TA2944 RHD ZZ XX SP X 0001 Scope of Works & Technical Specifications

SPECIFICATION
Technical Tender Documentation
Waste Water Treatment Plant at Cimanggis
Client: PT Bayer Indonesia
Reference : TA2944-RHD-ZZ-XX-SP-X-0001
Status : S5/ P01
Date : 12 December 2023
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HASKONINGDHV NEDERLAND B.V.
Laan 1914 no.35
Water & Maritime
+31 88 348 20 00
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Document title : Technical Tender Documentation
Subtitle: Waste Water Treatment Plant at Cimanggis

Reference : TA2944-RHD-ZZ-XX-SP-X-0001
Your reference
Status : S5/ P01
Date: 12 December 2023
Project name : Treatment Plant at Cimanggis Plant
Project number : TA2944
Classification
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Unless otherwise agreed with the Client, no part of this document may be reproduced or made public or used for any
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purpose other than that for which the document was produced. HaskoningDHV Nederland B.V. accepts no
responsibility or liability whatsoever for this document other than towards the Client.Please note: this document
contains personal data of employees of HaskoningDHV Nederland B.V.. Before publication or any other way of
disclosing, this report needs to be anonymized, unless anonymisation of this document is prohibited by legislation.
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Revision Date Description Prepared Checked Approved
0 14-12-2023 Tender document Bart Zwart Zwingli Visser Zwingli Visser
Receipt/ Acceptance of document:
Name : Hamzah Bahmudah Date ………………. Signature: ………………
Notes:
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1 Introduction 1
1.1 Project description 1
1.2 Background 1
2 Basis of design 2
2.1 Feed and effluent characteristics 2
2.2 Solution Development 4
3 Project overview 5
3.1 Project objectives 5
3.2 Key Project Contacts 5
3.3 Summary of Contractor’s Scope 5
3.4 Project Schedule 6
4 Project Site Information 6

4.1 Works Area 6
4.2 Access to Site 7
4.3 Working with other Contractors 7
4.4 Storage 7
4.5 Services provided to the Contractor (Bayer) 8
4.6 Environmental and Occupational Health & Safety (OH&S) 8
4.6.1 Health, Safety and Environmental Plan 8
4.6.2 Health and Safety Co-ordinator 8
4.6.3 Emergency contacts 8
4.6.4 Maintainability 8 R
4.6.5 HSE Induction 9
4.6.6 Insurance 9 E
4.7 Construction / Installation Procedure 10
5 Project General requirements 11

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5.1 Preamble 11 T
5.2 Contractor’s Responsibility 11
5.3 Material Supply 11 R
5.4
5.5
Equipment Supply
Packing, Shipping and Delivery
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5.6 Warranties 12 C
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6.1
Scope of Work
Preamble
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6.2 General Inclusions 13

6.3 Process Design 14
6.4 Civil / Structural Works 14
6.4.1 Civil Works 14
6.4.2 Structural Works 16
6.5 Mechanical Works 19
6.6 Electrical, Instrumentation and Control 20
6.7 HVAC 21
6.8 General work 21
6.8.1 Introduction 21
6.8.2 Demolition 21
6.8.3 Lab equipment 22
6.8.4 Fire prevention, fire fighting & Health & safety 22
6.8.4.1 Firefighting equipment details 22
6.9 Work Excluded 22
6.10 Reference Drawings 22
6.11 Tie-in Points 25
7 Contractor Documentation 26
7.1 Documentation 26
7.2 Reporting 26
8 Performance requirements 26
9 Installation & Process Acceptance testing 27

9.1 Commissioning, Validation, Start-up Approach 27
9.1.1 Dry & wet Commissioning Approach Mechanical checks 27 R
9.1.2 Electrical checks 27
9.1.3 Civil / Hydraulic commissioning 27 E
9.2 Training Approach 27
9.3 Monitoring Period + Process Acceptance Test 27 S
10 General requirements 29 T
10.1 Approvals/Regulations 29
10.2 Quality 29 R
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10.2.1 Quality Assurance (QA) 29
10.2.2 Quality Control Plan 30
10.2.3 Categorisation of QCPs 30
10.2.4 Laboratory Testing 31 C
10.2.5 Verification (Acceptance Control) 31
10.2.6 Quality Management Audit 31 T
10.2.7 Corrective Action 32
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10.2.8 Quality Assurance Enhancement 32

10.2.9 Quality Assurance Staff 32
10.2.10 Client's Quality Assurance Representative/Inspector 32
10.2.11 Sub-Contracting 32
10.2.12 Disqualification 32
10.3 Review by Bayer 32
10.4 Workmanship 33
10.5 Materials 33
11 Completion 34
Table of Tables
Table 1 Design influent characteristics & effluent demands for discharge to the surface water
Sungai KalibaruTable 2
Table 2 Summary of Bored Pile Number for Each Building 16
Table 3 Summary of Pile Testing Number for Each Building 16
Table 4 Scope of Work for Sub-Structure & Upper Structure 17
Table of Figures
Figure 1 Current aerial view WWTP. 6
Figure 2 Aerial view with schematical lay-out. 7
Appendices R
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A – Reference design
B – Standards & Technical specifications S
C – Bill of Quantities (BoQ)
D – Detail conversion plan
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E – Contractor Document requirement list R
F – Existing site information provided by client
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1 Introduction
1.1 Project description

This Document details the design, requirements and standards for the supply, installation and
commissioning of an upgrade for the Wastewater Treatment Plant (WWTP) at the Bayer’s Cimanggis site
in Indonesia.
1.2 Background
PT Bayer Indonesia (hereinafter referred Bayer) is an Indonesian entity of Bayer Company, which is active
in the area of life science products. Bayer’s Cimanggis site is one of its factories in Indonesia, which is the
supply centre of health care products i.e. vitamins.
The factory has an existing on-site wastewater treatment plant (WWTP) to treat domestic and residual
cleaning wastewater by using anaerobic and aerobic treatment. However, since the commissioning, the
anaerobic treatment received much lower influent loads than what it was designed for, and it was
therefore underloaded. As a result of this, the anaerobic system has been by-passed for the past seven
years and the wastewater has been only treated aerobically. Furthermore, the WWTP cannot remove the
occasionally discharged reddish colour which remains in the effluent and the final clarifier occasionally
shows sludge flotation. In the coming years, Bayer plans to expand the factory which will result in higher
wastewater loads.
From December 2020 to March 2021, Royal HaskoningDHV (hereinafter referred RHDHV) carried out a
site assessment of the WWTP. This resulted in proposed recommendations in terms of operation and on
potential plant upgrades, additions, and modifications to optimize the performance of the WWTP in light of
treating predicted wastewater production while meeting effluent limits. This includes full decommissioning
of the anaerobic treatment, changes to the aerobic treatment system requiring plant and layout changes
as detailed further in this report, and an additional effluent polishing step to treat the intermittent red
colour.
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Due to an updated local authority regulation of effluent limits (PP no. 22 / 2021). Bayer now needs to
comply to stricter effluent limits of Class 4. Next to the stricter effluent demands Bayer also decided to
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include a water reuse system to comply with the company’s water saving program. The reuse water is to
be used as feed water for the wet scrubber, which removes exhaust ethanol from a gas stream.
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TECHNICAL TENDER DOCUMENTATION WWTP AT
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12 December 2023 TA2944-RHD-ZZ-XX-SP-X-0001 1
BAYER CIMANGGIS
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2 Basis of design
2.1 Feed and effluent characteristics
Table 2 summarizes the influent data of 2020-2022 and the expected flow rates and loads for 2027. Empty
cells indicate unknown values. The final effluent needs to comply with Class 4 which is stricter than
(Permen LH No. 5 /2014) on some parameters, especially on the heavy metals but also on COD/BOD.
Table 1 Design influent characteristics & effluent demands for discharge to the surface water Sungai KalibaruTable
Feed (Influent Characteristic)
Parameter Unit 2020 20221 2027 Permen

LHK 5 / Class 4
Av. Max Av. Max. Av. Max. 2014
m3/d 63 245 90 238 115 304 - -

Flow2
m3/h 2.6 10.2 3.8 9.9 4.8 12.7 - -
Colour - Red-coloured (intermittently) N/A N/A
pH - 6.2 8.5 6 7.2 - - 6-9 6–9
Temperature °C 30.6 37 - - - - 38 -
COD kg/d 55 77 106 231 136 295 - -
COD mg/l 100 80
BOD mg/l 246 857 942 2,130 - - 50 12
TSS mg/l 63 158 199 689 - - 200 400
TDS mg/l 686 2,200 - - - - 2000 2000
Total Nitrogen (TN) mg/l 22 63 - - - - 30 -
NO3-N
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Total Nitrogen (TN) kg/d
mg/l
1.4
0.7
15
3.8
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-
-
-
-
-
-
-
20
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NO2-N
E mg/l 0.06 0.2 - - - - 1 -
NH3-N mg/l 4.1 13.7 - - - - 5 -
TP S mg/l 1.6 6.2 - - - - - -
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TP kg/d 0.1 1.5 - - - - - -
FOG mg/l <1.4 <1.4 - - - - 10 10
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Methylene Blue
Active Surfactant
mg/l
0.5 1.5 - - - - 5 -
(MBAS)
I [MPN/
Total coliform 100ml 4,173 9,100 - - - - 10,000 10,000
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Dissolved iron (Fe) mg/l 0.50 0.9 - - - - 5 -
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Dissolved Manganese
mg/l 0.11 0.4
- -
- - 2 -
(Mn)
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Feed (Influent Characteristic)
Parameter Unit 2020 20221 2027 Permen

LHK 5 / Class 4
Av. Max Av. Max. Av. Max.
2014
Barium (Ba) mg/l 0.18 1 - - - - 2 -
Copper (Cu) mg/l 0.12 0.34 - - - - 2 0.2
Zinc (Zn) mg/l 1.08 4 - - - - 5 2
Hexavalent chromium
mg/l 0.004 0.004 - - - - 0.1 1
(Cr6+)
Total chromium (Cr) mg/l 0.004 0.014 - - - - 0.5 1
Cadmium (Cd) mg/l 0.01 0.05 - - - - 0.05 0.01
Mercury (Hg) mg/l 0.017 0.02 - - - - 0.002 0.005
Lead (Pb) mg/l 0.02 0.04 - - - - 0.1 0.5
Stanum (Sn) mg/l 0.07 0.10 - - - - 2 -
Arsenic (As) mg/l <0.006 <0.006 - - - - 0.1 0.1
Selenium (Se) mg/l <0.002 0.005 - - - - 0.05 0.05
Nickel (Ni) mg/l 0.01 0.01 - - - - 0.2 0.1
Cobalt (Co) mg/l <0.008 <0.008 - - - - 0.4 0.2
Cyanide (Cn) mg/l <0.006 <0.006 - - - - 0.05 -
Sulphide (H2S) mg/l 0.15 0.46 - - - - 0.5 -
Fluoride (F) mg/l 0.28 0.83 - - - - 2 -
Free chlorine (Cl2) mg/l 0.04 0.2 - - - - 1 -
Phenol mg/l 0.21 0.34 - - - - 0.5 0.02

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Chlorides (Cl ) mg/l - - - - - - - 600
(DO) R
Dissolved oxygen mg/l - - - -
- - - 1
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Sulphate (SO4) mg/l - - - - - - - 400
DDT μg/l - - - - - - - 2
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Data 2022 is based on the record of January - June
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The estimated daily flows (av. & max.) were 90 m3/d and 238 m3/d (2022), respectively. In consultation with Bayer, the average was
increased with 115 m3/d and the maximum with 304 m3/d to correct for the flows by 2027 (increase 5% per year).
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2.2 Solution Development

Based on the assessment caried out in 2020 the conclusion was that the organic load to the wastewater
treatment plant was much lower than where the plant originally was designed for. The outcome of the
assessment was that the following equipment had no added value to the treatment process and could
therefore be removed:
- Anaerobic reactor
- Trickling filter
Parallel to this, the design of the current clarifier tank is insufficient. A new clarifier is needed to ensure
proper sludge/water separation to prevent solids from being discharged into the final effluent and to
ensure a stable MLSS concentration in the aeration tank. The final effluent needs to comply to PP no. 22 /
2021 Class 4 for this only one aeration tank needs to be operation to prevent under loading of the
biological system.
To prevent bulking sludge a selector tank is included in the design to ensure a proper sludge selection
which enhances the settling properties of the activated sludge.
Occasionally the wastewater has a reddish colour caused by using Allura Red in the primary process
which currently in ineffectively being removed resulting in the discharge of coloured final effluent. To
remove the incidental discharge of colour an activated carbon step (with sand filtration as pre-treatment) is
integrated in the design.
To upgrade the final effluent to a quality suitable for reuse the final effluent polished on a NF/RO-package
unit. The WWTP is designed in such way that the brine of the RO plant still complies with the effluent
limits. In case of exceeding the effluent limits an online TOC analyser will swich of the RO plant and
generates an alarm that the activated carbon is saturated and needs to be replaced.
Details of the process design per process step/ item can be found in TA2944-RHD-ZZ-XX-RP-EI-4201-
Control Narrative P04 (Appendix A)
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3 Project overview
3.1 Project objectives

The Upgrade of the Cimanggis WWTP project is to install and commission new upgrades to the existing
WWTP which will:
 Meet the Class 4 (PP no. 22 / 2021) effluent limits.

 Reduce the water usage of the WWTP in respect to Bayer’s water saving program by implementing a
water reuse system to recycle effluent.
 Allow for the stable operation of the WWTP as per the RHDHV concept.
 Removal of the occasional reddish colour in the effluent.
 Be implemented without health, safety and environmental incident and in line with all relevant local and
international standards.
 Upgrading of the plant without any disruption to the existing processes – it is imperative that the
existing treatment processes continues uninterrupted during the construction process.
3.2 Key Project Contacts

The project will be managed by
 Project Manager : Hamzah Bahmudah (hamzah.bahmudah@bayer.com)
 Project Engineer : Putu Ayustin Suriasni (putuayustin.suriasni@bayer.com)
3.3 Summary of Contractor’s Scope

The summary of the Contractor’s scope of this contract refers to all components of the design and
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installation of the WWTP upgrade as described in this document and the appendices. The scope includes
but is not limited to:
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Engineering, construction design, documentation, installation, project management, coordination of
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activities between disciplines, commissioning, and provision of maintenance manuals.
Demolition and/or disposal of obsolete structures, filters, equipment, and tanks
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Site management, including fencing, work permitting and traffic management.
Supply, delivery and off-load of all equipment and first consumables.
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 Mechanical, civil and structural installation including supports and foundations, and tie-in to existing
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equipment and piping.
 All associated electrical installation and control programming works, including connection with the
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existing site electrical and control systems.
Commissioning, testing and operation during the handover period
 FurtherT develop of the tender design to a detailed construction design in consultation with Bayer.
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3.4 Project Schedule

The construction process will be carried out from June 2024 with estimated 12 month of construction time.
4 Project Site Information
4.1 Works Area

Below the current set-up is shown with the proposed building plot for the WWTP upgrade (Figure 1) and a
description of the new elements and pipe routes. A more detailed 3D model export concerning the
upgrade can be found in: SITE LAYOUT – 3D View (Appendix A)
Figure 1 Current aerial view WWTP.
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Figure 2 Aerial view with schematical lay-out.
4.2 Access to Site

Bayer will provide the access to the site, however the Contractor must maintain or recondition the existing
access, if necessary to ensure the performance of the Works. The Contractor shall be responsible for the
security of its own facilities and all equipment and materials stored in Contractor’s facilities. Bayer shall not
be liable for or pay for, any expenses, losses or damages of any facilities, equipment, or materials in that
location.
4.3 RWorking with other Contractors
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Allowance must be made for working with operational suppliers and other Contractors which may include
and unloading, civil / structural Contractors, mechanical equipment installers, fire system
Contractors and electrical Contractors.
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4.4 T
Storage
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The Contractor shall provide all necessary facilities at Contractor’s cost for the performance of the
Contract. The
temporary offices, workshop and stores inclusive of utilities. The space for the facilities will be provided by
I cost, in the location of the project. The location, size and layout drawings of the facilities shall
Bayer, at no
be subject to Bayer’s approval. The contractor shall establish the facilities at the Bayer’s existing facilities.
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4.5 Services provided to the Contractor (Bayer)

Electrical and sanitation is available in site office contractor area. Water, first aid and fire extinguisher will
be provided and maintained by the Contractor.
4.6 Environmental and Occupational Health & Safety (OH&S)
4.6.1 Health, Safety and Environmental Plan

All health and safety requirements should be compliant to Annex B- Bayer Regulations and Standards for
Construction Safety Management Procedure.
A Health and Safety Plan shall be prepared by the Contractor and submitted to the Client’s Engineer for
his approval at least 14 days prior to any programmed construction activities on site. The Health and
Safety Plan shall include, but not be limited to:
- construction risk assessment and control measures;
- organisation and management arrangements for implementing the plan;
- appropriate specified safety requirements;
- welfare arrangements for staff messing, first aid and sanitary arrangements.
The Contractor shall not take possession of the Site before the Client’s Engineer has approved his Health
and Safety Plan.
4.6.2 Health and Safety Co-ordinator

The Contractor shall appoint a Safety Co-ordinator whole role shall be to promote, monitor and enforce
safe working practices on the Site. The Safety Co-ordinator shall be a senior member of the Contractor’s
staff.
The Contractor shall arrange and undertake regular safety briefings for all of his staff, workmen and sub-
Contractor’s staff. In addition, he shall ensure that regular safety liaison meetings are held between the
Contractor, Client’s Engineer and Employer. The Contractor shall carry out a safety audit of the Site at
intervals not exceeding six months.
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The Contractor shall ensure that all statutory safety obligations are met in respect of anyone entering the
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4.6.3 Emergency contacts
The Contractor shall maintain arrangements whereby labour can be called out outside normal working
T out any work needed for an emergency associated with Construction of the Works. The
hours to carry
Contractor shall ensure that the Client’s Engineer and Employer are provided at all times with a list of
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addresses and telephone numbers of supervisory personnel who are from time to time responsible for
emergency work.
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4.6.4 Maintainability
C valves, or any other item that will require regular operation, inspection and/or
The whole of the plant shall be designed in such way that all mechanical and electrical equipment,
instrumentation,
maintenance, shall be easily and safely accessible.
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Plant to be accessed for routine maintenance, inspection or operation at higher levels (higher than can be
accessed comfortably when standing upright) shall be accessed by means of platforms, and any location
that poses a risk of falling from height (to local legislation, guidelines or requirement) shall include
handrails, which shall all be part of the Contractor’s scope of work, including design thereof. The
construction must be designed to carry a load of at least 1,500 N/m².
The contractor shall observe all required local legislation, standards, guidance and practise for Health and
Safety, ergonomics and specific plant requirements for this.
All the safety aspect including Personal protective equipment (PPE), permits, and other Occupational
health and safety are stated in Annex B- Bayer Regulations and Standards for Construction Safety
Management Procedure.
4.6.5 HSE Induction

Contractor shall conduct induction programs throughout the project to instruct the WORK force in
maintaining safe and healthful working conditions, in following safe construction practices and in
maintaining their safety awareness.
Each Contractor’s employee including supervisors and engineers, prior to beginning WORK at WORK
SITE, shall be given an induction that will do the following.
 Acquaint the employee with the WORK SITE, the nature of the job, the hazards that Contractor may
encounter and the equipment and safe practices to be used to minimize accidents.
 Review the contents of safety and health manuals, stressing the sections applicable to the Contractor
and his job.
 Advise of the requirements for working safely and that failure to follow safe practices may result in
disciplinary action including dismissal.
Additionally, each craftsman shall be given a safety discussion by his craft supervisor after 2 - 3 weeks of
employment when the craftsman has become familiar with the job.
4.6.6 Insurance
The Contractor shall obtain, maintain, and pay all premiums on all insurance as being the responsibility of
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the Contractor and shall upon request by Bayer to provide copies of applicable polices including receipts
of payment.
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The Contractor agrees to abide by the terms and requirements of any policy of insurance provided by
Bayer and the Contractor shall be included on any policy taken out by Bayer.
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The following insurances are required to be provided by the Contractor from the commencement of
Contract until the completion of Defects Liability Period:
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(1)RWorkman’s Compensation
Shall cover accident which occurs whilst on duty, temporary disablement, permanent
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(2) Construction equipment
CThe Contractor shall and shall cause any Subcontractor to, without limiting Contractor’s
obligations and responsibilities, ensure the Contractor’s and Subcontractor’s Equipment and
Tother things brought onto the Site by the Contractor or Subcontractor for a sum sufficient to
provide for their replacement at the site.
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The Insurances provided by Contractor shall be in the name of the Contractor issued by the first class
insurance company with good record subject to Bayer’s approval.
Any costs not insured or not covered from the insurances shall be borne by the Contractor.
4.7 Construction / Installation Procedure

The Contractor will be required to provide a written statement of the planned construction/installation
procedures prior to commencement of the works. The Client’s engineer may at its discretion request
changes to the procedures, reject the procedures or request Safe Work or another statutory body to
approve such procedures. The Vendor may not make any claims for costs or extension of time as a result
of reaching agreement on construction procedures. In any event the contractor will be deemed to have
adopted any changes to construction procedures and shall be responsible for ensuring such procedures
are followed by their employees and subcontractors at all times.
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5 Project General requirements
5.1 Preamble
The works covered by this section of the specification comprise the provision of all labour, materials and
equipment required for the described design, supply, installation, commissioning and testing as described
in this tender document.
The work shall be complete with full allowance made for all minor and incidental items necessary for the
proper installation of the whole system, even though not specifically detailed or mentioned. The Contractor
shall not assume any equipment or materials will be provided by Bayer unless specifically stated in this
document.
5.2 Contractor’s Responsibility

The Contractor shall be wholly responsible for the works in accordance with the requirements of this
Specification and the requirements of all relevant Statutory Authorities. The Contractor is to submit all
drawings and materials of construction for review by Bayer.
5.3 Material Supply

The Contractor shall be responsible for the supply of all materials required to complete the installation
unless specifically stated within this document. This includes all concrete, ducting, piping, flanges, fittings,
seals, supports, cabling etc. required to complete installation of the equipment. These materials must be
supplied in accordance with the drawings in Appendix A and the specifications in Appendix B
5.4 Equipment Supply

All equipment (plant, valves and instruments) for this contract will be supplied by the Contractor, in
accordance with relevant equipment specifications referred to in this document and its Appendices.
The Contractor will be responsible for:
 The shipment, receipt, temporary storage, unloading, un-crating including correct removal/disposal of
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dunnage, positioning and fixing of all supplied equipment and components.
The receipt, unloading, un-crating including correct removal/disposal of dunnage, positioning and fixing
E issued equipment and components.
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of all free
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Packing, Shipping and Delivery
All materials and equipment must be packed so that it can be transported to site without damage and be
unloaded in Ta safe and orderly manner. All equipment is to be cleaned and wrapped in plastic to prevent
contamination during shipping. The Contractor is required to coordinate deliveries, truck and/or container
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unloading with the relevant Bayer personnel.
all freight, Icustoms pre-clearance, duties and insurances.

All materials and equipment supplied by the Contractor is to be delivered to the Cimanggis site inclusive of
All plant and C equipment will be carefully examined upon delivery and any items not complying with the
Specification, or the requirements of the Contract, or having defects or showing damage will be rejected
T shall make arrangements for the offloading, stacking and storage of all plant and
and shall be removed and replaced by the Contractor at his own cost.
The Contractor
equipment delivered under the Contract and his Tender price shall include for all costs in this regard.
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The Contractor shall programme delivery to meet his installation programme and the Client’s Engineer
reserves the right to require that the Contractor stores equipment at his own premises until such time that
it may be incorporated in the Works.
The Contractor will be required to provide the necessary racks and bins for storage of small items of
equipment. All other items of equipment shall be supported off the floor by adequately sized wooden
spacers.
All equipment delivered and held in storage shall be the responsibility of the Contractor who shall provide
adequate protection against theft, damage from all adverse weather conditions, fire and other hazards or
interference until such time as it is installed and accepted by the Employer as complete in terms of the
Contract. Where deterioration or damage has occurred the plant shall be renovated, repaired or replaced
to the satisfaction of the Client and at the Contractor’s expense.
5.6 Warranties
Within 14 days of receipt of the Letter of Acceptance from Bayer, the successful Tenderer shall furnish to
Bayer a performance security in the form of an unconditional, irrevocable Bank Guarantee issued by bank
using a form of wording acceptable to Bayer in the amount of ten (10) percent of the Contract Price.
Failure of the successful tenderer to comply with the requirements of this Clause shall constitute a breach
of contract, cause for annulment of the award, forfeiture of the Tender Security and any such other remedy
Bayer may take under the contract, and the Bayer may resort to awarding the contract to the next ranked
Tenderer.
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6 Scope of Work
6.1 Preamble
The Contractor is being engaged under a Design and Construct arrangement whereby the Contractor is
responsible for the final design of the upgrades to the existing WWTP. It is the Contractor’s responsibility
to ensure that the features installed as part of this Scope or Work operate as intended and within the
design parameters provided. The Contractor shall also ensure that the existing and un-modified functions
of the WWTP operate as originally intended. Information that has been made available by Bayer about the
existing site has been included in appendix F.
6.2 General Inclusions

 Project management, site installation and supervision (including where local Contractors are
performing installation.)
 Ensuring the point of scope interface between the main Contractor and sub-contractors are agreed
insofar as its impacts on the works within this scope, and if found, raise any concerns to the immediate
attention of Bayer prior to commencing that portion of the work.
 Undertaking and providing necessary risk assessments, method statement and construction
procedures. The Contractor will also be required to attend a risk assessment workshop (HAZOP)
during the planning phase of the works to review existing hazards and identify any new hazards
associated with works. The method statement and risk assessments are required to be submitted to
Bayer for approval before any work can be undertaken.
 Attendance at planning and scheduling meetings leading up to the commencement of the works onsite,
and continuing throughout the duration of the project, with due allowance for out of hours work such
that continued safe operation of the existing facility is not hindered.
 Providing all temporary access platforms and scaffolding necessary to enable the works to be carried
out safely and maintaining the temporary platforms and scaffolding in a good and safe condition
throughout the duration of the works.
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Supplying and maintaining temporary lights (including flashing lights), fencing, guard rails, barriers,
handrails, walkways etc. in compliance with safety requirements
 SupplyE of all equipment to safely complete hot works as per Bayer’s requirements, including fire
extinguishers, fire blankets, smoke detectors etc.

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Hire/ supply of any cranes, mobile equipment, elevated work platforms (EWPs), specific lifting and
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transportation equipment, etc.
 Supply of any extraction/ventilation systems required to safely complete the work.
 SupplyR of any dust suppression systems and physical barriers required to minimise the spread of dust
throughout the worksite, roof space and the process plant.
 I removal and reinstallation of any equipment, services structures, handrails, walkways etc.
Temporary
required during the installation/ removal process is the responsibility of the Contractor and shall be
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agreed to by Bayer prior.
 Daily cleaning of the Site and work faces, including removal of equipment shipping materials, frequent
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disposal of all rubbish on a minimum basis of twice/week to ensure a neat/ safe site camp and working
area.
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 Provisions of coatings that have been approved by Bayer and are to a standard typically accepted on a
cosmetical manufacturing site.
 Completion of testing and provision of proof that testing has been satisfactorily completed as specified,
including provision of technical support for practical completion and acceptance testing.
 Attendance at a hand over inspection with Bayer or its Representative
 All signage and barriers pertaining to OHS requirements and safety requirements.
 List of recommended spares where applicable.
6.3 Process Design

The process design is summarized in TA2944-RHD-XX-XX-RP-PT-0001-Process Design, TA2944-RHD-
ZZ-XX-DR-ME-0001 – 0011 and TA2944-RHD-ZZ-ZZ-DR-PT-1001 PFD Class 4 (Appendix A)
The remaining process related scope for the WWTP extension comprises the following components:
1. Only primary control loops are indicated on the P&ID’s and the Contractor should add all
secondary and safety loops as per the control narrative and the contractor’s detail design.
2. The NF/RO plant needs to be designed as a package unit, the supplier is responsible for the
design/supply and commissioning of this package unit including all required auxiliaries (chemical
dosing systems, CIP system and local control cabinet).
3. The UV plant needs to be designed as a package unit, the supplier is responsible for the
design/supply and commissioning of this package unit including all required auxiliaries and local
control cabinet.
Any changes in the process design needs to be communicated and agreed with Bayer/ RHDHV before
any construction work commences.
For pricing of the remaining process design TA2944-RHD-ZZ-XX-BQ-Z-0001 BoQ General works v1.1
should be used (Appendix C)
6.4
RCivil / Structural Works
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6.4.1 Civil Works
S for the WWTP extension comprises the following components (in general):
The Civill scope
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1. Demolition works;
2. Laboratory, dosing and MCC-building;
3. Construction Management Office pump pit;
4. UV, RRO and screen slab;
5. Modifications and conversion equalization tank;
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6. Conversion Aeration tanks;
7. Selector tank;
C WAS sludge pit and effluent pump pit;

8. Clarifier;
9. RAS/
10. Pumps, sand and carbon filter;
T press building;
11. Water
12. Access road and paving for access;
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13. Pipework in culverts.

14. Drainage Plan
Refer to TA2944- RHD-ZZ-XX-RP-Z-0001-Civil Specifications for the Civil Specifications (Appendix B)
Details considering the finishes of the different structures can be found In TA2944-RHD-ZZ-XX-L-Z-0003-
Finishes (Appendix B)
General plan lay-outs, Civil drawings and arrangements can be found in TA2944-RHD-XX-XX-DR-C-0001,
0002 and 0010-0020. (Appendix A)
The Civil Bill of Quantities can be found in TA2944-RHD-ZZ-XX-BQ-C-0001 BoQ Civil works v1 (Appendix
C)
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6.4.2 Structural Works

The piling design and structural design are dependant on the actual geotechnical conditions encountered
on site. It is the responsibility of the contractor to finalize the piling design and the structural design in-line
with the on-site geotechnical conditions encountered on site. If required the contractor needs to complete
a detailed geotechnical investigation to confirm the structural/ pile design.
The Structural scope for the WWTP extension comprises of the following components:
a. Piling Work
Type of piles shall be the cast-in-place concrete bored piles with the diameter 500 mm, and the length
is 21 meter.
Table 2 Summary of Bored Pile Number for Each Building

Quantity
Building Name
(No's)
B13 - Selector Box 4
B15 - New Clarifier 16
B16 - Pumps, Sand, & Carbon Filter Building 12
B17 - RO & Screen Foundation 6
B19 - Lab, Dosing, & MCC Building 12
The cast-in-place concrete bored piles diameter 500mm and shall have a minimum compressive
strength fc’ = 30 MPa by cylinder specimens tested at 28 day-ages.
The concrete reinforcement, consists of main longitudinal rebar and stirrups (spiral type) shall be the
high yield deformed bars in accordance with yield strength of 400 MPa as per ASTM 615 grade 60 or
SNI 07-2052-2014 grade BJTS 40.
There are 2 piling tests will be applied on this project, consists of:
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- Pile dynamic load test (PDA test)
- Pile integrity test (PIT test)
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Table 3 Summary of Pile Testing Number for Each Building
S Building Name PDA Test

(No's)
PIT Test
(No's)
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B13 - Selector Box 2 1
B15 - New Clarifier 2 2
R Sand, & Carbon Filter Building
B16 - Pumps, 2 2
B17 - RO & Screen Foundation 2 1
I Dosing, & MCC Building
B19 - Lab, 2 2
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b. Sub-structure and Upper Structure Work

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Table 4 Scope of Work for Sub-Structure & Upper Structure
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General notes of the structural calculations can be found in TA2944-RHD-00-00-DR-S-1001_GENERAL
NOTES
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Each of the structures (6) are accompanied by a Calculation report & Drawings (Appendix A):
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TA2944-RHD-13-XX-RP-S-0001_Structural Calculation Report - Selector Box_P01
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TA2944-RHD-XX-XX-M3-S-0013_SELECTOR BOX
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TA2944-RHD-15-XX-RP-S-0001_Structural Calculation Report - New Clarifier_P01
TA2944-RHD-XX-XX-M3-S-0015_NEW CLARIFIER
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TA2944-RHD-16-XX-RP-S-0001_Structural Calculation Report - Pump, Sand, Carbon Filter Building_P01
TA2944-RHD-XX-XX-M3-S-0016_PUMPS, SAND & CARBON FILTER
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TA2944-RHD-17-XX-RP-S-0001_Structural Calculation Report - RO&Screen Foundation_P01
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TA2944-RHD-XX-XX-M3-S-0017_RO AND SCREEN
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TA2944-RHD-18-XX-RP-S-0001_Structural Calculation Report - New Water Press Building_P01

TA2944-RHD-XX-XX-M3-S-0018_NEW WATER PRESS BUILDING
TA2944-RHD-19-XX-RP-S-0001_Structural Calculation Report - Lab, Dosing, MCC Building_P01

TA2944-RHD-XX-XX-M3-S-0019_LAB, DOSING AND MCC BUILDING
The structural specifications for the different structure components can be found in TA2944-RHI-ZZ-XX-
SP-S-0001 – 0008 (Appendix B)
The structural works should be priced in TA2944-RHD-ZZ-XX-BQ-C-0001 BoQ Civil works v1 (Appendix
C)
6.5 Mechanical Works

The mechanical scope for the WWTP extension comprises the following components.
1. Centrifugal Pumps:
a. Submersible pumps for: Main Sump Pit (100m3 tank), New prefab Construction
Management Office pit (including pit itself), 250 m3 Equalization tank and Aeration tank.
Complete with guiderail and auto-coupling duckfoot system and lifting chain.
b. End suction pumps for: Return Activated Sludge, Clarified Effluent, Backwash of Sand &
Carbon Filter, and Re-use treatment system feed.
c. Multistage pumps for High Pressure RO Feed and the Re-use water reticulation.
2. Mixers for: Equalisation tank (submersible), Selector, Poly make-up and CIP tank (Top Entry
Agitators)
3. Screen for inlet to Equalisation Tank
4. Diffusers and aeration grid (if deemed required by Bayer for either one or both tanks) connecting
to the existing blowers
5. Clarifier scraper
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6. Sand filter & Carbon filter
7. Backwash blowers
8. Containerised RO package plant, including pre-filtration, HP RO feed pumps, RO modules,
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pipework, fittings and valves and electrical and control system with HMI. The anti-scalant,
H2SO4and CIP systems are part of the package plant but will be housed in the separate dosing
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room.
9. UV package plant, including electrical and control system with HMI
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10. NaOH, and polyelectrolyte dosing systems, including poly make-up station
11. Pipework, valves and fittings for the relocated existing Air Operated Double Diaphragm Waste
Activated Sludge Pumps, for the associated relocated existing compressor unit, and for the
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relocated existing Chamber Filter Plate Presses.
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The mechanical scope for new items listed above also includes the valves, pipework, fittings, supports and
fixing down associated with the equipment. In this tender enquiry documentation, the mechanical piping
Cpipe culvert, or where pipework runs above ground it connects to the flange connection of
either connects via a suitable coupling to PVC piping under the civil scope of works where it enters or exits
the nearest
other mechanical equipment or a tank.
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The equipment, valve and piping arrangement are according to the equipment list (TA2944-RHD-ZZ-XX-
DS-ME-3100), the valve list (TA2944-RHD-ZZ-XX-DS-ME-3101) P&IDs and layout drawings that
accompany this tender enquiry document.
Refer to TA2944-RHD-ZZ-XX-SP-ME-3200 for the Mechanical Specifications and TA2944-RHD-ZZ-XX-

BQ-ME-3300 for the Mechanical Bill of Quantities.
6.6 Electrical, Instrumentation and Control
The Contractor shall design, supply, install and commission the following equipment in accordance with
the relevant specifications and applicable Indonesian and IEC Standards. The works shall include the
supply, delivery, off-loading, positioning, installation, testing, commissioning and setting to work the
following services as briefly described below and as described in TA2944-RHD-ZZ-XX-SP-EI-1000 -
Electrical Specifications P01 (Appendix B)
1. Carry out the removal of all the redundant electrical services and all associated ancillaries as
described within the specification (also refer to section 6.8.2).
2. Test, validate and report services as specified in the relevant sections of the specification.
3. Design, supply, install and commission a new main incoming electrical feeder.
4. Design, supply, install and commission a new MCC panel.
5. Design, supply, install and commission a new distribution boards.
6. Design, supply, install and commission new small power to the laboratory, chemical dosing room
and MCC room.
7. Design, supply and install new power to mechanical plant.
8. Design, supply, install and commission new general and emergency LED lighting system to the
laboratory, chemical dosing room and MCC room.
9. Design, supply, install and commission a new external lighting system
10. Design, supply, install and commission new earthing and bonding systems.
11. Design, supply, install and commission PLC, software and programming for the WWTP.
12. Design, supply, install and commission HMI / SCADA.
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13. Design, supply, install and commission all electrical, data and communications cables necessary
within the WWTP.
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14. Design, supply, install and commission all electrical, data and communications cables necessary
to integrate the WWTP control system SCADA to the Site SCADA interface.
15. Carry out completion electrical testing.
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16. Provide operation and maintenance manuals and record drawings for the complete electrical
installation.
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17. Provide client training for correct use of the electrical installation.
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Electrical installation drawings can be found in TA2944-RHD-ZZ-XX-DR-EI-0010 – 0016 (Appendix A)
General arrangement of the MCC and Single line diagram can be found in TA2944-RHD-XX-XX-DR-EI-
0001 & 0002I (Appendix A)
C load and instrumentation list can be found in TA2944-RHD-ZZ-XX-DS-EI-4000 & TA2944-
The Electrical
RHD-ZZ-XX-DS-EI-4010
For cable T scheduling refer to: TA2944-RHD-ZZ-XX-DS-EI-4020 & RHD-ZZ-XX-DS-EI-4030 (Appendix A)
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6.7 HVAC
The Contractor shall design, supply, install and commission the following equipment in accordance with
the relevant specifications and applicable Indonesian and IEC Standards. The works shall include the
supply, delivery, off-loading, positioning, installation, testing, commissioning and setting to work the
following services as briefly described below and as described in TA2944-RHD-ZZ-XX-SP-HV-1000
HVAC Specifications:
- Ventilation and air conditioning in the building that houses the Lab, Dosing Equipment and MCC
- Ventilation for the superstructure of the 250m3 Equalisation Tank
The scope of works for HVAC is dealt with in TA2944-RHD-ZZ-XX-SP-HV-1000 HVAC Specifications -
P01 (Appendix B) and the BoQ can be found in TA2944-RHD-ZZ-XX-BQ-HV-2000 HVAC BoQ - P01
(Appendix C)
6.8 General work
6.8.1 Introduction
Items set out in the preceding sections (excluding 6.4 to 6.7) and in the following sections are to be priced
in document TA2944-RHD-ZZ-XX-BQ-Z-0001 BoQ General works v1.1
6.8.2 Demolition
The following Structures and Mechanical, Electrical and Electronic Equipment, as indicated in TA2944-
RHD-XX-XX-DR-C-0001 in red, are to be fully removed and disposed of (unless explicitly noted below as
to re-used):
1. Existing anaerobe system, comprising, conditioning & biomass vessel, EGSB reactor, flare,
dosing building, MCC/control room & lab and all associated slabs, paving, access metalwork (or
GRP equivalent handrailing, ladders, platforms, etc), equipment, pipework, valves, fittings,
concrete and supports and support structures, electrical and control systems.
2. Existing water pond at outfall structure
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3. Air blower pipework to existing sludge storage tank (to be reused as unaerated 250m3
Equalisation Tank) and removal of aeration grid and diffusers from that tank; blank off the
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connection from the remaining blower pipework.
4. Trickling filter, lamella clarifier and existing chemical dosing area and all associated concrete
structures, (or GRP equivalent handrailing, ladders, platforms, etc), equipment, paving, pipework,
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valves, fittings and concrete and supports and support structures.
5. Existing sand filter, carbon filter and pipework, valves, fittings and concrete and metal supports
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and support structures.
6. Slab, roof structures and paving of filters and dewatering area. NB existing diaphragm pumps
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feeding the dewatering units, the associated compressor unit, and the dewatering units
themselves are to be relocated to the new dewatering building. New pump suction pipework and
drainage pipework from the dewatering units will be required, and the similar existing pipework is
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to be to be removed and disposed of.
7. All the redundant electrical and electronic services, cables, containment, fixtures and all
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associated ancillaries shall be removed back to source.
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Civil demolition is specified in TA2944- RHD-ZZ-XX-RP-Z-0001 Civil Specifications. All the other
demolition
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6.8.3 Lab equipment

The following laboratory equipment for monitoring of the daily performance should be provided by the
supplier:
- Spectrophotometer (add preferred brand)
- BOD incubator
- Pipets including tips
- Digital reactor block for digestions
- Handheld pH/conductivity analyser
- Required test kits for COD, BOD, N-tot, P-tot, NO2-N, NO3-N, PO4-P for the commissioning period.
- Imhoff cones including stands for sludge volume analyses.
- Infrared moisture analyser for MLSS analyses
6.8.4 Fire prevention, fire fighting & Health & safety

Document TA2944-RHD-ZZ-XX-BQ-Z-0001 BoQ General works has listed the following items, however
the contractor shall add any items that are required under local legislation, standards, guidance and
practise for Health and Safety, ergonomics and specific plant requirements for such items:
 Fire prevention & fire-fighting

 First aid kits
 Safety shower with eye-wash station
 PPE
 Chemical spill kits
 Safety signage
6.8.4.1 Firefighting equipment details

The Contractor shall install fire hoses per as indicated by the engineer. Types and lengths shall according
to local requirements. The fire hoses and the cabinet shall have a RAL3000 Red color. Near all hoses a
sign shall be installed at eye level. The Contractor shall seal the hose to prevent improper use.
The Contractor shall also install CO2 fire extinguishers near every fire hose and in every room. The fire
extinguishers shall have a RAL3000 Red color. The extinguishers shall be able to extinguish fires of class
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B and E. The minimal content shall be 5kg. Including mounting provisions and a sign at eye level.
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6.9 Work Excluded
S excluded will be discussed during tendering process.
Other scope
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6.10 Reference Drawings
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Document Number Title Revision Appendix
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TA2944-RHD-13-XX-RP-S-0001
TA2944-RHD-15-XX-RP-S-0001
Structural Calculation Report - Selector Box
Structural Calculation Report - New Clarifier

P01
P01
A
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TA2944-RHD-16-XX-RP-S-0001
Structural Calculation Report - Pump, Sand, Carbon Filter
Building
P01 A
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TA2944-RHD-17-XX-RP-S-0001 Structural Calculation Report - RO&Screen Foundation P01 A
TA2944-RHD-18-XX-RP-S-0001 Structural Calculation Report - New Water Press Building P01 A
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TA2944-RHD-19-XX-RP-S-0001 Structural Calculation Report - Lab, Dosing, MCC Building P01 A
TA2944-RHD-XX-XX-M3-S-0013 Selector Box P01 A
TA2944-RHD-XX-XX-M3-S-0015 New Clarifier P01 A
TA2944-RHD-XX-XX-M3-S-0016 Pumps, Sand & Carbon filter P01 A
TA2944-RHD-XX-XX-M3-S-0017 RO and Screen P01 A
TA2944-RHD-XX-XX-M3-S-0018 New water press building P01 A
TA2944-RHD-XX-XX-M3-S-0019 Lab, Dosing and MCC Building P01 A
TA2944-RHD-00-00-DR-S-1001 General Notes P01 A
TA2944-RHD-ZZ-XX-RP-EI-4201 Control Narrative P04 A
TA2944-RHD-ZZ-ZZ-DR-PT-1001 PFD class 4 P05 A
TA2944-RHD-XX-XX-RP-PT-0001 Process Design P01 A
TA2944-RHD-00-00-DR-S-1001 General Notes P01 A
TA2944-RHD-XX-XX-DR-C-0001 General plan layout and sections - Site P01 A
TA2944-RHD-XX-XX-DR-C-0002 General arrangement and section - on new works P01 A
TA2944-RHD-XX-XX-DR-C-0010 General arrangement and section – Main Sump Pit P01 A
TA2944-RHD-XX-XX-DR-C-0011 General arrangement & sections - New Prefab CMO pump pit P01 A
TA2944-RHD-XX-XX-DR-C-0012 General arrangement & sections - New Equalisation Tank P01 A
TA2944-RHD-XX-XX-DR-C-0013 General arrangement & sections - Selecter box P01 A
TA2944-RHD-XX-XX-DR-C-0014 General arrangement & sections - Existing Aeration Tanks P01 A
TA2944-RHD-XX-XX-DR-C-0015 General arrangement & sections - New Clarifier P01 A
TA2944-RHD-XX-XX-DR-C-0016 General arrangement & sections - Pumps, sand & Carbon filter P01 A
TA2944-RHD-XX-XX-DR-C-0017 General arrangement & sections - RO and Screen P01 A
TA2944-RHD-XX-XX-DR-C-0018 General arrangement & sections - New water press building P01 A
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TA2944-RHD-XX-XX-DR-C-0019
General arrangement & sections – Lab , Dosing and MCC
building
P01 A
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TA2944-RHD-XX-XX-DR-C-0020 General arrangement & sections - Pipe Culverts P01 A
TA2944-RHD-XX-XX-DR-HV-0001 Lab Dosing & MCC AC P01 A
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TA2944-RHD-XX-XX-DR-HV-0002 Lab Dosing & MCC Vent P01 A
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TA2944-RHD-ZZ-XX-RP-S-1001 Structural Basic Design report P02 A
TA2944-RHD-XX-XX-DR-EI-0001 MCC GA P02 A
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TA2944-RHD-XX-XX-DR-EI-0002 MCC Single line diagram P01 A
TA2944-RHD-ZZ-XX-DR-EI-0010 Electrical Installations - Overview P01 A
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TA2944-RHD-ZZ-XX-DR-EI-0011 Electrical Installations - Main Routes P01 A
TA2944-RHD-ZZ-XX-DR-EI-0012 Electrical Installations - Site View P01 A

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TA2944-RHD-ZZ-XX-DR-EI-0013 Electrical Installations - Sections Part 1 P01 A
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TA2944-RHD-ZZ-XX-DR-EI-0014
TA2944-RHD-ZZ-XX-DR-EI-0015
Electrical Installations - Sections Part 2
Electrical Installations - Sections Part 3

P01
P01
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TA2944-RHD-ZZ-XX-DR-EI-0016 Electrical Installations - Key P01 A
TA2944-RHD-ZZ-XX-DS-EI-4000 Power consumer - Electrical load list P06 A
TA2944-RHD-ZZ-XX-DS-EI-4010 Bayer Instrumentation List P02 A
TA2944-RHD-ZZ-XX-DS-EI-4020 Power Cable Schedule P01 A
TA2944-RHD-ZZ-XX-DS-EI-4030 Instrumentation Cable Schedule P01 A
TA2944-RHD-ZZ-XX-DS-ME-3100 Equipment List P07 A
TA2944-RHD-ZZ-XX-DS-ME-3101 Valve List P01 A
TA2944-RHD-ZZ-XX-DR-ME-0001 P&ID Symbols P09 A
TA2944-RHD-ZZ-XX-DR-ME-0002 P&ID IDs P09 A
TA2944-RHD-ZZ-XX-DR-ME-0003 P&ID_Screening & Equalisation P09 A
TA2944-RHD-ZZ-XX-DR-ME-0004 P&ID Aeration P09 A
TA2944-RHD-ZZ-XX-DR-ME-0005 P&ID Clarifier P09 A
TA2944-RHD-ZZ-XX-DR-ME-0006 P&ID Filtration P09 A
TA2944-RHD-ZZ-XX-DR-ME-0007 P&ID Backwash & Effluent Tank P09 A
TA2944-RHD-ZZ-XX-DR-ME-0008 P&ID_Water Reuse Treatment P09 A
TA2944-RHD-ZZ-XX-DR-ME-0009 P&ID Chemical Storage and Dosing P09 A
TA2944-RHD-ZZ-XX-DR-ME-0010 P&ID Chemical_Storage & Dosing (RO) P09 A
TA2944-RHD-ZZ-XX-DR-ME-0011 P&ID Dewatering P09 A
TA2944-RHD-ZZ-XX-RP-Z-0001 HAZOP WWTP at Cimanggis Plant A
---------------------------------------------- SITE LAYOUT - 3D View - NAVISWORKS EXPORT A
TA2944-RHI-ZZ-XX-SP-S-0001 Technical Spesification - Piling P01 B
TA2944-RHI-ZZ-XX-SP-S-0002 Technical Spesification - Reinforcing Steel P01 B
TA2944-RHI-ZZ-XX-SP-S-0003 Technical Spesification - Structural Concrete P01 B
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TA2944-RHI-ZZ-XX-SP-S-0004 Technical Spesification - Non-Shrink Grouting P01 B
TA2944-RHI-ZZ-XX-SP-S-0005 Technical Spesification - Structural Steel Faming P01 B

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TA2944-RHI-ZZ-XX-SP-S-0006 Technical Spesification - Metal Fabrications P01 B
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TA2944-RHI-ZZ-XX-SP-S-0007
TA2944-RHI-ZZ-XX-SP-S-0008
Technical Spesification - Metal Gratings
Technical Spesification - Steel Coatings

P01
P01
B
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TA2944- RHD-ZZ-XX-RP-Z-0001 Technical specifications – Civil Specifications P01 B
TA2944-RHD-ZZ-XX-L-Z-0003 Finishes P01 B
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TA2944-RHD-ZZ-XX-SP-EI-1000 Electrical Specifications P01 B
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TA2944-RHD-ZZ-XX-SP-HV-1000 HVAC Specifications P01 B
TA2944-RHD-ZZ-XX-SP-ME-3200 Mechanical Specifications P01 B
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TA2944-RHD-ZZ-XX-BQ-C-0001
TA2944-RHD-ZZ-XX-BQ-Z-0001
BoQ Civil works
BoQ General works

v1
v1.1
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TA2944-RHD-ZZ-XX-BQ-HV-2000 HVAC BoQ P01 C
TA2944-RHD-ZZ-XX-BQ-ME-3300 Mechanical BoQ P01 C

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TA2944-RHD-XX-XX-RP-PT-0001 Conversion plan P01 D
TA2944-RHD-ZZ-ZZ-DT-CM-0001 Contractor Document Requirement list E
---------------------------------------------- Existing Site information provided by client F
6.11 Tie-in Points

All tie-in points need to be confirmed by the Contractor in consultation with Bayer before any construction
work commences. It is the responsibility of the Contractor to allow for any input required to prepare/
update any drawings to indicate these. The Conversation plan needs to be further developed and finalized
by the Contractor in consultation with Bayer before any construction work commences.
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7 Contractor Documentation
7.1 Documentation
The Contractor is responsible for the preparation of certain documentation required to undertake the
works.
The Contractor shall refer to Appendix E – Contractor Data Requirements List for the documentation
required to be submitted to the Bayer for review and comment following contract award. Contractors
should take into account time for review and comment by Bayer and shall resubmit any modification made
or responses to comments by Bayer.
The Contractor shall update and re-draft all construction drawings to ‘As Built’ status at the completion of
the Works and provide an electronic copy (PDF and native CAD files) of these drawings to Bayer.
HAZOP – a HAZOP has been carried out at Tender Design stage, which is included in TA2944-RHD-ZZ-
XX-RP-Z-0001-HAZOP WWTP at Cimanggis Plant (Appendix A), however certain elements have not
been fully reviewed during that process due to it being a Contractor package design with many details
unknown prior to Tender, and other elements are a factor of the Contractor’s detail design. As such the
Contractor shall carry out, process required design changes and record all step to close out for a HAZOP
with an independent facilitator and scribe, all to the requirements of the Client.
7.2 Reporting
 HSE management
 Progress to date against program
 Planned progress
 Financial Reporting
 Cashflows
 Other matters that need reporting on
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Performance requirements
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The effluent from the wastewater treatment plant should meet the discharge limits according to class 4 as
mentioned in Table 1 taking into account that the influent is not exceeding the design loads as described
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per 2027. The measured parameters are based on grab samples, in which the report will be delivered to a
local authority each month.
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9 Installation & Process Acceptance testing

Specific civil, mechanical and ECI acceptance testing is described in the relevant specifications; this
section relates to process acceptance testing.
9.1 Commissioning, Validation, Start-up Approach
9.1.1 Dry & wet Commissioning Approach Mechanical checks

When all equipment is installed according to the design, all items with moving parts will be checked if they
can run without obstructions. Specific mechanical testing requirements are set out in document TA2944-
RHD-ZZ-XX-SP-ME-3200 Mechanical Specifications. Once this is confirmed there can be started with the
electrical checks.
9.1.2 Electrical checks

During the electrical checks the motors of the mechanically driven equipment will be checked on the
rotation direction. The analogue input signals from level transmitters, flow meters and online analyze
equipment will be checked and calibrated. Specific electrical testing requirements are set out in document
TA2944-RHD-ZZ-XX-SP-EI-1000 - Electrical Specifications.
9.1.3 Civil / Hydraulic commissioning

When all equipment is checked on correction mechanical and electrical installation the installation is ready
for the hydraulic commissioning. During the hydraulic commissioning the different process steps are filled
with clean and/or wastewater to test each process step on its functionality.
From the initial pump pit normally the water line is followed in starting the equipment. Once all process
steps are tested the system will be set in automatic mode and the settings of the individual process steps
will be adjusted in such way that the system can run fully automatic.
Specific Civil testing requirements are set out in TA2944- RHD-ZZ-XX-RP-Z-0001-Technical specifications
- WWTP R
9.2 E
Training Approach
Once the system is commissioned training will be given to a team of operator(s), electrical engineers and
mechanicalSengineers. During the training from each process step the important process, electrical and
mechanical parameters will be explained. Contractor to propose detailed training protocol.
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9.3 R
Monitoring Period + Process Acceptance Test
Once the installation is commissioned a monitoring period will start followed by a Process Acceptance
I The Contractor indicates when the wastewater treatment is ready for a PAT, in common
Test (PAT).
agreement a period will be selected when the PAT will be carried out. The PAT needs to be carried out
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under the following conditions:
 During the PAT the installation will be run under super vision of a specialist from the Contractor
T needs to be on site for the duration of the PAT.
who
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 During the test run, samples of influent, effluent and/or in between, will be taken with auto-
samplers on regular intervals, with a 24 hours composite sample as result;
 Each sample will be analyzed per day in terms of the guaranteed parameters. From these results
the unrealistic values will be omitted, or analysis repeated. The mean values will be calculated
from the remaining values;
 Analysis of the samples takes place in a certified laboratory chosen by costumer and/or Aqua
I.W., or in common agreement with quick tests on site;
 If chosen for an external laboratory the analyses take place according to the methods described in
the handbook: “Standard methods for the examination of water and wastewater, the 20th edition or
later”;
 The test run is considered to be successful:
o when the mean daily values are in accordance with the guarantees during a period of 4
consecutive weeks. Bayer check
o when the exceeding of the guaranteed parameter(s) is a consequence of: exceeding the
influent parameter daily loads;
 The test run is not successful, and if the poor performance is due to the Contractor, some
modifications need to be applied to the plant on the Contractor’s recommendations, and on the
Contractor’s costs. Hereafter, another test period will be accomplished like the first one. This will
be repeated up to the moment the test run turns out to be successful. Mechanical warranties are
not changed: the wear and tear parts are excluded from warranty process and are charged to the
customer.
 After a successful test run Bayer shall sign the Process Acceptance Certificate, after which the
Contractor is free of its liability for process guarantees.
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10 General requirements
10.1 Approvals/Regulations
Make all necessary applications and pay all relevant fees to the relevant Authorities for connections,
inspections and approvals of all work included in the relevant sections of the Contract Works
10.2 Quality
Standard Codes and Procedures: Standards referred to in this specification are deemed to form a part of
this specification. In the event of this specification being at variance with any provision of these standards,
more stringent of the two shall apply. Reference to any standard includes any amendments thereto and
any standard in substitution, therefore. Industry recognised standards apply in the absence of specified
standards, unless expressly noted otherwise.
10.2.1 Quality Assurance (QA)

Tenderers shall submit, together with their tenders, an assessment report on their QA and Quality Control
(QC) system issued by an independent Quality Assurance Authority. The inspection on which the
assessment report is based shall have taken place not more than 12 months prior to the closing date for
this tender.
In the event that a tenderer does not have a QA system, then sufficient information shall be submitted with
the tender to demonstrate the Contractor's ability to prepare and implement a QA system that has been
prepared in conjunction with an independent Quality Assurance Authority so that it will achieve the
objective of full compliance with the requirements of the contract.
The Contractor will be solely responsible for the production of work that complies with the drawings and
specifications to the satisfaction of the Client. To this end it will be the responsibility of the Contractor to
institute an appropriate ISO 9001 type Quality Assurance (QA) system for the contract which shall make
provision for method statements for all activities. The Contractor’s QA System shall include quality
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management objectives, policies, organisation structure (organogram that includes the qualifications and
number of years of relevant experience of the named persons), procedures, method statements and work
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instructions that comply with the requirements of ISO 9001.
The proposed QA system shall be agreed with the Client prior to commencement of any work on site. The
S QA system will be subject to an audit by the Client on a regular basis but not exceeding three
Contractor's
monthly intervals to verify that adequate inspection, checks and tests are being carried out and to ensure
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that the Contractor's own control and record keeping is sufficient to identify any possible quality issues that
could cause a delay or failure.
R of a QA system by the Client will not exempt the Contractor from compliance with any of the
The approval
specifications and/or the quality requirements prescribed in, or implied by, the tender documents.
MonitoringIby the Client and/or the Client's Representative may be done at any time on any material or
construction process.
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The Contractor shall ensure that a sufficient number of appropriately qualified, trained and experienced
T own workmanship in accordance with his/her QA system. Attention is drawn to the fact
supervisory staff and the required transport, instruments, equipment and tools are available to control the
quality of his/her
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that it is not the duty of the Client or the Client's Representative to act as supervisor, foreman, surveyor or
QC manager.
Responsibility for compliance with this sub-clause, and all associated costs, shall rest with the Contractor
and will be deemed to be included in the tendered rates.
10.2.2 Quality Control Plan

The Contractor shall, within 20 days from the commencement date, submit an overall Quality Control Plan
(QCP) for the project. The QCP shall indicate how the QA System will apply to the specific requirements
of the Contract to ensure compliance with the requirements of the specifications. The QCP shall be
subject to approval by the Client.
Individual QCPs shall be prepared by the Contractor and/or his/her subcontractors for each group of
activities. These shall include Method Statements including plant, construction equipment, materials or
services required, as applicable, to achieve compliance with the drawings and the specifications. The
relevant QCP for each activity shall be submitted to the Client's Representative for approval and for the
inclusion of his/her construction monitoring activities at least two weeks in advance of any construction of
the permanent works commencing unless agreed to otherwise by the Client’s Representative and
recorded in a site instruction.
The following surveillance requirements shall be included in each QCP for review and/or comment by the
Client or his/her Representative.
Record (Rec): The Contractor shall prepare documentary evidence for every construction activity and
statistical analysis of the data to be retained, generally in the form of QC forms but other appropriate
documentation may apply, and copies shall be sent to the Client's Representative.
Witness (W): The Client or his/her Representative requires notification to enable witnessing of an activity.
The notice period shall be agreed (generally not less than 48 hours) and will depend on the nature and
location of the activity and shall be reviewed from time to time. QC forms for tests that have been
witnessed shall be signed in the field as having been “witnessed only” by the Client or the Representative
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who witnessed the test.
to witnessE
Verification (V): The Client or his/her Representative will not necessarily be present during the activity or
all subsequent QC testing but documentary evidence to permit verification of compliance with
the requirements is to be generated, retained and presented to the Client's Representative for signature
as part of S
on-going verification that QC is being carried out and that the results of each test as recorded on
the QC sheets meet the requirements of the specification.
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Hold (H): The Contractor may not proceed with such an activity until the preceding activity has complied
sheets andRverified that the information recorded by the Contractor complies with the specification.
with the specified requirements and the Client or the Client’s Representative has been given the QC
Documentary evidence shall be retained in accordance with the agreed QA system.

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Random (Ran): Construction monitoring by random inspection. Random construction monitoring may be
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carried out at any stage of the activity or during the preparation for the activity. Documentary evidence
shall be retained in accordance with the agreed QA system.
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10.2.3 Categorisation of QCPs

The following categories shall apply in determining the requirements for a Quality Control Plan:
Category Clarification Quality Control Plan

Critical A component, group of components, Required for all components.
structure, the failure of which to comply with
the specifications may affect the short or
long term performance of the Works or
which it is a part and /or will cause a
detrimental environmental impact, and/or
may result in hazardous or unsafe
conditions.
Major A component, group of components, As determined by the Contractor
structure, element of a structure or facility, and subject to approval of the
other than categorized as 'Critical', the Client.
failure of which to comply with the
specifications may compromise the
performance of the works of which it is a
part, result in increased maintenance and/or
impact negatively on the quality of the
Works.
Minor All items other than those categorised as As determined by the Contractor
'Critical' or 'Major' and which are visible and
capable of rectification during routine
inspections.
10.2.4 Laboratory Testing

The Contractor shall arrange for all tests required for process control to be done by a laboratory
acceptable and subject to approval by the Client.
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The Contractor may establish his/her own laboratory on site or he/she may employ the services of an
independent commercial laboratory.
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Whatever method is used, the Contractor must submit the results of tests carried out on materials and
workmanship at the end of every shift for verification by the Client's Representative. Unless otherwise
stated, theScosts of all of these tests will be deemed to be included in the relevant tendered rates and no
additional payment will be made for such testing as the case may be.
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10.2.5 Verification (Acceptance Control)
The processR control test results submitted by the Contractor for his own approval of materials and
workmanship may be used by the Client's Representative for verification (process control). However,
I any work, the Client's Representative may require further control tests to be carried out by
before verifying
a laboratory of his/her choice. The cost of such additional tests will be paid for, but tests that failed to
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confirm compliance with the specifications, will be for the account of the Contractor.
10.2.6 Quality Management Audit

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The Contractor shall carry out periodic assessments of the adherence to the QA system and the QCPs by
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senior qualified staff who are not normally employed on the Site. The Client and/or his/her Representative

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shall be invited to attend at the Contractor’s periodic assessments meeting and be afforded the
opportunity to view and comment on the report on the implementation of the QA system at the site.
10.2.7 Corrective Action

Failure to conform to the specified requirements will result in the issue by the Client's Representative of a
Corrective Action Request typically in the form of, or under cover of, a Site Instruction. Failure to rectify the
deficiencies covered by a Corrective Action Request within the period stated will result in the Client
invoking the provisions of the Conditions of Contract.
10.2.8 Quality Assurance Enhancement

Should the Contractor or any of the proposed sub-contractors not comply with Sub-Clause 10.2.1 at the
time of tender, a Contract may be awarded subject to a written undertaking to enhance his own and/or
Sub-Contractor's quality assurance system to the satisfaction of the Client before commencement of the
contract.
10.2.9 Quality Assurance Staff

The Contractor shall satisfy the Client that a quality specialist together with sufficient and suitably qualified
staff will be assigned to control the quality of the material used by each sub-contractor engaged in the
supply of critical and major components and sub-assemblies.
10.2.10 Client's Quality Assurance Representative/Inspector

The Client may elect to appoint an independent quality assurance representative(s) to act in a surveillance
capacity on his behalf for all or part of the Contract.
The Client’s Quality Assurance Representative will be a selected Sub-Contractor and will be paid by the
Contractor under this Contract for all tests passed by the Inspector and certified by the Client. The
Inspector will not act as the quality controller for the Contractor or his Sub-Contractors and accordingly
any tests failing inspection will be for the account of the Contractor. Similarly, the costs of all inspections
arising following any failed tests will be for the account of the Contractor.
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10.2.11 Sub-Contracting
E made, and contracts placed by the Contractor for critical components shall require that sub-
All enquiries
contractors comply with the requirements of the preceding sub-clauses. Responsibility for and all
applicable,STenderers must indicate what equivalent alternative Code of Practice is being implemented.
associated costs of compliance shall rest with the Contractor. In instances where ISO 9001 is not
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10.2.12 Disqualification
who do notRrespond in terms of Sub-Clause 10.2.2 above may be disqualified.

Tenderers who do not include the formally documented statements called for in Sub-Clause 10.2.1. and
10.3 ReviewI by Bayer
Cof the general performance, layout, principles and techniques involved, and shall not be
Review of Contractor’s pre-manufacture sketches, drawings, diagrams and material equipment data
means only
construed as implying in any way that the Contract Works, if supplied and constructed in accordance
therewith, T
will necessarily perform in the required manner, nor that the co-ordination and setting out is
correct, the responsibility for which rests wholly with the Contractor.
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Review means review for suitability of appearance and a general review of workmanship for apparent
compliance with the Contract requirements. Review by the Principal when used in relation to matters other
than above means a general review for apparent compliance with the Contract requirements.
Such reviews or inspections with “no exceptions taken” does not relieve the Contractor of any of his
obligations for producing materials, equipment and workmanship which are in compliance with the
Contract requirements.
10.4 Workmanship
All Workmanship shall:
 Comply with the Contract Documents.
 Be carried out by appropriately qualified, certified and experienced tradesmen and supervised
apprentices.
 Be carried out under the constant supervision of a competent foreman.
Install materials and equipment in accordance with the Manufacturer’s written instructions and where
necessary or requested by Bayer, have the installation checked by a fully qualified and trained
representative of the Manufacturer or his agent.
10.5 Materials
Means any raw or manufactured materials or goods and includes all machinery, equipment and
components which form a part of the Contract Works to be handed over to Bayer.
All materials and equipment to be:
 New (unless otherwise specified).
 Suitable for the specified performance.
 Proven in service.
 Suitable for installation in the spaces as shown on the drawings with suitable access and clearances
for normal and long-term maintenance requirements.

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Compatible with other materials and equipment to be used in the Contract Works (including Galvanic
similarity).

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Complying
 Supported by appropriate servicing facilities and locally available spare parts.

Sfor the structural loading limitations
Suitable

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Suitably connected and interfaced with other components.
Where any material or equipment is mentioned by a trade name or by any other specific reference, it is for
R of indicating suitable standards of quality (including but not limited to finish, durability and
the purposes
service ability), space requirements and structural loading for the purpose intended, and for no other
reason. I
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11 Completion
Final completion of the contract will occur when:
 All installation checks and site acceptance testing has been satisfactorily completed.
 All ‘as built’ drawings and documents are completed and handed to Bayer.
 The Monitoring Period has been completed satisfactorily.
 All punch list items have been resolved to the satisfaction of Bayer.
 Carry out a thorough clean-up of the site prior to handover.
 Approval and acceptance of the Works by Bayer
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Appendix
A – Reference design
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Appendix
B – Standards & Technical specifications
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Appendix
C – Bill of Quantities (BoQ)
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Appendix
D – Detail conversion plan
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Appendix
E – Contractor Document requirement list
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Appendix
F – Existing site information provided by client
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TA2944 RHD ZZ XX SP X 0001 Scope of Works & Technical Specifications

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TA2944 RHD ZZ XX SP X 0001 Scope of Works & Technical Specifications

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SPECIFICATION

Technical Tender Documentation

Waste Water Treatment Plant at Cimanggis

Client: PT Bayer Indonesia

HASKONINGDHV NEDERLAND B.V.

Laan 1914 no.35

Water & Maritime

Document title : Technical Tender Documentation

Subtitle: Waste Water Treatment Plant at Cimanggis

Revision Date Description Prepared Checked Approved

0 14-12-2023 Tender document Bart Zwart Zwingli Visser Zwingli Visser

Receipt/ Acceptance of document:

Name : Hamzah Bahmudah Date ………………. Signature: ………………

4 Project Site Information 6

5 Project General requirements 11

6.2 General Inclusions 13

9 Installation & Process Acceptance testing 27

10.2.8 Quality Assurance Enhancement 32

1.1 Project description

2.1 Feed and effluent characteristics

Parameter Unit 2020 20221 2027 Permen

m3/d 63 245 90 238 115 304 - -

Colour - Red-coloured (intermittently) N/A N/A

pH - 6.2 8.5 6 7.2 - - 6-9 6–9

COD kg/d 55 77 106 231 136 295 - -

COD mg/l 100 80

BOD mg/l 246 857 942 2,130 - - 50 12

TSS mg/l 63 158 199 689 - - 200 400

TDS mg/l 686 2,200 - - - - 2000 2000

Total Nitrogen (TN) mg/l 22 63 - - - - 30 -

NH3-N mg/l 4.1 13.7 - - - - 5 -

TP S mg/l 1.6 6.2 - - - - - -

FOG mg/l <1.4 <1.4 - - - - 10 10

Dissolved iron (Fe) mg/l 0.50 0.9 - - - - 5 -

Feed (Influent Characteristic)

Parameter Unit 2020 20221 2027 Permen

Copper (Cu) mg/l 0.12 0.34 - - - - 2 0.2

Zinc (Zn) mg/l 1.08 4 - - - - 5 2

Total chromium (Cr) mg/l 0.004 0.014 - - - - 0.5 1

Cadmium (Cd) mg/l 0.01 0.05 - - - - 0.05 0.01

Mercury (Hg) mg/l 0.017 0.02 - - - - 0.002 0.005

Lead (Pb) mg/l 0.02 0.04 - - - - 0.1 0.5

Stanum (Sn) mg/l 0.07 0.10 - - - - 2 -

Arsenic (As) mg/l <0.006 <0.006 - - - - 0.1 0.1

Selenium (Se) mg/l <0.002 0.005 - - - - 0.05 0.05

Nickel (Ni) mg/l 0.01 0.01 - - - - 0.2 0.1

Cobalt (Co) mg/l <0.008 <0.008 - - - - 0.4 0.2

Cyanide (Cn) mg/l <0.006 <0.006 - - - - 0.05 -

Sulphide (H2S) mg/l 0.15 0.46 - - - - 0.5 -

Fluoride (F) mg/l 0.28 0.83 - - - - 2 -

Free chlorine (Cl2) mg/l 0.04 0.2 - - - - 1 -

Phenol mg/l 0.21 0.34 - - - - 0.5 0.02

2.2 Solution Development

3.1 Project objectives

 Meet the Class 4 (PP no. 22 / 2021) effluent limits.

3.2 Key Project Contacts

3.3 Summary of Contractor’s Scope

3.4 Project Schedule

4 Project Site Information

4.1 Works Area

Figure 1 Current aerial view WWTP.

Figure 2 Aerial view with schematical lay-out.

4.2 Access to Site