k8v12 m1 Section i

BALANCE OF PLANT PACKAGE FOR3 x 660 MW SUPERCRITICAL TPS

AT TALWANDI IN MANSA DIST. PUNJAB

STERLITE ENERGY LTD.

VOLUME IISPECIFICATION M1

VOLUME – II

SPECIFICATION - M1

RAW WATER PRETREATMENT PLANT

3 x 660 MW SUPERCRITICAL TPS AT TALWANDI IN MANSA DIST. PUNJAB

Balance of Plant PackageVolume – IISPEC-M1 Page No.1





SPECIFICATION – M1 CONTENTS

SR. NO. DESCRIPTION

SECTION-I GENERAL SPECIFICATION

SECTION-II TECHNICAL SPECIFICATION FOR PUMPS

SECTION-III TECHNICAL SPECIFICATION FOR METERING PUMPS

SECTION-IV TECHNICAL SPECIFICATION FOR CLARIFLOCCULATOR, GRAVITY FILTER & CHEMICAL DOSING SYSTEM

SECTION-V TECHNICAL SPECIFICATION FOR MONORAIL HOIST

APPENDIX-I DATA SHEET FOR MECHANICAL & PROCESS EQUIPMENTS & ACCESSORIES OF WATER PRE-TREATMENT PLANT

APPENDIX-II DESIGN RAW WATER ANALYSIS


Balance of Plant PackageVolume – IISPEC-M1 Page No.2





SPECIFICATION – M1

SECTION – I

GENERAL SPECIFICATION


Balance of Plant PackageVolume – II

SPEC-M1; Sec-I Page No.1





SPECIFICATION – M1SECTION – I

C O N T E N T S

CLAUSE NO. DESCRIPTION PAGE

1.00.00 INTENT OF SPECIFICATION S-I: 1

2.00.00 GENERAL INFORMATION S-I: 1

3.00.00 SCOPE OF THIS SPECIFICATION S-I: 7

4.00.00 SALIENT DESIGN DATA S-I: 14

5.00.00 SERVICES TO BE RENDERED BY THE BIDDER S-I: 15

6.00.00 INSPECTION, TESTING & COMMISSIONING S-I: 17

7.00.00 PAINTING S-I: 22

8.00.00 TRANSPORTATION & PACKING S-I: 23

9.00.00 SPECIAL TOOLS & TACKLE S-I: 23

10.00.00 DRAWINGS, DATA & INFORMATION REQUIRED S-I: 23








SPECIFICATION – M1SECTION-I

GENERAL SPECIFICATION

1.00.00 INTENT OF SPECIFICATION

1.01.00 This Specification is intended to cover the design, engineering, manufacture, assembly/re-assembly, constructional features, tests at manufacturer’s works, forwarding (duly packed for transportation), transportation, delivery to the site at Talwandi, unloading, handling, storage and inplant transportation at site, complete execution of necessary and allied civil works, complete services of erection, testing at site, successful commissioning, operation and training to Sterlite Energy Limited personnel are handling the plant in a flawless operating condition to Owner, of the entire Raw Water Pre-treatment Plant.

1.02.00 This Specification also includes carrying out of performance guarantee

tests at site for each and individual unit as well as the plant as a whole after successful commissioning only. All necessary equipment, instruments, services, labour as required for this purpose shall be under the scope of this specification. All gauges for performance testing shall also be supplied by the Bidder, under this Specification.

1.03.00 Any additional plant, equipment, material, services which are not specifically mentioned here, but are required to make the plants/ system, in the scope of bidder, complete in every respect in accordance with the technical specification and for safe operation and guaranteed performance, shall be covered under the scope of this Specification.

1.04.00 Owner shall interpret the meaning of the Specification, drawings, requirement of operation, maintenance, redundancy etc., and shall have a right to reject or accept any work or material which in his assessments is not technically complete to meet the requirements of this Specification and/or applicable National and International standards mentioned elsewhere in this specification.

2.00.00 GENERAL INFORMATION

2.01.00 Raw Water Storage Reservoir

Raw water source for the proposed project is Bheni distributor of Kotla Branch of Sirhind canal at a disftance of about 38 kms. Bheni canal will be raised over a distance of about 20 Kms and a new channel/pipe line








from Bheni canal will be laid over a distance of about 18 kms upto power station boundary by Irrigation Department of State government. From plant boundary upto the Raw Water Storage Reservoir pipeline shall be laid. The Raw Water Reservoir shall be an earthen tank of RCC construction with an RCC partition wall. The reservoir shall be built in two compartments, each complete with inlet gates, screens, level instruments, pump sump, vents, drains etc. The reservoir shall have pump house which shall accommodate raw water pumps, fire water pumps and pumps for supplying water for Ash Handling System.

2.02.00 Raw Water Pumps and Ash water pumps

Three (3) x 50% capacity Raw Water Pumps (2 working + 1 standby) of vertical turbine type, each of 2700 m3/hr rated capacity to be located in the Raw water Pump House. Raw water pumps shall have suction from both the compartments, which shall be fed from both the compartments through isolation gates and screens.

2.03.00 Raw Water Pre-treatment Plant

The proposed Raw Water Pre-treatment Plant shall supply the water requirement of the 3 x 660 MW Thermal Power Station. The raw water shall be pumped to Raw Water Pre-treatment Plant with the help of R.W. pumps for clarification and further necessary treatment.

The raw water pre-treatment plant for meeting clarified, filtered and DM Plant water demand such as make-up water demand for the cooling water system, service water requirement, plant, colony drinking water demand, and heat cycle make up water demand, etc.

Raw water shall be taken to a cascade aerator and then to a stilling chamber where turbulence of water shall be broken. Water shall then flow through Parshall flume (for flow measurement) to flash mixer unit from where the water shall be fed to two (2) x 60% Clariflocculators each of 3000 m3/hr net capacity. There will be two (2) cascade aerator, two (2) stilling chamber, two (2) Parshall flume and two (2) flash mixer for 2 clarifiers. Chemicals such as alum, lime and coagulant aid shall be added at the downstream of the Parshall flumes.

The clarified water shall then be supplied to filters by gravity where it shall be filtered in three (3) nos. (2 Working & 1 Standby) twin bed type gravity filters, each of 150 m3/hr net capacity. The filtered water shall be stored in a Filtered water storage reservoir for The DM plant and for the plant Domestic use From the reservoir, the filtered water shall be supplied to








the DM Plant with the help of three (3) x 50% DM Plant feed pumps for further treatment.

. Fire fighting, CT make-up, HVAC make-up and Service water shall be taken from the clarified water storage tank.

2.04.00 Sludge Treatment

The under flow sludge from each clariflocculator shall be taken out to a common two chamber sludge sump. The effluent with sludge shall then be pumped from the sludge sump by three (3) x 50% vertical centrifugal pumps to the sludge thickener and centrifuges from where the treated water shall be recirculated back to the stilling chambers.

2.05.00 Chemical Dosing System

All chemicals for the entire pretreatment plant shall be stored in the chemical storage area of the Chemical House. Chemicals shall be directly unloading from the trucks in the chemical storage area and shall thereafter be stacked in the respective storage space by means of manually operated hoists. The preparation of chemical solution for dosing to raw water shall be carried out in a two (2) storied Chemical House. While ground floor of chemical house shall be used for storage of chemicals, solution preparation and dosing system shall be located in first floor. Chemicals shall be lifted from ground floor to first floor to the respective solution preparation tanks by means of electrically operated monorail hoists.

Alum solution preparation system shall consist of two (2) tanks fitted with dissolving baskets. Each tank capacity shall be suitable for 12 hours demand of the complete clariflocculation plant. While one (1) tank shall be in normal operation, the other shall be under solution preparation/ cleaning. Solution preparation shall be done by recirculation pumps and also by air agitation system. Two (2) x 100% air blowers shall be provided for this purpose. Maximum dosing level to be considered shall be 60 ppm of alum.

The lime dosing system shall consist of two (2) tanks for lime slaking, two (2) tanks for slaked lime solution preparation, each having a capacity to cater 12 hours plant demand. While one tank shall be in service, second tank shall be under slaking/ solution preparation. For solution preparation both air agitation and recirculation pumps shall be provided. For slaking of lime, agitator shall be provided in each lime-slaking tank. Maximum dosing level to be considered shall be 20 ppm.








The coagulant aid dosing system shall consist of two (2) tanks for coagulant dosing, each having a capacity to cater 12 hours plant demand. While one (1) tank shall be in normal operation, the other shall be under solution preparation. The dilute solution preparation shall be achieved by air agitation and chemical dosing shall be done by coagulant aid solution dosing pumps.

Water for dissolving chemicals shall be taken from the overhead filtered water tank located at the roof of Chemical House. Pipe sizing for chemical dosing line shall be minimum 25 NB.

2.06.00 Filtered water storage tank shall be located in filter house. In the filtered water storage tank, gravity filter backwash pumps along with sludge flushing pumps shall be located. The required number of pumps, to be supplied and erected by Bidder shall also be located in the storage tank.

2.07.00 Codes and Standards

2.07.01 All electrical equipment supplied shall comply with latest revision of the Indian Electricity (Supply) Act, Indian Electricity Rules, Indian Standards (IS) or International Electric technical Commission (IEC). Publication including Codes & Standards mentioned on Different Section of Electrical Specification Volume - II and also within the statutory requirements of the Government of India and Government of Maharashtra as regards safety, earthing and other provisions specified therein for installation and operation of electrical equipment.

The Bidder shall be responsible for obtaining necessary approval and making whatever additions/ modifications considered necessary by the electrical inspectors and other authorities to bring the installation in conformity with the above Rules/ Regulations.

2.07.02 The components of all other equipment shall be designed, assembled

and tested in accordance with the relevant standards published by Bureau of Indian Standards and/or as specified in the relevant technical specification. Components, which are not falling under any Indian Statutory Regulations and manufactured as per reputed National Standards/ ISO shall also be accepted unless it is in conflict with the requirements of this Specification in which cases the stipulation of Specification shall prevail. Such codes/ standards other than Indian Codes/ Standards must be equal to or more stringent than the Indian Codes/ Standards and must be submitted to the Owner, with four (4) copies of their English versions duly certified.








In general, the materials and methods for this work shall meet the requirement of standards as noted in the Specification. Where standards are not stipulated, detailed specifications may be given. In any case, materials shall be those specified or suitable for the purpose intended, in accordance with modern water treatment plant practice. Previously used materials shall not be incorporated into the plant. Substitutions for specified materials or equipment shall be permitted only as approved by the owner. Such approvals shall be granted only if a compelling reason exists for making a substitution.

Trade names mentioned in the Specification are for the purpose of establishing the type and quality of products to be used. Competitive products of equal quality and function may be substituted, if approved by the Owner. All products and equipment shall be used or installed in strict accordance with the manufacturer’s recommendations, unless otherwise directed by the Owner.

2.08.00 Standardization

Contractor shall standardize various types and make of equipment and accessories in order to reduce diversity for convenience of operation and maintenance.

2.09.00 All moving part of equipment, which can conceivably cause injury to the operator and otherwise authorized personnel within the vicinity of working area, shall be suitably guarded according to the safety regulations. The complete assembled units shall be easily accessible for inspection, maintenance and replacement, with minimum loss of time. All equipment supplied shall allow access to facilitate connecting up and shall operate satisfactorily under such variations of load, pressure and climate conditions as may occur in working.

2.10.00 The plant and equipment offered shall be of proven latest design and of adequate capacity strictly as per the requirement mentioned under this specification. The material shall be new and of first grade quality. The workmanship and design shall be in accordance with the best engineering practice and shall be such as have been proved to be suitable for the intended purpose and for giving satisfactory performance under the prevailing climatic conditions and proposed system of supply. Liberal factor of safety shall be used throughout the design and special consideration shall be given for parts subjected to alternating stresses of shocks.








Systems shall be designed incorporating the latest technology and maximum flexibility in operation with sufficient stand-by provisions. All system design shall be subjected to approval by the Owner.

2.11.00 Equipment furnished by the Bidder shall be complete in every respect with all mountings, fittings, fixtures and standard accessories, which are normally supplied even though not specifically detailed in the specification. The Owner shall not be called for any extra payment in respect of such mountings, fittings, fixtures and accessories which are needed for the safe operation of the equipment as required by applicable codes within Indian territory though they may not have been included in this contract.

2.12.00 All equipment shall have suitable approach and platform for repair and maintenance wherever necessary.

2.13.00 On each equipment a stainless steel name plate indicating pressure rating (wherever applicable), code number of the equipment, electrical characteristics in case of electrical equipment and name of the instruments, manufacturer, shall be fixed at proper place.

3.00.00 SCOPE OF THIS SPECIFICATION

The scope of supply for plant and equipment and services shall include but not be limited to the followings:

3.01.00 The scope of plant/ equipment to be furnished and put into operation and all other required services are detailed herein under. The items, though not specifically mentioned but needed to make the system complete in all respects and reliable for safe & smooth operation and guaranteed performance, shall also be treated as though included and the same shall be furnished, unless otherwise specifically excluded elsewhere.

3.02.00 Overall scope of work under this package shall be as specified in various specifications attached subsequently and as described in the following clauses. The Bidder shall also refer to the various drawings enclosed with the specification attached subsequently and as described in the following clauses. The Bidder shall also refer to the various drawings enclosed with the specification for general guidelines of the minimum requirement under this specification.

3.03.00 All equipment and accessories envisaged for the plant are as follows :

i) Two (2) Cascade Aerators.








ii) Two (2) stilling chambers of RCC construction. The stilling chambers shall have minimum 2 minutes retention time with respect to the rated flow to be handled. Net volumetric capacity for DM stilling chamber shall be minimum 110 m3. Suitable draining arrangement shall be provided for the stilling chambers & the drain lines shall be extended upto the nearest sludge well for final disposal to the common sludge sump. Bypass to the cascade aerators shall be provided to allow maintenance for the aerators.

iii) M.S. raw water piping from Raw Water Pump House to upstream of the cascade aerators.

iv) Motor operated isolation valves along with manually operated butterfly valves and necessary valve pits shall be provided for each system. All the motor operated valves shall be remote operable along with hand wheels for local manual operation. All valves shall have remote as well as local & positioning indicators & ‘Open-close’ (panel mounted) push buttons for inching operation of valves.

v) RCC inlet channel shall be constructed for each system for connecting the flash mixer and the stilling chamber.

vi) Two (2) flash mixers including mixing agitator, electric drive, isolation gates, etc. Suitable sludge draining arrangement shall be provided for the flash mixer and the stilling chamber. The flash mixer shall be provided with minimum 1 minute residence time.

vii) Flow measuring elements (Parshall flume) at the inlet channel to the flash mixers.

viii) Clariflocculators

Two (2) clariflocculators complete with rake mechanism (bridge type rake arm) along with drive and drive motors, flocculator mechanisms along with drive and drive motors, telescopic type continuous sludge discharge arrangement, intermittent timer operated main sludge disposal system etc. for each clariflocculator. Unit design shall be circular, center feed type, with concentric flocculation zone & clarifier zone.

The bottom of clarifier shall be adequately sloped towards the center & mechanically driven sludge scraper, and collectors shall








be used to remove the settled sludge down the sloping bottom to the sludge hopper.

x) Clarified Water Storage Tank

One (1) clarified water storage tank (of RCC construction in two compartment). The filtered water storage tanks shall be located below the gravity filter house.

xi) Gravity Filters

Gravity Filters shall be twin bed type each complete with control chamber, isolation valve etc.

Filter box shall be water tight R.C.C. structure. Gravity filters to be installed shall be three (3) in number (2W & 1S).

xii) Filtered Water Storage Tank

One (1) filtered water storage tank (of RCC construction in two compartment). The filtered water storage tanks shall be located below the gravity filter house.

xiii) Blowers for Air scouring

Three (3) air blowers along with air filters, drive motors, etc. for all the gravity filters for air scouring of filter beds.

xiv) Three (3) vertical centrifugal pumps for gravity filter backwash shall be installed on the filtered water storage tank for supplying back wash water from filtered water storage tank, and two (2) vertical centrifugal pumps for sludge flushing.

However, total backwash water requirement for each filter shall be limited to 2% of total filtered water produced by each filter between two (2) successive backwashing. The backwash shall be carried out once in a day. The velocity of water during backwashing shall not be more than 30.0 m/hr, when air scouring is employed.

xv) Backwash Water Transfer Pumps

The backwash water from the gravity filters shall be taken by gravity into a common two-compartment backwash storage tank.








Two (2) backwash water transfer pump shall be provided to transfer (recirculate) the backwash water collected in the backwash storage tank to the stilling chamber.

xvi) Chemical Solution Preparation and Dosing system

One (1) set of equipment, piping instruments etc. for Alum Dosing system, one (1) set for lime dosing system and one (1) set for polyelectrolyte (coagulant aid) dosing system. The Alum Dosing System shall consist of two (2) RCC epoxy painted Alum solution preparation tanks with dissolving baskets, air agitator in each tank, two (2) Alum dosing pumps, connecting pipe lines, valves, level gauges & alarms etc.

The Lime Dosing system shall consist of two (2) RCC epoxy painted lime slaking tanks with dissolving baskets, two (2) RCC epoxy painted lime solution preparation tanks with agitator in each tank, two (2) lime dosing pumps, connecting pipe lines, valves, level gauges & alarms etc.

The coagulant aid dosing system shall consist of two (2) RCC epoxy painted coagulant aid tanks for solution preparation with air agitation in each tank, two (2) coagulant dosing pumps (metering pumps), connecting pipelines, valves, level gauges and alarms, etc.

There shall be provision for air agitation of chemical solutions in tanks by two (2) air blowers each of 100% capacity for each system, complete with drive motors, air filters, etc. which shall be common for all solution preparation tanks.

xvii) Overhead Filtered Water Storage Tank

One (1) overhead filtered water storage tank shall be provided by the Bidder at the roof of the chemical house. Also, one (1) no drinking water tank shall be provided on the same roof for meeting drinking water demand of chemical house, various pump houses, filter house, switch gear room and other houses of this plant facilities.

xviii) Waste Water Recycling

Sludge produced from the clariflocculators, stilling chambers, flash mixers, chemical house etc. shall be taken by gravity into a








common two compartment sludge sump. The sludge pipes from the clariflocculators shall be routed to the common sludge sump. From this sump, the sludge and water shall be transferred with the help of sludge pumps to sludge thickener and centrifuges. The treated clear water from the centrifuges shall be recirculated back to the inlet of the stilling chamber.

xix) Sludge Sump

A common sludge sump in two (2) compartments shall be provided with three (3) sludge pumps for transferring the sludge from the sump to sludge thickener and centrifuges, complete with sludge flushing arrangement, drive motors, necessary isolation gates and associated piping.

xx) Chemical Storage Area and Chemical House

For dosing of chemicals in the clariflocculation plant, a two storied ’Chemical House’ shall be provided for housing chemical storage area, various chemical solution tanks, laboratory, pumps, MCC and control room. The ground floor of chemical house shall be used as chemical storage space. The storage space in chemical house shall have suitable partitions sufficiently large to accommodate at least thirty (30) days requirement of alum, lime and coagulant aid. Suitable staircase, walkways, platforms with hand rails shall be provided to have clear access from chemical house to different units like stilling chamber, parshall flume, flash mixer, clarifiers, sludge sump etc. and also various sub systems / units of pretreatment plant. One weighing scale shall be provided in the chemical house for weighing chemicals.

xxi) Sampling Rack

A centralized sampling rack for the entire raw water pre-treatment plant shall be provided and this sampling rack shall be installed in the chemical laboratory located in the first floor of the chemical house. Samples of water shall be taken from the following points and supplied to the sampling rack:

i) Raw water inlet to stilling chambers.

ii) Sludge water from clarifiers (individually)

iii) Clarified water from the launders (individually)








iv) Sludge water from the discharge of sludge pumps

v) Filtered water from filtered water reservoirs (individually).

The water samples shall be taken to the centralized sampling rack through small diameter pipes of polypropylene or suitable material. Suitable monoblock pumps, if required, for carrying the water samples at the sampling rack shall also be provided by the bidder and shall be located near the supply source itself at suitably accessible location.

xxii) Lifting and handling arrangements as detailed below.

a) Adequate number of manually operated monorail hoists in the chemical storage area, each of 1.0 T capacity (minimum) with a vertical lift of 5.0 m (minimum) along with chain pulley blocks and traveling trolley.

b) Adequate number of electrically operated monorail hoists, each of 1.0 T capacity (minimum), both hoisting and traveling electrically operated, complete with pendent station runway and cross conductors, down shop leads with incoming switch fuse unit, crane rails, with all fixing attachments including control / protective / supervisory equipment / accessories as required, and chain pulley block, traveling trolley, located in chemical house for chemical handling in ground floor and operating floor of chemical house.

c) One (1) 2.0 T capacity (minimum) manually operated monorail hoist, complete with chain-pulley blocks, traveling trolley in the blower rooms of gravity filter house.

d) Adequate number of electrically operated monorail hoist, with electrically operated trolley of 3.0 T capacity, complete with chain-pulley blocks, traveling trolley for the handling of filtered water feed pumps.

xxiii) Isolating gates and shutters:

a) One (1) isolation gate for each clariflocculator along with hand wheel, at the outlet of flash mixer.








b) One (1) isolation gate with handwheel on each clariflocculator by-pass line

c) One (1) isolation gate with handwheel on the clariflocculator by-pass line.

d) One (1) isolation gate with handwheel at the inlet to each gravity filter.

e) Two (2) isolation gates with handwheel at the inlet to sludge sump and two (2) at the outlet of sludge sump.

xxiv) All integral and interconnecting piping, valves, gates control valves, all types of pipe support etc. for the entire pre-treatment plant.

xxv) The following piping shall be included:

a) Pipes from the filtered water storage tank upto the inlet chamber of DM Plant supply filtered water pump house.

b) All necessary sludge piping with manholes from the respective clarifiers, stilling chambers, flash mixers, chemical house, etc. upto the sludge sump.

c) Necessary chemical dosing piping and fittings which shall be of CPVC, PN10 rating.

xxvi) Supply and application of shop painting and final painting at site for the entire pretreatment plant as specified elsewhere.

3.04.00 Complete electrical system for the pre treatment plant.

3.05.00 Complete instrumentation and control for the entire pretreatment plant. Operation of pre-treatment plant shall be from a PLC based Local Control Panel and the PLC shall be connected to water post treatment plant PLC. For basic philosophy and details of the control and instrumentation, the bidder shall refer to the relevant clauses of the Specification on instrumentation & control.

3.06.00 Complete civil, structural & Architectural work for the pre treatment plant as described in Civil Specification.








4.00.00 SALIENT DESIGN DATA

4.01.00 The water analysis to be adopted for the design of Pretreatment Plant has been furnished in Appendix-II enclosed along with this Specification. The operation of the plant shall be in general manual.

4.02.00 Various chemical handling and design equipment in the pretreatment plant shall be designed for the following dosing rates.

Alum : 60 ppm (Max.)

Lime : 20 ppm (Max.)

Coagulant : 1 ppm(Polyelectrolyte)

4.03.00 All pipes and cables shall be taken through pipe and cable racks only. Pipe sizing for chemical dosing line shall be minimum 25 NB.

4.04.00 Raw water at the inlet to pre-treatment plant shall be available at a normal pressure of 1.0 kg/cm2 g.

4.05.00 Data specification sheets of Mechanical & Process equipment and accessories are given in Appendix-I.

4.05.01 For Details of Electrical Equipment refer relevant Electrical Specification of Volume – II.

4.06.00 For the design of gravity filters, an inlet turbidity of 25 NTU shall be considered for the clarified water.

4.07.01 All the valves, gates, shutters etc. used in the complete plant shall be “rising spindle type” as much as possible. All motor/ pneumatic actuated valves shall also have hand wheels for local manual operation as and when required. The spindle material for all gates and shutters shall be of brass construction.

4.07.02 All the chemicals to be used in the pretreatment plant shall generally conform to the requirement of technical grade as per relevant IS.

4.08.00 All the isolation gates used in the pretreatment plant shall have necessary extended spindle, penstock, handwheel and brass lining to have drop tight effect. All isolation gates shall conform to the requirements of AWWA.








4.09.00 Rubbers, used for rubber lining shall be of natural rubber and rubber-lining tanks/ equipments shall have shore hardness 65 + 5% in scale ‘A’.

4.10.00 Water temperature varies seasonally. All the equipments used in the pretreatment plant shall perform satisfactorily at the minimum and maximum temperature as indicated in the climatological data enclosed along with this specification.

4.11.00 All the valves used in sludge lines shall have draining and flushing arrangement at valve seat. All nuts, bolts, washers etc. in under-water and corrosive application shall be of SS 316.

4.11.01 The complete clariflocculator unit shall be over ground as much as possible so that sludge draining arrangement becomes under the ground to the minimum extent possible. The total water loss due to sludge blow down shall be limited to 5% of the total inflow to clarifier unit. Each clarifier unit shall be suitably designed to make good of sludge blow down.

4.11.02 For all pipes handling lime and sludge, only flanged piping shall be used and pipe sizes shall be not less than 80 NB. Within clarifier, sludge pipe shall be of C.I. with socket and spigot joint with lead cocking, and outside clarifier units, sludge piping shall be of C.I. double flanged. For all lines carrying lime and sludge, suitable slope shall be provided and tees shall be used instead of bends and crosses shall be used instead of tees with the remaining end blanked for flushing purpose. For all buried piping, suitable marker plates shall be provided for easy identification of pipe location.

5.00.00 SERVICES TO BE RENDERED The following services are to be rendered by the successful bidder of this contract :

5.01.00 Arrange for access to Owner’s representative for the different specified stage inspection and testing at manufacturer’s works.

5.02.00 Arrange for despatch of all the material by rail / road to sites.

5.03.00 Arrange for transportation of all the items upto site.

5.04.00 Receiving and unloading of all equipment, plant and materials at site, checking with consignment note and reporting for missing damaged items.








5.05.00 Proper stacking, storing under contractor’s custody and security, providing proper maintenance of stored items and keeping proper records of materials at store for convenience & proper scheduling of erection work and for quick identification and when required. Stores as required shall have to be constructed by the bidder in the open space provided.

5.06.00 Issue of materials from stores and maintaining detail account of the same as required.

5.07.00 Transportation / shifting of materials from stores to erection site.

5.08.00 Pre-assembly at site after proper checking/ overhauling, as required.

5.09.00 Services for fabrication, erection and subsequent cleaning/ flushing as required at site.

5.10.00 Carry out pre-start check of the installation to ensure correctness of the erection.

5.11.00 Startup, testing, commissioning and handing over of the complete plant / equipment / system / sub-systems in a flawless operating condition.

5.12.00 Supply of all mandatory, erection/ commissioning and recommended spares, tools & tackle including required after-sales services during and after the warranty period. (Refer mandatory spares lists).

5.13.00 Supply of performance test instrument on returnable basis for carrying out performance and guarantee test at site.

5.14.00 Supply of all lubricants for all equipment included under this contract as necessary upto successful commissioning and till successful completion. of trial operation.

5.15.00 Supply of all consumables and chemicals required for commissioning upto the successful completion of trial operation.

5.16.00 Furnishing of all document, drawings, design basis reports, optimization, study reports, instruction manuals, test certificates etc. including "As built" drawings, as called for in the specification.

5.17.00 Provide all skilled, semi-skilled/unskilled workmen labour supervisory staff, inspectors, erection and commissioning engineer, electrical staff








watch and ward staff, store keeper, driver etc. as required for all services including O & M training till handing over of the plant.

5.18.00 Equipment shop painting and final painting including supply of paints.

5.19.00 Supply of a phased time schedule for various stages of completion of plant, which shall be the essence of the contract and guaranteed.

5.20.00 Any other service, although not specifically called for but required for such a vital contract of the size and nature indicated in this specification.

6.00.00 INSPECTION, TESTING & COMMISSIONING

6.01.00 Tests at Manufacturer’s works

Shop tests shall include all tests to be carried out at contractor’s works, works of his sub contractor and at works where raw materials supplied for manufacture of equipment is manufactured. The tests to be carried out shall include but not be limited to the tests described under each specification.

a) Composition of all materials, castings, forgings etc.,

b) Hydraulic test for pressure vessels, pipes, valves, specialties, pump casing etc.

c) Test to check faults in rubber lining (as per IS: 4682 (Part – I) or its equivalent) and painting.

d) Static balancing test on agitators, stirrers, paddles etc.

e) Static & dynamic balancing test on all impellers.

f) Performance test (Head, Capacity, Power) on pumps and blowers.

g) Tests on motor as per Electrical Motor Specification.

h) Control panels are to be checked for dimensions, wiring continuity, insulation, tubing leakage etc.

i) All panel mounted instruments, local instruments and accessories are to be checked for performance, over range protection etc., as per I.S.A or other relevant standards.








j) Control valves are to be tested for body/ seat/ diaphragm chamber leakage, lift characteristics, body, seat bonnet and material composition.

k) Load test on monorail hoists & cranes.

l) Calibration tests for weigher / load indicator.

m) Calibration tests of all standard orifices, nozzles, pressure and temperature switches & other instruments.

n) Functional test of the control system.

6.02.00 Tests Before Trial Run

6.02.01 Tests at sites

Contractor shall carry out tests at site to prove to the Owner that the equipment of the plant complies with the requirement stipulated and is erected in accordance with requirements. Before the plant is put on trial run, the contractor shall be required to conduct tests to demonstrate to the Owner that each item of the plant is capable of correctly performing the functions for which it is specified. These tests may be conducted concurrently with those required under commissioning sequence. Tests required shall in general be as follows:

a) All piping and valves, after installation, shall be tested hydraulically at a pressure 1½ times of the maximum attainable pressure in the system, to check against leak tightness.

b) All valves / gates (Manual / automatic / remotely operation) shall be operated throughout 100% of the travel and these should function without any trouble whatsoever.

c) All pumps shall be run with the specified fluid from shut-off conditions to valve wide-open condition. Head developed shall be checked from the discharge pressure gauge reading. Capacity may be checked from flow indicators where applicable. If flow indicators are not available in the system, capacity can be checked from the volume of fluid handled (determined from level indicator reading of concerned tank) and duration of test.

During the test, the pumps and drive motors shall run smoothly without any undue vibration, leakage through gland, temperature rise in the bearing parts, noise, flow pulsation etc.








d) Pumps, blowers etc. shall be tested at site to run smoothly without undue vibration, flow pulsation, temperature rise in bearing parts, noise etc.

e) The tests to be carried out for site fabricated storage vessels are to include :

A. During fabrication and before lining:

i) Bottom testing for leakage by soap solution, after the bottom and at least the bottom course of the shell plate have been welded.

ii) Hydraulic shell testing for leakage.

iii) Fixed roof test for leakage by soap solution.

B. After rubber lining : Water leakage test for storage tank by filling it with water upto the overflow level.

f) All the rubber lining shall be subjected to the following tests as per IS: 4682 (Part – I).

- Adhesion test

- Resistance to bleeding

- Thickness measurement

- Shore hardness

- High voltage spark test

Epoxy painting shall be checked by dry type thickness gauge.

g) Visual check on all structural components, welding, rubber lining, painting etc. and if doubt arises these shall be tested again.

h) All testing and calibrating instruments and equipment shall be furnished by the contractor free of cost to the satisfaction of the Owner.

i) All monorail hoists shall be subjected to full working load during all motions without showing any sign of defect.








j) All the rotating components of the clarifier cum concentric flocculator units namely bridge, carriage, scrapper paddles, agitators, current collector etc. shall be run at the rated speed with water upto the normal level for a period of twenty four hours.During this period, all the components shall function smoothly, without any undue deflection, unbalance vibration, flutter, slipping or sticky motion, excessive play and overheating at bearing parts, sparking etc.

k) All the rotating / moving components like agitators, paddles, etc. shall be run at the rated speed with water / chemicals upto the normal water level for a period of twenty four (24) hours. During this period all the components shall function smoothly without any unbalance, vibration, overheating at bearing parts etc.

l) Filter Media:

Determination of the following parameters of filter media :

I. Bulk density

II. Sieve analysis, uniformity co-efficient, ash content & surface area, silica content etc.

m) Checks on electrical items as mentioned under electrical

specifications enclosed herewith.

6.03.00 Performance / Guarantee Tests

6.03.01 Any special instruments, sub standard gauges, calibration instrument/ equipment, tools and tackle necessary for performance and guarantee tests shall be arranged by the contractor free of cost.

6.03.02 The guaranteed performance figures of the equipment shall be proved by the contractor during these tests. Should the results of these tests show any deficiency from the guaranteed values, the contractor shall modify the equipment as required to enable it to meet the guarantees. In such a case, performance and guarantee tests shall be made and the cost of additional testing to prove that the equipment meets the guarantees shall be borne by the contractor.

6.03.03 Performance








i) After water supply is established, the valve at inlet to stilling chamber should be adjusted to give desired flow.

ii) Isolation gates shall be adjusted to ensure equal flow distribution to each unit as determined by flow measuring device.

iii) This test shall be continued for four (4) hours. Turbidity in effluent shall be determined from the arithmetic average of all the test figures. The average turbidity shall not exceed 10 NTU and any individual reading shall not exceed 15 NTU.

iv) The test shall be deemed to be a failure when either of the limits as indicated in (iii) is exceeded and retesting shall have to be arranged.

v) During this test, alum and lime dosage shall be calculated by determining the concentration, level gauge readings and duration of test. The chemical consumption value shall not exceed 15% over the requirement as established from Jar test result.

vi) Sludge disposal and recovery system shall be checked with respect to flowability, sludge consistency and water recovery.

vii) Soluble iron shall not exceed 0.3 ppm as Fe and insoluble iron shall be “Not Detectable”.

viii) By adjusting the control valve, flow is adjusted to 120%, 75%, 50% and 25% and tests (ii) to (vii) shall be repeated each time. Lime, alum and coagulant aid feed rate shall be adjusted proportional to raw water flow.

ix) Tests (ii) to (viii) shall be conducted three (3) times during the guarantee period of equipment so as to cover low (upto 50 unit), and high (upto 5000 unit) turbidity, iron value, chemical consumption and ensure satisfactory performance of the chemical dosing & sludge disposal system in each test run.

x) Following tests shall be performed for gravity filters:

a) Determination of bulk density, sieve analysis, uniformity co-efficient, effective size, silica content, soluble fraction in HCI and ignition loss for the filtering media.








b) Test shall be conducted to determine that each filter runs at its rated capacity for 24 hours continuously designed with an inlet clarified water turbidity level of 10 NTU, to give an average effluent turbidity less than 2 NTU and any individual reading not to exceed 3 NTU.

c) Backwash water requirement not to exceed 2% of the water treated between two backwash.

6.03.04 Guarantee

a) All pumps shall be guaranteed for capacity, total dynamic head and power consumption.

b) Each clarifier cum concentric flocculator unit shall be guaranteed for an effluent capacity of not less than 3000 m3/hr (net) with raw water turbidity as given in the Appendix – II.

c) Outlet water from clarifiers shall be guaranteed for the following:

Organic matter : Traces (Less than 1.0 as KMnO4 Value)

Iron content : Less than 0.3 ppm as FeManganese content : NilTurbidity : Less than 10 NTUInsoluble iron : Nil/ Not detectable

d) Gravity filters :i) The normal capacity of each gravity filter shall be not less

than 150 m3/hr (net) continuous with one backwash and air sourcing in 24 hours.

ii) Turbidity at outlet of gravity filter shall not exceed 2 NTU with an inlet clarified water turbidity of 25 NTU maximum.

7.00.00 PAINTING

All mechanical, electrical and structural items included in the scope of the bidder shall be suitably protected with paints and protective coatings, specifically mentioned at the relevant Section of Specifications. Painting shall be in general as specified in painting specification enclosed herewith.








8.00.00 TRANSPORTATION & PACKING

8.01.00 All the equipment shall be suitably protected, coated, covered or boxed and crated to prevent damage or deterioration during transportation, handling and storage at site at time of erection, considering tropical humid climate. While packing all the materials, the limitations from point of view of railway wagon sizes in India both from dimension and weight consideration shall be taken into account. Details of various wagons consideration shall betaken into account. Details of various wagons normally available with Indian Railways for transportation of heavy equipment shall be obtained by the contractor. Contractor shall be responsible for any loss or damage during transportation, handling and storage due to improper packing. Owner takes no responsibility regarding availability of wagons.

8.02.00 For transportation if totally enclosed boxes are not used, the equipment shall be mounted on skids and enclosed in open wooden crates.

9.00.00 SPECIAL TOOLS & TACKLE

9.01.00 The bidder shall quote separately for a complete and unused set of all special tools and tackle, including required number of the tool boxes, as required for erection, maintenance, overhaul/or complete replacement of the equipment and components required for the plants. The bidder shall enclose with his proposal the list of tools and then item wise price.

9.02.00 The tools shall be supplied in separate containers clearly marked with the name of the equipment for which they are intended.

9.03.00 The tools & tackle shall include all necessary equipment for calibration of instruments shall be included.

10.00.00 DRAWINGS, DATA AND INFORMATION REQUIRED

10.01.00 The Bidder’s formal proposal must be accompanied by the following but not limited to the drawings / information and documents as required for all the basic components of the pre-treatment plant.

General

i) Schematic flow & instrumentation diagram indicating scope of supply.








ii) Detail layout drawing of the plant showing equipment, pipe work etc.

iii) A list showing guaranteed power consumption data of drive motors as listed elsewhere in this specification.

iv) General arrangement drawing of control – desk and panel showing layout of instruments, annunciators, switches, push buttons, indicating lamps etc.

v) Characteristic curves of all centrifugal pumps & blowers from zero to 150% of rated flow. (Showing head, power consumption, efficiency & N.P.S.H or submergence requirement against capacity, as applicable).

vi) Description & illustrative literature/ drawings with materials of construction for equipment & instruments offered.

vii) Schedule of valves.

viii) Schedule of piping

ix) Schedule of instruments with specification.

x) General cross sectional drawings of all basic components, equipment and machinery.

xi) List of all guaranteed data.

xii) Installation drawings for instruments offered.

xiii) Power consumption for the different auxiliaries/ system.

xiv) Consumption of instrument air.

xv) Requirement of construction power & water with the required characteristics, quantum etc.

xvi) Experience list, showing the locations where bidder has supplied and commissioned similar plant as under this bid document, for similar application under similar duty conditions, with complete details.

xvii) List of non-indigenous components.








xviii) List of potential sub contractors.

xix) Preliminary foundation and storage requirements, including shipping and operating weights.

xx) Literature with catalogues (for particular model numbers) of the different instruments/ control offered.

xxi) Schedule of terminal points and their characteristics.

xxii) A comprehensive write up or brochure indicating the details of the testing facilities including different tests that can be performed in the shop of the manufacturer.

xxiii) Organizational set up with number, categories and duration of stay, plant wise and system wise for the following case:

a) During unloading, transporting, storing, maintenance erecting, testing, commissioning and handling over at sites – deployment of which is totally contractor’s responsibility.

b) During normal & reliable operation and maintenance period of the plant after taking over by the Owner deployment of which shall be Owner’s responsibility.

xxiv) In case bidder is offering equipment / plant / test procedures as per international standards not mentioned specifically in the Bid Documents, he should furnish at least 3 copies of English version of the same along with the offer, for consideration.

xxv) Hydraulic gradient diagram of the pretreatment plant.

xxvi) Layout drawings of ground and operating floor of chemical house, showing equipment and pipe work in plant & section, sludge pump house, chemical storage area, filtered water pump house, drinking water chlorination room, gravity filter house, sludge pump house and pretreatment plant switch gear room.

xxvii) General arrangement drawings of the following equipment showing major outline dimensions of civil works necessary, in plan & section.

a) Stilling chamber








b) Flash mixer with mechanical agitation and isolation arrangements.

c) Clarifier-cum- concentric flocculators showing details of rotating bridge, rail, scrapper, paddles, sludge connection and blow down, power distribution arrangement, sludge collection and disposal system etc.

d) Gravity filters, showing the details of gravity filters house, distribution system, filtered water collection system, under drainage system etc.

e) Sludge disposal arrangement and sludge disposal pump house and sludge recirculation pump house.

f) Arrangement of filtered water storage tanks and filtered water pump house showing equipment and pipe work in plant & sections.

g) Pretreatment plant switchgear room.

h) Sludge Handling and Treatment System

i) All drainage systems.

10.02.00 Technical Information, Drawings, Data to be submitted for approval after award of Contract:

Owner’s requirement of information, drawing and data from the successful bidder after finalization of contract in respect of equipment covered under the pre-treatment plant specification are indicated in this section.

The actual schedule of these data / drawings shall be discussed and mutually agreed to, between the owner and the successful bidder before the issue of notice of award of contract.

All technical data / information already furnished as per clause 10.01.00 shall be confirmed. Revision of any data must meet the approval of the Owner.

Following drawings shall be furnished:








i) Single line flow and instrumentation and control diagram of Pre-treatment Plant.

ii) Piping layout with suitable sectional views of pre-treatment plant, chemical house, drinking water chlorination room, Pre-treatment plant chlorination room, gravity filter house, filtered water pump house, filtered water reservoirs, sludge pump house, sludge recirculation pump house, pre-treatment plant switch gear room etc.

iii) Detailed dimensional drawing of all the equipments of the pretreatment plant.

iv) Detailed cross sectional drawings of all equipment and bill of materials.

v) Detailed dimensional drawings of electric drive motor frame, bearing cable boxes, cable termination arrangements etc.

vi) Detailed interlocks, logic diagram (incorporating Boolean concepts) and schematics separately for pretreatment, demineralising, ozonization plant.

vii) Dimensioned drawings of Control panels showing arrangement of instruments, switches, push buttons, lamps etc. along with the schematics and wiring diagram.

viii) Complete specification of instruments.

ix) Design calculation in respect of process and mechanical design, engineering to the extent found necessary by the owner.

x) Detailed procedures of testing shall be submitted to the owner for approvals before performance tests.

xi) Following test certificates/test curves/data shall be furnished:

j) Material test certificate

k) Performance test results & characteristic curves of pumps, blowers, air compressors and electric drive motors.

l) Test results of filter fill.








m) Hydraulic test results of vessels, pipes, valves, fittings etc.

n) Test result of anti corrosive coatings.

o) Non-destructive test results as applicable.

xii) Detailed technical particulars of electric drive motors, shall be furnished in the proforma as exhibited in relevant section of the specification.

xiii) Detailed technical particulars of valve actuators.

xiv) Following lists/ tables shall be furnished, complete with tag nos. as described in this specification

i) Instrument bill

ii) Valve bill

iii) Pipe bill

10.03.00 General

10.03.01 All drawings, specifications, design calculations and bills of material prepared by the Contractor shall comply with the following instructions unless otherwise directed in writing by Owner. The terms “drawing” as used in this specification shall mean and include design calculations, specification and bills of materials unless otherwise defined. Design calculations to be submitted by the contractor shall include the working stress, the safety factor used, codes & standards used etc. Drawings and data, as such and shall bear the signature of one of the authorized persons, whose names shall previously be given in writing to Owner.

10.03.02 The bidder shall submit all drawings for approval, as well as a drawing list from which the Owner shall select those drawings, which they consider necessary for completion of drawing approval.Before starting manufacturing of the equipment, the contractor shall have to take approval of the design drawings from the Owner. Any manufacturing done prior to approval of the drawing shall be rectified in accordance with approved drawings by the bidder at his own cost, if any discrepancy arises and the equipment shall be supplied within stipulated period.








10.03.03 It is understood that approval or release by Owner does not include the checking for drafting and other errors, but only review of basic concepts and general principles involved. Approval does not relieve the vendor of responsibility for correctness of design, details and dimensions.


