements.
The Contractor shall be responsible for the security of the Site and shall provide
adequate security staff at all times to maintain site security and check incoming and
outgoing traffic and persons for the duration of the Operation Service.
The Contractor shall maintain throughout the Operation Service Period a set of
‘Emergency Procedures’. The procedures shall identify the potential accidents and
emergencies which could occur on the Works and set out a clear plan of action to be
followed should any of these occur. The Contractor shall ensure that employees are
aware of these procedures and display, in prominent positions, posters stating these
procedures with emergency telephone contacts.
The Contractor shall agree emergency procedures with the emergency services and
carry out emergency drills in accordance with statutory requirements and when
recommended by the emergency services.
With respect to health and safety, the Contractor shall:
a) implement safe working and reporting procedures and promote safety awareness in
every element of operation and maintenance;
b) ensure adequate regard to site safety including:
• safe working procedures in all Works operation and maintenance activities;
• cleanliness and care of the facility;
• reporting accidents and hazards;
• safe practice in sewers, tanks, and all other elements within the wastewater
treatment facility;
19.7 Suppliers and Subcontractors
The Contractor shall be permitted to enter into contracts and agreements with
Subcontractors and suppliers for the delivery of non-critical parts of the Operation
Service and/or for the supply of goods or services relevant to the Operation Service.
Before entering into such arrangements, the Contractor shall submit details of the
Subcontractors and suppliers he proposes to use to the Employer's Representative for

approval. He shall provide and update these details, as part of the O&M Plan.
19.8 Operation Service Monitoring Group
An Operation Service Monitoring Group (OSMG) will be formed for this Contract. The
purpose of the OSMG is to provide a forum for regular discussion by representatives of
the Employer and Contractor of relevant ongoing matters relating to the Contract.
Meetings of the OSMG will normally take place at monthly intervals, or at such longer
intervals as may be agreed by the OSMG from time to time (such intervals not to exceed
three months). A special meeting of the OSMG may be convened to address abnormal
circumstances.
The Monthly Status Report (MSR) and in particular the Executive Summary of that report
will provide the basis for much of the discussion at the OSMG meetings.
The primary role of the OSMG is to facilitate the harmonious implementation of the
Contract and to provide comfort to the main stakeholders that the interests of all parties
are protected. The Employer and Contractor will be kept informed by their
representatives on the OSMG of relevant operational aspects of the Contract. However,
the Employer’s Representative, as defined in the Contract Documents, will be solely
responsible for the issuing of instructions under the Contract.
It is proposed that the Employer be represented on the OSMG by one senior member of
the Employer’s organisation and by the Employer’s Representative. It is proposed that
the Contractor be represented on the OSMG by one senior member of the Contractor’s
organisation (operations manager) and by the most senior member of the Contractor’s
personnel on site, the Plant Manager.
One of the Employer’s nominees will normally chair the meetings of the OSMG and one
of the representatives of the Contractor will normally minute the proceedings. In certain
circumstances, a special meeting of the OSMG may be held, to which an external
stakeholder, such as a major local industry, may be invited, at the discretion of the
Employer and Contractor.
The meeting agenda shall be generally based on the following generic headings, which
may be changed as the Contract progresses and circumstances may change:
1) Minutes of last meeting;
2) Monthly Status Report(s);
3) Complaints;
4) Plant Maintenance Plan;
5) Facility Maintenance Plan;
6) Asset Replacement Schedule;
7) Operational changes;
8) Compliance monitoring;
9) Third party interfaces;
10) Any other business.
19.9 Real Time Reporting
The Contractor is required in Section 13 to provide access to the SCADA system for the
Employer. However, to facilitate an appropriate level of real time reporting of relevant
data, the Contractor shall provide easy and direct access to a view and report facility for
a limited number of parameters including:
Daily Readings;
• Power consumption from external supply;
• Power generated on Site from biogas.

Continuous Monitoring
• Inlet flow;
• Outlet flow;
• Outlet dissolved oxygen.
19.10 Monthly Status Report
A Monthly Status Report (MSR) is required to report the main events that have occurred
and the significant aspects of the Works performance since the previous MSR. The
Contractor shall provide such a report to the Employer’s Representative on a monthly
basis throughout the Operation Service Period. These reports shall be submitted within
14 days of the start of the month following that covered in the report. The MSR forms the
basis of the agenda for the OSMG meetings.
The Contractor is responsible for ensuring all relevant information required is gathered
on Site and compiled correctly in the format required in the MSR.
The Contractor may add further reports by agreement with the Employer’s
Representative.
The MSR shall include a summary narrative section relating to the performance of the
Works, covering the key performance areas listed in the Contract and any relevant
issues that have arisen since the last report. The report shall also include performance
indicators under each section, together with a comparison against the requirements of
the Contract.
The MSR shall be completed in the sequence shown and in full and in accordance with
the minimum requirements outlined in Appendix E in order to deliver an acceptable MSR.
19.11 Service Delivery Review Report
The Contractor shall complete a Service Delivery Review Report at the frequencies
stated in Section 8. The initial review shall be completed by the date stated in Section 8.
The review shall focus on the effectiveness of service delivery and any issues arising,
which require attention under the Contract. Each review shall at a minimum cover: -
• Wastewater quantities delivered and discharged;
• Influent, sludge and effluent quality results;
• Environmental monitoring;
• Process monitoring;
• Routine and real time reporting;
• Operational issues;
• Maintenance, (Routine, Planned, Breakdown, Emergency);
• Plant Maintenance Plan;
• Facility Maintenance Plan;
• Health and safety compliance;
• Emergency procedures;
• Inspections and audits;
• Testing;
• Change procedures.
The Contractor shall develop a procedure for the Service Delivery Review Report as part
of the Operation Service quality control procedures. The procedure shall outline the
method for reviewing the above aspects of service delivery.
The Contractor shall carry out the review and shall present it in report format to the

Employer’s Representative. The report shall include summary information and any
necessary appendices of data for reference purposes. Three copies of the report shall be
provided. The reports shall be considered at the OSMG meetings.
19.12 Operational Change
Operational changes may arise from the Service Delivery Review Report, or at the
behest of the Employer, Employer’s Representative or the Contractor. They may also
arise where there is any deviation from the service delivery requirements of the Contract.
Operational change proposals shall be submitted to the Employer’s Representative for
approval prior to implementation.
The Contractor shall develop a procedure for operational changes as part of the
Operation Service quality control procedures. The procedure shall ensure that if
operational changes are required then the changes will not affect the Contractor’s
delivery of the service. This procedure shall be implemented for any operational change
within the Contract that is considered significant by any party to the Contract.
19.13 Management Meetings
Additional management meetings may be required to deal with specific issues during
Operation Service.
19.14 Hours of Operation
Normal working hours shall be as stated in the Contract Data. Working on Site by
personnel outside these hours in special circumstances, excluding any response to
emergency events, may be permitted by the Employer’s Representative but this shall be
at his discretion and he shall have no obligation to allow it.
19.15 Routine Reporting
The Contractor shall ensure that all tests, analyses and measurements are routinely
reported and that they clearly distinguish between the monitoring required to meet
regulatory requirements and the monitoring required to meet Contract requirements.
19.16 Spares
The Contractor shall during the Operation Service Period, replenish the stock of spares
to maintain at all times an equivalent stock of spares as required at the commencement
of the Operation Service Period.
The minimum stock of spare parts held shall be the comprehensive spares required for a
two year period of Operation Service and shall be detailed in the Operation &
Maintenance Plan. The Contractor shall monitor the use of spare parts and make
recommendations to the Employer’s Representative to vary the stock in accordance with
the experience gained during the Operation Service Period.
Recommomded spare list shall be submitted for approval of Employer’s representative
along with the technical document of equipment during detail engineering. A two year
stock of recommended spare parts shall be provided by the Contractor with the Works
handed back to the Employer on completion of the Contract.
All spare parts used for the equipment in the maintenance of the system must be from
the manufacturer of the equipment or, if the equipment itself has been made with parts
from other manufacturers, the parts must be of the same make as used in the equipment
supplied and installed.
All spare parts shall be packed for long storage period as specified under the climatic
conditions prevailing at the Site. Each spare part shall be labelled on the outside of its
packing with its description, number and purpose and, if more than one spare is packed
in a single case, a general description of the case contents shall be shown on the

outside and a packing list enclosed.

19.17 Public Liaison
The Contractor acknowledges that the Employer shall be the sole point of contact for
dealing with comments or complaints from customers of the Employer or members of the
public relating to the provision of the Operation Services.
Where a customer of the Employer or member of the public makes a complaint to the
Contractor, whether written or oral, in relation to any aspect of the Contractor’s provision
of the Operation Services, the Contractor shall notify the Employer’s Representative as
soon as practically possible.
Where any complaint or an enquiry has been received directly by the Contractor or
received by the Employer and notified by the Employer to the Contractor, the Contractor
shall report to the Employer’s Representative within 24 hours in such a way that the
Employer’s Representative can respond prudently to the complaint in accordance with
the good customer service expected.
Where a customer or member of the public has made repeated or ongoing complaints,
the Contractor shall manage such complaints on a case by case basis, prepare an action
plan, keep records of meetings and discussions with the customer and submit regular
progress reports at least monthly to the Employer until such time as an agreed resolution
or outcome is made with the customer or member of the public.

Operation and Maintenance Plan

20 OPERATION AND MAINTENANCE PLAN

20.1 Overview of Requirements
The Operation and Maintenance Plan (O&M Plan) shall be agreed between the
Employer and the Contractor as a fundamental part of the Contract for service delivery.
The O&M Plan shall then become an evolving plan, agreed on an annual basis, which
will include all aspects of the Operation Service as they are developed and applied within
the Contract.
The Contractor’s O&M Plan for the Works shall comprise three main sections, as
follows:-
• O&M Manual
• Operation Management Plan
• Maintenance Management Plan
At the end of 14 year of operation and maintenance, contractor shall carry out structural
audit of all civil structures and and submit report.
The general structure of the O&M Plan shall be as highlighted in Figure 20.1 below. The
Section of the Employer’s Requirements describing the element is contained in brackets
in the figure below.
O&M Plan (20)
OSMG (19.8)
Operation O&M Manual Maintenance

Management (20.4) Management Plan
Plan (21) (22)
Plant Facility Asset

Maintenance Plan Maintenance Management
(22.2) Plan (22.3) Database
(22.4)
Figure 20.1: General structure of O&M Plan

The Contractor shall submit the O&M Plan to the Employer’s Representative by the
times stated in Section 8.
The O&M Plan shall ensure that the operation of the service consistently complies with
the output quality and quantity sections of this document. In addition the O&M Plan shall
ensure that the treatment and transportation and disposal of sludge shall be carried out
in an efficient and cost-effective manner in compliance with Contract.
The O&M Plan shall also ensure that the maintenance aspects of the service will be in
compliance with all requirements on a continuous basis. It shall include systems for the
safe, efficient and effective operation and maintenance of the Works, together with safe

systems of work and safe working procedures in compliance with current legislation.
The O&M Plan shall contain procedures for quality control which shall be contained in a
separate section, together with procedures for compliance auditing and quality auditing.
These shall confirm service delivery and compliance with technical, regulatory and
performance requirements.
The O&M Plan shall contain, amongst other matters:
• Staffing and details – responsibilities, qualifications and training;
• Plant replacement progress;
• Design information;
• Operation and maintenance systems;
• Health and safety;
• Quality control;
• Monitoring;
• Reporting requirements and links to other documents;
• O&M Manual (Standalone).
20.2 Preparation and implementation of the O&M Plan
The Contractor shall issue the O&M Plan in a ‘manual’ form, with covering document
control sheet to denote document status and date of issue. The O&M Plan shall be
divided into sections, as per the structure outlined in Figure 20.1, with appendices where
necessary for additional data. Three original copies of the O&M Plan shall be issued at a
minimum. One copy shall be held at the treatment facility at all times and controlled
copies shall be issued to the Employer and the Employer's Representative (one each).
Should other copies be required, up to 3 additional copies shall be issued to the
Employer, upon request.
The O&M Plan shall be a central point of reference for the Contractor in the delivery of
the service and shall be compiled and issued to the satisfaction of the Employer’s
Representative prior to the commencement of the Operation Service Period. The O&M
Plan shall be implemented in accordance with the time limits in Section 8. To achieve
this, the Contractor shall ensure that all resources and fully qualified and trained
personnel are in place and that service requirements are being consistently met in
accordance with the plan. The Contractor shall demonstrate this fully to Employer’s
Representative.
The Contractor shall update the O&M Plan as appropriate, following the Service Delivery
Review Report or at the intervals stated in Section 8.
20.3 Auditing the O&M Plan
The Employer’s Representative can, at his own discretion, or at the behest of the
Employer, audit the Contractor’s Operation Service performance against that required
under the service as set out in the Contract and O&M Plan. The Employer’s
Representative and/or a third party specified by the Employer’s Representative can carry
out the audits. The audits are described in Section 23 of this document.
Any remedial actions to the O&M Plan or its implementation that are deemed necessary
shall be discussed with the Contractor and the appropriate initiatives shall be agreed and
issued to him, in writing, by the Employer’s Representative. This shall include a specific
timeframe for remedial actions to be taken.
Where there is a failure, on the part of the Contractor, to implement such initiatives within
the specified timeframe, the Conditions of Contract provide that the Employer shall have

the right to withhold payment until such time as the failure(s) are remedied. Should this
measure fail, the Employer shall retain the right to terminate the Contract and shall
recover all costs associated with the employment of replacement staff or Contractors.
20.4 Operation and Maintenance Manual
The Contractor shall provide an Operation and Maintenance Manual (O&M Manual) to
the Employer and the Employer’s Representative in a ‘manual’ form, with covering
document control sheet to denote document status and date of issue.
The manual shall be provided under the O&M Plan, but as a separate standalone
document, which shall form a hard copy technical reference for the works, (both new and
existing). The manual shall apply specifically to the functional and technical aspects of
existing and new installations, processes, equipment and components.
The manual shall commence with an introduction and general section comprising
contents, description of the whole installation and relevant addresses and phone
numbers of manufacturers and suppliers. This shall be followed by a description of the
Works and its design, operation, control and protection. Following this, it shall contain
clear, factual descriptions, instructions, diagrams, drawings and explanations of all
installations, processes, plant and equipment. These shall be free from such irrelevant
matters as might be contained in contractors’, manufacturers’ or suppliers’ general or
promotional literature.
Three original copies of the O&M Manual shall be issued at a minimum. One copy shall
be held at the Site at all times and controlled copies shall be issued to the Employer and
the Employer's Representative (one each). Should other copies be required, these shall
be issued as agreed between the Employer and the Contractor.
All textural materials shall be bound in A4 ring binders and drawings bound in A3 4-ring
binders, except where they accompany A4 text, where they shall be folded to A4 size.
Binders shall have clear pockets in the front and spine.
The O&M Manual shall read such that it has been written specifically for the Works by
the Contractor and shall not refer to Plant or Materials that are irrelevant. It shall be
divided and sub-divided logically into a series of volumes to ease their use on a day to
day basis and to ease the location of plant details, reporting procedures and policies.
The preparation of the O&M Manual shall be to a programme to be agreed with the
Employer’s Representative which shall indicate the delivery schedules, draft submissions,
collection and submission of suitable asset and maintenance data, collection and
submission of the supplier’s operation and maintenance manuals and a system for
vetting and approving the manual. The O&M Manual shall be provided within the time
shown in Section 8.
For all installations and processes, the manual shall contain at a minimum:
• Introduction;
• Safety, health and welfare information;
• Overview of the facility;
• Description of the operation of processes;
• Design information and relevant calculations;
• Routine tasks and staff duties & task check lists;
• Functional descriptions of plant elements;
• Details, charts and calibrations for chemical systems;
• Routine wastewater sampling and analysis instructions;
• Chemicals and chemical systems type, quantities, storage, safety and safe use
information;

• As-built documentation;
• Calibration reports for instrumentation, control and analogue circuits;
• Fault finding instructions;
• Maintenance instructions stating maintenance routines and intervals
• Procedures for disassembly, repair and assembly;
• List of components indicating manufacture, type, component number, ordering
numbers, position and other data;
• Manufacturer’s or supplier’s literature and data leaflets;
• Lists of spare parts (including order references and part numbers);
• Lists of tools;
• Lists of consumables
For mechanical installations, the manual shall contain at a minimum:
• Machinery type and serial number;
• Machinery rated capacity and load information;
• Operating instructions;
• Safety instructions;
• Lubrication charts (all equipment included in one chart);
• Maintenance instructions stating maintenance routines and intervals;
• Fault-finding details for rectification of basic faults;
• List of spare parts giving part numbers in relation to a drawing preferably of the
exploded view type (including order references and part numbers);
• Manufacturer’s or supplier’s brochures accompanied with names and addresses;
• Performance curves and diagrams;
• Test certificates;
• Specification of corrosion protection;
• Specifications for repair of all painted/coated surfaces.
For electrical components the manual shall be divided into separate sections for the
following installations:
• Control panels;
• Instruments;
• Control and measuring components (signalling system);
• Other components.
For electrical and ICA equipment the manual shall contain at a minimum:
• CE labelling and declaration of conformity;
• Layout drawings;
• Schematic and wiring diagrams;
• Detailed descriptions;
• Safety instructions;
• Operating instructions;
• Fault-finding charts;
• Maintenance instructions stating maintenance routines and intervals;
• Component lists;

• Lists of spare parts (including order references and part numbers).

20.5 Plant Manager
No later than six months before the anticipated start of the Process Commissioning, the
Contractor shall nominate a Plant Manager. The Plant Manager shall have at a minimum:
• 10 years’ experience in the O&M of municipal Treatment Plants;
• At least one municipal WwTFs as a Plant/Operations Manager which included
sludge handling, and energy recovery facilities of similar size, process technologies,
complexity and capacity in the last 10 years.
The submission shall include details of the nominee’s experience and qualification (CV).
If a plant manager was identified in the prequalification process and if a different person
is nominated during the Contract Period, the appointment of the Plant Manager shall be
subject to approval by the Employer’s Representative.
The Plant Manager shall be appointed before the commencement of the Tests on
Completion of Design-Build for the whole of the Works (including pre-commissioning
tests) and shall be a full time appointment.
The Plant Manager shall be involved in the development of:
• Operations management plan including the organisation chart;
• Compile a full asset register of the facility and set up an asset maintenance system
and operations systems;
• Put in place necessary training plan and hire staff ahead of operations as necessary.
Whenever the Contractor wishes to replace the Plant Manager, a nomination shall be
submitted to the Employer’s Representative for approval at least three months prior to
the intended replacement date. The Contractor shall use best endeavours to ensure that
the replacement Plant Manager shall have a working overlap of at least one month with
the current Plant Manager.
20.6 Plant O & M Staff
Apart from plant manager Contractor shall appoint Lead Operator and Laboratory
Technician. In addition, the Contractor shall appoint suitable number of operators, fitters,
electricians, helpers, gardeners, office peons, security guards, labourers as required for
the operation and maintenance of the plants for three shifts and adequate other staff /
supporting personnel during general shift.
Table 20.1 - Minimum Staff and Qualifications Requirements during O&M Period
Designation Qualifications Experience Total No.
in Years for WwTF
Plant Graduate in Civil/Chemical/Mechanical, 10 2Nos
Supervisor/ Public Health, or Environmental
Superintendent Engineering with specialization in
wastewater collection and treatment.
Shall have experience in STP O&M
Shift-in-charge Diploma in Civil/Chemical/Mechanical / 5 4 (Three
Electrical, Public Health, or Shifts)
Environmental Engineering with
specialization in wastewater collection
and treatment.
Shall have experience in STP O&M
Operators for Graduation/Diploma 3 8 (Three
STP Shall have experience in STP O&M . Shifts)

Designation Qualifications Experience Total No.

in Years for WwTF
Plant Chemist Graduate in Environmental Science / 3 4Nos
Chemistry having experience
laboratory (sampling / analysis)/
operation and maintenance.
Electrician Diploma/ ITI Certification in Electrical 3 8 (Three
Engineering with experience in WwTF Shifts)
Erection, Testing, Commissioning,
Operation & Maintenance.
Instrumentation Diploma/ ITI Certification in 3 4 (Three
and Control Instrumentation and Control Shifts)
Technician Engineering with experience in WwTF
Fitter/Mechanic Diploma/ ITI Certification in Mechanical 3 8 (Three
Engineering with experience in WwTF Shifts)
Peon 10th Pass 2 2 Nos
Security 8th Pass 3 4 Nos
Guards for
STP
Gardener 8th Pass 1 2 Nos

Helpers for - - 9 Nos
Sludge
Handling
Note:
a) The above requirement is minimum only. The Contractor will arrange extra work
force, as and when required, so as to smoothly run the operation and maintenance
including preventive maintenance, repairs etc. and general cleanliness of the
installations.
b) The above staff strength is exclusive of leave reserve required for different category
of staff. The Contractor shall ensure availability of the personnel given in the above
table for all seven days in a week.
c) The Contractor shall make appropriate arrangements for maintenance of items like
road work, buildings, arboriculture, patrolling and maintenance of civil structures,
vehicle operations and other activities to fulfill smooth operation of facilities without
obligations under O&M works.
The Contractor shall furnish complete resumes/biodata for all personnel proposed two
months before the start of Operation and Maintenance period to the Employer’s
Representative for approval.
20.7 Operational Cost Model
The Contractor shall develop and maintain current throughout the Operation Service
Period an Operational Cost Model which shall be based on the financial cost model
submitted with the Tender Submission but which shall fully reflect the actual costs being
incurred and anticipated to be incurred during the Operation Service. The Operational
Cost Model shall be submitted to the Employer’s Representative for review as requested
by him.
The Operational Cost Model and shall be made available for review by the MCGM and
shall be updated quarterly. The MCGM shall be entitled to see any financial information
relating to the Operation Service that may be reasonably requested from the Contractor.

Operation Management Plan

21 OPERATION MANAGEMENT PLAN

21.1 General
The Operation Management Plan shall be one of the three main parts of the O&M Plan
and in itself shall comprise the procedures for the operation of the treatment facility.
The Operation Management Plan shall be capable of demonstrating in an easily
identifiable schedule that the Works are and have continued to comply with the terms of
all relevant licenses and legislation.
At the end of 14 year of operation and maintenance, contractor shall carry out structural
audit of all civil structures and submit report.
21.2 Procedures for the Operation Service
The Operation Management Plan shall contain detailed procedures for the operation of
the Works, including equipment and processes, which the Contractor proposes to use in
delivering the service. A detailed control philosophy shall be provided for the overall
process and for each process stage, which shall be accompanied by a procedure for the
operation of each individual item of plant and/or system. This shall form a set of clear
instructions to operators and management in the WwTF.
The treatment facility control system shall be capable of continuous automatic operations.
The treatment facility shall be capable of running under manual control, although normal
operation shall be in automatic mode.
Optimum performance of the Works is an important requirement of the control system.
21.3 Non-Compliant Operation
Notwithstanding the requirements of Section 17, where the Employer is dissatisfied with
test results, he may vary the location, parameter or analysis methodology for specified
tests, or may instruct the Contractor to carry out additional tests. If these varied or
additional tests show that the tested quality or quantity of influent or effluent, Plant,
Material or Workmanship is not in accordance with the Contract, the cost of carrying out
these tests shall be borne solely by the Contractor. If, as a result of an examination,
inspection, measurement, analysis or testing, any Plant, Materials, design or
workmanship is found to be defective or otherwise not in accordance with this document,
the Contractor shall promptly make good the defect at his own expense and ensure that
the item complies with the appropriate standards.
Notwithstanding any previous test or certification, the Contractor shall, if so instructed by
the Employer: -
• Remove and replace any Plant or Materials, which is not in accordance with this
Contract.
• Remove and re-execute any other work which is not in accordance with this
Contract.
• Execute work which is urgently required for the safety of the Works, whether
because of an accident, unforeseeable event or otherwise.
Non-compliance determined by the Employer’s Representative will be communicated to
the Contractor by the most appropriate means and confirmed in writing. The Contractor
shall determine the cause of non-compliance, identify the corrective measures and report
in writing within five days.

Maintenance Management Plan

22 MAINTENANCE MANAGEMENT PLAN

22.1 General
The Contractor’s Maintenance Management Plan shall comprise of four main sections as
follows:
• Section 1 Plant Maintenance Plan;
• Section 2 Facility Maintenance Plan;
• Section 3 Asset Management Database
• Section 4 Asset Replacement Schedule.
The Maintenance Management Plan shall include the following:
• Operational maintenance issues;
• Equipment calibration records;
• Equipment service records;
• Plant maintenance records;
• Emergency event records.
The Contractor shall also develop and implement a comprehensive computer-based
maintenance management system, which shall include data on each of the above
sections. The computerised system shall address all Plant and Materials. It shall be
capable of developing readily available historical data, including an inventory of spare
parts and provision for enforcing warranties on Plant or Materials purchased. The
Contractor shall incorporate the computerised system into the Contractor’s SCADA
system, thus enabling all operational and maintenance details of Plant to be accessed by
the Contractor, the Employer and the Employer’s Representative. The Contractor shall
also develop an Asset Management Database that includes every component of the
Works. The database shall be structured to have "parent/child" relationships for each
component. The requirements of this Database are provided in Section 22.4.
All maintenance activities and Plant usage shall be logged through the SCADA system to
provide the necessary input to the computerised Maintenance Management Plan and
Asset Management Database. The system shall be capable of generating work orders
and asset lifecycle information that are specific to any items of equipment. These work
orders shall outline the required maintenance, describing previous history and the work
to be undertaken. The asset management database and software applicable shall be
capable of deriving the requirements as prescribed in section 22.4, based on the real
time monitoring of assets by SCADA system”
The resultant maintenance work shall be logged as to when the work order was issued,
when completed, by whom, duration of work, and listing of parts and consumables used
in expediting the work. This information shall be continuously updated for all equipment
and presented on an annual basis to the Employer to confirm that work is being
undertaken as required to protect investment in the infrastructure. The Employer,
however, may request to review records more frequently.
The Contractor shall provide a weekly inspection to detect any significant variance from
the baseline condition. Corrective action shall be taken by the Contractor to prevent
major damage to equipment, as well as protect warranties on new equipment.
22.2 Plant Maintenance Plan
The Plant Maintenance Plan shall provide for the routine, planned, breakdown and repair
maintenance of mechanical, electrical, instrumentation and electronic plant, equipment
and infrastructure (the WwTF assets) contained within the WwTF. The plan shall be for

the duration of the Operation Service Period and shall be continually evolving, including
all new equipment as it is installed.
The Plant Maintenance Plan shall reflect procedures and standards for a modern
wastewater treatment facility. All routine and preventative maintenance activities shall, as
a minimum, meet the requirements of suppliers and shall be based on the premise than
in no event shall maintenance be less frequent and less comprehensive than that
specified in manufacturers’ warranties and instruction manuals.
The Plant Maintenance Plan shall serve as the framework for developing the detailed
maintenance plans for each item to be included in the O&M Manual. It shall therefore be
based on a recognised quality maintenance methodology, for example the Reliability
Centred Maintenance (RCM) approach. It shall also serve as a record of maintenance
carried out on an ongoing basis, with reference to the O&M Manual where appropriate.
The Contractor shall provide a statement of the methodology he proposes to the
Employer's Representative for review before developing it in detail.
At a minimum, the Plant Maintenance Plan shall include:
i) Schedules for the maintenance of the Works to include but not be limited to:
• A complete list of the WwTF assets to be maintained
• The frequency and type of routine and planned maintenance for each WwTF asset
• Calibration of all instrumentation
• A listing of all essential spare parts to be carried
ii) Methods for dealing with breakdown and repair of WwTF assets to include:
• Callout response times for each WwTF asset
• Communication with the Employer's Representative when breakdowns occur
iii) Procedures for the maintenance of the WwTF assets;
iv) Methods for the planned replacement of minor WwTF assets;
v) Records of all maintenance carried out at the WwTF. These are to be kept up to date
and held electronically and in paper format at the Site at all times.
Plant and Materials shall meet the residual life requirements specified in Section 24.2
and shall be replaced as determined by the manufacturer’s life warranties or earlier.
22.3 Facility Maintenance Plan
The Facility Maintenance Plan shall provide for the routine, planned, and repair
maintenance of all buildings/strutures (including plumbing, water proofing, painting and
other structural repair works etc.), roads, paths, accesses, green areas, gardens, shrub
and tree areas, etc., contained within the Site. All routine and preventative maintenance
activities shall, as a minimum, meet the requirements of suppliers.
The Contractor’s facilities maintenance plan shall include procedures and standards for a
modern wastewater treatment facility. It shall be based on the premise that in no event
shall maintenance be less frequent and less comprehensive than that specified in
suppliers’ or manufacturers’ warranties and manuals.
The plan shall ensure that maintenance is carried out at a level adequate for the efficient,
long-term reliability and preservation of the Employer’s capital investment. It shall also
ensure that buildings, grounds, and landscaping are kept in an aesthetically attractive
and clean condition and are in compliance with all national regulations.
The Contractor shall carry out grounds maintenance so that all areas of the Site are kept
neat and tidy and free of any item which could constitute a nuisance or pose a threat to
the safety of any person, property or the environment or to the provision of the Operation

Services.
In the plan, the Contractor shall at a minimum include for the following activities relevant
to the buildings and grounds:
Buildings and Structures
• Repairing/ replacing all worn out items, breakages and leaks immediately;
• Cleaning roof guttering and drainage, windows and doors at six monthly intervals;
• Cleaning and maintaining ventilation systems at six monthly intervals;
• Washing down walls and wall tiles at least every six months, or more frequently, as
appropriate;
• Painting internal and external surfaces regularly (every 3 years as a guideline) and
as detailed in maintenance schedules.
Grounds and Site
• Mowing the grass once per week in the growing season and once per month
otherwise, including trimming of any edges, cutting hedges, shrubs, weeding and
applying weed killer to maintain an attractive appearance of the Works;
• Pruning trees once per annum to minimise interference with or damage to the
WwTF and Site work;
• Cleaning paths and roadways on a monthly basis, including freeing surface water
drainage systems, gulleys and manholes;
• Inspect and repair, as required, cracks, erosions, depressions, and potholes and
slab shifts on paved areas, sidewalls and other areas on a monthly basis;
• Inspect and repair, as required, security fencing, access gates and secure accesses
to all Site areas on a monthly basis;
• Resurfacing to paved areas when required.
22.4 Asset Management Database
The Contractor shall develop an Asset Management Database that includes every
component of the Works. The database shall be structured to have "parent/child"
relationships for each component. The first level shall be for the process areas, such as
grit removal, primary treatment, etc. The second, third and fourth levels shall be
established based on the design of each process area and will generally relate to the
systems, assemblies and components of the process area, respectively. A sample asset
hierarchy is provided in Appendix G to illustrate the required approach to the parent/child
relationship of the Asset Management Database.
The number of systems, assemblies and components for each process area in the Asset
Management Database shall be based on a threshold replacement value of each asset
INR 10 lakhs. If an asset does not exceed the threshold then it shall be grouped with
similar assets that are part of the same component, assembly or system until the value
of the group of assets exceeds the threshold value.
The following variables shall become fields in the database and the Contractor shall
populate the fields for each component during the development of the Asset
Management Database:
• Process Area;
• Component category (Process structural, building structural, architectural, building
mechanical, building electrical, site works, piping, process equipment, process
electrical or instrumentation);
• Replacement Cost;

• Year of Construction;
• Useful life;
• Consequence of failure of the component on the operation of the facility on a 1 to 5
scale;
• Probability of failure of the component on the operation of the facility on a 1 to 5
scale;
• Risk of failure of the component on the operation of the facility on a 1 to 25 scale.
Risk is defined as the product of the probability of failure and the consequence of
failure;
• size/capacity of the component;
• Photograph of the component;
• Estimated replacement time frame (0-5 year, 6-10 year, 11-25 years, > 25 years).
• Record of maintenance and / or replacement of the products used including the
down time
The Contractor shall develop the Asset Management Database in a commercial Asset
Management software application. All the software licenses shall be procured in the
name of the Employer. The Asset Management Database and software application shall
be subject to approval by the Employer’s Representative.
22.5 Asset Management and Replacement Schedule
Section 4 of the Maintenance Management Plan shall contain all information in regard to
the set-up, operation and status of the Asset Replacement Schedule and Asset
Replacement Expenditure Provision. The Asset Replacement Schedule shall be
developed using the information that is contained in the Asset Management Database
and asset replacement schedule provided by Contractor during bidding.
The Contractor shall manage the assets during the O&M period such that the quality of
the effluent is always maintained. The quality verification shall be subjected to the audit
by a third party employed by the MCGM.
The Contractor shall maintain or replace any of the equipment / components to ensure
the effluent discharge standards within the specified limits.
The Contractor shall be responsible to maintain the plant as per proposed asset
replcement schedule in the bid (original) or adjusted during O&M. No asset replacement
payment shall be allowed within first 5 years of O&M of WwTF plant. The Contractor
shall be allowed to replace assets as per the asset replacement schedule (orginal or
adjusted as the case may be) from 6th year of O&M period. The Contractor shall replace
any of the equipment/components in case of failure before specified period in original
asset replacement schedule without any financial implication to the Employer during the
Contract period. However if Contractor replace the asset within 3 months before
scheduled period as specified in asset replacement schedule, Contractor can apply for
payment from asset replacement expenditure at the period as specified in Asset
replacement schedule.
The Asset Replacement Expenditure Provision shall be operated in accordance with

Schedule of Payments in Volume 3.
During the Contract the Contractor shall keep the Asset Replacement Schedule up to
date to reflect any changes that have occurred. This Modified Asset Replacement
Schedule shall be based on the anticipated life expectancy of installed process plant.
The Modified Asset Replacement Schedule shall be based initially on the Asset
replacement Schedule included with the Contractor’s Tender Submission but updated
annually as experience is gained on the actual reliability of the various items of plant, to

accurately reflect the planned operation and maintenance of the Works. The tenth and all
subsequent annual reviews shall extend the period covered by the Modified Asset
Replacement Schedule to cover an additional five years beyond the Operation Service
Period.
The Contractor shall be encouraged to introduce innovation and improved efficiency into
the operation of the Asset Replacement Expenditure Provision, where it can be
demonstrated to be economically advantageous to the Employer in terms of improved
efficiency, reduced environmental impact or cost reduction.
When the Contractor wishes to introduce an innovation, he shall put forward his proposal
in writing to the Employer's Representative in accordance with the Schedule of
Payments. In such cases, the Employer, after evaluating the proposal, may consider
delaying the replacement. This agreement shall be made in writing and if agreed, there
shall be no with holding of regular O&M payments.

Independent Compliance Auditing

23 INDEPENDENT COMPLIANCE AUDITING

23.1 General
As part of the O&M Plan, the WwTF shall be inspected annually by the Employer’s
Representative and/or an independent Engineer approved and over seen by the
Employer’s Representative. The purpose of the annual inspection shall be to verify that
the operation and maintenance of the treatment facility is performed in conformance to
the O&M Plan and the requirements of the Contract. The Contractor shall develop a
compliance auditing plan which shall address:
• Tests to be conducted for each piece of equipment to determine their physical and
operational conditions;
• The physical and operational conditions and general status of repairs of all
equipment, buildings, structures, pavements, grounds, utility lines, spare parts,
inventories, etc.
The Employer’s Representative and/or the independent Engineer shall prepare a
detailed report documenting the findings of the inspection. The report shall include an
assessment of the current conditions of each item or component, its estimated remaining
service life, and whether the current conditions are consistent with the maintenance and
general upkeep requirements of the contract and in accordance with the O&M Plan. A
copy of the report shall be submitted to Employer’s Representative for review.
In the event that such inspections reveal work not in accordance with the O&M Plan or
with the Contract or lack of repairs or necessary maintenance to the WwTF or equipment,
the Employer’s Representative shall bring to the attention of the Contractor such items
and the Contractor shall perform the repairs and maintenance activities identified by the
inspection.
The annual inspection shall also review:
• Laboratory conditions and procedures – All laboratories where tests are conducted
on samples shall be inspected to ensure conformance and compliance with
laboratory procedures and requirements.
• Chemicals - All areas where chemicals are stored or used and hazardous materials
procedures and records shall be inspected to ensure compliance with the O&M
Manual and all applicable regulations and standards.
• Operation Service records - All records kept by the Contractor, including safety and
emergency conditions records shall be reviewed.
• O&M Plan – conformance to approved plan.
• Training and staffing plans – conformance with approved training and staffing plans.
• Health and Safety Plan.
• Influent and Effluent test results

Handback Requirements

24 HANDBACK REQUIREMENTS
24.1 General
At the end of the Operation Service Period the Contractor shall handback the Works to
the Employer.
Immediately prior to the end of the Operation Service Period the Contractor shall carry
out final repairs to the Works. These shall include repainting as necessary and making
good any defects or damage. The Contractor shall replace all spare parts and
consumable stores used in the Works and top up all fuel, oil and water tanks.
The Works shall be handed back in a condition which would permit the Works to receive
influent, treat and dispose of effluent subsequent to Handback in accordance with the
standards required by the performance requirements (assuming that the Works are
operated and maintained in accordance with the Operational Specifications and
Maintenance Specifications).
The whole of the Works shall be handed back in a clean and maintained state and in full
operation and good working order.
The Plant and Materials shall have been maintained in accordance with the Maintenance
Management Plan.
24.2 Residual Life and Planned Asset Replacement at Handback
The Contractor shall manage the scheduling of the replacement of assets such that there
are no planned replacements (as identified in the Modified Asset Replacement Schedule)
during the 2 years following Contract Completion.
24.3 Notification of Expiry of the Operation Service Period and Joint Inspection
The Employer shall notify the Contractor of the intended date for the expiry of the
Operation Service Period not less than two years before the said date. Any time after this
notification is issued, the Employer will start the process of selecting a new contractor for
the operation and maintenance of the system for further period of time as decided by the
Employer. The selection process of the new Contractor will be carried out with an
objective to have the new party on board with an overlap of 3 months to the final
handover.
Upon receipt of the Employer’s notification and in accordance with Clause 11.8 of the
Conditions of Contract, the Contractor and the Employer’s Representative shall carry out
a joint inspection of the Works to identify any defects, damage and plant replacements
that may be necessary prior to the expiry of the Operation Service Period.
The Contractor shall provide a programme for making good the defects and damage and
replacing items of plant, all as identified in the joint inspection, for approval by the
The Contractor and the Employer’s Representative will carry out further joint inspections
at intervals not exceeding 6 months. They will assess the Works condition and operation,
progress with the implementation of the above measures and identification of any further
measures to be implemented.
The prospective bidders for the new O&M contract may also have inspections of the
facility and the Contractor will facilitate such inspections also.

24.4 Tests Prior to Contract Completion
24.4.1 Duties and Responsibilities
All cost for the examination, tests and preparation of any documents of the activities shall
be the Contractor’s responsibility.
The Contractor shall provide all necessary labour, materials, and fuel required for tests.
Conduct Joint Inspection Prior to Contract Completion:
To verify the condition of Works / Facilities at the end of 15 years of operation and
maintenance for identifying damaged works, replacements and other works to be carried
out to satisfy the requirements of Operation and Maintenance Plan, a joint inspection will
be carried out by the Engineer, Employer and contractor.
Conduct Tests prior to Contract Completion:
To verify the plant condition and performance of plants including pumps, blowers, valves,
gates, cranes and other equipment at the end of 15 years of operation and maintenance,
Contractor shall conduct all the required Tests prior to Contract Completion. The
contractor is responsible to conduct annual inspections of cranes & other lifting
equipment, pressure vessels and other equipment as required by law/Govt. of
Maharashtra
24.4.2 Specifications
The specification of materials used for repairs shall be the same as have been used in
the original work. Specifications for any materials which were not used during
construction shall be approved by the Employer’s Representative
Table 24.2- Items to be examined at the End of 15 Years O&M Period
S.No Items Description
1 Appearance test /Visual - All Civil structures, building including
examination (Damage/crack, interior/exterior, fence/gate, stairs, others
differential settlement, soil - All Mechanical & Electrical
settlement, peel off painting, equipment/accessories, others
missing/lost, leakage of - All Pipe line valves and gates, others
water/solution/gas, corrosion, - All Instrumentation and Control equipment,
condition of structures, others) others
2 Performance examination - Check Sequence, or Manual operation

(Selection of operation mode, including water level, pressure
selection of facilities, sensors/protections, others
flow/water level, overflow, - Check specification of all Mechanical
vibration/noise level, speed of equipment including pressure and water level
pump/motor, smoothness, gauges, pressure relief valves, others
gap/spaces, accuracy, setting - Check specification of all Electrical
value, condition of structures, equipment, others
others) - Check specification of all Pipeline including
valves, gates, others
- Check specifications of all Instrumentation
and Control equipment, others
- Check specification of all accrual condition
after troubleshooting, others
- Performance tests of pumps, blowers and
other equipment

S.No Items Description

3 Verification of rectified works - Check a list of all defect items, history,
(System, leakage, crack, tendency, repeating, others
damage, soil settlement, - Check a list of all miss operation and
corrosion, others) maintenance items, others
- Check all factors of defect / miss operation ,
others
- Verification of action on the take measures,
others
- Verification of all rectified works with the
reports and photo, others
- Check emergency works and its factor,
action plan, others
- Check actual condition after rectified works,
others
4 Operation skill (Staff member, - Review of summary reports on O&M
others) activities
- Check time and motion of staff member,
others
- Interview operator regarding
troubleshooting, others
- Paper test (basic knowledge, calculation of
chemical dosing, safety, others)
- Field test (using/put on the safety gear, drill
of chlorine leakage accident, others)
5 Waste Water analysis - Location of sampling and time, and date
(Sampling and analysis, - Raw sewage and treated sewage
others) - All each process
- Authorized certificate
6 O/M Record - Check inventory list (parts, chemical,
reagent, others)
- Check the quantity of inventory, others
- Check maintenance tools and equipment,
vehicle, others
7 Spare parts and others - Check inventory list (parts, chemical,
reagent, others)
- Check the quantity of inventory, others
- Check maintenance tools and equipment,
vehicle, others
24.5 Handback of the Works to the Employer
The Works shall be transferred to the Employer at the date stated in the Contract
Completion Certificate in accordance with Clause 8.6 of the Conditions of Contract.
Shortly before Handback of the Works the Contractor and the Employer’s Representative
shall carry out a final joint survey of the Works. A schedule of minor defects shall be
compiled by the Contractor and submitted to the Employer’s Representative. Upon the
Employer’s Representative being satisfied regarding such final inspection, and subject to
the Contractor having successfully completed the Tests Prior to Contract Completion, the
Employer’s Representative shall issue to the Employer and the Contractor a Contract
Completion Certificate stating any minor works remaining to be completed. The
Employer shall thereafter be responsible for the care, safety, operation, servicing and
maintenance of the Works.

24.6 Training of the Employer’s Operators

The Contractor shall provide formal training and hands-on experience to the Employer’s
operators as required by Section 16.2 during the last twelve months of the Operation
Service Period.
24.7 Final Documentation
Prior to the commencement of the Tests Prior to Contract Completion the Contractor
shall submit minimum 3 sets of softcopies and 3 sets of hard copies of a final version of
all the documentation to the Employer’s Representative. This shall as a minimum be the
documentation as per the Employer’s Requirements apart from health and safety
documentation required by legislation. It shall include inter alia up to date records of
complete WwTF.
The hard copies shall be spiral bounded clearly indicating the version/revision submitted.
All the contents shall be indexed. The contents of completion documents shall be clearly
legible and shall include original manufacturer’s literature on a minimum, and in-
corporate any changes as per site conditions.
The comprehensive updated operation and maintenance manuals (six sets) shall be
submitted at the end of the operation and maintenance period.
Also, revised As-built drawings based on all modifications during O&M Period shall be
submitted at the end of O&M period. It shall include all drawings of treatment units(plan
and all necessary sections), utility and ancillary buildings, site layout, and all other
mechanical equipment GA drawings and piping, all electrical drawings like Single Line
Diagrams, Schematic Diagrams, Control Circuits Equipment Layout, Cable Layout&
Cable Schedules, Earthing Layouts and all ICA Drawings like P&ID, System
configuration diagram (PLC & SCADA architecture), Instrument installation drawings,
Instrument cable schedule, and cable layouts. And all structural drawings.
Six sets of the revised as-built drawings shall be submitted in hardcopies and softcopies
(editable form).
Table24.2- Minimum Documents to be handed over at the End of 15 Years O&M
Period
S.No Contents Description
1. 1 2. Outline Outline
- - Summary of project, scope of work, location of
project, main component with specification,
others
2 Completion Photographs - Photographs with short description
(At acceptance complete - - Civil (structural, buildings, others)
inspection, completion
- - Mechanical, Electrical and I&C (equipment,
inspection and final facility, others)
inspection) - Piping works
3. 3 4. Inspection summary Appearance test /Visual/ Performance
5. (At acceptance complete examination
inspection, completion - Table of Summary of test activity based on
inspection and final daily and monthly
inspection) - - List of type of test, date, inspector, evaluation,
comments
- - Civil (name of structure, drawing no.,
drawings, design dimension, previous
dimension, actual dimension, others)
- - Mechanical (name of facility and equipment,
tag no., quantity, others)


- - Electrical (name of facility and equipment, tag
no., quantity, others)
- - Instrumentation and Control (name of facility
and equipment, tag no., quantity, others)
6. 4 7. Main inspection data Summary of data with graphic /chart
8. (At construction) - Civil (plate load bearing test, compressive
9. strength test, water retaining test, compaction
10. field test, road construction works in WwTF,
hydrostatic test, others)
- Mechanical (disinfection test, others)
- Electrical (earthing resistance test, others)
- Instrumentation and Control
5 Inspection record Appearance test /Visual/ Performance
(At acceptance complete examination/ Verification of rectified works for
inspection, completion Civil, Mechanical, Electrical and ICA works
inspection and final
inspection)
6 Training and commissioning - Summary (Schedule of training and
record commissioning, attendance rate, impression
(At first and second training on training program)
program) - Training attendance list (participants, trainings
date, others)
- Commissioning daily record (Sewage flow rate
of designed and actual, name of operated
facility, list of measurement and its time and
reading value, raw sewage and treated
sewage quality, value of V/A/kW of each
equipment, others)
- Photographs with short description
7 Sewage quality citification - Location of sampling and time, and date
data - Raw sewage and treated sewage
(At acceptance complete - All Unit Process
inspection, completion - Issued from Authorized certificate
inspection and final
inspection)
8 Operation and Maintenance - Updated O&M Manual
manual -
(Civil, Mechanical, Electrical
and ICA works)
9 O/M records -Sewage quality analysis data and production of
electricity for complete O & M Period
-Sludge and screenings handling amount
-List of O/M record,
Ledger and operation record
-Various types of Ledgers and other plant
organization charts and plant management
records including cost and expenditure
-History of troubleshooting
-O/M record of a process, unit operation and
equipment
- - Mechanical (name of parts, tag no., quantity,
location of stock, others)
- - Electrical (name of parts, tag no., quantity,


- - Pipes & fittings (name of parts, tag no.,
quantity, location of stock, others)
- - Valve & Gates (name of parts, tag no.,
- - Instrumentation & Control (name of parts,
tag no., quantity, location of stock, others)
- - Others (name of parts, tag no., quantity,
10 Spare parts list - - Mechanical (name of parts, tag no., quantity,
- - Electrical (name of parts, tag no., quantity,
- - Pipes & fittings (name of parts, tag no.,
- - Valve & Gates (name of parts, tag no.,
- - Instrumentation & Control (name of parts,
tag no., quantity, location of stock, others)
- -Safety equipment and devices including for
staff and for testing
- - Others (name of parts, tag no., quantity,
11 Key list with boxes - Name of key, location, tag no., quantity, Civil
(all related material: reinforcement bar,
cement, aggregate, sand, gravel, asphalt,
crashed stone, chemical admixture, water
reducing agent, pozzolana, water-tightness
sheet, construction equipment, manhole,
water-resistant coating, paint, windows, door,
others)
- Mechanical (all related equipment; screens,
pumps, blowers, dewatering Centrifuge, heat
exchanger, Gas engines, Gas scrubbers,
Chlorinators, scarper, conveyor, hopper,
central drive & rotating mechanisms, pipes,
valves, gates, pressure gauges, safety valves,
safety equipment, flow meters, coating,
painting, others)
- Electrical (all related equipment: electrical
wire, electrical conduit, motor, control panel,
relay, transformer, heater, generator and
silencer, timer, breaker, light/lamp, switch,
street light, earthing, measurement
equipment, air condition, communication
equipment, electric pole, coating painting,
ventilation fan, air duct, others)
- ICA works (all related equipment, others)
- Safety equipment
- Others
12 Manufacture produced - Civil (all related material: reinforcement bar,
catalogue cement, aggregate, sand, gravel, asphalt,
(Civil, Mechanical, Electrical crashed stone, chemical admixture, water


and Instrumentation & reducing agent, pozzolana, water-tightness
Control) sheet, construction equipment, manhole,
others)
central drive & rotating mechanisms, pipes,
painting, others)
- ICA works (all related equipment, others)
- Safety equipment
- Others
13 Instruction manual - See above (11)
(Civil, Mechanical, Electrical
and Instrumentation &
Control)
14 Factory inspection record or - Civil (all related material: reinforcement bar,
Quality assurance cement, aggregate, sand, gravel, asphalt,
(Civil, Mechanical, Electrical crashed stone, chemical admixture, water
and Instrumentation & reducing agent, pozzolana, water-tightness
Control) sheet, construction equipment, manhole,
others)
central drive& rotating mechanisms, pipes,
painting, others)
- Instrumentation & Control (all related
equipment, others)
- Safety equipment


- Others
15 Photograph History of construction
(During Operation & Replacement of defect liability
Maintenance period and joint - Civil: construction site before starting
completion inspection) construction, earthwork, arrangement of bar,
(Civil, Mechanical, Electrical, cleaning before placing, formwork, concrete
Instrumentation & Control) mixing work, placing, vibrating, curing,
remove of formwork, backfill, compaction, all
field inspection and lab test, others
- Mechanical: inspection at factory, receiving
inspection, completion inspection, all field
inspection and lab. test, others
- Electrical: inspection at factory, receiving
inspection, completion inspection, all field
inspection and lab. test, others
- Instrumentation and Control: inspection at
factory, receiving inspection, completion
inspection, all field inspection and lab. test,
others
16 Production samples All samples for technical approval
(Civil, Mechanical, and - Attach Analytical instruments name,
Instrumentation & Control) approved sign of the Engineer.
17 Report - Monthly and Annual report
- Others

Inspection, Testing and Commissioning Requirements

25 INSPECTION, TESTING AND COMMISSIONING REQUIREMENTS

25.1 Inspection and Testing During Manufacture
25.1.1 General
a) All inspection and testing shall be carried out in accordance with the approved
documents & Drawings and Specification. In absence of Specification relevant Indian
Standard or internationally approved equivalent standard. After award of contract,
Contractor shall furnish a QA plan for approval by Employer’s representative. QA
plan shall include testing for incoming supply of raw materials and bought out items,
stage inspections and tests on finished products at manufacturer’s works /
appropriate testing station. QA plan shall clearly indicate tests which are intended to
be witnessed by the Contractor alone and those by both contractor and Employer.
b) Inspection and tests schedule shall be as follows;
• Manufacture tests
• Acceptance inspection / Quantity checking
• Install /site inspection
• Site acceptance test
• Tests on Completion
• Process Wet Tests (by Raw Sewage)
• Operation Test (Tests After Completion)
• Complete performance tests of Plant after 15-year Operation (Before plant handing
over)
• Test furnished as per IS Code/manufacturer QAP
c) The Contractor shall carry out inspection of equipments at the place of manufacture,
as per approved QAP.
d) The Employer and/or duly authorised and designated representative(s) shall be
entitled to attend the aforesaid inspection and/or tests.
e) The Employer and his duly authorised representative shall have access to the
Contractor’s premises at all times to inspect and examine the material and
workmanship of the mechanical and electrical plant and equipment during its
manufacture there. Testing (including testing for chemical analysis and physical
properties) shall be carried out by the Contractor and certificates submitted to the
Engineer who will have the right to witness or inspect the above mentioned
inspection /testing at any stage desired by him. Where inspection or testing is to be
carried out at a subcontractor’s works, a representative of the Contractor shall be
present.
f) Contractor shall provide test procedure, pre-factory test results, and calculation sheet,
photo in advance and provide all of test result with necessary document including its
data and photo to show Engineer that test is carried out in proper condition and the
its test results. Construction material shall be tested by contractor at the approved
laboratory.
g) The procedure for the testing and inspection to be carried out during or following the
manufacture of the materials to ensure the quality and workmanship of the materials
and to further ensure that they conform to the Contract in whatever place they are
specified shall be as described below.
i) The Contractor shall give the Employer at least 15 clear days notice in writing of

the date and the place at which any plant or equipment will be ready for
inspection/testing as provided in the Contract. Prior to notice, contractor should
submit pre factory test results as per clause 25.1.1(f) The Employer or his duly
authorised representative shall thereupon at his discretion notify the Contractor of
his intention either to release such part of the plant and equipment upon receipt
of works tests certificates or of his intention to inspect. The employer shall then
give notice in writing to the Contractor, and attend at the place so named the said
plant and equipment which will be ready for inspection and/or testing. As and
when any plant shall have passed the tests referred to in this section, the
Engineer shall issue to the Contractor a notification to that effect after obtaining
clearance from the consultants/engineer’s representative.
ii) The Contractor shall forward to the Employer 6 duly certified copies of the test
certificates along with characteristics performance curves/tables if any for all
equipment obtaining dispatch clearance from the consultants/Engineer’s
representative.
iii) If the Engineer(s) fails to attend the inspection and/or test, or if it is agreed
between the parties that the Engineer(s) shall not do so, then the Contractor may
proceed with the inspection and/or test in the absence of the Engineer and
provide the Employer with a certified report of the results thereof as per (ii) above.
iv) If any materials or any part of the works fails to pass any inspection / test, the
Contractor shall rectify or replace such materials or part of the works and shall
repeat the inspection and/or test upon giving a notice as per (i) above. Any fault
or shortcoming found during any inspection or test shall be rectified to the
satisfaction of the Engineer before proceeding with further inspection of that item.
Any circuit previously tested, which may have been affected by the rectification
work, shall be retested.
v) Where the plant and equipment is a composite unit of several individual pieces
manufactured in different places, it shall be assembled and tested as one
complete working unit, at the manufacturer’s works.
vi) Neither the execution of an inspection test of materials or any part of the works,
nor the attendance by the Engineer (s), nor the issue of any test certificate
pursuant to (iii) above shall relieve the Contractor from his responsibilities under
the Contract.
vii) The test equipment, meters, instruments etc., used for testing shall be calibrated
at recognised test laboratories at regular intervals and valid certificates shall be
made available to the Engineers at the time of testing. The calibrating instrument
used as standards shall be traceable to National/International standards.
Calibration certificates or test instruments shall be produced from a
recognised/Laboratory for the Engineer’s consent in advance of testing and if
necessary instruments shall be recalibrated or substituted before the
commencement of the test.
viii) Items of plant or control systems not covered by standards shall be tested in
accordance with the details and program agreed between the Engineer and
Contractor’s Representative. If such materials or works are found to be defective
or not conforming to the Contract requirements, due to the fault of the Contractor
or his sub-contractors the Contractor shall defray all the expenses of such
inspection and/or test and of satisfactory reconstruction.
ix) Tests shall also be carried out such that due consideration is given to the Site
conditions under which the equipment is required to function. The test certificates
shall give all details of such tests.

x) The Contractor shall establish and submit a detailed procedure for the inspection
of materials or any part of the works to the Employer for approval within the date
indicated in the Programme Details. The detailed procedure shall indicate or
specify, without limitation, the following :
• Applicable code, standard, and regulations.
• Fabrication sequence flow chart indicating tests and inspection points.
• Detailed tests and inspection method, indicating the measuring apparatus to
be used, items to be measured, calculation formula, etc.
• Acceptance criteria.
• Test report forms and required code certificates and data records.
• Method of sampling, if any sampling test to be conducted.
• Contractor’s or Employer’s witness points.
xi) The Contractor shall not pack for shipment any part of the Plant until he has
obtained from the Employer or his authorised representative his written approval
to the release of such part for shipment after any tests required by the Contract
have been completed to the Employer’s satisfaction.
xii) The following Inspection and Testing procedures shall be carried out for the
equipment as per approved QAP.
The detailed procedure shall indicate or specify, without limitation, the following:
• Raw Material
• Visual Inspection/Appearance.
• Chemical and Mechanical property tests
• Dimension Checking
• Dynamic balancing for all rotating parts
• Stage inspection
• Hydrostatic / Leak testing for all pressure parts, Pneumatic Leak Test wherever
applicable
• Repair procedure
• Operation check
• Procedure Qualification Record (PQR); Welding Procedure Qualification (WPQ) and
Welders Qualification Report (WQR)
• Material Test
• Assembly/Connection
• Documentation
h) The Contractor shall maintain proper identification of all materials used, along with
reports for all internal / stage inspection work carried out, based on the specific job
requirement and or based on the datasheets / drawings / specifications.
i) The All expenses incurred by the Engineer or his representative or persons
nominated by the Engineer including third party in attending inspection/ re-inspection
and tests of Plant carried out within India and abroad shall be borne by the contractor.
Maximum two persons from Employer side will witness the Inspection and testing
along with the contractor’s representative.The expenses incurred during inspection
shall include, all expenses but not be limited to all travelling, boarding, lodging
including visa charges etc. Cost of inspection when material or any part of the
facilities is not ready at the time specified by the Contractor for inspection or when re-

inspection is necessitated by prior rejection shall also be borne by the Contractor

j) Witnessed testing will normally be waived on standard types of equipment such as
small motors made by approved manufacturers, individual standardised instruments,
small mass produced components used in the manufacture of Plant items, small bore
pipework and fittings and minor installation materials. In order to remove doubt this
shall not relieve the Contractor of his obligation under the Contract to ensure that all
Plant is tested at the manufacturer's works prior to delivery to Site.
k) As a guide to the Contractor the Employer reserves the right to witness testing of the
following but not limited to the following Plant items:
a) Electrical:
o HT & LT Transformers
o HT Metal enclosed switchboards & Switchgears.
o 415 V Metal enclosed switchgears (PCC / MCC)
o HT and LT Power capacitor and control panel
o Diesel Standby Generator with AMF Control Panel
o Uninterrupted power supply system
o Battery, battery charger and DC Distribution Board
o Variable Frequency Drives
o Non Segregated Bus Duct
o Power & control cables
o Lighting System
o Earthing and lightning system
o Electrical Motors
b) Mechanical:
o Storage and process vessels Clarifier and thickener bridges, drives, and
sludge/scum mechanisms
o Chemical dosing systems complete with pumps, Valves & tanks
o Mixers, pumps and blowers including their motors ,Valve and penstock
actuators
o Valves
o Pipes
o Sluice Gates
o Expansion/Dismantling Joints.
o Weir Gates
o Screens
o Grit removal system
o Dewatering Centrifuge and associated plant
o Screw Pumps
o Biogas Engine (If any)
o Hydrolysis System (If any)
o Fine Bubble Diffuser systems
o Complete Disinfection System
o Process Air Blowers
o EOT Cranes and Hoists
o SBR Equipment and Associated Plant.
o Heat Exchangers
o Hot water Boilers

o Biogas scrubbers
o Gas Flare Assembly , valves and safety Devices
c) Instrumentation and Control:
o Level Measuring System
o Pressure Gauges
o Pressure Transmitter
o Flow Measuring System
o DO analyzer
o ORP analyzer
o Temperature Measuring System
o Residual Chlorine Measuring System
o Instrumentation and Control Cables
o Instrument Control Panel
o Programmable Logic Controller
o SCADA / HMI System
o Uninterruptible Power Supply System
o Wireless GPRS gateway testing
o FAT & SAT for complete ICA system
l) All destructively tested samples shall be replaced with new.
m) The Employer reserves the right to be present during the testing and inspection of all
Plant items.
25.1.2 Materials, Plant, and Equipment
The Contractor shall submit the detailed technical and its drawings from the approved
manufacturer and the procedure of submission, review and revision shall be as specified
herein below.
The Contractor shall inform the Employer about the likely dates of manufacturing, testing,
and dispatching of any material and equipment to be incorporated into the Permanent
Works. The testing and approval for dispatching shall not absolve the Contractor from his
obligations for satisfactory performance of the plant.
Dispatch Clearance
All mechanical/electrical/instrumentation equipment shall be tested at their respective
factory which will be witnessed by parties (viz.Contractor, Client /Consultant inspecting
team) in line with approved QAP and Equipment Data sheet.
The test observation sheets, material tests certificates (chemical and mechanical test at
laboratory) and joint inspection report shall be signed by the Contractor,
Client/Consultant officials after successfully completion of tests.
Contractor shall forward all original reports to Client and copy to Consultant for
verification and issuances of Dispatch Clearance Certificates as per clause 25.1.1 g (ii).
25.1.3 Factory Acceptance Test (FAT) Document
Fifteen (15) days prior to commencement of inspection of each Plant item / equipment
the Contractor shall supply a Factory Acceptance Test (FAT) Document for approval.
This shall comprise two copies of the following:
• Details of the inspection and test procedures to be carried out.

• Pre-factory test results and its photos.

The FAT Plan shall provide comprehensive details of the tests to be carried out, the
purpose of each test, the equipment to be used in carrying out the test and the methods
to be adopted in carrying out the tests. The FAT shall provide space within the
documentation for results of the tests to be added and for each test and for the FAT as a
whole to be signed off by the Contractor and the Engineer.
On completion of the tests the Contractor shall provide two copies of all test certificates,
curves etc. for the inspected Plant item. To remove doubt, test certificates shall be
provided for the Plant item as a whole plus certificates for the relevant component parts
such as:
• Motors;
• Mixers, pumps and Blowers;
• Instruments;
• Gear boxes;
• Electrical switchgear
• Integral control and switchgear panels;
• Valve gear;
• Castings.
• Actuators
• Cranes and Hoists
• Screens
• Grit Removal System
• Diffusers
• Storage and process vessels
• Pumps /blowers
• Air blowers
• Centrifuge Decanters
• Chlorinators
• SBR Equipment and associated Plant
• Heat Exchangers
• Hot water Boilers
• Biogas scrubbers
• Gas Flare assembly, valves and safety devices
• Biogas Engine
• Hydrolysis System
25.1.4 Inspection and Testing Program
The Contractor shall submit to the Engineer not later than 15 days prior to the
commencement of the first inspection and test during manufacture a program detailing
the inspection dates for all Plant. Those items of Plant that the Engineer has specifically
identified for witness testing test shall be highlighted in the program
The Contractor shall keep the Engineer informed of any changes to the program.
The Engineer shall not be requested to inspect an item of Plant until the Contractor has
satisfied himself that the equipment meets all requirements of the Employer’s
Requirements.
The Contractor shall inform the Engineer in writing at least 15 days in advance regarding

readiness for carrying out inspection of equipment/material etc. at manufacturer's works

or at places of inspection. The programme for inspection shall be finalised by the
Engineer after the receipt of the above case equipment/material etc. is found not to
comply with the specification, dates for re- inspection shall be finalised and expenses
incurred by the Employer for such visits shall also be recovered from the Contractor.
Contractor's Representatives shall essentially be present during all inspections of Plant
items. The following information shall be given in the inspection call letter mentioned
above:
a) Name of manufacturer/supplier;
b) Address of place where inspection is to be carried out;
c) Proposed date/s and equipment to be inspected;
d) Name/s of contact personnel at manufacturer's/ supplier/s works with their telephone
and fax numbers.
e) Name of Contractor's Representative who will be present during the inspection.
f) Confirmation that internal testing has been completed. Submission of internal testing
report for review before visiting the plant
The Contractor shall provide all the necessary instruments, test facility, water / electric
power, test piece, samples, engineers/ workers, all cost and others to carry out the tests
after assembly. All instruments used for such tests shall be calibrated and certified by
and approved by an independent testing authority not more than one year prior to the
tests in which they are used. Calibration certificates with expire date and name of
authorization agency for instruments used for such tests shall be produced for the
approval of the Engineer and if necessary, instruments shall be recalibrated before the
commencement of the tests.
No material shall be delivered to the Site without Dispatch clearance certificate having
been carried out or waived in writing by the Engineer.
If during or after testing, any item of plant fails to achieve its intended duty or otherwise
proves defective, it shall be modified or altered as necessary and retested and re-
inspected as required by the Engineer.
25.2 Tests at Manufacturer's Premises – Mechanical Equipment
As per approved QAP and releavent code.
25.3 Chlorination and Gas Pipeline System
a) All items of plant shall be tested at manufacturer's works and test certificates shall be
provided.
b) All chlorine gas piping from chlorine drums to chlorinator shall be pressure tested
with dry air/nitrogen to a pressure of 15 kg/sq.cm.
c) The chlorine gas piping from the chlorinators up to injectors shall be pressure/
vacuum tested with dry air/nitrogen to a pressure/vacuum equal to 1.5 times the
maximum pressure/vacuum to be encountered during operation.
d) The motive water piping shall be hydrostatically tested for a pressure of 1.5 times the
operating pressure or the maximum pump discharge pressure at pump shut off
whichever is higher.
e) After the chlorine system has been completely tested as above leak tests shall be
conducted admitting chlorine gas. Leakages if any shall be identified using ammonia
stick. During this test all chlorine leak detectors shall be in place and all safety
procedures shall be adhered to.
f) Gas cylinder shall provide the pressure test certificate issued by authority and
manufacture year.
g) Chlorine gas detector sensors shall be tested, and results shall provide to the

Engineer.
h) Ventilation system. The ventilation fans shall be tested at manufacturer's works to
verify the design flow and pressure.
i) Process Plant Items. All process plant items shall be tested to ensure they meet the
Employer’s Requirements for inlet and outlet quality of workmanship, construction
and system performance.
25.4 Mechanical Equipment Test at Site
All mechanical equipment shall be tested at site as following items in bellow,
a) The test will be verified any damage/missing part, No. of equipment to be installed,
material, location as specified in drawing, levelling, centreline, solid installation and
condition of installation to be fit in levelling of pipeline and valves.
b) Testing run will be conducted for verifying rotation direction, vibration, noise, and
stability and any leakage, if possible.
c) The test will be verified to check maintenance space and ease of equipment
maintenance work.
d) The testing shall be performed in full compliance with the latest version of the
applicable standard testing protocol. These tests shall be witnessed by Engineer per
procedures set forth for witnessing elsewhere in this document.
25.5 Plant Tests at Site
a) In addition to the progressive supervision and inspection by Engineer, the Contractor
shall offer for inspection to Engineer, the completely erected plant/part of Plant on
which tests are to be carried out. After such inspection, each equipment/sub-system
shall be tested by the Contractor in accordance with the applicable standards in the
presence of Engineer. Such tests shall include but not be limited to the tests
specified in following clauses.
b) The Contractor shall possess during the entire working period the Electrical
Contractor's licence of appropriate class from the concerned statutory authorities
governing the area of work place. The Contractor shall fully comply with the relevant
statutory rules and regulations. On completion of the installation or at intermediate
stages, if required by the statutory authorities, the Contractor shall arrange for
inspection and obtain the approval from the concerned statutory authorities. If any
fees are to be paid to statutory authorities for testing, inspection and calibration these
shall be paid by the Contractor and shall be included in his erection and
commissioning charges.
25.6 Pumps, Piping and Valves
a) The erected pipe work shall be subjected to a hydraulic test at 1.5 times the
maximum pressure or twice the working pressure whichever is higher to test the
soundness of the joints. Provision of the necessary pumps, gauges, blank flanges,
tappings etc. for carrying out these tests shall be included in the Contract. All gas
piping shall be air tested to twice normal working pressure.
b) Leakage tests shall be carried out on all erected pipework, pumps and valves
immediately after erection and where possible before being built in.
c) Operating tests shall be conducted on valves.
d) The pump set shall be tested for satisfactory operation. The vibration and noise level
shall be checked to be within the specified limits.
25.7 Motors
Condition of winding insulation be tested and insulation values shall be restored to
required level by suitable heating arrangements locally.

25.8 Cranes
The crane and lifting tackle shall be tested to 125% of the safe working load. The
Contractor shall arrange the test load. The contractor shall also arrange for the
appropriate certificates from the concerned authorities before regular use of the cranes
and other lifting equipment.
25.9 Screens and Grit Removal System
After erection, all screens and Grit removal system shall be tested for smooth operation
and capability to handle typical wastewater solids and grits including stringy materials.
Clearance between the dead plate and tines shall be checked as applicable.
25.10 Gates and Penstocks
a) Leakage test shall be performed by the Contractor after installation of all Gates.
b) Under the design seating head and unseating head the leakage shall not exceed the
limit specified in applicable IS codes, for shop testing.
25.11 Laying and Joining of Reinforced Cement Concrete Pipes
a) After laying and jointing of RCC pipes is completed the pipe line shall be washing out
with sufficient water and be tested at work site as per the Employer’s Requirements
and as directed by the Engineer. All equipment for testing at work site shall be
supplied and erected by contractor. Water for testing of pipes shall be arranged by
him. Damage during testing shall be contractor's responsibility and shall be rectified
by him to full satisfaction of the Engineer. Water used for the test shall be removed
from pipes and not released to the excavated trenches.
b) After the joints have thoroughly set and have been checked by the Engineer and
before back filling the trenches, the entire section of the sewer or storm water drain
shall be proved by the contractor to be water tight by filling in pipes with water to the
level of 1.50m above the top of the highest pipe in the stretch and heading the water
up for a period of one hour.
c) The apparatus used for the purpose of testing shall be approved by the Engineer.
Contractor if required by the Engineer shall dewater the excavated pit and keep it dry
during the period of testing. The loss of water over a period of 30 minutes should be
measured by adding water from a measuring vessel at regular 10 minutes intervals
and noting the quantity required to maintain the original water level. For the approval
of this test the average quantity added should not exceed 1 litre/ hour/100 linear
metres / 10mm of nominal internal diameter. Any leakage including excessive
sweating which causes a drop in the test water level will be visible and the defective
part of the work should be removed and made good.
d) In case of pressure pipeline, the completed stretch of pipeline shall be tested for site
test pressure. The site test pressure should not be less than the maximum operating
pressure plus the calculated surge pressure, but in no case should it exceed the
hydrostatic test pressure as specified in IS:458.
25.12 Laying and Joining of Steel Cylinder Pipes and Specials
a) After laying and jointing of steel cylinder pipes and specials with concrete lining and
coating is completed the pipeline shall be washing out with sufficient water and be
tested at work site as per the following Employer’s Requirements and as directed by
the Engineer. All equipment for testing at work site shall be supplied and erected by
Contractor. Water for testing of pipes shall be arranged by him. Damage during
testing shall be Contractor’s responsibility and shall be rectified by him to the full
satisfaction of the Engineer. Water used for test shall be removed from pipes and not
released to the excavated trenches.
b) Each section of the pipe line shall be slowly filled with clean water and all air shall be

expelled from the pipeline. The pressure in the pipeline should then be raised and
maintained by means of pump to the test pressure. The test pressure should not be
less than 1 1/2 times the working pressure at the lowest point or the static head
pressure, whichever is higher. Under the test pressure no leak or sweating shall be
visible at the welded joints. The duration of test shall be not less than 24 hours. The
exposed joints shall be carefully examined and all such joints showing visible leaks
shall be rewelded. Any cracked or defective pipes and specials in consequences of
this pressure test shall be removed and replaced by sound material by Contractor
and the test shall be repeated to the satisfaction of the Engineer.
c) Hydrostatic shop test for pipes and fittings shall be as per code/standard requirement.
After erection at site, complete pipes and fittings shall be hydrostatically tested for a
pressure of 1.5 times operating pressure.
d) Where directed by the Engineer welded joints on pipes larger than 675 mm diameter
shall be subject to a nitrogen gas test after welding.
e) A tapped hole (approximately 6 mm diameter) shall be made in the socket end of
each pipe by the Contractor and shall be fitted with a suitable non-return valve.
Nitrogen, at 400 kPa pressure, shall then be pumped into the annular space between
the spigot and socket and the pump disconnected.
f) If no drop in pressure occurs over the ensuing period of 30 minutes the test shall be
deemed to be successful. If the test pressure cannot be maintained for 30 minutes all
defects in the weld shall be cut back and rewelded and the test reapplied until
successful. The cost of initial and subsequent testing of defective welds shall be at
the Contractor's own expense.
g) The Contractor shall provide all items necessary for the nitrogen tests including
compressor, valves, gauges and tubing.
25.13 Laying and joining of Cast Iron, Ductile Iron Pipes and Fittings
a) After the pipes and fittings are laid, jointed and the trench partially backfilled except
at the joints the stretch of pipe line as directed by Engineer shall be subjected to
pressure test and leakage test after washing the pipe line out with sufficient water.
b) Where any section of the pipeline is provided with concrete thrust blocks or
anchorages, the pressure test shall not be made until at least five days have elapsed
after the concrete was cast. If rapid hardening cement has been used in these blocks
or anchorages, the tests shall not be made until at least two days have elapsed.
c) Each section of the pipe line shall be slowly filled with water and all air shall be
expelled from the pipe by tapping at points of highest elevation before the test is
made and plugs inserted after the tests have been completed. The specified test
pressure based on the elevation of the lowest point of the line or section under test
and corrected to the elevation of the test gauge shall be applied by means of a pump
connected to the pipe as directed by the Engineer.
d) The duration of test shall not be less than 5 minutes. The exposed joints hall be
carefully examined and all such joints showing visible leaks shall be recaulked until
water tight. Any cracked or defective pipes and fittings in consequence of this
pressure test shall be removed and replaced by sound material by Contractor at no
extra cost to the Engineer and the test shall be repeated to the satisfaction of the
Engineer.
e) After the satisfactory completion of pressure test, the section of pipe line shall be
subjected to leakage test. The duration of test shall be 2 hours. No pipe installation
shall be accepted until the leakage is less than the number of cm3 /h as determined
by the formula:
Where,
q L = NDP

3.3
q L= The allowable leakage in cm3/hr
N = Number of joints in the length of the pipeline
D = Diameter in mm, and
P = The average test pressure during the leakage test in Kg/cm2
f) Should any test of pipe laid indicate leakage greater than that specified above, the
defective joints shall be repaired by Contractor at no extra cost to the Engineer until
the leakage is within the specified allowance.
g) Necessary equipment and water used for testing shall be arranged by Contractor at
his own cost. Damage during testing shall be Contractor's responsibility and shall be
rectified by him at no extra cost to the Engineer. Water used for testing shall be
removed from the pipe and not released in the excavated trenches.
h) After the tests mentioned above are completed to the satisfaction of the Engineer,
the backfilling of trenches shall be done as per the Employer’s Requirements
specified elsewhere.
25.14 Manufacturer's Works Acceptance Tests on Electrical Equipment
The following equipment / items shall be subjected to inspection, routine /acceptance
tests as per latest edition of relevant Indian / International standards in the presence of
Employer/ his Engineer
a) HT and LT Transformers
b) HT Metal enclosed switchboards & Switchgears.
c) 415 V metal enclosed switchgears (PCC / MCC)
d) Power capacitor and control panel
e) Uniterruptable Power Supply system
f) Battery, battery charger and DC Distribution Board
g) Variable Frequency Drives
h) Non Segregated Bus Duct
i) Power & control cables
j) Cable carrier system
k) Lighting system
l) Earthling and lightning protection systems
Copies of test Certificates for the type tests and Special tests not later than 5 years
conducted as per relevant Indian / International Standards for all the equipment /items of
above shall be furnished for the perusal of Employer / his Engineer. If type tests and
special tests have not been conducted on any of these items, the same shall be carried
out in the presence of owner/ Engineer at no extra cost.
25.15 Manufacturer's Works Acceptance Tests on ICA Equipment
A. Instrumentation:
Inspection, Testing and Setting to Work:
General
Each item of plant shall be subjected to the manufacturer’s own tests which shall be
certified.
Each item of plant and its installation shall be subject to inspection and testing at the
place of manufacture.
The Contractor shall be responsible for the provision of all necessary test equipment.

The Contractor shall demonstrate to the Engineer, the correct operation of any item of
plant and the Engineer may witness any test. Tests which, in the opinion of the Engineer,
were failed or not performed correctly shall be repeated.
Calibration tests for field instruments and analytical instruments should be conducted on
site after installation and the same should be witnessed by the Engineer.
Before any test is made, the Contractor shall submit to the Engineer a full list of test
equipment & test procedures (method statements) to be used. Each item of test
equipment shall have a standard of accuracy better than that stated by the manufacturer
of the item to be tested. The Contractor shall provide evidence of the condition and
performance of any item of test equipment, in the form of test certificates issued by an
appropriate authority independent of the Contractor and manufacturer, or as otherwise
directed by the Engineer. Test equipment shall be checked frequently during the period
of the tests.
The Contractor’s staff responsible for supervising and carrying out tests shall be fully
conversant with the various items of equipment of other manufacturers and if necessary
the Contractor shall arrange for his personnel to attend suitable training courses on his
own expense.
Any fault or shortcoming found during any inspection or test shall be rectified to the
satisfaction of the Engineer before proceeding with further inspection or testing of that
item. Any circuit previously tested, which may have been affected by the rectification
work, shall be re-tested.
Preliminary Inspection and Testing at the Place of Manufacture
Field-mounted instruments
After the successful completion of the manufacturer’s own inspection and testing of
instruments
supplied under the Contract, similar tests shall be carried out in the presence of the
Engineer and the Contractor. Such tests shall include a demonstration that an increase
or decrease of the measured value at several points over the full range of the instrument
produces a corresponding increase or decrease in the instrument output signal. These
tests shall include checks on the specified accuracy of the instrument at all points.
Instrument Panels, Enclosures and Mounting Boards
The manufacturer shall not present instrument panels, enclosures and mounting boards
(assemblies) for inspection and testing until the manufacturer’s own tests and inspection
has been completed. A preliminary inspection and test of these assemblies may then be
witnessed by the Engineer. The Contractor shall give not less than 7 days’ Prior notice in
writing that he has completed.
His tests and inspection and is ready for the witnessed tests and inspection. Where this
notice period is different in the Conditions of Contract this shall take precedent.
The witnessed inspection and testing shall include the following:
a) A visual inspection of the panel assembly to show that the design, construction and
finish are satisfactory and in accordance with the Specification;
b) A check that equipment is securely mounted, accessible for removal or calibration
without damage to or undue disturbance of other components, wiring or piping;
c) That all engraving and labels are correctly positioned, fixed and designated in
accordance with the Specification;
d) Panel power-distribution circuits have the correct breaker/fuse rating coordination
and designation;
e) Power-isolation facilities meet the Specification;

f) The main incoming supply voltage, frequency and/or pneumatic supply pressure is
within the required limits, these being checked at the beginning and end of the test
and the results recorded on test certificates;
g) The output of all power supply units again at the beginning and end of the testing
with results being recorded;
h) The power supply voltage or air pressure of all component instruments of the
assembly(s), these voltages/pressures being recorded on the test certificate;
i) The insulation resistance of all circuits except sensitive electronic equipment which is
liable to damage by application of the test voltage, such circuits being disconnected
before making the insulation resistance tests and these tests being carried out in
accordance with IEE Wiring Regulations;
j) That the clean earth bar is isolated from main frame of the panel.
Internal lighting and anti-condensation heaters and associated thermostats, isolators,
limit switches and wiring shall be checked for compliance with the Specification.
Spare capacity within the panel(s) shall be checked to see that it complies with the
Specification. This shall include future equipment space, spare terminals, space in wiring
trunkings and provision for additional cable entry.
Functional Testing at the Place of Manufacture

General Requirements
Once the preliminary inspection and testing is complete to the satisfaction of the
Engineer, functional testing shall commence. The purpose of the functional tests are to
demonstrate that instrument panels enclosures and mounting boards (assemblies)
conform with requirements of the Specification.
Not less than 30 days before the commencement of functional tests, the Contractor shall
submit to the Engineer, for approval, two copies of comprehensive test procedural
documents detailing each test to be carried out. The document shall include results
forms on which the results of each test will be entered. The forms shall include spaces
for numerical values, where necessary, and witness signatures.
All applicable drawings and data shall be provided at the place of inspection by the
Contractor. The Contractor shall provide all test instruments and equipment necessary to
test the assemblies in their entirety.
The following is a typical list of the equipment required:
• Switch boxes;
• Indicator light boxes;
• Analogue signal sources;
• Dummy loads;
• Meters;
• Simulators;
• Desk-top computers;
• Programmers for DCS or outstations;
• Insulation test equipment
B. Programmable Logic Controller (PLC) and SCADA
The Contractor shall carry out specified tests as follows in addition to any tests stated or
implied by the foregoing sections of this clause.
The tests shall be carried out on the fully assembled control panel containing the PLC

and associated equipment in order to demonstrate correct functional operation of the

hardware and software systems.
Factory Acceptance Test (FAT)
The Contractor shall conduct a full program of tests of the PLC & SCADA system at the
Contractor’s testing facility in the presence of the Engineer to verify that all features of
the system have been provided, are operating correctly and are in full compliance with
the Specification. FAT shall include PLC based SCADA system for STP and PLC based
control system with panel mounted HMI with wireless communication system for the all of
the above. Unless otherwise specified or agreed by the Engineer, the entire PLC &
SCADA system shall be assembled and tested together as an integrated system,
including all master station equipment, all operators’ consoles, all outstations and
telemetry equipment all instrumentation panels and uninterruptible power supplies
included in this Specification. The scheduled date for the factory acceptance test shall be
as agreed by the Contractor and the Engineer at least four weeks before the test.FAT
shall be conducted with a hardwired simulation panel connected to the PLC based
SCADA system. Contractor shall note the importance of the requirement. No software
based simulation testing shall be accepted or allowed.
Not less than one month before the scheduled factory acceptance test, the Contractor
shall submit to the Engineer for approval two copies of a comprehensive manual
detailing each test to be conducted. The manual shall include a results form on which the
results of each test will be entered, including spaces for numerical values where
appropriate and witness signatures.
Not less than 7 days before the scheduled factory acceptance test, the Contractor shall
give written notification to the Engineer that a complete dry-run of the factory acceptance
test has been performed successfully and that, in the opinion of the Contractor, the
system exhibits stable operation and is ready for the formal factory acceptance test.
The factory acceptance test will be considered successfully completed only when the
system has successfully passed all factory tests. The system shall not be delivered to
Site until the successful completion of the factory acceptance test is certified by the
Engineer or unless otherwise approved by the Engineer. Delay in the delivery of the
system due to failure of the factory acceptance test shall not constitute an unavoidable
delay. If the system fails the factory acceptance test, the test shall be extended or
rescheduled at the discretion of the Engineer.
All hardware to be used in the testing of the system shall have passed an agreed
preliminary hardware performance test to ensure known hardware operability before
software testing begins.
After successful completion of the factory acceptance test, no software changes shall be
made to the system without written authorisation by the Engineer. Any changes to the
system which effect the system software documentation, such as input scale
modifications or changes to the control logic, shall be entered into the system
documentation before delivery of the system to Site.
Factory Acceptance Test Procedures
General
The scope of the tests shall include the proving of every aspect of hardware and
software operation and functions as detailed below.
Hardware Tests
a) Verify the correct inventory of hardware including cables and printed circuit boards;
b) Demonstrate that all spare-memory, disk-capacity and system-expansion
requirements have been met;

c) Demonstrate all hardware and software diagnostics;

d) Verify all power supply voltages are within tolerance;
e) Verify proper earth connections and isolation of instrumentation earth for all
equipment;
f) Demonstrate operation of test simulation and indication equipment and its Suitability
for adequate functional testing of all system functions.
Software Tests
a) Demonstrate the editing of all system parameters including set-points, timers and the
like;
b) Demonstrate system configuration capabilities including the addition and deletion of
input and output points, outstations, and all data base parameters;
c) Demonstrate the addition, deletion and modification of mimic displays and report
formats;
Functional Tests
The functional tests shall verify proper operation of every specified system function as an
integrated system. These tests shall be conducted in conjunction with functional tests of
instrumentation and control panels as specified elsewhere. All failures or discrepancies
found shall be documented in the test manual.
Following a failure of any functional test, should software or hardware modifications be
required it shall be the decision of the Engineer whether the factory acceptance test is to
continue, re-start or be aborted. If testing is allowed to continue, any changes which are
required shall be described in a system modification document, signed by both
Contractor and Engineer and be incorporated into the final factory acceptance test
documentation. The failed test shall be re-conducted and the Engineer may require the
retest of functions which may be affected by the modification.
The functional tests shall include, as a minimum, the following:
a) Demonstration that the system meets the requirements of the Specification for
response time and speed of screen update;
b) Verification of the accuracy of all analogue input points in the system. The procedure
shall include applying the appropriate signal to each analogue input at a minimum of
three points within the range of the input, checking for expected numerical results,
and verifying appropriate update of related mimic displays. Proper sensing and action
by the system to high and low out-of-range inputs shall also be verified;
c) Verification of the proper logic sense, pulse accumulation and rate computation
where appropriate, of all digital inputs and verifying appropriate update of related
mimic displays;
d) Verification of all control and sequencing operations and proper operation of all digital
and analogue outputs. The procedure shall include simulation of all related process
variables for both normal and abnormal conditions, including instrument and
component failure, and demonstration of fail-safe response of the system. System
outputs shall be indicated with appropriate lamps and indicators;
g) Simulation of outstation communications errors and failures and demonstration of
error detection and handling, failure detection and handling, and appropriate changes
to control actions as designed and specified;
h) Verification of fault detection and diagnostics by inducing a sufficient variety of fault
conditions in the system to ensure that detection processes and fail-safe operation
are adequately tested;
i) Demonstration of proper operation of all mimic displays, help pages, reports,
operator procedures and historical data accumulation;

j) Demonstration of proper operation of all outstations following a simulated master

station central processor failure;
k) Demonstration of proper operation of all equipment during both a system wide or
isolated power failure, and following power restoration. The procedure shall include
the demonstration of battery backup of both master station and outstation for the full
length of time specified, and proper operation of power fail, low voltage warning and
all associated alarms.
Reliability Test
The test shall be passed if no system function is lost or no hardware or software failure
occurs. Hardware failure is defined for this test as the loss of a major component such as
the computer, an outstation, a VDU or a peripheral device. Non-repetitive mechanical
failures of loggers, push-buttons and the like are excluded.
During this test, the system shall be exercised with simulated inputs and conditions in a
manner which approximates the on-site operational environment. Unstructured testing by
the Engineer shall be included during this test. Upon any system failure during this
period, it shall be the decision of the Engineer whether the reliability test is to continue or
be aborted. If testing is allowed to continue any changes to the system which are
required shall be described in a system-modification document, signed by both
Contractor and Engineer and the document shall be incorporated into the final factory
acceptance test documentation.
Factory Acceptance Test Documentation
As a minimum, the following information shall be included in the Factory Acceptance
Test manual for each test:
• Test identification number;
• Test name and description;
• List of all equipment to be tested including any special test equipment required;
• Description of the test procedure broken down into logical steps;
• Description of the expected system response verifying the completion of each
logical step;
• Space for recording the results of the test and the time and date of the test;
• Space for signatures of the Contractor and the Engineer.
In addition, the Contractor shall provide a method for recording and tracing all problems,
discrepancies, queries and suggestions regarding the system and software, and for
formalized control of any modifications to the system.
Pre-commissioning Tests
The Contractor shall perform pre-commissioning, or preliminary, testing of the SCADA
system in accordance with that specified for instrumentation. The purpose of
pre-commissioning tests is to confirm readiness of the system for commissioning.
The scope of pre-commissioning tests shall be generally as specified for factory
acceptance tests but real field inputs and final control elements shall be used wherever
practical to provide inputs to the system and to confirm proper outputs.
Where this is impractical, simulation signals shall be injected as near as possible to their
ultimate sources so as to include in the tests as much of the cabling system as possible.
Each process system shall be set to work under manual control and the system tested to
confirm proper operation. After proper operation of manual control mode has to be
verified, tests of automatic controls of each process system shall be conducted wherever

practical.
Commissioning
Site Acceptance Tests (SAT)
The Contractor shall submit all relevant draft operating manuals for the PLC & SCADA
System to the Engineer for approval prior to commissioning tests.
Any faults or failures of the system detected during the previous tests shall be noted and
corrected to the satisfaction of the Engineer before commissioning is allowed to
commence.
During this period, the system will perform the normal functions according to the
procedures described in the SAT documentation approved by the Engineer.
The system shall have passed the SAT if all major components have been free from fault
or failure and exhibit full error-free functionality for 100 % of the total duration of the test,
unless otherwise agreed by the Engineer. Major components include all master station
equipment, outstations, communications facilities and instrument panel components,
excluding push-buttons, switches and lamps and any equipment not supplied by the
Contractor.
During SAT, no modifications to the system shall be made by the Contractor without the
written approval of the Engineer. Erroneous functioning which requires software
modifications or re-configuration to correct, other than set-point or parameter changes,
shall constitute a failure of the availability test. Any changes to the system which are
required and approved shall be described in a system-modification document, signed by
both Contractor and Engineer and the document shall be incorporated into the final test
documentation. The test shall be restarted after corrections have been made.
25.16 Manufacturer's Works Acceptance Tests on Uninterruptible Power Supplies
The Contractor shall carry out further specified tests as follows in addition to any tests
stated or implied by the foregoing sections of this clause.
The tests shall be carried out on the fully assembled unit utilizing the batteries that are to
be supplied with the unit.
The Contractor shall demonstrate the following:
1) Change-over from full load with mains present to full load on battery supply
2) Carry out a discharge test on the system at full load and for the specified duty
bridging time period.
3) Carry out recharge test after operation for the specified duty bridging time at full load.
The UPS shall supply the full load during the recharge cycle.
25.17 Inspection at Site
During erection of the Plant the Engineer will inspect the installation from time to time in
the presence of the Contractor's Supervisor to establish conformity with the requirements
of the Specification. Any deviations found shall be corrected as instructed by the
Engineer.
25.18 Plant Protection on Site
Factory finished plant shall be adequately protected both before and during installation
against damage to finished surfaces, fitted components, and the ingress of dust. It may
be necessary for structural finishing operations to be carried out in the vicinity of installed
plant before it is taken over and the Contractor shall take this into consideration in
complying with the requirement of this clause.
25.19 Erection Staff

The Contractor shall provide at least two approved senior English speaking working
erectors to supervise the erection of all Plant in the Contract and in each case to act as
the Contractor's Representative as set out in Clause 13 of the general conditions of
contract.
In the case of a foreign firm based overseas the Contractor's Representative shall be
thoroughly conversant with the manufacturer's Plant and equipment, and its erection and
shall be an expatriate.
The Contractor shall also provide sufficient erectors skilled in electrical, mechanical and
instrument engineering, with such skilled, semi-skilled and unskilled labor as are
necessary to ensure completion of the various sections of the Contract in the time
required. The Contractor shall not remove any supervisory staff or labor from the site
without the prior approval of the Engineer.
The Engineer will give the Contractor at least one month's notice in writing of the date on
which the erection staff will be required on site, and the Contractor shall confirm the date
of arrival in writing to the Engineer. The Contractor shall make all the necessary
arrangements to ensure that sufficient plant has been or is about to be delivered to site,
so that there shall be no delay to the start of erection.
It shall be the responsibility of the contractor to obtain necessary License / Authorization/
Permit for work from the Licensing Boards of the Locality/State where the work is to be
carried out. The persons deputed by the Contractor’s firm should also hold valid permits
issued or recognized by the Licensing Board of the Locality/State where the work is to be
carried out.
25.20 Erection and Building-in
The installation work shall comply with the latest applicable Standards, Regulations,
Electricity Rules and Safety Codes of the locality where the installation is to be carried
out. Nothing in this specification shall be construed to relieve the Contractor of this
responsibility.
It will be the Contractor’s responsibility to obtain approval/clearance from local statutory
authorities including Electrical Inspector, wherever applicable for conducting of any work
or for installation carried out which comes under the purview of such authorities.
The Contractor shall carry out the complete erection of all plant, including the provision
of all necessary skilled and unskilled labor, material, transportation, supplies, power and
fuel, Contractor's Equipment and appurtenances necessary, for the complete and
satisfactory erection of the Plant.
The Contractor shall have a separate cleaning gang to clean all equipment under
erection and as well as the work area and the project site at regular intervals to the
satisfaction of the employer. In case the cleaning is not up to the employer’s satisfaction,
he will have the right to carry out the cleaning operations and any expenditure incurred
by the employer in this regard will be to the Contractor’s account.
Erectors
The Contractor's employees shall include skilled erection staff in sufficient number, who
shall arrive on the site on or before the respective dates set out in the approved work
programmed and prior to delivery of any item of Plant to the Site. The Engineer will not
entertain any claim by the Contractor in respect of delayed erection due to a delay in the
delivery of any items of Plant to the site.
Contractor's Equipment, materials and appurtenances
The Contractor shall have available on the Site sufficient suitable equipment and
machinery, as well as all other materials and appurtenances required by him, of ample

capacity to ensure the proper erection of Plant and to handle any emergencies such as
may normally be expected in work of this character.
The Contractor shall be responsible if any installation materials are lost or damaged
during installation. All damages and thefts of equipment/component parts, after takeover
by the Contractor, till the installation is taken over by Employer shall be made good by
the Contractor to the satisfaction of Engineer.
Workmanship
Plant shall be erected in a neat and workmanlike manner on the foundation and at the
locations and elevations shown on the approved drawings and other Engineering
documents. Unless otherwise directed by the Engineer the Contractor shall adhere
strictly to the aforesaid drawings and no departures there from will be permitted.
All plant shall be correctly aligned, leveled and adjusted for satisfactory operation and
shall be installed so that the proper and satisfactory connection can be made readily
between the various units and pipe work and equipment installed under the Contract.
The mounting arrangements for pump sets and blowers shall be such that the alignment
offset between motors and the driven equipment shall be well within 0.1 mm.
Building-in
Erection of Plant shall be phased in such a manner so as not to obstruct the work being
done by other contractors. Before commencing any erection work, the Contractor shall
check the dimensions of structures where the various items of plant are to be installed,
and shall bring any deviations from the required positions, lined or dimensions to the
notice of the Engineer and shall take such measures as are necessary for their
correction.
The Contractor shall take particular care for the correct positioning and alignment of all
puddle pipes which are required through concrete structures prior to, and during the
pouring of concrete. The Contractor shall pin and plug in the holes prepared, all small
clips, plugs, screws, nails, sleeves, inserts, etc., required for fixing electric wires and
conduits, small pipe work and all other apparatus.
The Contractor shall align all equipment and holding down bolts and shall inform the
Engineer before proceeding with grouting-in the item or item concerned. The Contractor
shall ensure that all equipment is securely held and remain in correct alignment before,
during and after grouting- in.
The Contractor shall properly bed in cement grout each item of plant or its supporting
base resting on foundations, and shall grout-in where required holding down bolts placed
in the holes prepared in the foundations. The materials and workmanship used in
grouting shall be such as will result in a solid anchoring of foundation bolts and complete
filling of the gaps between the Plant or its base and the foundations, without shrinkage or
cracking.
During erection of the Plant the Employer will inspect the installation from time to time in
the presence of the Contractor’s Site representative to establish conformity with the
requirements of the Specification. Any deviations and deficiencies found or evidence of
unsatisfactory workmanship shall be corrected as instructed by the Employer.
All plant shall be installed in accordance with the recommendations or instructions of the
manufacturer, for the particular application. Each mounting position shall be chosen to
give correct operation of the equipment, ease of operation, access for maintenance and
servicing and freedom from any condition which could have adverse affects.
Precautions
The approval by the Engineer of the Contractor's proposals for rigging and hoisting of

any item of plant into its final position shall not relieve the Contractor from his
responsibility for avoiding damage to completed structures, parts or members thereof or
other installed equipment. He shall at his own cost make good, repair or replace any
damaged or injured items whether structural, mechanical, electrical, architectural, or of
any other description, promptly and effectively to the satisfaction of the Engineer.
No plant or other loads shall be moved across the floors of structures without first
covering the floors with timber of sufficient size so that applied loads will be transferred
to floor beams and girders of steel or concrete. If it is required to reduce bending
stresses or deflection, the beam and girders shall be provided with temporary supports.
Any movement of Plant and other loads over the floor structures shall be subject to the
prior approval of the Engineer.
25.21 Civil Inspection (Water Leakage Test)
25.21.1 Tanks and Basins
Refer Volume 2A Clause 17.18.5 – Hydraulic Testing of Water Retaining Structures.
25.21.2 Field Control Inspection
Contractor shall be conduct periodic field control inspection to prevent any field accident.
The Engineer shall joint field inspect or conduct unannounced inspections.
25.21.3 Inspection after Erection
After the erection of any item of Plant and its associated equipment has been completed,
it shall be offered to the Engineer for inspection in its static state prior to commissioning
the item.
Completion of erection and procedure prior to setting to work.
The mechanical completion of plant under erection shall be deemed to occur if all the
units/systems of the Works are structurally and mechanically complete as noted below:
All rotary, static, structural equipment, piping, electrical/instrumentation and other
equipment under the scope of the Contract have been erected, installed and grouted and
are as per the specifications.
All systems have been washed/flushed/drained/boxed up where necessary.
All system testing including pressure, vacuum and nondestructive tests, no load tests
and such other tests are completed with safety valves/relief valves set to operating
conditions installed in position.
All panels, local control desks erected with power/control cable terminations with all
continuity checks, insulation checks and other installation checks are carried out.
Prior to pre-commissioning checks, the Contractor shall erect the entire Plant and ensure
readiness of civil works to the satisfaction of Employer, so that the Works are physically
ready to undergo pre- commissioning checks. Pre-commissioning checks will include
checks like no-load running of machinery, checks on instruments and electrical including
calibration and loop checks, functional checks, inter-lock checks etc.
At the stage of mechanical completion of erection, the Contractor shall ensure that all the
physical, aesthetic and workmanship aspects are totally complete and the Plant is fit and
sound to undergo pre- commissioning checks.
The following documentation shall be completed before the Contractor notifies

Mechanical
Completion of Erection to the Employer
a) All shop inspection records compiled and bound in 4 (four) copies.
b) All erection and commissioning procedures duly approved.
c) All instruction manuals in draft form - with each sheet bearing a stamp to indicate
"DRAFT FOR REVIEW ONLY" submitted in 4 (four) copies.
Upon achieving mechanical completion, the Contractor shall notify the Employer of such
completion of section/units/systems and readiness for inspection for acceptance of
mechanical completion of erection. The Employer/ Engineer shall proceed with
inspection of such sections/units/systems within 10 days of such notice.
Consequent to inspection, the Employer will inform the Contractor a list of deficiencies
for rectification and the Contractor shall complete the rectification work within a jointly
agreed period prior to start of pre- commissioning tests. The erection period allowed by
the Contractor shall include all activities of mechanical completion as noted above.
25.22 Site Acceptance Test Document
Twenty one (21) days prior to commencement of Tests on Completion the Contractor shall
supply a Site Acceptance Test (SAT) Document for approval. This shall comprise two copies
of the details of the inspection and test procedures to be carried out in testing the Works.
The SAT Plan shall provide comprehensive details of the tests to be carried out, the
purpose of each test, the equipment to be used in carrying out the test and the methods
to be adopted in carrying out the tests. The SAT shall provide space within the
documentation for results of the tests to be added and for each test and for the SAT as a
whole to be signed off by the Contractor and the Engineer.
The SAT shall categorise tests as follows:
a) Dry tests : Dry tests are those tests carried out without process fluid being present.
b) Wet tests which can be further sub-divided into
1) Hydraulic tests: Hydraulic wet tests are those tests carried out with potable water in
order to prove the hydraulic capability of the Works.
2) Process tests /System tests : Process wet tests are those tests carried out with raw
Sewage as the feed stock to prove the process capability of the Works.
The Contractor shall make his own arrangements for water supply, chemical, electric
power, fuel, instrument and labour during hydraulic wet tests.
It shall be assumed that the co-operation of other contractors in the carrying out of Tests
on Completion will not be unreasonably withheld.
25.23 Deleted
25.24 Dry Test Requirements
As a minimum requirement the following dry tests shall be carried out as a general
requirement:
1) A general inspection to check for correct assembly and quality of workmanship
2) A check on the presence of lubricant, cooling medium, electrolyte, etc.
3) A check on adequacy and security of Plant fixing arrangements.
4) A general check to ensure that all covers, access ladders, water proofing, guard
railings etc are in place.
5) A check on damp-proofing, rust-proofing and vermin-proofing and particularly the
sealing of apertures between building structures, chambers etc and the outside.

a) Civil and Building Works

As a minimum requirement the following dry tests shall be carried out on the civil
engineering and building works:
o Check for the presence of foreign bodies in pipe work and structures.
b) Mechanical Works
As a minimum requirement the following dry tests shall be carried out on the
mechanical systems:
o Carry out preliminary running checks as far is permitted by circumstances in
order to ensure smooth operation of Plant.
c) Electrical Works
As a minimum requirement the following dry tests shall be carried out on the
electrical systems:
o Check phasing and polarity.
o Carry out point to point check on all cables.
o Check on security of cable terminations.
o Check on completeness and adequacy of earthing systems.
o Check setting on protection relays, sizes of fuses and motor overload settings.
o Carry out checks on cabling systems in accordance with the requirements of
the relevant standards.
o Check operation of main circuit breakers by secondary injection methods.
o Check rotational direction of Plant.
o Check instrument loop integrity, functionality and calibration.
o Check operation of standby generator installation and mains / generator
changeover procedures; a 4 hour load test (using the normal load of the
Works) shall be carried out on the generator when the load is available.
o Check plant functionality.
o Check functionality of the central MMI and its power supply.
25.25 Process Plant Item / Equipment
All process plant items / equipment shall be tested to ensure they meet the Employer’s
Requirements for quality of workmanship, construction and performance.
25.26 Hydraulic Wet Test Requirements
Hydraulic wet tests shall be carried out on completion of dry tests.
Clear Water shall be used for hydraulic wet tests. The purpose of the tests is to prove the
hydraulic performance of the Works. In order to demonstrate this, the Contractor shall
ensure that each part of the Works is hydraulically loaded to its rated throughput for a
period of at least four hours.
In order to ensure a sufficient supply of water to carry out these tests the Contractor shall
provide all required facilities, including but not limited to any temporary facilities that may
be required for storage and recycle of Clear Water or facilities for the disposal of the
water off Site in an approved manner.
The following tests inter alia shall be carried out:
1) Pressure testing of all piped systems laid direct in ground in accordance with the
relevant standards.
2) Fill all structures and check for leaks.
3) Filling of all storage vessels to check for leaks and distortion.

4) Running of all pumped systems in order to check for.

o Correct functionality.
o Absence of leaks.
o Correct running temperatures.
o Smoothness of running and the absence of undue vibration or stress.
o Check drive running currents.
5) Carry out calibration of instruments where appropriate.
6) Carry out valve operation, diversions etc. to fully hydraulically load each process
element (or where there is a requirement to withstand an over load), overload each
process element.
7) Demonstrate correct functionality of electrical, control and instrumentation systems.
The Contractor shall simulate the conditions that will prevail when operating as a process
in order to demonstrate the correct functionality of process control loops etc.
During these tests a check on the performance of Plant shall be made to compare its site
performance with the factory test data and to identify any constraints on performance
due to site conditions.
25.27 Safety Audit
After satisfactory completion of hydraulic wet tests and prior to introduction of process
fluid to the plant a safety audit shall be carried out to ensure compliance with the
necessary requirement for safety and for operation of Plant. The safety audit shall be
documented. The safety audit document shall be approved by the Engineer prior to
commencement of Plant commissioning.
25.28 Process Wet Tests (with Raw Sewage)
On approval by the Engineer the Contractor shall carry out process wet tests.
Raw Sewage shall be used as the main feed stock for process wet tests. These tests
shall be carried out to demonstrate the process performance of the Works. In order to
demonstrate this, the Contractor shall ensure that each part of the Works is loaded to its
rated throughput (including a period of overload if required in order to demonstrate
compliance with the Employer’s Requirements) for a continuous stable operating period
of not less than 48 hours. If necessary, Contractor shall create design loading conditions
for testing purposes by testing fewer than the total number of installed units of process
tanks or equipment at a time. In such cases, multiple tests shall be conducted to ensure
that all installed units are tested.
The Contractor shall provide all required facilities for the disposal off Site in an approved
manner.
The following tests inter alia shall be carried out:
1) Check for leaks on vessels, structures, pumps and pipe work.
2) Running of all pumped systems in order to check for.
o Correct functionality.
o Absence of leaks.
o Correct running temperatures.
o Smoothness of running and the absence of undue vibration or stress.
o Check drive running currents where the solution pumped is different from that
pumped during hydraulic wet tests.
3) Carry out calibration of instruments.
4) Carry out valve operation, diversions etc. to fully hydraulically load each process
element (or where there is a requirement to withstand an over load), overload each

process element.
5) Demonstrate correct functionality of electrical, control and instrumentation systems
not checked during dry or hydraulic wet tests or which may have changed as a result
of the different operating conditions now prevailing.
On completion of the tests on the various parts of the works the Contractor shall run the
plant as a whole in order to demonstrate the full functionality and performance of the
Works at various throughput rates for a continuous period of not less than 30 days.
During the various process tests the Contractor shall perform sampling and analysis of
all the process streams (locations) and parameters listed in the “Sampling/Analysis
Locations and Frequencies” table provided in the “Tests after Completion” Section below.
The frequencies listed in this table shall be followed for the Tests After Completion.
However, for the Process Wet Tests performed as part of the Tests On Completion, the
sampling frequency for all locations and all parameters shall not be less than once every
hour. The Contractor shall demonstrate to the Engineer that the Works is functioning in
accordance with the Employer’s Requirements. Each sample shall comprise two 1 litre
(minimum) quantities and shall be labelled to identify the contents, where taken and time
and date. The flow recorded at the time of sampling shall also be indicated in the log
book or record. One sample shall be used by the Contractor for his analysis; the other
shall be handed over to the Engineer.
The Engineer reserves the right to take additional samples and to carry out his own tests
or to check the samples taken by the Contractor.
The Engineer shall be given reasonable access to the premises where analysis is taking
place in order to check on working practices and the procedures being adopted.
25.29 Effluent Quality Criteria for Passing the Tests On Completion
The Works shall be considered to have achieved the required effluent quality standards
for passing Tests On Completion if all samples taken during a 30 day continuous
operational period comply with the criteria set down for passing the Tests After
Completion. This includes criteria relating to the reliability of the plant.
The Effluent quality Tests On Completion shall not be commenced until all tests
associated with the civil/building, electrical and mechanical works and individual process
tests have been completed to the satisfaction of the Engineer.
25.30 Co-operation with other Contractors in the Execution of their Tests
The Contractor shall, where required, assist other contractors in carrying out their tests
on completion and or tests after completion.
Where this assistance does not constitute part of the Contractors own work associated
with Tests on Completion or Tests after Completion the Contractor shall be reimbursed
at the rates approved by the Engineer.
25.31 Tests after Completion
General
On successful completion of “Test on Completion” the Contractor shall carry out over a
period of time not exceeding six months two separate 30 days operational tests. These
tests shall be used to prove the operation of the Works at varying flows and with varying
raw Sewage quality. During these tests Effluent produced by the Works will be entering
the disposal system. These tests after completion shall be undertaken in accordance
with Clause 11 of the General Conditions of Contract.
The timing of the tests shall be determined by the Employer who shall give notice to the
Contractor in accordance with Sub-clause 11.1 of the General Conditions of Contract.
The total time for carrying out the tests shall not be less than six calendar months. One

of the tests for each part shall be carried out in a period of high raw Sewage BOD and
suspended solids.
On commencement of each 30-Days test the Employer shall allocate a continuous
period of not greater than 60 days to complete the test. Any failure to perform during the
60 days period shall restart the ‘30 day clock’. If the part of the Works fails to pass the
test in the 60 days period the test shall be deemed as a failure and the Contractor shall
carry out any necessary remedial work to the satisfaction of the Engineer before the
Contractor restarts the test.
During the tests the Contractor shall take samples to demonstrate that the part of the
Works is performing in accordance with the Employer’s Requirements. The procedure for
taking the samples shall follow the pattern adopted for Test on Completion. Samples
shall be taken at locations and intervals detailed below. The results of the Tests after
Completion shall be compared and evaluated by the Employer and Contractor.
The Contractor will not be held responsible for interruptions to the sewage treatment
process as a result of Grid power failures (unless as a result of a Plant failure)
interruptions in the raw Sewage supply etc. which are out of his control. However, the
Contractor shall be required to demonstrate that the Works can cope with these
inevitable interruptions in an orderly fashion and recover to a normal operational state
with the minimum of manual intervention.
All consumables needed for operation of the Works shall be provided by the Contractor.
The Contractor shall provide all facilities and equipment not supplied under the contract
and which are deemed necessary for the Contractor to carry out and monitor the Tests
after Completion.
Sampling and Analysis
Sampling and analysis shall be performed to measure the parameters indicated in the
table below, at the locations and frequencies indicated in the table. In case of multiple
units (such as multiple aeration basins or clarifiers), the indicated sampling and analyses
shall be performed for each individual module.
Table 25.1 - Sampling/Analysis Locations and Frequencies
Sample Location and Parameters Sampling

Frequency
to be Measured Method
Plant Effluent:
Flow-weighted 24-
All parameters specified under the Appendix “B”, Daily
hour composite
Table B1.2 of Volume 2.
Dewatered Sludge: Composite of

samples from each
All parameters specified under the “Dewatered Daily
container or vehicle
Sludge Quality Requirements” , Appendix “ B” filled during the day
Raw Sewage Influent, Plant Effluent, Primary
Continuous
Sludge, MLR, RAS, WAS, Thickened Sludge,
Continuous instantaneous flow
Digester Effluent, Dewatering Influent, Plant
from recorder
Recycles: Flow
Raw Sewage Influent, Primary Effluent, and
Flow-weighted
Secondary Effluent: Daily
24-hour composite
TSS, VSS, Temperature, pH

Sample Location and Parameters Sampling

Frequency
to be Measured Method
Raw Sewage Influent, Primary Effluent, and
Secondary Effluent: 3 times per Flow-weighted
BOD, COD, TKN, Ammonia-N, Nitrite-N, Nitrate-N, week 24-hour composite
Alkalinity, Total Phosphorus, Soluble Phosphorus
Aeration Basins: MLSS, MLVSS, Temperature, SVI Daily Grab
Aeration Basin Zone Profiles (Anaerobic, Anoxic,
Aerobic): 3 times per
Grab
Ammonia-N, Nitrite-N, Nitrate-N, pH, Soluble week
Phosphorus, VFAs, RBCOD
PSL, RAS, WAS, Thickened Sludge, Digested
Daily Grab
Sludge, Dewatered Sludge: TSS, VSS
Anaerobic Digesters;
Sludge temperature, sludge concentration, sludge
VSS destruction, sludge pH, alkalinity, VFA Daily Grab
concentration, gas production volume, gas
pressure, gas methane content, gas hydrogen
sulphide content, gas humidity,
Biogas Scrubber:
Hydrogen sulphide concentration at inlet and Daily Grab
outlet, chemical consumption
Biogas engine: (wherever applicable)
Feeding biogas component, Gas moisture, Gas Daily Grab
temperature, Exhaust gas etc. Inlet and exhaust
gas flow, composition, temperature, and pressure
Chemicals/Scum/Screenings/Grit:
3 times per
Specific weight, volume, weight, Chemical Grab
week
consumption
All costs associated with the taking and analysis of samples shall be met by the
Contractor.
The analysis shall be carried out by certified laboratory approved by the Engineer, and
shall be performed in strict compliance with appropriate analytical methods published in
Indian Standards, or in “Standard Methods for the Examination of Water and Wastewater”
published by the American Public Health Association, or as published by the US
Environmental Protection Agency. The Contractor shall submit to the Engineer a
comprehensive report of the above sampling and analysis, including details of each
analytical test as well as a summary of all the data and results in a Microsoft Excel
spreadsheet.
Criteria for Passing the Test After Completion
1) Treated Effluent and Dewatered Sludge Quality Criteria
i) at least 95 %ile of the plant effluent samples described above meet the
requirements specified under the
a) Performance Requirement for the Plant (effluent for disposal) Appendix B,

Table B1.2 of Volume 2.

ii) at least 95 %ile of the dewatered sludge samples described above meet the
requirements specified under the performance Tests Concerning Dewatering of
Sludge, Appendix B, Table B 1.5 of Volume 2.
2) Operational Cost Criteria
The plants shall have fulfilled the operating cost criteria if the operating costs
determined during the Tests After Completion are in agreement with or less than
those detailed in the Contractor’s Functional Guarantee or an amount of liquidated
damages are agreed by the Contractor and the Engineer to compensate for any short
fall in performance up to an agreed maximum amount if stated.
3) Plant Reliability Criteria
A part of the Works shall be deemed to have failed its test if:
1) A single item of Plant / equipment fails more than twice during the test.
2) More than four individual Plant items / equipment fail.
An item of Plant / equipment shall be deemed to have failed if manual intervention is
required in order to restore the Plant / equipment to its fully operational state: i.e. the
failure of a duty drive will be considered as one failure, if the standby drive fails to start
that will be considered as a second failure.
25.32 Performance Certificate
The conditions for issuance of a Performance Certificate as detailed in Clause 12 of the
Conditions of Contract shall inter alia comprise:
a) The completion of the six months operation of the Works (Tests after Completion) to
the satisfaction of the Engineer.
b) The O & M Manuals have been updated following one year’s operational experience
and approved by the Engineer.
c) All defects identified prior to Taking Over and defects identified during one year
operation of the Works have been rectified.
d) All Tests “After Completion” have been completed to the satisfaction of the Engineer.
e) All training detailed in the Employer’s Requirements has been completed.

APPENDIX A

APPENDIX A – DESIGN STAGE CONTRACTOR’S DOCUMENTS
The following are typical minimum design stage details that shall be submitted as part
of the Contractor’s Documents.
A1 Civil
A.1.1 General
• Site layouts providing information on levels and detailing the location of:
o Buildings
o Storage tanks
o Process plant
o Roadways
o Drainage
o Buried pipelines
o Cable routes for direct in ground and ducted systems;
• Plans, elevations and main sections of all structures and buildings
• General arrangements and main sections of all facility areas
• Drainage provisions
• General arrangement drawings showing the location of each plant item
• Detail drawings of:
o Cable and pipe work chambers
o Buried pipe work
o Pipe work connections
o Contract interfaces
• Reinforcement drawings
• Bar bending schedules;
• Calculations for:
o Structural
o Civil design
o Earthworks and foundation design
A2 Process
• Drawings:
• Process flow and mass balance diagrams
• Comprehensive P&IDs including details of:
o Pipeline sizes and materials valve size and type
o Instrumentation
o Identification of controlling PLC
• Calculations for Process and mass balance
• Pumping hydraulic calculations (including surge analyses if appropriate)
o Plant hydraulic flows
o Chemical process
o Sludge process flows
o Bypass process flows
o Plant water recovery
• Dynamic simulation of process modelling using biowin®
• Dynamic simulation hydraulic modelling with CFD

• Plant draining system

• Plant Water System
• Potable Water System
• Odour Control modelling and designs
• Noise Control modelling and designs
• HAZOP and CHAZOP
• Electrical drawings:
o Motor Curves
o Power system single line drawing for the treatment facility
o Single line and schematic drawing (see note 1) for each switchboard and mcc
o Internal and external (see note 2) general arrangement for each switchboard and
mcc
o Transformer schematic and general arrangement drawings
o Standby generator schematic and general arrangement drawings
o Cable block diagrams
o Cable connection diagrams (or schedules)
o Cable routing / installation drawings
o Foundation and fixing details drawings
o Earthing system general arrangement drawings
• Electrical schedules cable schedules
o Load and power consumption schedule junction box schedule
o Protection relay setting schedule
• Electrical calculations for:
o Cable sizing fault level
o Co-ordinated protection study standby generator sizing
• Documentation:
o Functional design specification (FDS)
o Factory acceptance test document (FAT)
o Site acceptance document (SAT)
A3 Electrical Building Services
• Drawings:
o Single line schematic for each distribution and sub-distribution board
o General arrangement drawings showing the location of each luminaire, socket
outlet, fan etc, including details of mounting height
o Fixing details
• Schedule:
o Luminaire data sheets socket outlets data sheets
o Fans data sheets
o Cable sizing lighting levels
A4 Control And Instrumentation
• Drawings:
o Power supply distribution single line and schematic diagrams (see note 1) for
each control panel
o Internal and external (see note 2) general arrangement for each control panel
(dimensional)

o Control and instrumentation loop drawings (see note 3)

o Instrument installation detail drawing (hook up, see note 4)
o Cable block diagrams
o Cable routing / installation drawings
o Foundation and fixing details and trench drawings
o Mimic general arrangement
• Schedules:
o Cable schedule
o Cable interconnection schedule
o Control and instrumentation load schedule for each control panel
o I/o schedule
o Junction box schedule instrument schedule
o Instrumentation, process control set point schedule instrument data sheets
• Documentation:
o Functional design specification (FDS)
o Factory acceptance test document (FAT)
o Site acceptance test document (SAT)
Notes:
1. Schematic drawings shall include a comprehensive schedule of the components
used in each switchboard, MCC and control panel, including details of the type,
manufacturer and rating of each component.
2. The external arrangement of each switchboard, MCC and control panel shall show
the arrangement of all components, including details of panel section, switch and
instrument labels.
3. Control and instrumentation loop drawings shall show on a single drawing the
complete circuit associated with an instrument or device including details and
location of power supplies, cabling and terminations.
4. Hook up drawings shall detail how an instrument or device is installed. Electrical
control schematics, loop diagrams and schedules shall, where practical, be A3 size
drawings, all other drawings shall be A1 size.
A5 Mechanical
• Drawings:
o General arrangement of plant, pipe work and ducting, including sections
o Isometric views of pipe work and ducting systems
o Detail drawings of proprietary and fabricated plant items.
• Schedules:
o Pump curves
o Plant performance details
o Pipeline schedules
o Valve schedules
o Pumps pipelines
• Data sheets and reports
A6 Mechanical Building Services
• Drawings:

o
Single line schematics for hot and cold water system and drainage systems
o
General drawings showing the location of each mechanical building service plant
item fixing details
• Schedule:
o Plant data sheets pipeline schedules
o Valve schedules
o System sizing
A7 DESIGN SUBMISSION – ASSESSMENTS PROCEDURES
The Contractor’ design submissions will be assessed by Employer’s representative

within 28 days from the day of submission. The Form and detail of assessment shall be
as determined by the Employer’s representative and according approval to a submission
will not release or remove the Contractor’s responsibility for the design under the
Contract. The submission will return along with comment resolution sheet (CRS) for the
obtaining a notice to proceed from the Employer. The submission will be Coded A or B or
C or D or E, whose meaning is listed as below;
i. Code ‘A’ - Approved
ii. Code ’B’ – Approved with Comments. Work may proceed subject to incorporation of
comments
iii. Code ‘C’ – Objected. Revise and resubmit. Work may not proceed.
iv. Code ‘D’ – Rejected.
v. Code ‘E’ – Review not required. Work may proceed
(1) The issue of an approval shall be without prejudice to the issue of any future Notices.
(2) The contractor shall, prior to the submission of design Data, obtain all required
statutory approvals that related that submission including, where appropriate, the
approval of the concern Government Authorities and utilities undertaking, and
demonstrate that all required approval have been obtained.

APPENDIX B

APPENDIX B – PERFORMANCE REQUIREMENTS
Appendix B1 Wastewater treatment facility Design Loads
Appendix B2 Performance tests during the Plant Proving Period
Appendix B3 Monitoring, sampling and analysis frequency during Operation Service Period

APPENDIX B1 – DESIGN FLOWS AND LOADS
Table B1.1 – Influent Parameters
Design Parameter Units Design flows and Loads Remarks

Average Dry Weather m3/d 240000
Flow (ADWF)
This shall be derived from the To be designed for Relevant
data of flows of WwTF as in Flows and checked Hydraulic
Maximum Daily Flow m3/d
Tender volume 5 : Background Loading in consonant with
information Employer’s Requirement
Pass Forward
Flow (PFF)-
Maximum m3/hr 22500
Instantaneous
Flow rate
Ambient Temperature Min. 100C
Max. 380C
*Note: PFF of total plant capacity shall be equally distributed in all modules.
Table B1.1a –Minimum Design Load Parameters
Parameters Unit Range Remarks

Biochemical Oxygen Demand
kg/d 60000
(BOD)
Chemical Oxygen Demand
kg/d 120000
(COD)
Ammonia-Nitrogen (NH3-N) kg/d 7800
Total Suspended Solids

kg/d 96000
(TSS)
Oil & Grease( O & G) kg/d 12000
For evaluation
Min. 100C purpose only.
Ambient Temperature
Max. 380C
Volatile Suspended Solids May vary 60% - 70% of TSS
May vary 0 – 1150mg/L
Chloride (and may vary ± 200mg/l in
one hour)
Sulphate kg/d 24000
pH 6.5-8.3
MPN/10
Faecal Coliform 105 - 106
0ml
NOTE:
1. The plant design should be robust enough to handle the Sewage flows as per Table B1.1
above.
2. The plant design should be robust enough to handle loads as per actual and should meet
effluent quality as per Table B1.2 of Volume 2.

3 Other parameters not specifically mentioned in above tables shall be as per CPHEEO manual
4. Table B1.1 (a) above indicates minimum loads for designing the plant.
Effluent Parameters
Table B1.2 – Treated Wastewater Quality (for Disposal )
S.No Parameters Unit Value

1 pH 5.5 - 9.0
2 BOD mg/L 10
3 COD mg/L 50
Total Suspended
4 mg/L 20
Solids (TSS)
5 Total Nitrogen (N) mg/L 10
6 Total Phosphorus mg/L 1
7 Fecal Coliform (MPN/100mL) <100
Table B1.3 – Treated Water Quality of effluent from Lagoon during construction
of WwTF in one stream of Lagoon (for disposal)
S.No Parameter Unit Value
1 pH 6.5 - 9.0
2 O
BOD5 (3 days at 27 C) mg/L ˂50
3 Suspended Solids mg/L ˂50
As per MPCB consent order number : BO/JD (WPC)/CC/ 1703001394 dated: 21/03/2017
Table B1.4 Tertiary treated effluent standards (for reuse)
Parameter Unit Limits
pH 6.5 – 8.3
BOD5 at 20OC mg/L 10
COD mg/L 50

mg/L 5
(TSS)
Turbidity NTU 2

Total Nitrogen (TN) mg/L 10
Total Phousphorus mg/L 1
(MPN/100
Faecal Coliform BDL
ml)
Residual chlorine mg/L >1

Note: Above parameters shall be complied as 95%ile criteria specified in performance
requirements
Table B1.5: Treated sludge quality requirements

Parameter Criteria Compliance
Criteria
Salmonella < 3 MPN / 4 g Total Continuously less
Dry Solids than the standard
Fecal Coliforms < 1000 MPN/g of total
dry solids
Enteric Viruses < 1 PFU / 4 g Total
Solids
Viable Helminth < 1 / 4 g Total Solids
Ova
Minimum dry solids 25% Dry Solids Greater than the
concentration criteria
Reliability ≤4% Less than/ equal

(downtime) to the criteria

Table B1.6 - Lookup table for 95%ile compliance
Number of Samples per period Allowable No. of exceedances per period
4-7 1
8-16 2
17-28 3
29-40 4
41-53 5
54-67 6
68-81 7
82-95 8
96-110 9
111-125 10
126-140 11
141-155 12
156-171 13
172-187 14
188-203 15
204-219 16
230-235 17
236-251 18
252-268 19
269-284 20
285-300 21
301-317 22
318-334 23
335-350 24
351-365 25

APPENDIX B2 – PERFORMANCE TESTS DURING PLANT PROVING

PERIOD
During the Plant Proving Period it is likely that the flows and loads will be less than the
maximum values. In order to replicate the loading conditions that would be experienced at
maximum plant capacity the plant shall be configured to achieve these conditions. This is likely
to include the plant to be operated with only some lanes or units receiving flow. The exact
configuration is to be agreed with the Employer prior to testing.
During the Plant Proving Period daily samples of Influent and Effluent shall be taken in
accordance with the following requirements:
1. Samples shall be 24 hour composite flow proportional samples taken using an automatic
sampler and kept in a refrigerated enclosure.
2. Samples of Influent shall be taken from sample point 1 as shown in Appendix B3.
3. Samples of Effluent shall be taken from sample point 3 as shown in Appendix B3.
4. The sampling method for Influent shall aim to exclude debris, floating grease and grit from
the sample.
The daily Influent and Effluent samples shall be analyzed for the parameters shown in table
B2.1. Analysis of sewage and treated effluent shall be commenced as soon as possible and in
any case within a maximum of 24 hours from the end of the sampling period, and completed
without delay.
Influent and Effluent shall also be continuously monitored for the parameters indicated in table B2.2
Available Data shall be collected by the SCADA system and shall be capable of being
transferred to office personal computer (PC) networks via Windows Direct Data Exchange
(DDE), or other equal database exchange software. The data shall be in a format which permits
it to be automatically uploaded into Microsoft Access or Excel tables, and other proprietary
software packages, to permit data graphing and analysis.

Table B2.1 – Suite of analyses and measurement for Influent and Effluent
Effluent
Effluent (After
S.No Parameter Unit Influent (After
Tertiary)
Secondary)
Biological Oxygen Demand
1 mg/L X X X
(BOD5)
Chemical Oxygen Demand
2 mg/L X X X
(COD)
3 mg/L X X X
(TSS)
4 Turbidity NTU - X X
Total Kjeldahl Nitrogen
5 mg/L X X X
(TKN)
6 Total Nitrogen (TN) mg/L X X X
7 NH4-N mg/L X X X
8 Phosphorus mg/L X X X
9 Sulphate (SO4) mg/L X X X
10 Alkalinity (as CaCO3) mg/L X X X
Total Dissolved Solids
11 mg/L X X X
(TDS)
12 Fecal Coliform (MPN/100mL) X X X
13 Residual Chlorine mg/L X
Note: all other parameters as mentioned in the General Standards for Discharge of Environmental
Pollutants, Part A: Effluent as per Schedule VI of the Environmental Protection Rules 1986, shall be
analysed.
Table B2.2 Parameter Unit Influent Effluent Effluent

– (After (After Tertiary
Parameters Secondary Treatment)
for which Treatment)
continuous
monitoring
and
recording
is S.No
1 Temperature °C X X X
2 pH N/A X X X
3 Conductivity μS.cm-1 X - -
4 Flow rate m3/h X X X
5 Dissolved Oxygen mg/L X X -

Table B2.3(a) – Performance during plant proving period (Effluent for Disposal)
Parameter Treated Sewage Performance Criteria

In every consecutive 30 days, allowable exceedance of maximum 15
BOD
mg/l.
COD
mg/l.
Total Suspended In every consecutive 30 days, allowable exceedance of maximum 30
Solids (TSS) mg/l.
Total Nitrogen (N)
mg/l.
In every consecutive 30 days, allowable exceedance of maximum 1.5
Total Phosphorus
mg/l.
In every consecutive 30 days, allowable exceedance maximum 150
Fecal Coliform
MPN/100ml.
Table B2.3(b) Performance during plant proving period (Effluent for re-use)
Parameter Treated Sewage Performance Criteria
BOD No more than one value in every consecutive 30 days shall be greater
than 15 mg/L.
COD No more than one value in every consecutive 30 days shall be greater
than 75 mg/L.
Turbidity No more than one value in every consecutive 30 days shall be greater
than 3 NTU.
Total Nitrogen No more than one value in every consecutive 30 days shall be greater
(TN) than 15 mg/L.
Total No more than one value in every consecutive 30 days shall be greater
Phosphorous than 1.5 mg/L.
Residual No more than one value in every consecutive 30 days shall be less than
Chlorine 0.75 mg/L.
Faecal No more than one value in every consecutive 30 days shall be greater
Coliform- than 14 MPN/100 ml.
Instantaneous
Table B2.4 – Performance tests concerning sewage screening and screenings

handling
Test background and

Parameter Performance criteria
procedure

Test background and

procedure
Dry solids content in the Not more than one spot sample There will be no formal
washed and dewatered of screenings taken over seven sampling programme.
screenings consecutive days shall have the Measurements may be made
dry solids content lower than the at the request of the
designed value Employer’s Representative.
Organics content in the Not more than one spot sample There will be no formal
washed and dewatered of screenings taken over seven sampling programme.
screenings consecutive days shall have the Measurements may be made
concentration of organic solids at the request of the
content higher than the specified Employer’s Representative.
performance standard.
Screenings removal There shall be minimal carryover The carry over shall be
efficiency and quality of screenings during the test assessed visually at random
period. The screenings shall be by the Employer’s
sufficiently clean at all times for Representative.
disposal at the Designated
Landfill Site.
Continuous operation and The downtime of any unit over The Contractor shall keep an
reliability of screens, the test period shall not be operation and maintenance
washing and dewatering greater than 4%. log for each unit.
plant.

Table B2.5 – Performance Tests Concerning Grit Separation and Handling
Test background and

procedure
Removal of grit from Grit removal shall be sufficient The Contractor shall report any
sewage to prevent blockages and blockages and grit
significant amounts of grit accumulations.
accumulating in pipes and
treatment units.
Dry solids content in the Not more than one spot sample
washed and dewatered of grit taken daily over any 7
grit consecutive days shall have a
value lower than the specified The quality of grit shall be
performance standard. assessed visually at random by
the Employer’s Representative,
Organic content of Not more than 10% of dry measurements may be made
washed and dewatered/ solids in any one spot sample at the request of the
classified grit of grit taken daily over any 7 Employer’s Representative.
consecutive days shall be of
organic nature.
reliability of grit the test period shall not be operation and maintenance log
separators and grit greater than 4%. for each unit.
classifiers.
Table B2.6 – Performance Tests Concerning Primary Settlement
Test Background and

Procedure
The scum removal system The system shall be The Contractor shall observe
effective. visually, and report daily
Continuous operation and The downtime of any unit The Contractor shall keep an
reliability of the primary over the test period shall not operation and maintenance
settlement units (including be greater than 2%. log for each unit.
de-sludging plant).

Table B2.7 – Performance Tests concerning Biological Treatment
Test background and

Parameter Performance Criteria
procedure
Aeration system shall be capable
It may be necessary to
of producing continuously (for
disable the automatic DO
continuous systems) during the
Aeration System control system to assess the
operation the dissolved oxygen
Capacity compliance with this
concentration required by the
requirement during the test
design in any location of the
period.
aeration tanks.
Continuous operation
The downtime of any unit over the The Contractor shall keep an
and reliability of aeration
test period shall not be greater operation and maintenance
blowers, mixers, valves
than 2%. log for each unit.
and distribution system.
Table B2.8 – Performance Tests concerning Final Settlement System
Test background and

procedure
Capacity of return Minimum and maximum capacity 1. The capacity is to be
activated sludge system shall be as the values specified demonstrated on one
in the Contract. occasion over a short
period during the tests.
2. It may be necessary to
disable the automatic
control system to assess
the compliance with this
requirement during the
test period.
reliability of the the test period shall not be operation and maintenance
secondary settlement greater than 2%. log for each unit.
units (including scraper
systems and desludging
plant).
The scum removal The system shall be effective. The Contractor shall observe
system visually, and report daily.

Table B2.9 – Performance Tests Concerning Thickening of Sludge (Primary and

Secondary)
Test Background and
Procedure
Dry-solids The average DS content over the 1. The Contractor shall take
(DS)concentration of entire test period shall not be daily samples (one
thickened sludges less than the specified values. composite comprising 3
sub-samples collected
over one hour) of the
thickened sludges and
measure DS content.
2. Sampling and analysis
shall be in accordance
with Section 17.
Solids recovery by the Solids recovery over any 1. Samples of sludge liquor
secondary sludge consecutive 14 days shall be from the thickening plant
thickening system greater than the specified value. shall be taken daily over
any 14 consecutive days.
2. On each sampling day,
three sub-samples of
liquor of an equal volume
shall be collected
manually (simultaneously
with the thickened sludge
sub-samples) and
combined into one
sample which shall be
analysed for DS and SS
concentration.
3. Alternatively, solids
recovery may be
estimated based on the
DS content in the feed
and in the thickened
sludge.
reliability of thickening the test period shall not be operation and maintenance
units greater than 4%. log for each unit.

Table B2.10 – Performance Tests Concerning Dewatering of Sludge
Test Background and

Procedure
Dry-solids concentration The daily DS content over the 1. During the performance
of dewatered sludges entire test period shall not be test, the Contractor shall
less than the specified take daily samples (one
performance standard. composite comprising 3
sub-samples collected
over one hour) of the
dewatered sludges.
2. Sampling and analysis
shall be in accordance
with Section 17.
Dry-solids concentration Solids recovery over any 1. Samples of sludge liquor
of dewatered sludges consecutive 14 days shall be from the thickening plant
greater than the specified value. shall be taken daily over
any 14 consecutive days.
2. On each sampling day,
three sub-samples of
liquor with an equal
volume shall be collected
manually (simultaneously
with the sludge cake sub-
samples) and combined
into one composite
sample which shall be
analysed for DS and SS
concentration.
3. Alternatively, solids
recovery may be
estimated based on the
DS content in the feed
and in the sludge cake.
reliability of dewatering the test period shall not be operation and maintenance
units, including pumping, greater than 4%. log for each unit.
polymer, and washing
systems.

Table B2.11 – Performance Tests Concerning Digestion of Sludge
Parameter Performance Criteria Test Background and

Procedure
Temperature of the The average set point Temperature in the digesters
sludge in the digesters temperature of the sludge in the shall be continuously recorded.
digesters shall be between 18°C The temperature shall be
to 40°C, but not be outside the measured at a minimum of two
set point by a range of 2.0°C positions in each digester.
on any day during the test
period.
Minimum retention time The sludge retention time shall The Contractor shall record the
in the digesters be as per CPHEEO daily flow of the sludge to the
digesters in order to estimate the
retention time.
Continuous operation The downtime of any unit over The Contractor shall keep an
and reliability of the the test period shall not be operation and maintenance log
digestion plant greater than 4%. for each unit.

Table B2.12 – Performance Tests Concerning Sludge Generally
Test Background and

Procedure
Consumption of poly- For each particular sludge 1. On at least three
electrolyte treatment process occasions during the
(thickening/ dewatering) performance tests,
requiring addition of agreed with the
polyelectrolytes (or Employer’s
polymers), the consumption Representative, the
of polyelectrolyte shall not be Contractor shall measure
greater than the stated value consumption of
expressed in gram of solid polyelectrolyte for each
polyelectrolyte per kg of particular sludge
sludge dry solids. treatment process over a
minimum period of two
hours.
2. On each occasion, a two
hour test shall be
conducted. During the
test the amount of
polyelectrolyte used shall
be measured.
3. The volume of the sludge
feed to the process
during the test shall be
measured.
4. The samples of the
sludge feed to the
particular sludge process
unit shall be taken at
minimum 20 minutes
intervals during the test.
The samples shall be
analysed for dry solids
and the mean value shall
be used for assessment
of dry solids load during
the test.
5. The Contractor shall
provide a detailed test
procedure for Employer’s
Representative’s
approval.
Sludge storage at design load
Blended Primary sludge + The Contractor shall
thickened WAS sludge – all demonstrate the available
for Sludge Pre -Treatment or storage.
for Digester Feed: 12 hours
Digested sludge: 12 hours
Dewatered sludge: 12 hours

Table B2.14 – Performance Tests concerning the Whole WwTF
Test Background and

Procedure
Pass Forward Flow for preliminary 1. Flows shall be measured

treatment. continuously during the
Minimum hydraulic test period.
capacity of the Diurnal PFF plus the return and/or 2. Compliance shall be
Works: recycle flows which would normally be demonstrated to the
applied to the unit under test for Employer’s
primary, biological and further Representative.
treatment.
Table B2.15 – Performance Tests Concerning Noise
Test background and

procedure
The noise level of The noise level 1m in a 1. Noise levels shall be
equipment perpendicular direction from any measured by the
point on any item of equipment Contractor using a
or the shell of a building or suitable hand held
enclosure shall be continuously instrument.
less than 80dBA. 2. Noise measurement shall
be carried out to ISO
Recommendations R1996
& 1996/1, 2 and 3 as
appropriate.
Noise levels at Site Noise levels from the Works
boundary between shall be continuously less than
22:00hrs and 06:00hrs 45dBA (15 min Leq) at the Site
boundary.
Noise levels at Site Noise levels from the Works
boundary between shall be continuously less than
06:00hrs and 22:00hrs 55dBA (15 min Leq) at the Site
boundary.
Noise levels in rooms The noise level in rooms subject
between 00:00hrs and to regular occupation such as
24:00hrs Admin rooms, PLC/SCADA
rooms, laboratory and mess
rooms shall be not more than 55
dB(A)
Note:
On the completion of the Works the contractor shall demonstrate that the constructed plant
meets the required noise limits as detailed. Items of plant that exceed the noise limits specified
shall be replaced or modified, to meet the necessary limits, at the Contractors own expense

APPENDIX B3 – MONITORING, SAMPLING AND ANALYSIS
Figure B3.1 Treatment Facility - Location of Measurement and Sampling Points
Note : Exact locations of measurement points may vary if process design differs from generic arrangement above. Locations to be confirmed
following confirmation of process design.
Volume II Page 283 Employer’s Requirement

Table B3.1a – Minimum monitoring, sampling and analysis during normal operation
Thickener: Primary Sludge Thickener: Secondary Sludge Sludge Pre-Treatment Digesters Combined
Settled Mixed
Parameter Influent Feed Thickened RAS Feed Thickened Return
Sewage Liquor Liquor Liquor Feed Contents Liquor Feed Contents Liquor Biogas
(WAS) Sludge (WAS) Sludge Liquors
Measuring Point 1 2 17 4 7 13A 5 6 8 13B 9 10 11 22 13D

Type of sample CF CT/CF S CF/S CF/S S CF/S CF/S CF/S S CF/S S S CF/S S C/S S CF/S
Flow
C C C/I C/I C C C/I C/I C/I C/I C/I C/I C/I
rate/volume/ weight
BOD (mg/l) 7X 1X 1X
COD (mg/l) 7X 5X 5X
pH C 1X 5X 1X 1X 1X 1X 1X 1X
SS (mg/l) 7X 5X 5X 1X 1X 1X
SSV (ml) 2X
SVI (ml/g) 2X
DO (mg/l O2) C
% TSS (% W/W) 1X 1X 1X 1X 1X 7X 7X 7X 1X 7X
% VS (% W/W) 7X 7X 7X 1X 7X
Alkalinity (mg
7X 1X 1X 1X
CaCO3/l)
Conductivity C C C
Temperature (°C) C C C C C C C
Faecal Coliforms C 7X
Hydrogen Sulphide 1X
Methane (% W/W) 1X
Microscopic
1X 1X 1X
Examination
Sulphide C 1X
REDOX Potential C C C C
For notes see following page.

Table B3.1b – Minimum monitoring, sampling and analysis during normal operation
Dewatered Final Sludge Treated Polymer Potable
Site Energy
Energy
Parameter Product Effluent
Screenings Grit
Usage Water
Boundary Generated on
Imported
Reuse Wash water
Feed Dewatered Sludge Liquor Receptors site
Measuring Point 11 12 13C 12 3 14 15 19,20,21 18 23 24 25 26
Type of sample C/S C/S C/S C/S CF CF CF S S CF CF
Flowrate/volume/weight C/I I C I I C C C
BOD (mg/l) 7X 7X
COD (mg/l) 7X 7X
pH 1X M C C
SS (mg/l) M 7X 7X 7X
DO (mg/l O2) C C
Total Nitrogen (TN) 7X 7X
Total Phosphorus 7X 7X
Residual Chlorine 7X 7X
% TSS (% W/W) 7X 1X 7X
% VS (% W/W) 7X 7X
Alkalinity (mg CaCO3/l) 1X
Dry solids or Organic Content 1X 1X
Turbidity C
Conductivity C C
Faecal Coliforms 7X 7X 7X
Hydrogen Sulphide 1X
Odour 1X
Noise 7X
Energy (kWhrs) C C
1. Measurement point references refer to Figure B3 and are indicative. To be confirmed following confirmation of process design.
CF 24 hour composite, flow proportional. nX n times a week

CT 24 hour composite time proportional, or composite time proportional collected during discharge. M Monthly
S Spot, or composite comprising three spot sub-samples. O Occasional and when complaints or problems encountered.
C Continuous measurement and recording.
I Intermittent measurement (whenever discharged or transported on or off site).

Table B3.2 – Main programme of analyses – for compliance purposes

Secondary Tertiary Final Site Boundary,
All
Parameter Treated Treated Sludge and External
Buildings
Effluent Effluent Product Receptors
Type of sample CF CF S
Flow rate or weight C C I
BOD 7X 7X
COD 7X 7X
SS 7X 7X
Total Notrogen 7X 7X
Total Phousphorus 7X 7X
Turbidity 7X
TDS
Residual Chlorine 7X
Dry solids 7X
Faecal Coliforms 7X 7X 7X
Odour C 1X
Noise C 1X
Notes
Additional measurement points may be required in order to comply with the Contract.
CF - 24 hour composite, flow proportional

C - continuous measurement and recording
S - spot, or composite comprising three spot sub-samples
I - Intermittent measurement (whenever discharged or transported off site)
nX - times a week

Table B3.3 – Programme of analysis – for payment purposes

Secondary Tertiary Treated
Potable
Influent Treated Treated Sludge
Water
Effluent Effluent
Measurement 12
1 3 25 18
Point
Type of S
CF CF CF
sample
Flow rate / I
C C C C
mass
COD 7X
Notes
CF 24 hour composite, flow proportional
C Continuous measurement and recording
S Spot, or composite comprising three spot sub-samples
I Intermittent measurement (whenever transported off site)
nX n times per week
All Measurement Point 1 shall be used to calculate the Influent COD loading to the facility for
payment purposes.
Measurement Point 3 minus and 25 minus Measurement Point 18 shall be used to calculate the
treated Effluent flow for payment purposes.
When determining the exact measurement points and references it shall be based on the
generic layout in Figure B3.1 and shall not be changed from that unless the process, plant
layout, or pipework arrangement make it inappropriate.
The measurement points in Table B3.3 above shall be corrected to eliminate measurement of
any recirculation flows, return flows or diverted flows following a review of the Contractor’s
pipework arrangements.
The influent measurement point shall be the influent prior to the addition of any recirculation,
washwater, or return flows.
The effluent measurement point shall be the treated effluent leaving the wastewater treatment
facility but shall not include any other diverted flows.

APPENDIX C

APPENDIX C – EMPLOYER’S ACCOMMODATION
Appendix C1 Employer’s Accommodation for Design-Build Period
Appendix C2 Employer’s Accommodation for Operations & Maintenance Period

APPENDIX C1 – EMPLOYER’S ACCOMMODATION FOR DESIGN-

BUILD PERIOD
C1.1 Furnished Container with Air Conditioner (40 feet X 10 Feet) : 4 Nos inclusinve of
items specified in C1.2 below and one container with conference facility with media
projector and video conferencing facility..
C1.2 Office Equipment and Supplies

Accommodation to be fitted out as required by the Employer’s Representative. All
equipment shall be of Brandnew.
S.No Item No.
1 Office Desk min. size 1.5m x 0.85m with 3 drawers 16
2 Arm chairs swivel type 16
3 Swivel chairs (no arms) 16
4 Table 1.5m x 0.85m 10
5 Stacking Chairs 10
6 A0 drawing hangers complete with A0 hangers. 4
7 Four draw suspension type filing cabinets 8
8 Shelving 225mm wide x 50m 1
9 Plan Chest A0 size, 6 drawers 2
10 15” Rotating Electric fans 8
11 Wastepaper bins 20
12 Boot scraper 2
13 Boot brush and waist height handle 2
14 Pin-up boards and pins 10
15 Door mats 10
16 Coat hooks 30
17 A3/A4 high speed photocopier 2
18 Mobile phone 4
C1.3 IT Equipment
The following IT equipment shall be provided by the Contractor and fitted out in the
accommodation. It shall all be brandnew and from a source to be approved by the
Employer’s Representative and the Contractor shall take out a Maintenance Contract for
all of the supplies equipment for the duration of its life on Site. The Maintenance
Contractor shall report only to the Employer's Representative.
• 8 No. high specification modern laptops complete with large capacity hard disc drive
and 16GB RAM, large colour monitor, mouse, fax modem, DVD/CDRW drive, USB
drives etc.
• 4 No. high specification modern desktops complete with large capacity hard disc
drive and 32GB RAM, large colour monitor, mouse, fax modem, DVD/CDRW drive,
USB drives etc.
• file server with networking software, large capacity network storage and associated
backup device.

• All computers shall be provided complete with standard software including Microsoft
Windows and latest MS Office Suite. Additionally 2 Nos of the desktop computers
shall be provided with AutoCAD 2017 and one of the laptops shall be provided with
Primevera.
• The Contractor shall be responsible for cabling, setting up, configuring and
maintaining the network.
• Network Printers, scanners and copiers (All Printers to contain approved Network
card connected to all office computers)
• 2no. Laser A4/A3 Color
• 3no. Laser A4
Other Items
The Contractor shall be responsible for the provision of high speed broadband
connection (100 mbps) with WiFi router for E-mail/Internet access at all office computers
for the duration of the Design Build period.
C1.4 Equipment
The Contractor shall provide the following equipment for the exclusive use of the
Employer’s Representative and staff for the duration of the construction phase of the
Works.
The equipment shall be brand new and from an approved supplier. The Contractor shall
supply current calibration certificates for survey equipment and maintain, calibrate and
insure the equipment through the Construction Phase of the Works.
S.No Item Nos.
1 Total Station and ancillaries of approved manufacture 2
2 Automatic level, tripod and 5m staff of approved manufacture 2
3 Ranging rods, 2m long and coloured red/white 12
4 Steel 50m tape 2
5 Fibre 50m tape 2
6 5m steel pocket tapes 12
7 1m spirit level 2
8 Maximum/Minimum thermometer 2
9 High powered waterproof battery inspection lamp 4
Digital camera (with latest version available) including serial
10 2
port cable and associated software
11 Camcorder including battery charging unit and batteries 2
Hand held noise measurement device and recharging unit, with
12 2
L(A) eq. and Max. Sound level capabilities
13 Sledge Hammer 2
14 Lump Hammer 2
15 Marker paint As required
16 Wooden pegs As required
17 Survey Books As required

C1.5 Protective Clothing

The Contractor shall provide the following brand new protective clothing for the exclusive
use of the Employer’s Representative and staff.
S.No Item Nos
1 Gortex or equivalent Waterproof coats and leggings 20
2 Reflective jackets 20
3 Disposable Overalls 10
4 Work Boots steel toe capped 20
5 Wellington or equivalent boots steel toe capped + Sole lined 20
6 Hardhats 20
7 Ear plugs, pairs 100
8 Gloves 20
9 Gumboots 20
10 Sunglasses 20
11 Harness 20
12 Portable H2S Monitoring device 10
13 Storage cupboards 12
C1.6 Kitchen & Dinning Equipment

The Contractor shall equip the kitchen with the following brand new items:
S.NO Item Nos

1 Fully plumbed stainless steel sink and draining board 2
2 Work top (3 m2) 1
3 Stools 8
4 Cupboard 2
5 Refrigerator 2
6 4 ring gas burner 1
7 Microwave oven 2
8 Kitchen Table 1
9 Dining tables 3
10 Chairs 12
11 First Aid box 1
12 Mugs 24
13 Plates and cutlery (sets) 24
14 Washing up bowl 2
15 Tray 12

C1.7 Stationery & General

The Contractor shall provide brand new stationery and general consumable office
supplies for the sole use of the Employer’s Representative and staff.
• Office stationery(pens, pencils, erasers, stapler, punching machine, highlighter,
post- it, filing, filing ancillaries, note books, A4 writing pads, paper cutting knife,
A3/A4 Papers, A3/A4/A5 envelopes, etc.)
• Postage stamps
• Batteries
• Printer Cartridges
• Washing up liquid
• Hand towels
• Soap
• Hand Cleanser
• Paper towels
• Replacement items for first aid box
• Barrier Cream
• Disinfectant
• Cleaning materials
• Dustpan, brush
• Soft broom
• Hard Broom
• Waste Bin
• Doormats
• Bucket and mop

APPENDIX C2 – EMPLOYER’S ACCOMMODATION FOR

OPERATIONS PERIOD
The Contractor shall be responsible for supplying, fitting out, and equipping the offices
for the sole use of the Employer as described in sections 13.7.4, 13.7.5 and 14.6
C2.1 Office Equipment and Supplies
The offices to be provided for the sole use of the Employer in accordance with Section
14.6 shall be fitted out as follows and as required by the Employer’s Representative. All
equipment shall be brand new.
Note: This requirement is additional to any furniture required under Section 13.7.5.
Office No 2 – 20m2
S.No Item Nos
3 Table 1.5m x 0.85m 1
4 Stacking Chairs 4
5 Shelving 225mm wide 10m
8 Wastepaper bins 1
10 Door mats 1
11 Coat hooks 1
Office No 2 – 30m2
S.No Item Nos
3 Table 1.5m x 0.85m 1
4 Stacking Chairs 4
5 Shelving 225mm wide 10m
8 Wastepaper bins 2
10 Door mats 1
11 Coat hooks 2
12 Fax machine 1

APPENDIX D

APPENDIX D – TYPICAL PLC INPUT/OUTPUT (I/O) SCHEDULE

Typical I/O Schedule
S.No Item PLC I/O

DI DO AI AO
1 Each drive
Running X
Trip/fault X
Available X
Alarm state X
Speed command X
Run command X
Emergency stop operated X

Available X
Hours Run X pulse
Duty drive selected X
2 Each motor actuated valve
Open state X
Closed state X
Fault X
Available X
Open command X
Close command X
3 Main distribution board incomers and generator incomer
Closed X
Tripped X
Power consumed incomer 1 X pulse
Power consumed incomer 2 X pulse
Loss of Mains Power X
4 Generator
Running X
On load X
Available for automatic use X
Fault X
Fuel system fault X
Low fuel level X
5 Level (digital)
High high X
High X
Low X

S.No Item PLC I/O

DI DO AI AO
Low low X
6 Level (analogue)
Value
Fault X X
7 Flow (analogue)
Value X pulse X
Fault X
8 Pressure differential (analogue) Value X
9 Each Monitoring and Control Instrument
pH value X
Analogue Output Instrument X
Digital Output Instrument X
10 Control systems / General Equipment
110 V ac mcb tripped (common for each CP) X
24 V dc mcb tripped (common for each CP) X
UPS fault X
UPS battery low X
PLC Fault X
Radio System Fault X
11 General Equipment
Intruder Alarm Activation X
Fire Alarm Activation X
Gas Detection Alarm X
Notes
DO Digital Output
DI Digital Input
AO Analog Output
AI Analog Input

APPENDIX E

APPENDIX E – MONTHLY STATUS REPORT IN OPERATIONS

PERIOD
Contractor shall develop a proprietary software which shall record the following
minimum requirements of Monthly Status Report (MSR) and data from MSR software and
SCADA shall be exchangeable
S.No Section Minimum Requirements

1 Introduction A brief summary, including:
• The date on which the Operation Service Period commenced, in
accordance with the Commissioning Certificate
• The number of MSRs produced since the Operation Service
commenced
• The period covered by the report
• Confirmation that all issues relevant to the Site activities and
Works performance during the reporting period covered are
included in the body of this report
2 Executive A clear, concise summary of the main events that occurred and the
summary significant aspects of Works performance during the reporting period.
This Section shall include, where applicable, descriptions of:
• analysis results for the reporting period and whether the results
were within the specification of the Contract
• any reasons why the analysis results are not within the required
specification
• recommendations to improve the efficiency of the treatment
process and quality of the outputs of the facility
• any complaints that were received and how they were dealt with
• any alarm callouts
• any new procedures that were implemented and when they
commenced
• any health and safety issues raised since the last report
• any equipment that was taken out of / put into service
• Planned Vs Actual Operation & Maintenance activities and Target
ratios
• other issues of relevance (e.g. utilization of Asset Replacement
Expenditure Provision, implementation of Independent
Compliance Audit, as encountered)
3 Graphical Flow data and analysis results shall be tabulated and graphed for
presentation of each process parameter listed using a proprietary computer package:
data • Total daily inlet flows
• Total daily outlet flow
• BOD, Suspended Solids and other parameters of final effluent as
per the consent.
The permissible flow and effluent limits, as defined by the Contract,
are to be indicated on all graphs.
4 Comments on The analysis results shall be discussed in sufficient detail to allow the
analysis performance of the Works to be assessed thoroughly in comparison to
results the requirements of the Contract. During any problematic period of
service delivery, all aspects of the Site results shall be commented on


in detail. Specific reference shall be made to the following:
• Influent parameter compared to design data
• the final effluent quality compared to discharge standard
requirements
• Screening and grit performance as per employer requirements
• BOD and TSS removal from primary clarifier as per employer
requirements
• Anaerobic and anoxic condition checking and profile
• DO and temperature indicator
• MLR profile
• MLSS profile
• Alum dosing Indicator
• RAS profile
• Secondary clarifier SOR and SLR checking
• Overall secondary clarifier performance
• Scum profile
• Chlorine dose profile to meet outlet performance
• Reuse water quality as per tender requirements
• Reuse water usage profile
• the thickened sludge figures
• Ploy dosing profile to WAS
• Sludge pre-treatment performance profile
• Sludge Pathogen Indicator in line with EPA class A sludge
requirement
• the digester contents results and profile
• The dewatering performance results and profile
• Sludge storage and disposal as per tender requirements
• the microscopic analysis results
• any major change in results since the previous reporting period
• any other issues of relevance
5 Process Table showing any process operational changes made with the
operational following headings:
changes • description of the change made to the operational process
• the purpose of the change
• the date the change was implemented
• the name and position of the person who carried out the change
6 Health and Health and safety issues that have arisen on Site during the reporting
safety issues period are commented on in this section. It shall include details of any
Site inductions or training undertaken. Also, any accidents or incidents
shall be reported in full together with statistical results.
7 Operational The snags, listed in tabular format, that are dealt with on Site during
maintenance the reporting period are taken from the previous MSR. Table to
issues include:
• the snag number
• the nature of the snag, i.e. mechanical, controls, electrical, etc.
• a description of the snag
• the priority status of the snag
• any comments relevant to any corrective action already taken


• the date the snag was first reported
8 Complaints Complaints shall be logged in a standard, systematic fashion and shall
register be dealt with appropriately in accordance with the Contract and
reported in this Section of the MSR. The information required to
complete the complaints register is:
• the complainant’s name and address
• the date and nature of the complaint
• the date of acknowledgement to the complainant and author
• the action taken to eliminate or mitigate the cause of the complaint
• the cause of the complaint
• the author of the final outcome report
• the date the final outcome report was forwarded to the Employer
9 Alarm The details of all alarm call-outs (events outside of normal working
callouts and hours) and Site incidents (events occurring during normal working
hours).
Site incidents
10 Analysis The results of sampling and laboratory analysis required in
results accordance with the Contract.
11 Site visit A record of all visitors shall be kept on Site and presented in each
records MSR. The record shall include:
• the date the Site visit occurred
• the name, company and position of the person(s) that visited
• arrival and departure time
• the purpose of the visit
12 Weather A log briefly describing the weather for each day during the reporting
records period shall be recorded. Also any events of Abnormal weather
conditions that may severely affect the plant overall performance
13 Equipment Site equipment shall be calibrated regularly, in accordance with the
calibration manufacturer’s instructions, and based on the calibration schedule
records available from the Site database or when a piece of equipment is put
back into service. If Site equipment is calibrated during the reporting
period the details are entered into the equipment calibrations record
and included in this section of the MSR. The data to be included, in
tabular format, is as follows:
• the date the calibration occurred
• a description of the equipment that was calibrated
• the serial number of the equipment that was calibrated
• by whom the equipment was calibrated (name and company)
• when the next calibration is due
• whether a calibration certificate was produced any relevant
comments
14 Equipment Site equipment shall be serviced as frequently as stated in the
service records suppliers literature or the operations and maintenance manual or if a
fault occurs with the equipment and it needs repair. The equipment
service record shall present, in tabular format, the details of each
service, including:
• the date the service occurred
• a description of the serviced equipment


• the serial number of the serviced equipment
• by whom the equipment was serviced (name and company)
• when the next service is due
• any relevant comments in relation to the service
15 Plant The Contractor shall undertake examination and maintenance of all
maintenance plant and equipment in accordance with the frequency recommended
records by the manufacturer, the O&M Manual and in accordance with the
Contract. The examinations and maintenance activities shall be
recorded in a plant maintenance schedule and presented in this
section of the MSR. The information required to complete the plant
maintenance schedule report, which shall be in tabular format, is as
follows:
• a description of the equipment
• the serial number of the equipment
• the section the maintenance schedule was taken from in the O&M
Manual
• the items that need to be checked every week, month, 3 months,
6 months or year for that piece of equipment
As the item of work is checked for each piece of equipment, it is
marked on the Table and initialled to indicate that it has been
examined.
16 Non-sludge Any non-sludge waste that is removed from Site shall be documented
waste disposal in the Site database and the information is transferred to the non-
records sludge waste disposal record for inclusion in the MSR.
The information required for the non-sludge waste disposal record is
as follows:
• the date the waste was removed
• a description of the waste
• the amount of waste removed at that time
• by whom the waste was removed (name and company)
• the intended destination of the waste
• receipt for acceptance of the waste
17 Sludge Any sludge that is disposed of from Site shall be transported for
disposal disposal in accordance with the Contract. A record is kept on Site of
records all sludge that is taken from the Site. The following information is
required for completing the outgoing sludge record which shall be
presented in tabular format in this section of the MSR:
• Batch number - Each load of outgoing product is allocated a
batch number to have a record and facilitate traceability of the
product
• Date - The date the product is exported
• Destination of the product - Where the product is to be
delivered,
• Type of product - A description of the type of product being
exported, i.e. liquid, cake, other
• Quality of product – The quality product must printed on the
product being exported including date and time
• Quantity of the product - The quantity of the product being
exported to the destination facility is recorded in kg or m3


depending on the consistency of the final product
• Certificate of origin/delivery - A certificate of origin or delivery
docket for the outgoing product must be given to the driver
delivering the load.
• Receipt returned from destination - A receipt is returned to the
Contractor from the facility that receives the product, to verify that
the delivery was completed
• Contact at destination – The contact details of destination to be
included
• Complaints from end user – The complaints that received if from
the end user to be included
• Closing of Complaints – The action taken to close the
complaints and same to be communicated to employer and end
user to be included
18 Analysis Samples of the raw influent, settled sewage and mixed liquor shall be
results for raw analysed and results presented in clear tabular format for the specific
influent, parameters required and the frequencies specified in the Contract.
The Food/Mass Ratio shall be calculated and presented on the right
settled sewage
hand side of the table for each date.
and mixed
The Contractor shall also monitor, and report on, any further
liquor
parameters necessary for proper and efficient operation and
maintenance of the Works such as:
• Flow, level and performance monitoring throughout the WwTF
• Raw, inter-stage and treated wastewater quality monitoring
• Flow and quality sampling on sludge stream
• Flow and pressure monitoring on pumping mains
19 Analysis Samples of the sludge feed and digester contents shall be analysed
results for and results presented in clear tabular format for the specific
anaerobic parameters required and the frequencies specified in the Contract.
digester The details of the biogas composition and efficiency of the digester
shall be included in the table.
20 Analysis Samples of the final effluent shall be analysed and results presented
results for final in clear tabular format for the specific parameters required and the
effluent frequencies specified in the Contract. Additional samples taken for
independent analysis by the Employer shall be recorded in this
section of the MSR.
21 Analysis Samples from the sludge thickeners and dewatering units shall be
results for analysed and results presented in clear tabular format for the specific
sludge parameters required and the frequencies specified in the Contract.
dewatering Additional samples taken for independent analysis by the Employer
shall be recorded in this section of the MSR.
22 Analysis The Contractor shall carry out microscopic analysis on the activated
results for sludge as frequently as the Contract requires, or if there are problems
microscopic with the sludge or settlement. The following characteristics of the
analysis sludge are to be commented on in this section of the MSR:
• floc size
• floc shape
• floc form and strength
• the presence of colonies, dispersed bacteria, fungi, protozoa and


higher organisms
• the presence of filaments and their effect
23 Analysis The Employer may collect as many of the split samples as desired
results of and may analyze the samples in accordance with the Contract. The
random analysis results are forwarded to the Contractor by the Employer and
sampling by are presented in this section of the MSR for comparison with the
Employer results obtained by the Contractor for the same sample.
24 Facility Certain aspects of the site must be checked regularly to ensure that
maintenance the facility is maintained in good order. A record in tabular format shall
records be presented in this section of the MSR together with any relevant
comments. The aspects that must be kept under constant surveillance
shall be established and agreed and shall include as a minimum:
• Lawn Maintenance
• Shrub Maintenance
• Hard Surfaces
• Exterior Painting
• Housekeeping
• Buildings
• Interior Painting
• Welfare & Sanitation
Each of the listed aspects of site maintenance are examined and
deemed to be in “excellent” condition, “acceptable” condition or
“unacceptable” condition. When an item is in an unacceptable
condition, steps must be taken to improve the condition of that item.
25 Emergency Any emergency events that occur during the reporting period must be
event records reported in this section of the MSR and must include the following
information:
• the date the emergency occurred
• how the emergency was noticed
• the location of the emergency
• a description of the emergency
• how the emergency was dealt with
• the person(s) involved in dealing with the emergency
• the duration of the emergency situation
• the date of the Emergency Response Review Meeting
• the attendees at the Emergency Response Review Meeting
• the action(s) taken to prevent such an emergency occurring again
A separate sub-section shall be compiled for each emergency event
that occurred during the reporting period.
26 Plant A detailed record shall be kept and presented here of any failure of
breakdown any element of the Works or of the Works itself.
records
27 Analysis for The analysis and measurement for payment, including any deductions
payment for failures, and including the calculations for payment of the variable
charges shall be included in this section of the MSR.
28 Plant A record of all plant or asset replacements undertaken during the
replacements reporting period.


29 Record of A record of the laboratory analysis undertaken.
laboratory
services
30 Training record Records of all personnel training that took place in relation to the
operation and maintenance of the Works during the reporting period.
31 Employee Any absence from the works due to illness or otherwise of members of
sickness and the Contractor’s personnel together with the details of temporary
absence replacement personnel.
records
32 Use of energy, The Contractor shall keep records of the hours of operation of each
utilities and item of electrical plant and the total energy usage on a daily, weekly
chemicals and monthly basis as part of the procedures for operation of the
facility.
Total energy usage records shall include day, night and total kWhrs,
wattless units and maximum demand usage. The records shall clearly
define energy used from the energy generation facilities on Site and
that energy taken from the external supply
The Contractor shall also report on the Renewable Energy Certificate
process under this section.
The Contractor shall keep records of all chemicals used for the
treatment of wastewater or sludge as part of the procedures for
operation of the facility. This shall include weekly records of bulk
storage and deliveries and daily use of all treatment associated
chemicals.
33 Process The details of any process stoppages or unit cleaning undertaken are
stoppages & to be presented in this section of the MSR.
unit cleaning
34 Vermin control The Contractor shall employ a recognized vermin control company to
provide and maintain bait points at the Works. The Contractor shall
also ensure that the Works is kept in good condition and free of any
organic waste material that could attract vermin. All the vermin control
measures shall be incorporated into the procedures for operation of
the facility.
35 Unusual or Unusual circumstances arising like:
abnormal • Industrial disputes,
conditions
• Accidental spillage of chemicals,
• Chlorine gas leakage,
• Pipe break down,
• Mechanical breakdown,
• Stoppage for essential maintenance
Shall be noted by the Contractor in detail and necessary actions shall
be taken into consideration to avoid similar future incidents.
37 Greenbelt and The contractor shall employ the sufficient number of staffs to take care
Landscaping Greenbelt and Landscaping area to maintain aesthetically clean and
area green environment around WwTF facilities for round the clock

APPENDIX F – PROCEDURES FOR CONSTRUCTION PERMIT

Directorate of Industries, Government of Maharashtra
As per Doing Business Report of World Bank Group, the procedures for obtaining construction
permit are outlined below:-
1) Submit application and design plans at Building Proposal office of BMC and pay
scrutiny fee
2) Receive Site inspection from Building Proposal Office
3) Obtain Intimation of Disapproval from the Building Proposal Office and pay fees
4) Submit structural plans approved by a structural engineer to BMC
5) *Apply for No Objection Certificate (NOC) from Tree Authority
6) *Receive inspection from Tree Authority
7) *Obtain NOC from Tree Authority
8) *Request and obtain NOC from Storm Water and Drain Department
9) *Request and obtain NOC from Sewerage Department
10) *Request and obtain NOC from Electric Department
11) *Request and obtain NOC from Environmental Department
12) *Request and obtain NOC from Traffic & Coordination Department
13) *Request and obtain NOC from CFO
14) Obtain Commencement Certificate from Building Proposal Office and pay
Development Charges
15) Request and receive inspection of plinth
16) Submit letter stating completion of building works to obtain an Occupancy Certificate
and Certificate of Completion
17) Request and receive competition inspection from BMC
18) Obtain Occupancy Certificate
19) Obtain Completion Certificate
20) Apply for permanent water connection
21) *Receive on-site inspection for connection to water by the Water Supply Department
22) *Obtain permanent water connection
23) Apply for permanent sewerage connection
24) *Receive on-site inspection for connection to sewerage by Sewerage Department
25) *Obtain permanent sewerage connection
26) *Apply for permanent power connection and pay fees
27) Receive on-site inspection from BEST
28) *Obtain power connection from BEST
29) *Apply for telephone connection
30) *Receive on-site inspection and connection to telephone by the utility provider
31) The Bidder should provide compliance as per Environmental Clearance from MOEF,
No. 11-49/2007-IA-III Dated 28th January 2008.
* Takes place simultaneously with another procedure.
Additionally,
• Clearance for sludge/solid waste disposal from the Employer
• Approval of design of the project under the Factories Act, 1948 and registration of
the Project under the same legislation as Project would constitute a factory as
defined therein.

APPENDIX G – SAMPLE ASSET HIERARCHY
•
•

APPENDIX H – LIST OF INDICATIVE SUPPLIERS
Indicative Vendor/Manufacturer/Make List
INDICATIVE MAKES LIST – CIVIL RELATED ITEMS

Sr. Category Sub Category Brand Name
No
1. Wood & PVC Work Wooden Flush Doors Kutty, Anand, Anchor, Duro, Kent.
2. Wood & PVC Work Flush Door Duraboard, Kit ply, Merino Ply
3. Wood & PVC work Flush Door Shutter Green, Century.
4. Wood & PVC Work Laminate Greenlam, Century, Merino
5. Wood & PVC Work Gypsum Board Saint Gobain, Lafarge
6. Wood & PVC Work Cement Bonded Board BISON by NCL
7. Wood & PVC Work Shower Partitions Dorma, Grohe, Hindware
8. Wood & PVC Work Calcium silicate False Hilux, Promat

ceiling
9. Wood & PVC work Door hardware Ingersolrand, Geze, Dorma, Guardian, Dorset,
Magnum, Union, Kitch
10. Wood & PVC Work Door Lock & Handle Ingersolrand, Geze, Dorma Guardian, D-
Line.
11. Wood & PVC Work Door Closer Ingersolrand, Geze, Dorma, Guardian
12. Wood & PVC Work Door Locks Ingersolrand/ Dorma, Haffle, Dorset
(Concealed/Surface
Mounted)
13. Wood & PVC work Locks Dorset, Sobeet, Godrej.
14. Wood & PVC Work Door Seal – Wool Pile Enviro Seal, Anand Raddiplex
Weather Strip
15. Wood & PVC work Door handle (Concealed/ Ingersolrand, Geze, Dorma, Alu Alpha
Surface)
16. Wood & PVC Work Metallic Steel Fire Door Naviar, Shakti Met, Promat, Godrej, Adhunik,
basic Arch Products, Radiant, Signum.
17. Wood & PVC work Fire Smoke Seal Hilti, CFS, SPWB Joints Spray
18. Wood & PVC Work Fire Related Hardware Ingersolrand, Gaze, Dorma
19. Wood & PVC work Non Metallic Fire Door Naviar / Promat, Signum
20. Wood & PVC Work Metallic Door Shakti Met/ Promat, Signum
21. Wood & PVC work Metallic Window Shakti Met
22. Wood & PVC work Stainless Steel Screws for Kundan/Puja/ Atul
fabrication and fixing of
windows
23. Wood & PVC work Two or Four Point Locking Gize, Alu Alpha
Openable Window Handle

24. Wood & PVC work Butt Hinges Openable Haffle, Alu Alpha
Window shutters
25. Wood & PVC work Mild Steel butt Hinges/ Jolly, Garg, AMIT, ASI Supreme
Piano Hinges

No
26. Wood & PVC work Nuts Bolts/ Screws Kundan/ Puja/ Atul
27. Wood & PVC Work Concealed Tower Bolt Ingersolrand, Alu Alpha
28. Wood & PVC work Patch Fitting Ingersolrand, Dorma, Geze
29. Wood & PVC Work Double side Tab, 3M

Decorative Tab
30. Wood & PVC Work UPVC Joinery Fenesta, Veka, Euro Plast, aluplast, Amon
Ra.
31. Wood & PVC Work Acoustic Insulation U.P. Twiga Ltd, Lloyd, Saint Gobain,
Ecophone
32. Wood & PVC work Glass Saint Gobain, AIS, Asahi, Pilkington, Modi,
Guardian Glass
33. Wood & PVC work Clear Float Glass AIS Glass/ Saint Gobain/ Modiguard
34. Wood & PVC work Source for Tempering GSC Toughened/ Gold Plus/ Gurind/ Art “n”
Refl. Glass / Clear. Glass/ Impact Safety.
35. Wood & PVC Work Glass (Toughened) Saint Gobain/ Modi Float/ Asahi Float
36. Flooring Work Vitrified Ceramic Tiles Diamontile, Marbo Granit, Granamite,
Boss, NITCO, AGL, Euro, Somany, Orient,
Kajaria, Simpolo
37. Flooring Work Precast Mosaic & P.C. NITCO/ MODERN
Tiles
38. Flooring Work Industrial Tile Endura
39. Flooring Work Glazed Ceramic Tile Orient Bell, Kajaria, Nitco, Somany, Swastik,
AGL, Euro
40. Flooring Work Timber Flooring Par-Ky, Ego Flooring, Beutex
41. Flooring Work False Floor Hewetson, Unifloor, Unitile
42. Flooring work Perquet Floor Nemo/ Prima/ Pergo
43. Flooring Work Floor Springs Ingersolrand/ Dorma/ Geze
44. Flooring Work Rubber Tile Flooring Ecoflex Surfaces Pvt. Ltd., Rudi Sports
Surfaces, the Floorsmiths
45. Flooring work Granamex Tiles Vyara Tiles Pvt. Ltd., Super Dcoratative
Floorings Pvt. Ltd., Sai enterprises.
46. Flooring Work Interlock Concrete Blocks Vyara Tiles Pvt. Ltd., Super Decorative
Floorings Pvt. Ltd., Sai enterprises,
Hindustan Tiles, Nimco Prefab, R.K. Tiles.
47. Finishing Works Paint/primer/ Oil Bound Asian Paints, ICI, Hindustan, Godavari
Distemper Acrylic Paint Paints, nerolac, Dulux, Spectrum, Unitile,
Berger, Aero paints, Jotun
48. Finishing works Water proof Cement paint Snowcem India Ltd, Asian Paints, Berger,
Nitco cem
49. Finishing works Fire Retardant Paint Jotun, Hilti, Akzonobel
50. Finishing works Mirror Modi Guard, Saint Gobain
51. Finishing Works Anti Corrosive Bitumastic Asian/ Berger/ J&N
Paint
52. Finishing Works Epoxy Paint Asian/ Berger/ J&N
53. Finishing Works Silicon Coating BASF & Dowcorning

54. Sanitary Ware Vitreous China Sanitary Cera, Roca, Parryware.

Ware
55. Sanitary ware Concealed Flushing Cera, Roca, Parryware
Cisterns
56. Sanitary Ware European Water Closet Parryware, Hindware, Cera
57. Sanitary Ware Sensor Operated Flushing Cera, Roca, Parryware
system

No
58. Sanitary Ware Seat Covers (Heavy Duty) Parry ware, Hindware, Cera
59. Sanitary Ware Flat Back urinal (Sensor Cera, Roca, Parryware
Operated)
60. Sanitary Ware Urinal Parry ware, Hindware, Cera
61. Sanitary ware Wash Basin Hindware, Parryware, Jhonsan Topaz
62. Sanitary Ware SEMI – RECESSED Hindware, Duravit, Raknova
BASIN
63. Sanitary ware Telephonic Shower Parryware, Jaquar, Hindware
64. Sanitary ware C.P. Fittings & bathroom Jaquar, Parryware, Hindware, ROCA, Cera
accessories
65. Sanitary Ware Geyser Racold, Venus Wave, AO Smith Jaquar
66. Sanitary ware Health Faucet Jaquar, kohler, Schell, Parryware, ESS
67. Sanitary Ware Soap Dispensar Jaquar, Roca, Cera
68. Sanitary Ware Flow Regulator Devices Arco
69. Sanitary Ware Stainless Steel sink Nirali, Franke, parry ware, Cera, Jayna, Amc,
Neelkanth
70. Sanitary Ware C.P. Bottle Trap Jaquar, Roca, Kohler, Parryware, Ess
71. Sanitary ware Sink mixer with regular Jaquar, Ess, Grohe
swinging spout
72. Sanitary Ware Basin Mixer Jaquar, Hindware, Ess
73. Sanitary Ware Waste Coupling Jaquar, Hindware, Parryware
74. Sanitary ware C.P. Grating GMGR, Chilly, Viking
75. Sanitary Ware CP / SS Grating For floor Neer, Aco, Vijay
trap & floor drain
76. Sanitary ware Stainless steel (304) Noway, Chilly, Camry
square frame grating
77. Sanitary ware Strainer RB, Intervalve, Zoloto, VB
78. Sanitary Ware C.I. Strainer More than Leader, kartar, Sant
65mm Dia.
79. Sanitary Ware Cast Brass Clean out GMGR, Neer, Viking
Plugs
80. Sanitary ware Concealed stop cock Jaquar, hindware, ESS
81. Sanitary Ware Shower arm, Rose Jaquar, Hindware, ESS
82. Sanitary ware Bath spout with wall flange Jaquar, Parry ware, Hindware
83. Sanitary Ware 4way diverter concealed Jaquar, Parry ware, ESS
fitting, with built in non
return valves and diverter
handle
84. Sanitary ware Double coat hook Jaquar, Hindware
85. Sanitary Ware Towel Rack (600 mm) Jaquar, Hindware, Parry ware
86. Sanitary ware Towel Ring Jaquar, ESS, Parryware
87. Sanitary ware Toilet Paper Holder Jaquar, Hindware, ESS
88. Sanitary ware Grab bar Jaquar, hindware
89. Sanitary ware Urinal Push cock Jaquar, Parry ware
90. Sanitary ware Piller cock Jaquar, ESS, American Standard – Cella
91. Sanitary ware Soap Dish Jaquar, Hindware, Parryware
92. Sanitary ware Two way Bib cock Jaquar, ESS, Parryware

93. Sanitary ware C.P. angle Valve Jaquar, Roca, Kohler

94. Sanitary ware Ball valve Rb, Intervalve, Zoloto, VB, Arco, Sant, Kartar
95. Sanitary Ware GM Peet Valve RB, Intervalve, Zoloto, VB
96. Sanitary ware GM Wheel valve RB, Intervalve, Zoloto, VB
97. Sanitary Ware Pressure Reducing Valves Hawa, Kirloskar, sant, VB, Zoloto, RB
98. Sanitary ware Butterfly valves RB, Intervalve, Zoloto, VB, KSB, Kartar, SKS,
Delval, Audco, Intervalve
99. Sanitary ware Float Valve (C.I.) Leader, Sarkar
100. Sanitary ware Gate valve Zoloto, Neta, leader

No
101. Sanitary ware G.M. Non return Valve RB, Intervalve, Zoloto, VB
102. Sanitary ware C.I. Non Return valve RB, Intervalve, Zoloto, VB
103. Sanitary ware Flap Type Check valve Hawa, Intervalve, Audco
104. Sanitary ware Solenoid valve Rotex, Asco, Switzer, Intervalve
105. Sanitary ware Automatic Air vent Hawa, RB, Zoloto
106. Sanitary ware Stoneware pipes/ Gully Rajora, Equivalent
traps
107. Sanitary ware SWR Pipe & Fittings Type Supreme, Finolex, Prince Pipes, Ashirwad,
B (For internal Drainage) Kisan
108. Sanitary ware SWR Pipe & Fitting type A Supreme, Finolex, Prince pipes, Ashirwad,
(For Rain water upto Kisan
160mm dia)
109. Sanitary ware UPVC Pipes/fitting Supreme, Finolex, Prince pipes, Jain pipes
110. Sanitary ware UPVC ASTM Pipes Supreme, Surya Roshni, Finolex
111. Sanitary ware CPVC Pipes and Fittings Astral, Ajay, Ashirwad Pipes, Supreme, Prince
pipes
112. Sanitary ware Foamcare/ Multilayered Ashirwad, Prince Pipes, Astral, Ajay
Pipes
113. Sanitary ware Copper Pipes Rajco, Maxflow
114. Sanitary ware G.I. pipes / M.S. Pipe Tata, Jindal, Zenith, Surya Roshni
115. Sanitary ware G.I. Fittings (malleable Unik, R brand, Zoloto M, Unco, KS
cast iron)
116. Sanitary ware C.I. Fittings Neel, kartar, Sarkar
117. Sanitary ware C.I. Pipe & Fittings Neco, Skf, Nagpur foundries
118. Sanitary ware Sand cast Iron Pipes & Neco, Rif, Hepco, Nagpur foundries
Fittings
119. Sanitary ware HDPE Pipes for Internal Supreme, Jain Pipes, Eonn Plast
Drainage
120. Sanitary ware RCC NP2 Class pipe Pranali, Shreeji, Pawan
121. Sanitary ware PVC KHURRA SUPREME, Prince, FINOLEX
122. Sanitary Ware Pressure gauge H. Guru / Forbes marshall / Waaree, Wika,
fiberg.
123. Sanitary ware RCC Grating Pratibha/ Alcock/ KK manhole
124. Sanitary ware Electronic flow meter Rockwin / Aquamate
125. Sanitary ware Water level Controller Technica / Waaree
126. Sanitary ware Water level indicator Technica / Waaree
127. Sanitary ware Grating K.K. Manhole Jain Spun pipe / pragati
128. Sanitary ware C.I. Manhole Cover & Neco, Bengal iron corporation
Framing
129. Sanitary ware FRP Manhole cover & KK Manhole, Aesthetic Pavers, Automatic
Frame tiles
130. Sanitary ware Water Meter Kay Cee / Kent / Deshmesh
131. Sanitary ware R.C.C. Pipe Jain spun pipe, Pranali, Amea Concretech,
Pawan Concrete
132. Sanitary ware Pipe Supports Hangers Intello Tech / GMGR / Chilly

133. Sanitary ware Insulation Thermaflex / Armaflex / Kiflex

134. Sanitary ware Solar system TATA BP / Racold / Jain solar / Sudarshan
135. Sanitary ware Storage Type hot Water Venus / Bajaj / Racold
Heater
136. Sanitary ware Pre-Fabricated structural CHILLY, EASYFLEX, CAMRY
supports and clamps
137. Sanitary ware Pumps Grundfos, ITT, DP
138. Aluminum work Aluminium systems/ Indal, Hindalco, Bhoruka, Midi, Royal Touch,
anodized aluminum fittings Alufit (Sapa), Kawneer, Schueco, Reynaers,
for doors/ windows Crown, ALANS, Classic, Bharat, Argent

No
139. Aluminum work Aluminum cleat Samples to be got approved by Engineer – In
arrangement for glazings/ Charge
cur. Wall size
140. Aluminum work Aluminum sections Hindalco / Jindal / Mahavir / Indal
141. Aluminum work E.P.D.M Gaskets Anand/ Roop/ Bohra/ Hanu
142. Water proofing Water proofing compound CICO, Pidilite, Laticrete
143. Water proofing Membrane waterproofing BASF, STP Limited, Texsa, W R Grace
system
144. Water proofing Chemical Waterproofing BASF, MC – Bauchemie, Sika, Sunanda
system Specialty Coatings, perma Construction
aids pvt. Ltd.
145. Water proofing Water stops Hydrotite, BASF, Hydroswell
146. Landscape & Garden benches Saflow products pvt. Ltd., Kanha Import
irrigation Export Pvt. Lt., Shardha Metalic,
Baijnath
147. Landscape & Granite benches Jayantilal & Co., Jayant Minerals Pvt. Ltd.,
Irrigation Ambaji stones décor Pvt. Ltd.
148. Landscape & Versicell mat ZTC International Landscape solutions Pvt.
Irrigation Ltd., Hesda Solutions, Matrix Solutions
149. Landscape & PVC Perforated pipes Rex Polyextrusion Ltd., Akash enterprises,
irrigation Zenplas pipes pvt. Ltd.
150. Miscellaneous Structural Sealant Wacker, Dow Corning, GE
151. Miscellaneous Polysulphide Sealant Pidilite, Chemetall – Rai
152. Miscellaneous Bitumen Impregnated Shalitex
board
153. Miscellaneous Polythylene backup rod Supreme Ind. Ltd.
154. Miscellaneous Epoxy Fosroc/ STP/ CICO/ Adrex
155. Miscellaneous False Ceiling members Gyp. Steel of india Gypsum ltd.
(perimeter, ceiling section,
intermediates, angles etc.)
156. Miscellaneous Welding rod ADVANI
157. Miscellaneous MS Black AKG, BEC, Steelkraft
enameled/Galvanized
ERW conduits
158. Miscellaneous Toilet Cubical Merino
159. Miscellaneous Metal deck sheet TATA/SAIL
160. Miscellaneous Shear stud/ Connector KOCO
161. Miscellaneous Clamp, Rebar, Chemical Hilti, Fischer, Wurth
Fastner
162. Miscellaneous Anchor Fastners/ Bolts Hilti, Fischer, halfen
163. Miscellaneous Masking tapes 3M, Sun control, Wonder Polymer
164. Miscellaneous Dash Fastners SS Grade, Hilti
165. Miscellaneous Stainless steel bolts, Kundan/ Puja/ Atul
Washers & Nuts

166. Miscellaneous Stainless steel Pressure Kundan/ Puja/ Atul

plate screws
167. Miscellaneous Weather Silicon make and Dow Corning/ Momentive (GE)
grade
168. Miscellaneous Structural Silicon Dow Corning/ Momentive (GE)
169. Miscellaneous Backer road Supreme Industries Ltd.
170. Miscellaneous GRC Jali Terrafirma, Ecovision & Mahesh GRC
171. Miscellaneous Tensile Fabric system Ferrari Mehler, Makmax
172. Miscellaneous Stainless steel Jindal, SAIL, Golden
173. Miscellaneous Polycarbonate sheet Danpalon, Alcox, Polygal, V.A. Corporation,
Joy Fab, Yadav Engineering
174. Miscellaneous Post tensioning System VSL, Utracon, BBR
175. Miscellaneous PT Strands DP wires, Tata, Usha Martin

No
176. Miscellaneous Prestressing systems Dynamic Prestress (I)
177. Miscellaneous Adhesive & grouts Bal, Laticrete, Kerakoll, Pidilite.
List of indicative makes for Mechanical Equipment / Items:

MECHANICAL ITEMS
Sr. No. Item Description Approved Vendor/ Manufacturer/ Make

1 Air Compressor M/s Ingersoll Rand
M/s Kaeser
M/s Kirloskar Pneumatic
M/s Atlas Copco
M/s Chicago Pneumatic
M/s ELGI
2 Air Blowers (Roots Type) M/s Swam
M/s Everest
M/s Kay International
M/s Altas Copco
M/s Airvak
M/s Arzen
3 Chlorination System M/s Industrial Device
M/s Pennwalt
M/s Capital Controls
M/s Siemens
4 Cranes (EOT, Hoists ,Jib M/s W.H. Brady
cranes)
M/s Transpade Engineers
M/s Demag
M/s Electromech
M/s Safex
M/s Hercules


5 Centrifuge Decanter M/s Pennwalt
M/s Humbolt Wedag
M/s GEA Westfalia
M/s Andritz
M/s Alpha Laval
6 Exhaust Fans M/s Alstom
M/s Flaktwood
M/s Bajaj
M/s Crompton Greaves
7 Flash Mixer/ Agitator M/s Fibre & Fibre
M/s Ceecons
M/s Voltas
M/s Remi Process
M/s Milton Roy
8 Horizontal Centrifugal M/s KBL
Pumps
M/s Grundfos
M/s Wilo /Mather & Platt
M/s KSB
M/s Kirloskar
M/s Flowserve
M/s Sulzer
M/s Xylem/ITT/Flyght
M/s Johnson
9 Submersible Pumps M/s KSB
M/s Xylem/ITT/Flyght
M/s ABS/Sulzer
M/s Grundfos
M/s Kishor
M/s Kirloskar
10 Submersible Pumps-Tube M/s ABS Sulzer
installed
M/s Xylem
M/s Wilo
M/s KBL
M/s Grundfos
M/s KSB
11 Helical Rotor Screw Pumps M/s Alfa lvevel
M/s Netzch technology
M/s Seepex
M/s Tushaco Pumps


M/s Roto Pumps
12 Chemical Dosing Pumps M/s Milton Roy
M/s Prominent
M/s V K Pumps
M/s Positive Metering Pumps
M/s Swelore
13 Submersible Mixer M/s ABS-Sulzer
M/s Grundfos
M/s Kishor
M/s ITT FLYGT-Xylem
14 Clarifiers and Thickener M/s Voltas
Mechanism (Conventional
M/s Triveni
Type)
M/s Shivpad
M/s Emco KCP
M/s Indofab
15 Vortex type Grit Removal M/s Triveni
Mechanism
M/s Bilfinger
M/s Huber
M/s Smith and Lovless
16 Butterfly Valve M/s Pentair
M/s Fouress
M/s VAG Valves
M/s AVK Valves
M/s KBL
17 Sluice Gate Valve M/s VAG
M/s Fouress
M/s IVC
M/s Makimura
M/s Dezurik
M/s IVI
M/s KBL
M/s AVK
18 PP Valve M/s Shenco
M/s U N Polyvalves
19 Penstock Gates M/s Jash
M/s Hambaker
M/s Orbinox
M/s VAG
M/s Yashwant


20 M.S - Cement Lined Pipes M/s Jindal
M/s PSL
M/s Welspun
21 SS Pipes M/s SAIL
M/s Jindal
M/s Remi
22 CI/DI/GI pipes M/s Electrosteel
M/s Lanco steel
M/s Jindal
M/s Kejriwal Castings
23 DI Fittings M/s Kiswok
M/s Kejriwal Castings
M/s Electrosteel
24 Motorized Weir Gates M/s Jash
M/s Yashwant
25 Chlorine Tonners M/s ISGEC
M/s Meenakshi Associates
26 Fine Bubble Diffusers M/s Environmental Dynamics
M/s OTT GMBH
M/s Rehau
M/s Sanitaire
27 Centrifugal Air Blowers M/s Howden
(Turbo Blower)
M/s Siemens
M/s Hoffman and Lamson
M/s Atasco Copco
M/s Neuros
M/s Godrej
M/s Aerzen
28 Mechanical Screens (Bar M/s Mahr Machinen Bau – MM2 MM
type)
M/s Headworks
M/s Huber
M/s Kuhn GMBH
29 Pressure Vessel M/s Thermax Limited
M/s Ion Exchange
M/s Cheema Boilers Ltd.
30 Electric Actuators M/s Auma
M/s Limitorque
M/s L Bernard
M/s Rotork


31 Pneumatic Actuators M/s Rotex
M/s Bettis
M/s Fetso
M/s Janson
M/s D Torque
M/s Elomatic
32 UPVC & HDPE Pipes M/s Jain Irrigation
M/s Finloex
M/s Duraline
M/s Time Technoplast
M/s Pennwalt Agro
M/s Supreme
M/s Astral
M/s George Fischer
33 Motors M/s Crompton Greaves Ltd
M/s Seimens
M/s Marathon Electric (Alsthom)
M/s Kirloskar Electric company
M/s Bharat Bijlee Ltd
M/s ABB
34 Ball Valves M/s BDK Engineers
M/s Flowchem
M/s Virgo
M/s KBL
M/s Audco
M/s Fouress
M/s Microfinish
35 Knife Gate valves M/s Jash Engineering
M/s VAAS
M/s Dezurik
M/s Fouress
M/s ORBINOX
M/s VAG
M/s AVK
36 Diaphragm valves M/s. Crane Process
M/s. Microfinish
M/s. BDK Engineers
M/s. Leader
M/s. Saunders


37 Eccentric Plug valves/ NRV M/s Dezurik
M/s KBL
M/s VAAS
38 Alum Rapid Induction Mixer M/s Rite water solution
39 Gas Scrubber M/s Innovative Environmental
M/s Combustion research associates
40 Gas Flare M/s Combustion research associates
41 Heat Exchanger M/s Alpha Laval
M/s Positron Engineering Corporation
M/s Ammus
M/s Rakhoh
42 Air conditioner M/s Bluestar
M/s Voltas
M/s O General
M/s Carrier
Ms. Daikin
43 Dissolved Air Floatation M/s Krofta
M/s Water Works
M/s K-Pack
44 Ultra Filtration M/s Hyflux
M/s Hydranautics
M/s Koch Membrane
M/s Toray
M/s Evoqua
45 Disc Filtration M/s Huber
M/s Xylem
M/s Aqua Aeraubic
M/s Nordic
46 Sludge Screens M/s Huber
M/s Auric
47 Solar Power System M/s Tata Power Solar System
M/s Bajaj Electricals
M/s Emmvee Solar Systems
M/s Waaree Energies
48 UV System M/s Trozen
M/s Calgon
M/s Xylem
49 Bio Gas Engine M/s Clark
M/s GMMCO


M/s Green Power
M/s GGE
50 Rectangular Clarifier M/s Brentwood, Germany
mechaniasm
M/s Evoqua
M/s Finchain
M/s Fairfield

List of Tentative makes for Electrical Equipment / Items:
Sr. No. Description Vendor/Manufacturer/Make

1 HV Switchgear ABB
Siemens
Schneider Electric
Pyrotech
Crompton Greaves Limited
2 Distribution Transformers ABB
BHEL
Schneider Electric
Voltamp Transformers Limited
3 Transformer Lighting - Dry Type SGB
(Cast Resin)
Schneider Electric
ABB
4 Switchgear/Switchboard MV – Siemens
11/33kV - Outdoor Type ABB
Pyrotech
Schneider Electric
5 Switchgear/Switchboard MV – Siemens
6.6/11/33kV - Indoor (VCB) ABB
Schneider Electric
Pyrotech
BHEL
6 Protective relays (Numerical Type) ABB
Siemens
GE
SEL (Schweitzer Engineering Laboratories)
Alstom
7 Protective Relays ABB

(Electromechanical
Siemens
Type)
GE
Schneider Electric (formerly Areva/EE)


8 Auxiliary Relay Schneider Electric (formerly Areva/EE)
ABB
Siemens
VA Tech
L&T
9 Electronic circuit Relay OEN
Omron
Allen Bradley
PLA
10 Control and Relay Panel ABB
Siemens
Easun Reyrolle
Alstom
Schneider Electric
11 Instrument Transformers (CT/PT) Automatic Electric
Crompton Greaves
Indcoil
Kappa
Precise
Pragati
Gilbert and Maxwell
Silkaans
Jyoti
ECS
Schneider Electric
ABB
Siemens
12 Switchgear/Switchboard L.V.- Siemens
Drawout/Fixed Type
L&T
(PCC/MCC/PMCC/MLDB/MPDB/
MOVDB/APFC) Schneider Electric
Pyrotech
ABB
13 Air circuit breakers L&T
Siemens
Schneider Electric (M&G)


ABB
14 MCCB’s L&T
Siemens
Schneider Electric (M&G)
Pyrotech
ABB
15 Switch Disconnector Fuse Unit Siemens
(SDF) Technoelectric
And Switch Disconnector Isolator
Schneider Electric
L&T
16 Change-over switch Havells (euroload)
C&S
Schneider Electric
GE Power
Kraus & Naimer
Siemens
BCH
L&T
17 V F Drives / Electronic Siemens
Soft starter Allen Bradley (Rockwell Automation)
Yaskawa
Schneider Electric
ABB Danfoss
18 MV capacitors (APP) Universal Cables
Manohar Brothers (Capacitors)
ABB
Epcos
Shreem
19 LV capacitors (APP) Universal Cables
ABB
Malde
Madhav
Epcos
Aswani
Schneider Electric


L&T
20 Series Reactors For Capacitors Manohar Brothers
WHEPL
Epcos
21 APFC Panel Epcos
Aswani
Manohar Brothers
Siemens
Pyrotech
L&T
Crompton Greaves
22 APFC Relay / Controller TAS Powertek
Syntel
ABB
Cummins
Epcos
Schneider Electric
23 AC Power Contactor Siemens
ABB
L&T
BCH
Schneider Electric (Telemecanique)
24 DC Power Contactor BCH
BHEL
Siemens
L&T
Schneider Electric
25 Auxiliary contactors Siemens
L&T
26 Electronic / Microprocessor based Siemens
overload relay ABB
Schneider Electric
27 Bi-metal / Overload Relay Siemens
Schneider Electric


L&T
28 Thermistor relay Alstom
Minilec
Insta controls
29 Single Phasing Preventer Siemens
Minilec
Alstom
Schneider Electric
L&T
30 Time switch GIC
Theben
Siemens
Schneider Electric
Legrand
31 Timers GIC
Theben
BCH
Siemens
Electronic Automation Pvt Ltd.
Minilec
L&T
Legrand
Schneider Electric
32 Time Delay Relay Schneider Electric
ABB
Siemens
BCH
L&T
Omron
PLA
33 Motors Siemens
Bharat Bijlee
Crompton Greaves
Marathon Electric Motors (India) Ltd.
(Formerly Alstom Ltd)


BHEL
ABB
Kirloskar
34 Battery Charger & DCDB Hitachi
Caldyne Automatics
Chhabi Electricals
Mass-tech Controls
HBL Power Systems
Automatic Electric
Amara Raja
Universal Instruments
35 Luminaire Philips
Zumtobel
Thorn
Osram
Crompton Greaves
Bajaj
Havell
GE
36 Lamps Philips
GE
Osram
Sylvania
LVD
Havell
Neptune, USA
37 Ballast Philips
Crompton Greaves
Bajaj
Havell
ATCO
38 Cables H.V. - 33 kV XLPE Universal Cables Ltd.
Insulated
NICCO
KEC International Ltd


Cable Corporation of India Ltd
39 LT Power Cables/ Earthing Cable Universal Cables Ltd.

NICCO
Finolex
INCAB
Polycab
LAPP
RR Kabel
40 LT Control Cables LAPP
Polycab
NICCO
Universal Cables Ltd.
Finolex
INCAB KEI
41 HFFR wires (including panel Finolex
wiring)
Polycab
LAPP
RR Kabel
42 Non-insulated Copper Earthing Gupta Industrial Corporation (Vasai,
conductors Palghar)
Bharat Wires & Ropes
Diamond Cables
43 Distribution Boards (other than Siemens
MLDB, MPDB, MOVDB) / Panels / C&S
Enclosures / JB / Marshalling
Panel Schneider Electric
Rittal
President
Enclotek
Eldon
Hensel


Legrand
Manshu Comtel
Pentair
ABB
BCH
44 MCB, RCCB, RCBO / MCB Legrand
Isolators Schneider Electric
Klockner Siemens
Moeller
ABB
45 MPCB Siemens
Schneider Electric
Moeller
ABB
L&T
46 Alarm Annunciators (solid state Digicont
type with LED illumination) / Facia
Industrial Instruments & Controls
Annunciator
Procon Inst. (P) Ltd
MTL India Pvt. Ltd.
Rochester Instruments System Ltd.
IDECIZUMI
Minilec
IICP
Proton Electronics
Alstom
Yashmun
ICA
Ronan (Waree)
47 Decorative switches, sockets and Honeywell (MK Electric)
metal boxes (single plate Anchor (Panasonic)
arrangement)
Havells (Crabtree)
48 Modular switch & socket Anchor (Panasonic)
(wraparound) (twin plate Anchor (Roma / Ave)
arrangement)
Honeywell (MK Electric)
Legrand
Havells (Crabtree)


Schneider Electric (Clipsal)
Siemens
ABB
Gewiss
49 Ceiling Fan Usha
Crompton Greaves
Bajaj
Orient
Khaitan
Almonard
50 Wall Mounting Fan Almonard
GEC
Crompton
Bajaj
Orient
Usha
51 Exhaust Fan / Ventilation Fan Nadi
Usha
Almonard
Bajaj
Crompton Greaves
52 Air Circulators/Man Coolers Almonard
(Pedestal/Wall Mounted) Bajaj
Crompton Greaves
53 Cable termination/jointing kits Raychem (Tyco Electronics / RPG)
3M(Cold Shrink/Push-on)
ABB Kabeldon
54 Control / selector switch Kraus & Naimer
Kaycee
GE Power controls
L&T
Siemens
ABB
Schneider Electric
55 Indicating Lamps (Multi-chip LED) Binay


Teknic Controls
Vaishno
Siemens
L&T
Schneider Electric
Concord
BCH
56 Terminal Block / Connectors Wago
Connectwell
Pheonix
Elmex
57 Control transformer Indcoil
Precise Silkaans NEC
Gauss Electricals
58 Semiconductor Fuse Siemens
Schneider Electric (Ferraz Shawmut)
Eaton (Cooper Bussmann)
GE
59 HRC fuse (Power & Control) Siemens
L&T
GE
Eaton (Cooper Bussmann)
Technoelectric
Schneider Electric (Ferraz Shawmut)
60 Push buttons Siemens
Teknic Controls
L&T
Concord
BCH
Vaishno Electricals
61 Push button station Siemens
Schneider Electric
R Stahl
Hensel


Bals
Gewiss
62 Non metallic enclosures (including Rittal
Industrial Receptacles) Hensel
SCAME
Menekkes
Bals
Siemens
Schneider Electric
BCH
PCE
Legrand
Gewiss
63 Digital Meter – Ammeter & Schneider Electric (Conzerv)
Voltmeter Automatic Electric
Rishabh
Schneider Electric (Power Measurement/
ION)
Circutor
Siemens
Masibus
64 Electromechanical – Ammeter & Automatic Electric
Voltmeter MECO
IMP
Rishabh
65 Load Manager / Multi Function Schneider Electric (Conzerv / (Power
Meter / kWh Measurement / ION)
Circutor
Rishabh
Schneider Electric
Alpha (ABB)
Schlumberger
SEMS (Secure)
Electro Industries / GaugeTech
66 Power quality analyser A-eberle
Schneider Electric (Power Measurement/


ION)
Schneider Electric (Conzerv)
Chino – Laxsons
Yokogawa
Rishabh
Fluke
Hioki
67 Cable lugs Dowells
Comet
3D (Billets Elektro Werke Pvt. Ltd)
68 Cable Glands (safe area - double Comet
seal cone grip type)
Jainson
Braco
Baliga
R.Stahl
Crouse Hinds
Siemens
Hex (Brass Copper & Alloy(I))
Cosmos
69 Polyamide Cable Glands Lapp
Hensel
Gewiss
Fibox
70 Lightning Arrestors WS
Jayshree
Elpro
Oblum
Crompton Greaves
71 Surge Suppressors OBO
Emerson
Furse
Dehn+Sohne
Erico
Pepperl+Fuchs
MTL


Schneider Electric
ABB
Weid Muller
Siemens
Phoenix Contact
72 Uninterrupted Power Supply (UPS) Emerson Network Power (India) Pvt. Ltd.
(Liebert / Chloride)
Schneider Electric (MGE / Gutor / APC /
Invensys)
Aplab
Fuji Electric , Japan
Hitachi
Eaton
Riello-PCI
Socomec
ABB (Newave)
73 Floor trunking system (GI trays, OBO
troughs & pull boxes) and GI Cable
Honeywell Patny
trays
Legrand
Indiana
Profab
Sadhana
Sterlite
Reliance
Jenco/Pentax Ferro Incorporate
Furniture trunking system / Cable Legrand
74 management System
Schneider Electric
Rittal
Panduit
Honeywell
Eubiq
75 UPVC Conduit/JB/flexible Precision
conduit/tees/ Bevels, elbow &
Polycab
accessories/fittings
Sudhakar
AKG
76 GI Conduit / Pipes JK Tube Company (AKG)


BEC Industries
Zenith
SAIL
TATA Steel
Jindal
77 MS Conduit JK Tube Company (AKG)
BEC Industries
Jindal
TATA Steel
SAIL
78 Casing Capping Precision
Circle ARK
Mody
79 Lighting Controller / Lighting Lutron
Management System
Zumtobel
Philips
Tridonic Atco
80 Lead Acid Battery (Plante / Exide
Tubular)
HBL Power Systems Ltd.
Amara Raja Batteries Ltd.
Hoppecke
81 SMF/VRLA battery Exide
Hoppecke
82 Ni – Cd Battery HBL Power Systems Ltd.
Hoppecke
Amco Saft
83 Lighting Poles Bajaj
Bombay Tubes and Poles
Valmont
Pyrotech
India Electric Poles
84 High mast lighting system Philips
Bajaj


Crompton Greaves
BP Projects
Valmont
85 SCADA / EMS ABB
Siemens
Alstom
Schneider Electric
Electro Industries / GaugeTech
Pyrotech
Rishabh
86 Fire Barriers / Sealing Brattberg
Roxtec Signum Navell Multikil
87 Water barriers/sealing system Roxtec
Rayflate (Tyco Electronics)
88 Decontactor BCH
89 Insulating mats Electromat
Dozz
Raychem RPG
90 Emergency Light / Installite / Prolite
Conversion module / Battery Pack
Legrand
Philips
Tridonic Atco
Zumtobel
91 Choke (for VVVFD) Siemens
ABB
Danfoss
Allen Bradley (Rockwell Automation)
Yaskawa
92 Power Supply Unit Siemens
MTL
Aplab
Pheonix
Cosel
93 Busduct C&S
Stardrive


Godrej
Schneider Electric
Siemens
94 Voltage / Power / Current / ABB
Frequency / Energy Transducer AE
Siemens
Schneider Electric
Rishabh
Masibus
95 Encoders Hubner
Honeywell
Turck
96 Limit Switch BCH
Honeywell
Siemens
Jay Balaji
Wago
97 Aviation Obstruction Light (multiple Binay
LED type)
98 Diesel Engines Cummins
Caterpillar
MTU
Mitsubishi
Wartsila
Rolls Royce
99 Alternators for DG Sets Cummins (Stamford / AvK)
Leroy Somer
BHEL
100 Digital Multimeter for Operation & Beckmann
Maintenance
Fluke
AVO
101 Clip-On Ammeter for Operation & HCK, Germany
Maintenance
Kyoritsu Electrical, Japan

List of Tentative Makes for Instruments:

a. Level Indicator Transmitter EMERSON
ABB,
Endress+Hauser
Yokogawa
Siemens
Honeywell India
b. Flow Meters / Flow Indicator/ EMERSON
Transmitter
ABB
Xylem
Yokogawa
Endress+Hauser
Krohne Marshall
Siemens
c. Level Gauges /Level Switches EMERSON
ABB
Endress+Hauser
Kobold
SBEM Pvt Ltd
Mangnetrol Pvt Ltd
Nivo Control Pvt Ltd
Punetechtrol Pvt Ltd
d. Pressure Gauges/Pressure ABB,
Switches
Wika
Kobold
Gen Inst Co
Baumer Technologies India Pvt. Ltd
Ashcroft India Pvt Ltd
H Guru Instruments Pvt Ltd
Manometer (India) Pvt Ltd
Forbes Marshall Pvt Ltd
Scientific Devices Pvt Ltd
e. Pressure Indicator Transmitter EMERSON
ABB,
Endress+Hauser


Siemens
Honeywell India
Yokogawa India Ltd
f. Temperature Indicator Kobold
Transmitters
Endress+Hauser
ABB
Radix Pvt Ltd
g. Water Quality Analyzers M/s SWAN
(Dissolved Oxygen, Residual
M/s Endress+Hauser
Chlorine, Turbidity, pH,
Conductivity, ORP, TSS, MLSS, M/s Yokogawa
SS, BOD, COD, TOC, etc.)
Hach
Xylem
ABB
Emerson
Forbes Marshall
Mettler - Toledo
WTW Gmbh
Dr. Lange
Royce Technologies

List of Makes for Un-interrupted Power Supply & Batteries:

a. Un-interrupted Power Supply APC
DB & ELECTRONICS
NUMERIC POWER SYSTEMS
Emerson
Schneider Electric (MGE / Gutor / APC /
Invensys)
Aplab
Fuji Electric , Japan
Hitachi
Eaton
Riello-PCI
Socomec
ABB (Newave)
Pyrotech
Amtech Electronics India Ltd.
b. Batteries Lead Acid Battery (Plante / Tubular)
Exide
Hoppecke
SMF/VRLA battery
Exide
Hoppecke
Ni-Cd Battery
Hoppecke
Amco Saft

List of Makes for Cables

a. Cables Universal Cables
Polycab
Havell’s
Finolex
NICCO
KEI Industries Limited
List of Makes for Enclosures/ Panels

a. Enclosures / Panels Rittal
ECIL
Pyrotech
Eldon
Universal
C&S Electric
Siemens India Ltd
Schneider Electric India Pvt Ltd
List of Makes for Alarm Annunciators

a. Alarm Annunciators ALAN
Unitech Instruments
Minilec
Digicont
Industrial Instruments & Controls
Procon Inst. (P) Ltd
MTL India Pvt. Ltd.
Rochester Instruments System Ltd.
IDECIZUMI
IICP
Proton Electronics
Pyrotech
Yashmun

List of Makes for Process Indicators

a. Process Indicator Masibus
Unitech Instruments
Nivam
GSV
List of Makes for Automation

Sr. No. Description Manufacturer/Make
a. Workstations , Servers Dell, HP, Compaq etc.
b. Programmable Logic Controllers Schneider Electric
Siemens
Rockwell Automation
ABB
Mitsubishi
GE
Omron
YOKOGAVA
c. SCADA Programming Software Intellution IFix,
Siemens
Wonderware,
WIN CC V 6.2,
RS View,
Visio Citect, Clear SCADA
Iconics,
CX-Supervisor V3,
Fast Tools
d. GSM/GPRS Equipment Motorola,
GE,
Seimens,
GSV Microtek,
DataRadio,
Sheetal Wire-less Systems
e. Printer Epson
HP
Brother


Canon
d. Interface Devices D-Link
Mrotek
Tmas
MTL Instruments Pvt Ltd
Osna Electronics Pvt Ltd
Phoenix
e. Communication Cables (OFC / Delink
Modbus / CAT 6 / TCP / IP)
Cords
RR CABLE
Icon
Aksh
List of Makes for Laboratory Instruments

a. Laboratory Instruments Hach India Pvt Ltd
Orbit
WTW Gmbh
Merc
Xylem
Thermo
The Tenderer shall provide list all mechanical, electrical and instrumentation equipment/items
indicating selected make .
Contractor can indicate up to Two makes selected either from the lists of approved suppliers
and accepted by the Employer during tendering stage.
Post award, no change in selected make shall be allowed except for extra-ordinary
circumstances.
The Successful Bidder/Contrctor may submit his proposal to Employer for acceptance of
change of make of equipment and technology provider in case of extra ordinary reson by clearly
stating reasons. The Employer shall reserve the right to accept or reject the contractors
proposal of change of make and technology provider.”
All the equipment, to be supplied under this contract has to be from experienced manufacturer.
The equipment of only those manufacturers, who have sufficient proven experience of
manufacturing the respective equipment of similar capacity, shall be considered. The naming of
a manufacturer in this specification is not intended to eliminate competition or prohibit qualified
manufacturers from offering equipment. Rather, the intent is to establish a standard of
excellence for the material used, and to indicate a principle of operation desired.

In order to achieve standardization for appearance, operation, maintenance, spare parts and
manufacturer's service, like items of equipment provided hereunder shall be the end products of
one (1) manufacturer.
The name of manufacturers specified in Dharavi, Worli, Bandra, Bhandup and Ghatkopar
WWTF tenders shall also be considered in “List of Indicative Suppliers”.

EMPLOYER'S REQUIREMENT - Relevant Soil Specs

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MUNICIPAL CORPORATION OF GREATER MUMBAI

Mumbai Sewage Disposal Project

180 MLD VERSOVA WASTEWATER TREATMENT FACILITY

Design, Build and Operate Contract

Municipal Corporation of Greater Mumbai

Volume 2 Page i Employer’s Requirement

5.5 Electrical Safety .................................................................................................... 35

Volume 2 Page ii Employer’s Requirement

9.18 Standby Requirements ......................................................................................... 66

Volume 2 Page iii Employer’s Requirement

13.9 Instrumentation ................................................................................................... 136

Volume 2 Page iv Employer’s Requirement

15.26 Returns of Labour and Plant Reports .................................................................. 173

Volume 2 Page v Employer’s Requirement

20.2 Preparation and implementation of the O&M Plan .............................................. 212

Volume 2 Page vi Employer’s Requirement

25.20 Erection and Building-in ...................................................................................... 251

Volume 2 Page vii Employer’s Requirement

Table B1.1a –Minimum Design Load Parameters ................................................................... 268

Volume 2 Page viii Employer’s Requirement

APPENDIX A – DESIGN STAGE CONTRACTOR’S DOCUMENTS ....................................... 262

Volume 2 Page ix Employer’s Requirement

Volume 2 Page 1 Employer’s Requirement

Volume 2 Page 2 Employer’s Requirement

Volume 2 Page 3 Employer’s Requirement

• Laying of infrastructure (including pumping and network) to convey tertiary

1.4 Description of the Works

Volume 2 Page 4 Employer’s Requirement

Volume 2 Page 5 Employer’s Requirement

a. Marketing of the tertiary treated water;

b. Laying of infrastructure (including pumping and network) to convey tertiary treated

c. Processing further, if required and/or Disposing of the Class A sludge to suitable

d. Monitoring / auditing quality of the outputs of the WwTF

Volume 2 Page 6 Employer’s Requirement

1.5 Future Expansion

Volume 2 Page 7 Employer’s Requirement

Existing Works, Structures and Services

Volume 2 Page 8 Employer’s Requirement

2 EXISTING WORKS, STRUCTURES AND SERVICES

2.2 Demolition of Existing Structures

Volume 2 Page 9 Employer’s Requirement

2.3 Existing Services to the Site

2.4 Existing Boundaries

Volume 2 Page 10 Employer’s Requirement

Volume 2 Page 11 Employer’s Requirement

Volume 2 Page 12 Employer’s Requirement

3.3 Related Contracts

Volume 2 Page 13 Employer’s Requirement

3.4 Blocking of Flow to Lagoons

Volume 2 Page 14 Employer’s Requirement

3.5 Lagoon Decommissioning

Volume 2 Page 15 Employer’s Requirement

Volume 2 Page 16 Employer’s Requirement

Volume 2 Page 17 Employer’s Requirement

Volume 2 Page 18 Employer’s Requirement

In addition the programme shall:

Volume 2 Page 19 Employer’s Requirement

4.3.2 Project Execution Plan

4.3.3 Failure to Provide Programme and Project Execution Plan

Volume 2 Page 20 Employer’s Requirement

of Design-Build or additional payment as a result of any delay incurred as a result of the

Design documentation shall be submitted to the Employer’s Representative in two