33 05 61 Concrete Manholes

SECTION 33 05 61
CONCRETE MANHOLES
PART 1 GENERAL
1.1 DESCRIPTION OF WORK
A. This Section covers the furnishing and installation of manholes, valve

chambers, wet wells, and catch basins as shown on the Contract Drawings.
B. The Contractor shall furnish all labor, materials, tools, equipment and other
incidentals as required to complete the Work in accordance with the Contract
requirements.
1.2 SECTION INCLUDES
A. Precast Concrete Manholes
B. Cast-in-place Concrete Manholes and Chambers
C. Precast Concrete Catch basins
D. Precast Concrete Sewage Wet Wells
E. Cast-in-place Sewage Wet Wells
F. Precast Concrete Valve Chambers
G. Installation of Covers/Gratings and Frames
1.3 RELATED SECTIONS
A. Section 01 3200 Construction Progress
B. Section 01 3300 Submittal Procedures
C. Section 01 4500 Quality Control
E. Section 01 6000 Product Requirements
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Riyadh Township-Site 1 33 0561 Page 1 of 19
Package 1-Infrastructure
1.4 REFERENCES
A. The referred codes and standards are intended to provide an acceptable

level of quality for materials, products and workmanship. In case of conflict
between these standards and the text of this Specification, the Specification
text shall govern.
B. The latest revision of the referred codes and standards shall be used
wherever applicable. In case of conflict, the Contractor shall propose
equipment, materials and processes conforming to one group of codes and
standards.
C. SASO Saudi Arabian Standards Organization
1. SASO 412 Methods of Test for Cast Iron Covers
2. SASO 413 Cast Iron Manhole Covers
D. BS British Standard
Black Bitumen Coating Solution for Cold
1. BS 3416 Application
2. BS 4164 Coal Tar Based Hot Applied Coating Materials

3. BS 7903 Guide to Selection and Use of Gully Tops and
Manhole Covers for Installation Within the
Highway
E. EN European Standard
1. BS EN 124 Gully Tops and Manhole Tops for Vehicular and
Pedestrian Areas - Design Requirements,
Type
Testing, Marking, Quality Control
BS EN
2. 1561 Founding - Grey Cast Irons
BS EN
3. 1563 Founding - Spheroidal Graphite Cast Iron
NAC
F. E National Association of Corrosion Engineers
SSP
C The Society for Protective Coatings
1. NACE No. 2 - SSPC SP10Near- White Metal Blast Cleaning
2. NACE No. 3 - SSPC SP6 Commercial Blast Cleaning

AST
G. M American Society for Testing and Materials
ASTM
1. A48M Standard Specification for Gray Iron Castings
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ASTM
2. A536 Standard Specification for Ductile Iron Castings
ASTM A Standard Specification for Carbon Structural

3 36 Steel
ASTM A Standard Specification for Steel Wire, Plain,

4. 82 for Concrete Reinforcement
5. ASTM A36M Standard Specification for Carbon Structural

Steel
6. ASTM A48M Standard Specification for Gray Iron Castings
7. ASTM A74 Standard Specification for Cast Iron Soil Pipe

and Fittings
8. ASTM A82 Standard Specification for Steel Wire, Plain,

for Concrete Reinforcement
9. ASTM A126 Standard Specification for Gray Iron Castings
for Valves, Flanges and Pipe Fittings
10. ASTM A185 Standard Specification for Steel Welded Wire

Fabric, Plain, for Concrete Reinforcement
11 ASTM A193M Standard Specification for Alloy-Steel and

Stainless Steel Bolting Materials for High-
Temperature Service
12 ASTM A194M Standard Specification for Carbon and Alloy

Steel Nuts for Bolts for High-Pressure or High-
Temperature Service or Both
13. ASTM A216M Standard Specification for Steel Castings,
Carbon, Suitable for Fusion Welding, for High-
Temperature Service
14. ASTM A276 Standard Specification for Stainless Steel Bars
and Shapes
15. ASTM A283M Standard Specification for Low and

Intermediate Tensile Strength Carbon Steel
Plates
16. ASTM A307 Standard Specification for Carbon Steel Bolts
and Studs, 60 000 PSI Tensile Strength
17. ASTM A395M Standard Specification for Ferritic Ductile Iron

Pressure-Retaining Castings for Use at
Elevated Temperatures
18. ASTM A449 Standard Specification for Quenched and
Tempered Steel Bolts and Studs
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19. ASTM A473 Standard Specification for Stainless Steel
Forgings
20. ASTM A496 Standard Specification for Steel Wire,
Deformed, for Concrete Reinforcement
21. ASTM A497M Standard Specification for Steel Welded Wire

Fabric, Deformed, for Concrete Reinforcement
22. ASTM A536 Standard Specification for Ductile Iron Castings
23. ASTM A569 Standard Specification for Steel, Carbon (0.15

Maximum, Percent) Hot Rolled Sheet and
Strip Commercial Quality
24. ASTM A570 Standard Specification for Steel, Sheet and
Strip, Carbon, Hot Rolled, Structural Quality
25. ASTM A576 Standard Specification for Steel Bars, Carbon,

Hot- Wrought, Special Quality
26. ASTM A615 Standard Specification for Deformed and Plain

Billet-
Steel Bars for Concrete Reinforcement
27. ASTM A635M Standard Specification for Steel, Sheet and

Heavy-Thickness Coils, Carbon, Hot-Rolled
28. ASTM A659M Standard Specification for Commercial Steel

(CS), Sheet and Strip, Carbon (0.16 Maximum
to 0.25 Maximum Percent), Hot-Rolled
29. ASTM A706M Standard Specification for Low-Alloy Steel
Deformed and Plain Bars for Concrete
Reinforcement
30. ASTM A744M Standard Specification for Castings, Iron-
Chromium- Nickel, Corrosion Resistant, for
Severe Service
31. ASTM A746 Standard Specification for Ductile Iron Gravity
Sewer Pipe
32. ASTM A1012 Standard Specification for Seamless and

Welded Ferritic, Austenitic and Duplex Alloy
Steel Condenser and Heat Exchanger Tubes
With Integral Fins
33. ASTM A1015 Standard Guide for Videoborescoping of
Tubular Products for Sanitary Applications
34. ASTM B127 Standard Specification for Nickel-Copper Alloy

(UNS N04400) Plate, Sheet and Strip
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35. ASTM C14M Specification for Concrete Sewer, Storm Drain
and Culvert Pipe
36. ASTM C33 Standard Specification for Concrete Aggregates
37. ASTM C76M Standard Specification for Reinforced

Concrete Culvert, Storm Drain and Sewer Pipe
38. ASTM C94M Standard Specification for Ready-Mixed

Concrete
39. ASTM C150 Standard Specification for Portland Cement
40. ASTM C425 Standard Specification for Compression Joints

for Vitrified Clay Pipe and Fittings
41. ASTM C443M Standard Specification for Joints for Circular

Concrete Sewer and Culvert Pipe, Using
Rubber Gaskets
42. ASTM C494M Standard Specification for Chemical
Admixtures for Concrete
43. ASTM C564 Standard Specification for Rubber Gaskets for

Cast Iron Soil Pipe and Fittings
Standard Specification for Vitrified Clay Pipe,

44. ASTM C700 Extra Strength, Standard Strength and
45. ASTM D1149 Standard Test Method for Rubber

Deterioration- Surface Ozone Cracking in a
Chamber
46. ASTM D1259 Standard Test Methods for Nonvolatile
Content of Resin Solutions
47. ASTM D1784 Standard Specification for Rigid Poly(Vinyl

Chloride) (PVC) Compounds and Chlorinated
Poly (Vinyl Chloride) (CPVC) Compounds
48. ASTM D1785 Standard Specification for Poly (Vinyl
Chloride) (PVC) Plastic Pipe, Schedules 40, 80
and 120
49. ASTM D1869 Standard Specification for Rubber Rings for
Asbestos-Cement Pipe

Chloride) (PVC) Pressure-Rated Pipe (SDR
Series)
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51. ASTM D2321 Standard Practice for Underground Installation
of Thermoplastic Pipe for Sewers and Other
Gravity- Flow Applications
52. ASTM D2464 Standard Specification for Threaded Poly
(Vinyl Chloride) (PVC) Plastic Pipe Fittings,
Schedule 80
Chloride) (PVC) Plastic Pipe Fittings, Schedule
40
54. ASTM D2564 Standard Specification for Solvent Cements for
Poly (Vinyl Chloride) (PVC) Plastic Piping
Systems
55. ASTM D2657 Standard Practice for Heat Fusion Joining

of Polyolefin Pipe and Fittings

Chloride) (PVC) Sewer Pipe and Fittings
57. ASTM D2751 Standard Specification for Acrylonitrile-

Butadiene- Styrene (ABS) Sewer Pipe and
Fittings
58. ASTM D2774 Standard Practice for Underground
Installation of Thermoplastic Pressure Piping
59. ASTM D2855 Standard Practice for Making Solvent-

Cemented Joints with Poly (Vinyl Chloride)
(PVC) Pipe and Fittings.
1.5 DEFINITIONS
A. area of waterway: The area of gully grating through which water can pass.
B. catch basin: A stormwater collection structure below ground designed to

collect and convey water into the storm sewer system.
C. clear area: The maximum unobstructed area through the frame (including the
area between the seats).
D. clear opening: The diameter of the largest circle that can be inscribed in the
clear area of the frame.
E. complete unit: The frame with the cover assembled on it.
F. cover: The movable part of a manhole top or a gully top which covers the
manhole or gully opening.
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G. cushioning insert: Material in a frame, grating or cover used to provide a
non-rock seating.
H. ductile iron: Spheroidal or nodular graphite cast iron.
I. dust trap: A removable basket made from plastic reinforced with fiberglass
or any other suitable material, fixed in the frame for collecting dust passing
through ventilation opening.
J. frame: The fixed part of a gully top or manhole top which receives and
supports a grating or a cover.
K. grating: The movable part of a manhole top or a gully top, which permits the
passage of water through itself to the gully.
L. gully: An assembly to receive surface water for discharge into a drainage

system.
M. gully top: That part of a gully, consisting of a frame and grating or cover and
which is placed on the gully pot at the place of installation.
N. gray iron: Flake graphite cast iron.
O. haunching: Lateral concrete backing of curbs and edgestones to restrain

them in position when loaded.
P. highway: Area that includes some or all of the following features:

carriageway, cycleway, footway, verge, hard shoulder, hard strip and central
reservation.
Q. keyway: A hole in the top of the manhole cover suitable for the insertion of
an appropriate lifting key.
R. manhole: A chamber or access shaft to underground systems.
S. manhole top: That part of a manhole consisting of a frame and a cover or a

grating.
T. pedestrian areas: Area reserved for pedestrians and only occasionally open
to vehicular traffic for delivery, cleaning purposes or in emergency.
U. pedestrian streets: Area where vehicular traffic is prohibited during certain

periods (e.g. pedestrian areas during business hours and vehicular traffic
outside these hours).
V. seating: The surface on which the grating or the cover rests in the frame.
W. test load: Load applied to the cover or grating and frame when tested.
X. vent: An opening in the cover of a manhole top to provide ventilation.
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1.6 SUBMITTALS
A. The Contractor shall submit to the Royal Commission, under the provisions of
SECTION 013300, the following items for review and approval before
commencing Work:
1. Certificate of compliance stating that the covers/gratings and frames

and all materials used in their construction conform to all requirements
of this Specification.
2. Certificate of testing including test data to show that all tests specified
have been performed and all requirements have been met.
3. Manufacturer’s recommended specification and instructions for

transporting, handling, loading, unloading and storage of the
covers/gratings and frames.
4. Catalog data showing illustrations and schedule of parts, material and

weights of the covers/gratings and frames.
5. Shop Drawings showing the principal dimensions, construction details,

and materials.
1.7 QUALITY CONTROL
A. The Contractor shall be responsible for the quality of work and shall develop
and propose programs and methods of construction and testing such as to
achieve the specified quality to the approval of the Royal Commission in
accordance with SECTION 014500.
1.8 HEALTH AND SAFETY CONSIDERATIONS
A. All works undertaken in relation to this Specification are to be completed in

full accordance with the respective health and safety requirements
established by the following:
1. Kingdom of Saudi Arabia
a) Legislation, Regulation, Standards and Codes.
2. Contractor
a) Health and Safety Standards and Systems as accepted by the

Client.
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B. In the absence of any of the above, best accepted industry practice shall be
employed throughout.
1.9 DELIVERY, HANDLING AND STORAGE
A. The Contractor shall deliver, handle and store equipment and material units
in accordance with SECTIONS 016600, as well as the following
requirements:
1. Packaging shall be provided as required for shipment of

covers/gratings and frames to the installation site.
2. All units shall be inspected at time of delivery for shipment damage and
for compliance with the Specifications.
3. Any product found to be damaged or not in accordance with the

Specifications shall immediately be repaired or removed from site and
replaced at no additional cost to the Employer, without impairing the
project’s performance or schedule.
4. Repairs shall not be undertaken before the Engineer’s review of the

Contractor’s proposed action.
5. All units shall be stored and handled at the construction site in a

manner to prevent damage and deterioration.
PART 2 PRODUCTS
2.1 GENERAL
A. All goods and products covered by these Specifications shall be procured,

when available, from an in Kingdom manufacturer. Procurement of all goods
and products manufactured out-of-Kingdom must be approved by the
Engineer.
B. The Engineer and Employer shall, at all times, have access to all places
where materials are being produced or fabricated or where tests are being
conducted, and shall be accorded full facilities for inspection and observation
of tests.
C. Proprietary products considered by the Contractor to meet this Specification

shall be approved by the Engineer, based on the Contractor's report and
recommendation prior to incorporation into the permanent works.
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2.2 DESIGN AND MANUFACTURE
A. STANDARD PRECAST CONCRETE MANHOLE AND DESIGNED

PRECAST MANHOLE
1. ASTM C 478M for Standard Precast Concrete Manhole
ASTM C 890 for A-16 (AASHTO HS20-44), heavy-traffic, structural

loading; of depth, shape, and dimensions indicated, with provision for
sealant joints.
2. Diameter: 1200 mm minimum unless otherwise indicated on the

drawings.
.
3. Thickness for Base, floor slab and walls shall be as per standard
detailed drawings.
4. Riser Sections: Thickness and height, refer to standard detailed

drawings.
5. Top Section: Eccentric-cone type unless concentric-cone or flat-slab-

top type is indicated, and top of cone of size that matches grade
rings.
6. Joint Sealant: ASTM C 990M, bitumen or butyl rubber.
7. Steps: 20mm diameter galvanized iron coated with polyethylene. The

wide shall be enough to allow worker to place both feet on one step
and designed to prevent lateral slippage off step. Cast or anchor
steps into sidewalls at 300 intervals.
.
8. Resilient Pipe Connectors: ASTM C 923M, cast or fitted into manhole
walls, for each pipe connection.
9. Adjusting Rings: Interlocking HDPE rings with level or sloped edge in

thickness and diameter matching manhole frame and cover, and of
height required to adjust manhole frame and cover to indicated
elevation and slope. Include sealant recommended by ring
manufacturer.
.
10. Grade Rings: Reinforced-concrete rings, 150- to 300mm total
thickness, to match diameter of manhole frame and cover, and height
as required to adjust manhole frame and cover to indicated elevation
and slope.
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B. MATERIALS
Except as otherwise specified, material shall conform to the following

section.
1. CEMENT
ASTM C 150 (Type I, II, III or V)
ASTM C 595 (for Blended Cements)
2. SILICA FUME
ASTM C 1240
3. SILICA AND POZZOLANS
ASTM C 618
4. GROUND GRANULATED FURNACE SLAG
ASTM C 989
5. WATER
ASTM C1602
6. AGGREGATES
ASTM C33
7. REINFORCEMENT
ASTM A707
ASTM A775 (EPOXY COATED REINFORCING)
8. WIRE WELDED REINFORCING

ASTM A183
9. INSERTS AND EMBEDED METAL
Structural Steel Plates, Angles, etc.
ASTM A 36
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Hot-Dipped Galvanized
ASTM A 152
10. Joint Sealants and Joint Gaskets

Rubber Gaskets for Circular Concrete Sewer Pipe
and Culvert Pipe ASTM C 443
11 External Sealing Bands for Noncircular Sewer, Storm
Drain and Culvert Pipe ASTM C 877
12. Preformed Flexible Joint Sealants for Concrete

Pipe, Manholes, and Manufactured Box Sections
ASTM C 990
Elastomeric
Joint Sealants
ASTM C 920
13. Pipe
Entry
Conn
ectors
ASTM
C 923
ASTM C 1478
14. Grout
Nonshrink Grout
ASTM C 1107
Cementitious Grout
Shall be of suitable mix design for the intended use, consisting of

Portland cement, sand, and water. Provide air entrainment for grout
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exposed to corrosive conditions or severe weather.
2.3 CONCRETE STRUCTURES
A. Cast-In-Place Concrete
1. Cast-in-place reinforced concrete channels, box culverts,

catchpits, manholes and chambers shall be constructed as
shown on the Contract Drawings and shall conform to the
requirements of SECTION 03 30 00.
B. Precast Concrete
1. Precast reinforced concrete catchpits and manholes shall be

constructed as shown on the Contract Drawings, in accordance
with the requirements of SECTION 03 40 00.
2. Precast concrete sections shall be constructed in compliance with
ASTM C478M or equivalent and shall be designed and formed with
male and female ends, with the provision for the rubber gasket joints.
Precast concrete female ends, with the provision for the rubber gasket
joints.
3. Manhole top shall be concentric cone, eccentric cone or flat

slab as indicated on the Contract Drawings.
4. Gaskets for joints between manhole sections shall conform to

ASTM C443M. Resilient connectors for making joints between
manhole and pipes entering manhole shall conform to ASTM
C923M or C990M.
C. Blinding Concrete
1. Unless otherwise specified on the drawing, blinding concrete

shall have a minimum thickness of 50 mm and shall be of Class
C20, unless shown otherwise on the Contract Drawings.
2.4 REINFORCEMENT
A. All reinforcement shall be fusion bonded epoxy coated deformed

Grade 60 bars, and shall be in accordance with SECTION 032000.
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2.7 MANHOLE COVERS AND FRAMES
A. Manhole covers and frames shall be constructed according to section

33 39 13, conforming to ASTM A48M, as shown on the Contract
Drawings.
2.8 STEP IRONS
B. Manhole Steps, where shown, shall be designed to support a

concentrated load of 2200 N and shall be fabricated from the
following materials, unless otherwise specified on the Contract
Drawings:
1. Stainless steel bar conforming to AISI Type 316L.
2. Deformed bar conforming to ASTM A615M Grade 60, hot-

dipped galvanized in accordance with ASTM A123M.
3. Deformed bar conforming to ASTM A615M Grade 60 coated

with polypropylene plastic conforming to ASTM D4101.
4. Malleable iron conforming to ASTM A47M and shall be coated

with epoxy coating with a minimum dry film thickness of 100
microns.
B. Steps shall be a minimum of 350 mm wide and project a minimum of

150 mm away from the wall, unless otherwise specified on the
drawings.
C. The top surface of the step shall have a studded non-slip surface.
Steps shall be placed at 300 mm centers.
D. All precast manholes step irons shall be integrally cast into precast
sections by the manufacturer.
2.9 CURB OUTLET GULLEYS
A. Curb outlet gulleys shall be as shown on the Contract Drawings and

shall be manufactured from cast iron to conform to ASTM A48M,
Class 30 or better.
2.10 GRATINGS AND FRAMES
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________
A. Gratings and frames shall be as shown on the Contract Drawings and
as specified in SECTION 33 39 13.
2.11 PERFORATED PIPES
A. Perforated pipes for subsoil drainage (if any) shall be uPVC pipes
conforming to SASO 14 Class III, PVC pipe conforming to ASTM
D3034 or corrugated PVC pipe in accordance with ASTM F949, as
indicated on the Contract Drawings.
B. All pipe shall be perforated except sections specifically designated as

non-perforated by the Engineer.
C. The perforations may be circular holes or slots as required by the

Royal Commission or shown on the Contract Drawings. However,
different filter requirements shall apply to each type.
D. The circular perforations shall be between 5 and 10 mm, preferably 8

mm in diameter, arranged symmetrically in a minimum of 4 rows
parallel to the axis of the pipe within a 120° arc. Perforations in each
row shall be at a spacing of 100 mm center to center maximum.
E. Slotted perforations shall be between 1.5 and 3 mm in width, and 25

to 40 mm in length measured on the inside of the pipe. Perforations
shall be in 2 rows, parallel to the axis of the pipe on each side of the
invert and shall be spaced between 20 and 30 times the average slot
width along each row.
F. Joints shall be bell and socket type, made with elastomeric jointing
rings in accordance with ASTM F477.
2.12 RODDING EYES, CLEANOUTS AND INSPECTION CHAMBERS
A. Rodding eyes, cleanouts and inspection chambers shall be

constructed as shown on the Contract Drawings.
2.13 AGGREGATE FILL FOR SUBSOIL DRAINS
A. Aggregate fill for subsoil drains shall consist of crushed or uncrushed

gravel, crushed stone or a combination of the two and shall be of
clean hard uncoated particles graded uniformly from 10 to 25 mm.
2.14 NO-FINES CONCRETE FILL
A. No-fines concrete fill shall be used as structural backfill around weep

holes, drains or in other locations as shown on the Contract Drawings
to prevent backpressure or uplift.
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B. No-fines concrete fill shall be composed of evenly graded
aggregate from
10 to 40 mm.
C. The ratio of aggregate to cement shall be 6:1 by volume.
2.15 MEMBRANE FILTER
A. Membrane filter material shall be non-woven fabrics and shall consist

of long chain polymeric filaments or yarns such as polypropylene or
polyester, formed into a stable network so that the filaments or yarns
retain their relative position to each other and remain free of defects
and tears.
B. The membrane filter shall be resistant to deterioration due to

ultraviolet exposure, ambient temperatures, acid and alkaline
conditions, oils, microorganisms and insects.
C. The membrane filter shall be free of any chemical treatment or

coating which might significantly reduce permeability, shall have no
flaws or defects which could significantly alter its physical properties.
D. Filter material shall be capable of restricting fine particles of silt and

sand from entering the drain.
E. The membrane filter material shall conform to AASHTO M288 and

shall meet the physical and hydraulic requirements as specified in
Table 2A.
TABLE 2A: MECHANICAL AND HYDRAULIC PROPERTIES OF

THE MEMBRANE FILTER
Property Test Method Unit Min. Value
a) Mechanical
CBR Puncture Resistance EN ISO 12236 N 2000
Puncture Strength ASTM D4833 N 420
Burst Strength ASTM D3786 kPa 2000
Grab Strength (CD/MD) ASTM D4632 N 700/470
Elongation at Break ASTM D4632 % 70
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Trapezoidal Tear (CD/MD) ASTM D4533 N 340/200
b) Hydraulic
Permeability ASTM D4491 cm/s 0.25
Apparent Opening Size (O 95 ) ASTM D4751 Micron 75 (max.)
2.16 PROTECTION OF CONCRETE SURFACES
A. Unless otherwise indicated, all concrete surfaces in contact with soil

shall be protected in the following manner:
1. All blinding concrete shall be laid on 200 micron thick

polyethylene sheet.
2. All horizontal surfaces of concrete shall be protected by

waterproofing membrane up to underside of the pipe in
accordance with SECTION 07130.
3. All vertical surfaces of concrete and external surfaces of

the concrete
manholes and inspection chambers shall be protected by
epoxy aromatic amine/epoxy amine coal tar system, as specified
below:
a) Epoxy Aromatic Amine

1) Primer/sealer, low molecular weight, low volume
solids.
b) Epoxy Amine Coal Tar

1) 100% solids.
2) Total Wet Film Thickness (WFT): 406 micron
4. Internal surfaces of concrete manholes and inspection

chambers shall be protected by epoxy polyamide/epoxy amine
system, as specified below:
a) Epoxy Polyamide
1) Primer/sealer, low viscosity, low volume solids.
b) Epoxy Amine
1) Spray clad, 100% solids.
2) Total Wet Film Thickness (WFT): 2500 micron
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PART 3 EXECUTION
3.1 INSPECTION
A. The Contractor shall inspect the cover/grating and frame prior to

installation to verify that they are in conformance with this
Specification.
3.2 INSTALLATION
A. The Contractor shall install the concrete manholes, wet wells and
catch basins strictly in accordance with the manufacturers instructions
and recommendations and the details shown on the Contract
Drawings.
.
B. The general contractor shall be responsible for providing adequate
access to the site to facilitate hauling, storage and proper handling
of the precast concrete units
C. Precast concrete units shall be lifted by suitable lifting devices at

points provided by the precast concrete producer
D. Field modifications to the product shall relieve the precast

producer of liability regardless if such modifications result in the
failure of the precast concrete unit The Contractor shall prevent
distortion of the frames during fixing and shall replace any distorted
cover/grating or frame.
E. Covers/gratings and frames shall be installed in such a manner as to

prevent infiltration of the surface or ground water between the frame
and the manhole section.
F. Covers/gratings and frames shall be set to the true locations, planes

and grades and shall not be subject to traffic loads until the elapse of
an adequate curing time for the bedding and haunching material.
G. All covers shall be bedded and leveled to prevent rocking and lateral
movement of the frame under the influence of the traffic or other
imposed loads.
H. In the paved areas and the road shoulders, the top of the covers shall
be flush with the finished surface. In unpaved areas, the top of the
covers shall be 100 mm above the finished grade.
END OF SECTION
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SECTION 33 10 00
WATER UTILITIES
PART 1 - GENERAL
1.1 DESCRIPTION
A. General :
1. Furnish all labour, materials, tools, equipment, and services for

potable water and fire protection systems in accordance with
provisions of the Contract Documents.
2. Completely co-ordinate with the work of other trades.
3. Although such work is not specifically indicated, furnish and install all
supplementary or miscellaneous items, appurtenances and devices
incidental to or necessary for a sound, secure and complete
installation.
4. See Division 1 for General Requirements.
B. Related Work Specified Elsewhere:
1. Section 31 23 16.13 Trenching.
2. Section 31 23 00 Excavation and Fill.
1.2 APPLICABLE CODES AND STANDARDS
The following codes and standards are intended to provide an acceptable

level of quality for materials and products. The contractor may propose
alternative codes and standards provided they give an equivalent degree of
quality as the referenced codes and standards and are submitted for
Engineer's review in advance of their use.
A. SASO - Saudi Arabian Standards Organization :
14 Standard for uPVC Pressure Pipe.
15 Methods of Testing uPVC Pipes.
B. ASTM - American Society Of Testing And Materials :
A 48 Gray Iron Castings, Specification for.
D 2774 Underground Installation of Thermoplastic Pressure Piping,

Recommendation for.
D 3035 Standard Spec for PE Pipe (DR-PR) Based on Controlled

Outside Diameter
D 3261 Butt Heat Fusion PE Fittings for PE Pipe & Tubing
D 3350 Standard Specification for PE Pipe & Fittings Materials
__________________________________________________________________________________________________
C. AWWA - American Water Works Association :
C 506 Back flow Prevention Devices, Specification for.
C 600 Installation of Grey and Ductile Cast IronWater Main and

Appurtenances.
C 601 Disinfecting Water Mains.
C 701 Standard for Cold Water Meter Turbine Type for customer
Service.
C 901 Polyethylene (PE) pressure Pipe & Tubing, ½ inch through 3

inch for water.
C 906 Polyethylene (PE) pressure Pipe & Fittings, 4 inch through 63

inch for water
D. BSI - British Standards Institute :
BSS 497 Manhole Covers, Road Gully Gratings and Frames for
Drainage Purposes.
ISO 2531 Ductile Iron (D.I.) pipes.
ISO 4427 Polyethylene Pipes for water supply- Specifications.
1.3 SUBMITTAL
The Contractor shall submit to the Engineer the following items for review
before commencing work :
A. Manufacturers test certificates and certificate of compliance stating that the

material used and construction of equipment, fittings and accessories
conform to all requirements of this specification.
B. Catalogue data for all equipment, fittings and accessories showing

illustrations and Schedule of Parts to facilitate assembly and disassembly.
C. Samples of materials as required by the Engineer.
D. Joint detail drawings and joint assembly procedures including connections to

washouts, etc.
E. Manufacturer recommended specification for transporting, handling, and

storage of materials.
F. Detail drawings and/or shop drawings.
G. Test reports.
H. Plant and equipment manufacturer's operating and maintenance manuals.
__________________________________________________________________________________________________
1.4 PRODUCT HANDLING
A. All products shall be delivered in manufacturer's original protective packaging.
B. All products shall be inspected at time of delivery for damage and for
compliance with specifications.
C. Any products that found to be damaged or not in accordance with the

specifications shall immediately be removed from site and replaced. Repairs
shall not be undertaken before the Engineer's review of the Contractors
proposed action.
D. All products shall be handled and stored as recommended by manufacturer to

prevent damage and deterioration.
E. Products shall be protected against damage and the ambient conditions both
during transport, site storage and immediately up to the time the products are
installed. Precautions shall be taken to protect the products from mechanical
damage and the effects of sunlight and heat, until the backfilling operations
have been completed. All site storage areas shall be shaded.
PART 2 - PRODUCTS
2.1 GENERAL
A. All goods and products covered by these Specifications shall be preferably

procured, when available, from an in-Kingdom manufacturer, subject to
approval by the Engineer and compliance to the specification. Procurement of
all goods and products manufactured out-of-Kingdom must be approved by
the Engineer.
B. All equipment, fittings and accessories shall be suitably rated to comply with
the system working and test pressures. The relevant pipes are to be tested
either at 150% of working pressure or at design pressure whichever is
greater.
C. All products shall be installed strictly in accordance with the manufacturer's

instructions.
2.2 PIPES
A. Pipe more than 250mm diamter, Ductile Iron Pipe shall be used.
Requirements for Straight Pipes: Ductile cast iron pipes shall comply with
AWWA C151, thickness class at least 51, or ISO 2531 of class k=9, with a
corrosion resistant coating on both internal and external surfaces. As a
complement to this, polyethylene sleeves shall be supplied along with this
materials.
Joints and Fittings: The pipes shall be flexible jointed with automatic rubber
ring joints (push-on-joints).
__________________________________________________________________________________________________
B. Pipes equal to or less than 250mm diameter, high density Polyethylene
(HDPE), Class PN16-SDR11, (Nominal operational pressure 16 bar) shall be
used, and shall conform to ISO 4427, and AWWA Specifications C906.
2.3 STEP IRONS
Step irons shall be manufactured from cast iron to conform to ASTM A 48 and
shall be coated with epoxy coating with a minimum dry film thickness of 100
microns; the stepping surface shall be non-slip.
2.4 EQUIPMENT, FITTINGS AND ACCESSORIES
A. Bronze fittings :
All bronze fittings and threaded connection pieces shall be of the non-
dezincifiable type.
B. Plug cocks :
Plug cocks shall be manufactured from bronze and shall be used in place of
gate valves on pipes having a diameter below 50 mm.
C. Corporation stops :
Corporation stops shall be manufactured from bronze and shall conform to

AWWA C800. Outlets shall be suitable for making water-tight joints with plain
end HDPE pipe.
D. Fire hydrants :
Fire Hydrants shall be in accordance with section 40 05 81.13, Wet Barrel

Fire Hydrants.
E. Water meters :
Water meters shall be in accordance with the Meters and Gauges

specifications.
F. Water meter boxes :
Water meter boxes and covers shall be manufactured from cast iron to
conform to ASTM A48 and shall be coated in epoxy coating to a minimum dry
film thickness of 100 microns. The cover shall be inscribed with the words
"POTABLE WATER METER" in Arabic and English. The fabricated boxes
and covers shall comply with BS 497.
G. Service clamps :
Service clamps shall be single strapped or double strapped as indicated on

the contract Drawings and shall have a galvanized malleable iron body fusion
epoxy coated at the factory and shall have stainless steel or bronze straps.
__________________________________________________________________________________________________
H. Gasket material :
Gasket material shall be 5 mm thick, full faced design, with a Durometer

shore reading of 40-60, as specified in ASTM E 140.
I. Bends, Elbows, Reducers and Tees:
1. All bends, elbows, reducers and tees for PVC pipes size 63 mm
nominal diameter and below shall be solvent weld type. Sizes larger
than 63 mm diameter shall be flexible rubber ring joint type.
2. All bends, elbows, reducers and tees for FRP pipes shall be FRP,
plain ended type, compatible with Amiantit double bell Reka couplings.
3. Bends, elbows, reducers and tees to be installed inside valve

chambers shall be made of carbon steel, ductile iron, cast iron,
bondstrand or FRP.
4. New branch tee material for connection to existing asbestos cement

pipe, shall be FRP suitable for ACP Class 24.
J. Couplings:
1. General: Couplings shall permit the connection of two pieces of pipe

without displacing the pipe longitudinally. The couplings will be used
for fitting closing lengths on pipelines, for withdrawing a pipe for
cleaning or inspection or for repair purposes and shall thus not be
supplied with any center register. Metallic coupling with external stud
bolts shall be coated in accordance with Section 09 91 00 In addition,
the external surfaces shall be wrapped with adhesive waterproofing
tape or polythene encasement as directed by site engineer.
2. PVC Couplings: Couplings for PVC pipe of 280 mm diameter or less

shall be class 5 with rubber gaskets for water distribution systems and
force mains; and shall be class 3 for sanitary and other gravity
systems.
3. GRP Couplings: Couplings for glass fiber reinforced plastic pipe shall
be made of GRP, double bell Reka type coupling.
4. Repair Couplings:
Repair couplings shall be used for repairing asbestos cement pipe,

PVC or GRP pipe and shall be manufactured in accordance with
AWWA C110 or ISO 2531. The coupling shall be made of PVC, GRP,
carbon steel, PVC coated carbon steel or hot dip galvanized carbon
steel and the minimum thickness of the zinc layer shall be 80
micrometers. Metallic couplings shall be protected with corrosion
resistant coating in accordance with Section 09 91 00. All metallic
repair couplings exposed to the soil shall be wrapped with adhesive
waterproofing tape.
5. Stepped Couplings:
__________________________________________________________________________________________________
Stepped couplings shall be used for connection of dissimilar pipe
diameter and be made of carbon steel, ductile iron or cast iron. All
metal surfaces shall be coated in accordance with Section 09 91 00.
2.5 IDENTIFICATION LABELS
Each valve, meter, piece of equipment shall be fitted with an identification

label as follows :
Identification labels shall be size 50 x 80 mm constructed from 2 mm brass

sheet with the service identifications engraved in 10 mm high lettering to
indicate the service handled in both Arabic and English with the word
"POTABLE WATER". A 2 mm diameter fixing hole shall be provided.
2.6 AIR VALVES
A. Air valves shall be installed at high points in pipe work to fulfill three functions
:
1. To exhaust air from pipe work automatically when it is being filled with
water, the air being released at a sufficiently high rate to prevent
restriction of water inflow rate.
2. To ventilate pipe work automatically when it is being emptied of water,

the air inflow rate being sufficiently high to prevent the development of
pressures in the pipelines.
3. To release air accumulating in pipe work automatically during normal

working conditions.
B. Air valves shall be from manufacturers approved by the Engineer.
C. Air valves shall be of two way double orifice type with a large orifice for
ventilation or exhaust of the pipeline and a smaller orifice for automatic
release of air under normal working pressure. The valves shall be suitable for
the system maximum working pressures. Valves shall be tested for leak
tightness in steps of 200 KN/M2 up to the maximum working pressures and
shall in addition be tested for mechanical strength, at 1.5 times maximum
working pressures. All air valves shall be provided with isolating valves and
flanged end connections.
2.7 BACK FLOW PREVENTOR
Back flow preventors shall conform to AWWA C506 and be a reduced

pressure principle type and shall be a complete assembly consisting of two
independently acting spring-loaded type check valves. The first check valve
shall reduce the supply pressure to a pre-determined amount, so the pressure
between the checks is less than the supply pressure. If leakage occurs in
either check at less than the supply pressure. Tightly closing shut-off valves,
fitted with properly located test cocks, shall be provided at each end of the
unit. All internal parts shall be removable without removing the back-flow
preventor from the pipe line. The unit shall have a maximum rated flow in
accordance with section 3, table 1 of AWWA C506. The main valve body
cover and trim shall be bronze and the relief valve shall be bronze with
stainless steel trim.
__________________________________________________________________________________________________
2.8 MARKER POSTS
The Contractor shall provide marker posts with indicator plates. These shall
be provided generally not less than 200 m apart, at all changes in direction,
adjacent to all line and outlet valves from the main transmission line, and at
all dead ends. Top of pipeline elevations shall be indicated on all markers.
2.9 MARKER TAPE
The Contractor shall provide marker tape to be laid in all trenches above each
utility main transmission line and service. For all potable water mains, the
tape shall be blue in colour, and for electrical supplies shall be yellow. Above
all non-metallic mains, the tape shall be detectable, except in specifically
approved circum-stances; elsewhere the tape shall be of polyethylene, PVC
or other plastic material. It shall be printed in Arabic and English alternately
with the words "CAUTION : BURIED WATER LINE BELOW", for potable
water mains and "CAUTION : BURIED ELECTRIC LINE BELOW", for power
supplies. The tape shall be 300 mm in width, 100 microns nominal thickness
and obtained from an approved supplier.
2.10 GATE VALVES
Valves for 63 mm size and larger shall be rising stem, outside screw and yoke
type with cast or ductile iron body and bronze trim. Ductile iron shall conform
to ASTM A536, Grade 60-40-18 and cast iron to ASTM A126, Class B, Valve
spindles shall be stainless steel complying with ASTM A479, Type 316.
Valve shall have solid wedge bronze or brass disc, steel hand wheel, and
flanged inlet and outlet. Valve shall be rated for 1.4 MPa water working
pressure and have the capability of being repacked while under pressure.
2.11 BUTTERFLY VALVE
Valves up to 300 mm shall be designed for a minimum of 0.68 MPa

differential pressure with the down stream flange removed. Factory test data
on differential pressure rating is required. Valves shall have cast iron body,
conforming to ASTM A126 class B body, tin bronze disc, in accordance with
ASTM B30 copper alloy, and EPDM seals. Shafts design shall be AISI 416
stainless steel. All valves shall have extended necks for a minimum of 50 mm
insulation. Valves 63 mm through 150 mm shall be provided with lever
operators and memory stop.
2.12 PRESSURE RELIEF VALVES
Relief Valves: Combination temperature-pressure relief valves shall have

bronze body, screwed connections, 1.0 MPa water working pressure, brass
working parts, ASME approved and labeled; size, capacity, and setting as
indicated.
2.13 SLEEVES
A. General :
__________________________________________________________________________________________________
1. Sleeeves for all pipes passing across roads shall be provided in types
as scheduled below, and of adequate diameter to allow minimum of
400mm clearance all around between sleeve and pipe.
2. Special sleeves detailed on drawings shall take precedence over this

section.
B. Pipe Sleeves:
1. Reinforced cement concrete pipe shall be of Class-V as per ASTM

C76M.
PART 3 - EXECUTION
3.1 INSPECTION
The Contractor shall inspect all products for damage immediately before
installation. Any products that are found to be damaged or not in accordance
with the specifications shall immediately be repaired or removed from the site
and replaced.
3.2 INSTALLATION
A. Excavation and Fill for Site, shall be in accordance with Sections 31 23 00.
B. Trenching, Bedding, Backfilling and Compacting shall be in accordance with

Section 31 23 16.13, Trenching, Bedding, Backfilling and Compacting.
C. Concrete reinforcement shall be in accordance with the Concrete

Reinforcement specification.
D. Cast-in-Place concrete shall be accordance with the Cast-In-Place Concrete

specification.
E. Pipe work shall be installed in accordance with Division 33.
3.3 EQUIPMENT, FITTING AND ACCESSORIES
Equipment, fittings and accessories shall be installed in accordance with

AWWA C600 and ASTM D2774. All threaded joints shall be made using
poly-tetra-fluoro-ethylene tape.
3.4 ANCHOR THRUST BLOCKS
Anchor and thrust blocks shall be provided at all tees, bends, valves and
hydrants. The concrete shall be made with type V cement.
3.5 PLUGGING OF DEAD ENDS
The dead ends of pipes and fittings shall be plugged and concrete anchors
shall be provided.
__________________________________________________________________________________________________
3.6 MARKER POSTS
The Contractor shall set up marker posts as specified in paragraph 2.08

above. They shall be set up as soon as practical after the backfilling of the
trench excavation, but the Contractor shall provide any temporary marking
required.
3.7 MARKER TAPE
The Contractor shall install the marker tape at a minimum height of 300 mm
above the buried utility in the trench during the backfilling operation.
3.8 IDENTIFICATION LABELS
The identification labels shall be connected to the equipment to be identified

by a brass chain through the fixing hole and looped around and fixed to the
equipment. The ends shall be sealed to provide a permanent fixing for the
labels.
3.9 WASHOUT
Washouts shall be constructed on mains of 150 mm and above, at all low

points. Each washout connection to the main pipe line shall include flanged
joint and isolating valve. As a general rule emptying or recharging time
should not exceed four (4) hours. Tees at connections shall either have level
inverts or be installed with the branch inclined downwards.
3.10 PIPES PASSING THROUGH RIGID STRUCTURES
A. Where pipes pass through a wall or other solid structure, anchor block, valve
chamber, manhole etc., at least one flexible joint shall be incorporated in the
pipeline either side of the structure at not more than one pipe diameter length
from the point of entry and exit. The external surface of iron pipe shall be
surrounded with a flexible material such as bituminized felt or building paper
for a minimum distance of 100 mm at the point of entry into the structure.
B. If appreciable movement of the structure is anticipated a further joint not

greater than 1.5 pipe diameters away from the above joint shall be included.
Special precautions need to be taken where large movements are expected.
3.11 BONDING OF PIPES TO STRUCTURES
A. The water tight bonding of pipes to walls and structures shall be achieved by
painting the external surface of the pipe with a bituminous compound and
blinding with sand prior to placing the bonding mortar, concrete or brickwork.
B. These methods apply to pipes with or without puddle flanges.
3.12 EXPANSION AND CONTRACTION
All necessary measures shall be taken to ensure that the effect of expansion
on the system shall be catered for including the provision of expansion
__________________________________________________________________________________________________
compensator units and any additional anchors or guides necessary whether
shown on the Contract Drawings or not.
3.13 PROTECTION OF WATER SUPPLIES
A. Horizontal separation :
Unless otherwise specified, the water main lines should be laid at least 3.0m
horizontally from any existing or proposed sewer or irrigation water line.
Should conditions prevent 3.0m separation, the water line, sanitary sewer line
or irrigation water line shall be separated by a minimum vertical distance of
500 mm and a minimum horizontal distance of 1.2m, measured between the
nearest outside diameter of the pipes. The water line shall be located above
the sewer or irrigation water line unless otherwise indicated on the drawings.
B. Vertical separation :
If water lines and sanitary sewer lines cross each other, sewer should be a
minimum of 500 mm below or above the water line. The crossing should be
arranged so that the sewer joints will be equi-distant from the water main
joints.
C. When a water main must be installed under sewers, the sewer piping shall be
constructed of ductile cast iron joint pipe for a distance of 3.0 m on each side
of the water main. One full length of the water main shall be centered under
the sewer such that the top of the water main is at least 500 mm below the
invert of the sewer line.
3.14 SYSTEM TESTING
A. General :
1. The Contractor shall ensure that all pipe work is watertight to the
satisfaction of the Engineer and shall supply all pressure gauges,
meters, hoses, pumps and other temporary supports and equipment
necessary for carrying out pressure tests.
2. 2. The Contractor shall, during testing, check the satisfactory

operation of each valve and hydrant installed under the Contract.
B. Initial system test :
1. Pressure mains shall be tested with water to the required pressure

while uncovered but adequately anchored. The testing shall be
carried out when lengths of pipe work not exceeding 1000 metres
have been laid or when shorter lengths of pipe work have been laid
between valve positions or structures. If a length should fail the test,
the Contractor shall trace and repair all leaks and defects and retest
the length before any further pipes or sections of adjacent pipe work
are laid.
2. Before filling or pressure testing is started the Contractor shall recheck

pipes and valves for clean-liness and shall recheck the operation of
valves. The open ends of the pipeline or sections shall normally be
stopped off by blank flanges or capped ends additionally secured
__________________________________________________________________________________________________
where necessary by temporary struts and wedges. All thrust blocks
and valve chambers shall be completed with back-fill placed around
them and the concrete shall have attained its specified 28 day
strength and all pipe straps and other devices intended to prevent the
movement of pipes shall have been securely fastened.
3. The section of the pipeline to be tested shall be filled with potable

water and all air expelled. After the pipeline has been completely
filled, the pressure shall be steadily and gradually increased until the
test pressure as specified in paragraph 2.01 B of this Specification
has been reached. The duration of each pressure test shall be
adequate settlement and jointing to stabilize or a minimum of four (4)
hours, whichever shall be the greater. A graph shall be produced
showing the run until the graph curve flattens out. Testing shall
comply with AWWA specifications and requirements.
4. The section under test is to be maintained full of water for a period of

twenty-four (24) hours prior to the start of the pressure and leakage
test.
5. During the test, all couplings, fittings valves and hydrants shall be
carefully examined for defects and leakage. Leaking couplings, fitting,
valves and hydrants shall be repaired or replaced and the section re-
tested as previously specified.
C. Final system test :
The test as specified above shall be repeated after the pipelines have been
backfilled, cleaned and inspected. Each test shall be restricted to pipes of
one class and particular care shall be taken to isolate air valves and not to
apply higher pressure than specified at any point of the pipeline and to ensure
that the pipelines are adequately anchored before any test is carried out.
D. Test results :
Written records of every test clearly identifying the tested section of the pipe
together with time of test and name of testing engineer in tabulated format
shall be submitted for review by the Engineer upon completion of the test.
3.15 FLUSHING AND DISINFECTION
A. Potable water pipelines shall be flushed with potable water after completion of
pressure testing and before introducing disinfection.
B. Disinfection shall be in accordance with Section 33 01 10.58.
END OF SECTION
__________________________________________________________________________________________________
SECTION 33 14 19
FIRE HYDRANTS
PART 1 - GENERAL
1.01 DESCRIPTION
A. General
1. Furnish all labour, materials, tools, equipment, and services for Wet BarrelFire
Hydrants, in accord with provisions of Contract Documents
2. Completely coordinate with work of all other trades
The following codes and standards are intended to provide an acceptable level of
quality for materials and products
A. AWWA – American Water Works Association, latest issue,
C503 Standard for Wet-Barrel Fire Hydrants
C110 Standard for Gray-Iron and Ductile-Iron Fittings for Water other Liquids
M 17 Installation, Operation, and Maintenance of Fire Hydrants
B. NFPA National Fire Protection Association, latest issue
194 Standard for Screw Threads and Gaskets for Fire Hose Couplings
291 Fire Hydrants, Uniform Markings
C. ANSI American National Standards Institute, latest issue
A216 Standard for Cast-iron Pipe centrifugally cast in metal moulds for water
and other liquids
A218 Standard for Cast-iron Pipe centrifugally cast in sand-lined mould for
waterand other liquids
A2151 Standard for Ductile-Iron Pipe centrifugally cast in metal mould or sand-
ined mould for water or other liquids
D. ASTM American Society of Testing and Materials, latest issue
A 47 Malleable Iron Castings
A 48 Gray Iron Castings
A 126 Gray Iron Castings for Valves, Flanges and pipe fittings
A 197 Cupola Malleable Iron
__________________________________________________________________________________________________
A 220 Perlitic Malleable Iron Castings
A 395 Ferritic Ductile Iron Pressure Retaining Castings for use at elevated
temperatures
A 575 Merchant Quality Hot-Rolled Carbon Steel Bars
A 576 Steel Bars, Carbon, Hot-Rolled, Special Quality
B 61 Steam or Valve Bronze Castings
B 62 Composition Bronze or Ounce Metal Castings
B 98 Copper-Silicon Alloy Rod, Bar, and Shapes
B 150 Aluminum Bronze Rod, Bar, and Shapes
B 2000 Rubber products in Automobile Applications
1.03 DESIGN CRITERIA
A. Fire Hydrant shall be wet-barrel type and shall conform to AWWA C 503 and C 110
codes listed in Section 1.02 of this specification
B. Hydrant barrel shall be not less than 150 mm diameter
C. Hydrant Connections:
1. Hydrant shall have two (2) 65 mm nominal diameter fire hose nozzles with 25-75
NH type threads per NFPA 194
2. Hydrant shall have one (1) 115 mm nominal diameter pumper connection with
4.5-4 NH type thread per NFPA 194
D. Hydrant shall be designed to withstand 2.0 megapascals hydrostatic test pressure

and 1.05 megapascals operating pressure
E. Operating Mechanism:
1. The operating nut shall be pentagonal in shape and shall measure 38 mm from
point to flat at the base of the nut and 36 mm at the top.
2. The hydrant shall be opened by turning the operating nut counterclockwise.
3. The force required to open or close the hydrant shall not exceed 27 Nm at any
time when the hydrant is not under pressure.
4. Hydrant shall operate normally following the application of an operating torque of

270 Nm at the operating nut to the hydrant being open and in the direction to
open it further the same torque shall be applied to the operating nut in the
direction of closure.
F. Loss of head due to friction, corrected for inlet and outlet velocity head, shall not
exceed 15 kilopascals with a total of 3167 liters per second water flow from both
outlet nozzles.
__________________________________________________________________________________________________
G. Hydrant body shall be painted FIRE HYDRANT RED Bonnets and nozzle caps shall
be painted red as per NFPA Nº 291
1.04 SUBMITTAL
The Contractor shall submit the following items for review:
A. Certificate of compliance stating that the material used and construction of the
hydrants conform to all requirements of this specification
B. Certificate of testing including test data to show that all tests specified have been
performed and all requirements have been met
C. Catalogue data showing illustrations and schedule of parts to facilitate assembly and
disassembly of the hydrant and ordering of replacement parts
D. Maintenance manual showing periodic maintenance including lubrication

requirements and procedure, and recommended spare parts list
A. Provide packing as required for shipment of hydrants to the installation site
B. Inspect hydrants at time of delivery for shipment damage and for compliance with
specifications Close hydrant valves and replace nozzle caps prior to storage
C. When damaged equipment or hardware that will require repair or replacement, or

equipment that does not comply with specification is found, immediate action shall
be taken to repair or replace equipment, so that the project's performance and
schedule are not impaired
D. Store and handle hydrants at the construction site in a manner to prevent damage
and deterioration.
PART 2 - PRODUCTS
2.01 GENERAL
A. All goods and products covered by these specifications shall be procured, when
available, from an in-Kingdom manufacturer Procurement of all goods and products
manufactured out-of-Kingdom must be approved by the Authority.
B. Cast Iron:
1. Gray iron castings for valves, flanges, and pipe fittings shall conform to ASTM A
126, Class B, or ASTM A 48, Class 30.
2. Centrifugally cast iron shall conform to ANSI A216 or ANSI A218.
C. Ductile Iron:
1. Ferritic ductile iron castings for valves, flanges, Piping, and pipe components
shall conform to ASTM A 395.
2. Centrifugally cast ductile iron pipe shall conform to ANSI A2151

__________________________________________________________________________________________________
D. Malleable Iron:
1. Malleable iron may used for structural parts, but shall not be used for pressure
containing parts.
2. Malleable iron castings shall conform to ASTM A47.
3. Pearlitic Malleable iron castings shall conform to ASTM A220.
4. Cupola Malleable iron shall conform to ASTM A 197
E. Steel:
1. Merchant quality hot-rolled carbon steel bars shall conform to ASTM A575
2. Special quality hot-rolled carbon steel bars shall conform to ASTM A 576
F. Bronze:
Each grade of bronze shall conform to the following specifications:
Grade Conforming to
I ASTM B 62
VI - Forged ASTM B 150
VII- Cast ASTM B 61
IX - Rolled ASTM B 98
The following grades of bronze may be used for the following components:
Component Grade of Bronze
Drain valve parts I, VI, VII, IX
Glands I, VI, VII, IX
Gland bushings I, VII
Outlet nozzles I, VII
Stems or threadedportion of stems Stem nuts I, VI, VII, IX
Stuffing Boxes I, VI, VII, IX
Valve seats orValve seat rings I, VI, VII, IX
G. Material for bolts and nuts shall be made from corrosion resistant metal such as low-
zinc bronze, monel, or 316L stainless steel, solution annealed after machining and
threading
H. Stuffing box packing material shall be either asbestos, flax, or Teflon impregnated
asbestos conforming to AWWA M17
__________________________________________________________________________________________________
I. O-ring material shall conform to ASTM D 2000
J. Gasket material shall be of, rubber, or paper free from corrosive ingredients, either
alkaline or acid
K. Valve facing material shall be rubber, leather, balata, or composition
L. Prime coating of hydrant, from the ground line up shall be in accordance with
manufacturer's standard practice and conforming to AWWA M17
M. Painting shall be in accordance with manufacturer's standard practice and

conforming to AWWA M17
2.02 FABRICATION
A. All castings shall be clean and without defects Plugging, welding, or repairing of such
defects shall not be allowed
B. All foundry and machine work shall be in accordance with good practice for the class
of work involved
C. All parts shall conform to the required dimensions and shall be free from defects that
will prevent proper functioning of the hydrant
D. Assembly of hydrants shall be well fitted, smoothly operating, and watertight
E. All like parts of hydrants produced by the same manufacturer shall be

interchangeable
F. All ferrous metal parts shall be thoroughly cleaned and painted and in accordance
with manufacturer's standard practice as follows:
1. All exposed exterior surfaces below the ground line and exposed interior
surfaces below the main valve shall be coated with asphalt varnish and shall be
covered with two coats, the first being allowed to dry thoroughly before the
second is applied.
2. All interior surfaces above the main line, except machined surfaces such as
threaded portion of the operating stem or nut, shall be coated with asphalt
varnish or primer and then painted with a coat of primer A second coat of primer
or paint of a colour specified shall be applied.
2.03 SHOP TESTING
A. Hydrostatic Testing:
Every assembled hydrant shall be subject to two shop tests under a hydrostatic
pressure of 20 megapascals as follows:
a) One test shall be made with the entire interior of the hydrant under pressure
(main valve open) There shall be no leakage through the stuffing box, castings,
or the joints of the assembled hydrant The leakage through the drain valve shall
not exceed 00025 litres/sec.
__________________________________________________________________________________________________
b) Another test shall be made with the main valve closed and the foot piece under
pressure from the inlet side There shall be no leakage through the main valve
B. Friction loss test shall be performed with a total flow from both outlet nozzles of 3167
litre/sec and the discharge from each nozzle being approximately equal The head
loss during this test shall not exceed 15 kilopascals
C. Operating mechanism torque test shall be performed on each hydrant The force
required to open or close the hydrant shall not exceed 27 Nm at any time when the
hydrant is not under pressure
PART 3 - EXECUTION
3.01 INSPECTION
The Contractor shall inspect each hydrant prior to installation to verify that the hydrants
are in conformance with this specification
3.02 INSTALLATION
A. Hydrants shall be installed in strict conformance with manufacturer's written

instructions and AWWA M17 The buried portion of the hydrant barrel shall be coated
with bitumastic paint The minimum cured dry film thickness of the paint shall be not
less than 03 mm After painting, the barrel shall be wrapped with PVC or polyethylene
tape to a minimum of 165 mm thickness
B. When placed behind the curb, the hydrant barrel shall be set so that no portion of the
pumper or hose nozzle cap will be less than 600 mm form the gutter face of the curb
C. When placed in the lawn between the curb and the sidewalk, or between the
sidewalk and the property line, the hydrant barrel shall be set so that no portion of
the pump or hosenozzle cap will be less than 300 mm from the sidewalk
D. All hydrants shall stay plumb and shall have their nozzles parallel with, or at right
angles to, the curb, with the pumper nozzle facing the curb.
E. Hydrants shall be set to the established grade, with nozzles 450 mm above the
ground.
F. When fire hydrant is joined to bell and spigot PVC or asbestos-cement pipe, suitable
adapter shall be provided.
G. The base of each hydrant shall be well braced against unexcavated earth with thrust
blocks as shown in the Contract Drawings or with other approved retaining type joint.
H. Hydrants shall be spaced so that no location on the protected roadway is more than
45m from the hose connections.
I. Spacing shall not exceed 85 meters between hydrants.
J. Hydrant shall be housed together with the following equipment:

__________________________________________________________________________________________________
1. Two hoses 2½”Ø.
2. Nozzles
3. Portable Fire Extinguishers
4. Fire Axe
5. Crowbar
6. Two electrical battery hand lights.
3.03 TESTING
After installation and before backfilling, a hydrostatic pressure test shall be performed
for each hydrant installation
The hydrostatic test shall be performed at a pressure of 105 megapascals for at least
one hour.There shall be no leaks at the hydrant and its connection to the supply pipe.
3.04 BACKFILLING AND CLEANING
After successful completion of the hydrostatic test, the pit shall be backfilled and
tamped.
The hydrant shall be flushed out of foreign material and, if necessary, the portion of
the hydrant above ground shall be repainted The Contractor shall obtain from the fire
hydrant manufacturer touch-up paint for the field use and no separate payment will be
made for this paint.
END OF SECTION
__________________________________________________________________________________________________
SECTION 33 30 00
SANITARY SEWERAGE
PART 1 - GENERAL
1.01 DESCRIPTION
A. General :
1. Furnish all labour, materials, tools, equipment and services for all sanitary
sewers as indicated, in accordance with provision of the Contract Documents.
2. Completely co-ordinate with work of all other trades.
supplementary or miscellaneous items, appurtenances and devices incidental
to or necessary for a sound, secure and complete installation.
B. Related work specified elsewhere :
1. Section 31 23 16.13, Trenching.
3. Section 03 00 00, Concrete.
1.02 QUALITY ASSURANCE STANDARDS

A. Comply with the latest issue of the following listed standards :
1. ASTM - American Society for Testing And Materials Publications :
ASTM D3262 GRP pipe Longitudinal Strength
ASTM 3517 GRP pipe Hydraulic Test on every pipe.
ASTM D 2412 or BS 5480 [11], GRP Pipe Stiffness
A 47 Malleable Iron Castings.
A 48 Grey Iron Castings.
C 150 Cement, Portland.
C 207 Hydrated Lime for Masonry.
C 270 Mortar for Unit Masonry.
C 478 Precast Reinforced Concrete Manhole Sections.
C 722 Chemical Resistant Resin Monolithic Surfacings
D3034 Type PSM PVC Sewer Pipe and Fittings.
D3212 Joints for Drain and Sewer Plastic Pipes Using Flexible
Flastomeric Seals.
C 104/ Cement Mortar Lining for Ductile Iron Pipe A21.4 and
Fittings for Water.
C 105 Polyethylene Encasement for Grey and ductile Cast-Iron Pipe.
C 110 Grey-Iron and Ductile-Iron Fittings.
(75 mm through 1200 mm)
C 111/ Rubber Gasket Joints for Ductile-Iron and
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A 21.11 Grey-Iron Pressure Pipe and Fittings.
C 115/ Flanged Ductile-Iron and Grey-Iron Pipe with Threaded
Flanges.
C 151 Ductile-Iron Pipe Centrifugally Cast in Metal Moulds or Sand
Lined Moulds.
C 600 Installation of Grey and Ductile Cast-Iron Water Mains and
Appurtenances.
2. Uni-Bell Plastic Pipe Association (UNI) publications:
UNI-B-5 Installation of PVC Sewer Pipe.
1.03 SUBMITTALS
A. Manufacturer's catalogue cuts and specifications for all materials.
B. Manufacturer's certification of materials.
C. Manufacturer's recommended methods for installation.
D. Manufacturer's operating and maintenance data as applicable.
E. Exfiltration test results.
F. Shop Drawings: Show Installation details related to this Section. Include plans,
sections, joint details, and details of connections showing fittings and accessory
items.
1.04 JOB CONDITIONS
A. Verify location and elevation of all underground utility lines prior to starting trench
excavation work
B. Protect all existing utility lines, overhead or underground, from damage due to any
construction activity. Repair any and all damage to existing utility lines or other
facilities or improvements and pay all associated costs.
C. Avoid overloading. keep surcharge sufficient distance back from edge of excavation
to prevent slides or caving. Maintain and trim excavated materials in such a manner
to be as little inconvenience as possible to public and adjoining property Employers.
D. Provide access to public and private premises, to fire hydrants, at street crossing,
sidewalks and other points as designated by the Engineer to prevent serious
interruption of travel.
E. Comply with all aspects of local Arriyadh or Kingdom of Saudi Arabia safety
standards.
PART 2 – PRODUCT
__________________________________________________________________________________________________
2.01 GRAVITY SEWER PIPING
A. Pipes equal to or less than 600mm diameter, Vitrified Clay (VC) pipes shall be used:
Vitrified Clay pipes shall conform to the requirements specified in:
1. All Pipe shall be vitrified clay pipe manufactured in accordance with ASTM
Specification C700 (latest revision). All pipe shall be furnished with flexible
compression joints conforming in all respects to ASTM Specification C 425,
latest revised edition, trade name Logan O-ring. The polyester resin castings
in the bell and on the spigot shall be factory applied. An “O” ring gasket shall
be provided to fit in the groove on the spigot end which will form a tight and
flexible compression joint when assembled. When installed in accordance
with ASTM C 12 (latest revision), pipe shall be tested for leakage according to
ASTM C 828 (latest revision).
2. AASHTO M65 (ASTM C700): Vitrified clay pipe, extra strength, standard
strength and perforated clay drain tile.
B. Pipes greater than 600mm diameter, GRP pipes shall be used:

Testing on GRP Pipes: The following tests shall be carried out on manufactured
pipes. Details of testing program shall be submitted to the Engineer for review and
approval prior to commencement of pipe manufacture. The manufacturer quality
control scheme shall be to BS 5750-8 [12] or ISO 9004. Guidance on quality control
and sampling shall be BS 5480 Appendix Q [11]. At least the following tests shall be
carried out and reported for approval.
− Visual inspection
− Longitudinal Strength : to ASTM D3262
− Hydraulic Test : to ASTM 3517 on every pipe.
− Stiffness : to ASTM D 2412 or BS 5480 [11]
− Wall Thickness : to BS 5480 [11]
− Diameter : to BS 5480 [11]
− Hardness : to ASTM 2583
− Loss of Ignition : to ASTM D 2584
− Hoop Tensile : to ASTM 3517
2.02 FORCEMAIN SEWER PIPING

A. HDPE Pipe shall be used for forcemain sewer piping.
1. Materials used for the manufacture of polyethylene pipe and fittings shall be
made from a PE 3408 high density polyethylene resin compound meeting cell
classification 345434C per ASTM D3350; and meeting Type lll, Class C,
Category 5, Grade P34 per ASTM D1238.
2. High Density Polyethylene (HDPE) pipe shall comply with AWWA

Specifications C906.
3. If rework compounds are required, only those generated in the Manufacturer’s

own plant from resin compounds of the same class and type from the same
raw material supplier shall be used.
4. Dimensions and workmanship shall be as specified by ASTM F714. HDPE

fittings and transitions shall meet ASTM D3261. HDPE pipe shall have a
__________________________________________________________________________________________________
minimum density of 0.955 grams per cubic centimeter. All HDPE pipe and
fittings shall have a Hydrostatic Design Basis (HDB) of 1,600 psi.
5. HDPE pipe and accessories 4-inch diameter and larger, shall be 160 psi at
73.4°F meeting the requirements of Standard Dimension Ration (SDR) 17 as
MINIMUM STRENGTH.
6. The pipe Manufacturer must certify compliance with the above requirements.
2.03 UPVC PIPING
. UPVC Pipes and Pipe Fittings:
Pipes: Unplasticized polyvinyl chloride (UPVC), if required, shall conform to

the requirements of ASTM D 1785.
Pipe Fittings: Unplasticized polyvinyl chloride (UPVC), shall match to that of

pipe and conforming to ASTM D 1785, socket-type
Jointing System:
Welded joints using solvent cement conforming to ASTM D 2564.
Flexible Joints: Flexible joints using Flex-Seal couplings shall be provided in

piping to service manhole. Stainless steel clamping bonds, shear rings and
components shall be made from marine grade 300 Series stainless steel to
BS 9570: part 1:1983. Synthetic elastomeric rubber conforming to the
requirements of BS 2494D: 1990.
2.04 SLEEVES
A. General :
1. Sleeeves for all pipes passing across roads shall be provided in types as
mentioned below, and of adequate diameter to allow minimum of 400mm
clearance all around between sleeve and pipe.
2. Special sleeves detailed on drawings shall take precedence over this section.
B. Pipe Sleeves:
1. Reinforced cement concrete pipe shall be of Class-V as per ASTM C76M.
2.05 CAST-IN-PLACE CONCRETE MANHOLE AND CHAMBER
__________________________________________________________________________________________________
A. All manholes and chambers shall have wall thickness designed to withstand
AASHTO HS20-44 loading and shall meet dimensions shown on the standard
detailed drawings.
B. All concrete exterior surfaces in contact with backfill soil shall be with as
specified in the standard detailed drawings or as approved materials.
C. Concrete Base and Collar: Cast-in-place concrete which shall attain a 28-day
compressive strength of not less than 21 MPa., unless other specified on the
drawings.
2.06 METAL ITEMS

A. Frames, covers, and gratings :
Heavy duty grey cast iron conforming to DIN specification 1229 with minimum tensile
strength of 207 MPa and machined horizontal and vertical bearing surfaces, non-
rocking type and 40 ton test load.
1. Cover :
Solid, non-ventilated with words "SANITARY SEWER" Cast in cover in both
English and Arabic.
2. Frame and Cover :
a. Minimum clear opening :
600 mm.
b. In paved areas subject to traffic :
Heavy duty type with minimum weight of 181 kg.
c. In areas not subject to traffic :
Medium duty type with minimum weight of 80 kg.
B. Manhole steps :
Galvanized steel iron confirming to ASTM A 153, non slip surface, designed to
support a concentrated load of 227 kg. Minimum tread length 300 mm and minimum
tread width 25 mm. To manholes deeper than 3 meter will be by means of built-in
access ladders. For manholes of less depth, galvanized steel safety steps and hand
bars will be used.
C. Cleanout covers :
Cast iron conforming to ASTM A 48 with machined bearing surfaces.
2.06 AIR RELEASE VALVE
Sewer air relief valves shall be used consisting of long float stem, float and valve
body type. Body and cover shall be made of cast iron following ASTM A48 Class 30.
Internal linkage shall be made from Delrin following ASTM 02133. Float and
internals shall be made of stainlesssteel following ASTM A240.
2.07 SEWAGE ODOR CONTROL UNIT

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A. Description: the unit shall consist of the following:
a. Odor control unit vessel.
b. Activated carbon filtering media.
c. Blower and blower motor.
d. Accessories such as drain valves. Overflow, air sampling devices, weather
cap, manhole, inlet chamber and as recommended by the unit supplier.
B. the unit shall be designed for the hot climates of the Middle East where high
concentrations of H2S and high humidities are encountered.
C. The odor control unit shall be constructed of GRP and provided with all the
necessary connections including, drain connection, overflow connection, air inlet
connection, air outlet connection with weather cap, air dampening connections, and
access manhole.
D.. Belt driven centrifugal air blower shall be constructed of corrosion resistant material
such as GRP, or aluminum and according to AMCA, and shall be supplied with
volume control damper.
E. The fan motor shall be FLC continuously rated for 50°C ambient temperature with
Class F insulation. Junction box shall be IP68 rated for outdoor installation.
F. Activated carbon filtering media shall be similar to Calgon IVP activated carbon,
which shall be chemically regenerated and restored in place. The filtering media
shall be specially designed and chemically enhanced for sewage odor control.
G. The odor control unit shall be similar to the units supplied by "Chemviron Carbon".
PART 3 - EXECUTION
3.01 PREPARATION
A. Clean all pipe, fittings and accessories of dirt, water and miscellaneous debris prior
to installation. Inspect all pipe, fittings and accessories for defects before installation.
Remove all defective materials from site.
3.02 TRENCHING AND BACKFILLING
A. Perform all trench excavations, backfilling and compaction, beeding in accordance
with Section 312316.13 (Trenching).
B. Trench alignment and trench depth shall be approved by the Engineer prior to
placing bedding material or pipe.
C. For sewers smaller than 600 mm diameter:
Minimum trench width = outside diameter + 300 mm.
D. Trenches shall not be back filled until the pipe alignment and pipe grade has been
checked and approved by the Engineer and exfiltration test results are within the
specified limits.
3.03 GRANULAR BEDDING
A. Granular bedding shall comply with requirements of Specification Section 31
2316.13, Trenching, Bedding, Back-filling and Compaction for materials and
gradation.
B. Place granular bedding materials in accordance with details indicated or directed.
__________________________________________________________________________________________________
C. Shape bed true to grade and to provide continuous, uniform bearing surface for
barrel of pipe. Do not use blocks when bedding pipe.
D. Shape transverse depressions as required to receive bell if bell and spigot pipe is
used. Compact full width of bed to at least 90% modified proctor density (ASTM
D1557).
3.04 PIPE INSTALLATION : GENERAL
A. Lay and join pipes in accordance with manufacturer's written instructions unless
otherwise specified herein.
B. Handle pipe with approved equipment. Do not use chains or cables passed through
pipe bore so that weight of pipe bears upon pipe ends.
C. Lay pipes on prepared bed, true to line and grade, with pipe invert smooth and free of
sage or high points. Ensure barrel of each pipe is in contact with shaped bed
throughout its full length.
D. Do not exceed maximum joint deflection recommended by the pipe manufacturer.
E. Do not allow water to flow through pipe during construction, except as may be
permitted by the Engineer.
F. Whenever work is suspended, install a removable water-tight bulkhead at open end
of last pipe laid to prevent entry of foreign materials.
G. Position and joint pipes by approved methods. Do not use excavating equipment to
force pipe sections together.
H. Commence laying gravity flow lines at the downstream end and set pipe sections
with the spigot end pointing downstream (bell and upstream).
I. Lay force main lines with the bell ends facing the direction of laying.
J. Service connection pipes will generally be 200 mm diameter and will be laid at a
minimum gradient of 2% although this may be reduced to 1.0 % where hydraulic
head conditions are critical.
K. Cut pipes as required for special inserts, fittings or closure pieces in a neat manner,
as recommended by pipe manufacturer, without damaging pipe or its coating and to
leave a smooth end at right angles to axis of pipe.
L. Make watertight connections to manholes. Use non-shrink grout when suitable
gaskets are not available.
M. Use prefabricated saddles or approved field connections for connecting pipes to
existing sewer pipes. Joint of saddle to pipe shall be structurally sound and water-
tight.
3.05 WASHOUT
Washouts shall be constructed on mains of 150 mm and above, at all low points.
Each washout connection to the main pipe line shall include flanged joint and
isolating valve. As a general rule emptying or recharging time should not exceed four
(4) hours. Tees at connections shall either have level inverts or be installed with the
branch inclined downwards.
__________________________________________________________________________________________________
3.06 MANHOLE CONSTRUCTION
Manholes and chambers shall be constructed as per Section 33 05 61(Concrete
Manholes)
3.09 CLEANOUT STRUCTURES
A. Construct in accordance with details shown on the drawing.
B. Use only factory made fittings.
C. Set cover carefully to finished grade.
D. Tamp back fill carefully to insure no settlement occurs.
3.10 METAL WORK

A. Workmanship and finish :
Perform metal work so that workmanship and finish will be equal to the best practice
in modern structural shops and foundries. Form iron to shape and size with sharp
lines and angles. Do shearing and punching so that clean true lines and surfaces
are produced. Make castings sound and free from warp, cold shuts, and blow holes
that may impair their strength or appearance. Give exposed surfaces a smooth finish
with sharp well-defined lines and arises. Provide necessary rabbets, lugs and
brackets wherever necessary.
B. Field painting :
After installation, clean cast-iron frames, covers, gratings and steps not buried in
masonry or concrete to bare metal of mortar, rust, grease, dirt and other deleterious
materials and give a coat of bituminous paint. Do not paint surfaces subject to
abrasion.
3.11 FIELD TESTS AND INSPECTION
A. General :
The Engineer will conduct field inspections and witness all field tests specified in this
section. The Contractor shall perform all field tests and provide all labour, equipment
and incidentals required for testing. The Contractor shall produce evidence, when
required, that any item of work has been constructed properly in accordance with the
Drawings and specifications.
1. Repair or replace pipe, pipe joint or bedding found defective.
2. Remove foreign material from sewers and related appurtenances by flushing
with water.
3. Perform exfiltration or pressure testing as soon as practicable after jointing
and bedding are complete.
4. Do exfiltration or pressure testing as directed. Perform tests in presence of
the Engineer. Notify construction manager forty eight (48) hours in advance
of proposed tests.
5. Carry out tests on each section of sewer between successive manholes.
6. Install watertight bulkheads unsuitable manner to isolate test section from rest
of pipeline.
B. Light test : gravity sewer
__________________________________________________________________________________________________
Check each straight run of pipeline for gross deficiencies by holding a light in a
manhole which shall show a practically full circle of light through the pipeline when
viewed from the adjoining end of line.
C. Exfiltration test : gravity sewers
1. Fill test section with water in such a manner as to allow displacement of air in
line. Maintain under nominal head for twenty-four (24) hours to ensure
absorption in pipe wall is complete before test measurements are
commenced.
2. Immediately prior to test period add water to pipeline until there is a head of
3000 mm over interior crown of pipe measured at highest point of test section
or when water in manhole is 1000 mm above static ground water level,
whichever is greater.
3. Duration of exfiltration test shall be two (2) hours.
4. Water loss at end of test period shall not exceed maximum allowable
exfiltration over any section of pipe between manholes.
5. No leakage is allowed.
6. Repair and retest sewer line as required until test results are within limits
specified.
7. Repair visible leaks regardless of test results.
3.12 DEFECTS TO BE MADE GOOD

If, at any time before the completion of the Contract, any broken pipes, or any
defects, are found in the sewer lines or in any of their appurtenances, the Contractor
shall cause the same to be removed and replaced by proper material and
workmanship, without extra compensation for the labour and material required. All
materials shall be carefully examined by the Contractor for defects, just before
placing and any found defective shall not be placed in the line.
END OF SECTION
__________________________________________________________________________________________________
SECTION 33 39 13
MANHOLE COVERS AND FRAMES
PART 1 - GENERAL
1.1 DESCRIPTION
A. Work Included: This section covers the furnishing of all materials, equipment,
and labour for furnishing and installation of iron, cast iron manhole
covers/gratings and frames and ductile iron manhole covers/gratings for utility
systems. “Utility Systems" shall include all underground piping and
appurtenances for liquids, gaseous products, buried cables, conduits for
electrical and communication lines, duct banks, chambers for pipe valves,
manholes and handholds. All works are to be carried out in accordance with
the various ministries and utilities authorities regulations and requirements
appropriate to the type of utility requiring installation, diversion, relocation or
otherwise. This section describes the minimum standards required by the
contract. Where these standards are in conflict with local regulations or the
requirements of ministries or authorities the most stringent standards will
apply.
B. For the purpose of this section the terms covers/gratings and frames shall
include but are not to be limited to all manhole, handhold, joint box, draw pit,
valve chamber and catch basin covers and frames or gratings and frames.
C. In addition to the requirements of this section all works are to be carried out in
accordance with the requirements and to the approval of the local utility
authorities having jurisdiction.
1.2 RELATED WORK SPECIFIED ELSEWHERE:
01 45 00 Quality Control
31 23 00 Excavations and Fill
33 10 00 Water Utilities
33 30 00 Sanitary Sewerage
33 40 00 Storm Water Utilities
1.3 RELATED OBLIGATIONS
A. The general requirements under Division 1 apply to work specified in the

section.
B. The Contractor shall examine all other sections of the specification for
requirements which may affect work of this section.
C. The Contractor shall coordinate work with all other trades affecting or affected
by activities of this section. Cooperate with such other trades to assure the
steady progress of all operations under the Contract.
__________________________________________________________________________________________________

level of quality for materials and products. The Contractor may propose
alternative codes and standards provided they give equivalent degree of
quality as the referenced codes and standards and are submitted for the
Engineer's review and approval in advance of their use.
A. ASTM - American Society for Testing and Materials
A48 Grey Iron Castings
A536 Ductile Iron Casting
B. BSI - British Standards Institution
BS 497 Manhole covers, road gully gratings and frames for

drainage purposes.
BS 1452 Grey Iron Casting
BS 2789 Ductile Iron Casting
BS 3416 Black bitumen coating solution for cold application
BS 4164 Coal tar based hot applied coating materials
C. SSPC - Structural Steel Painting Procedure
SP 6
SP 10
D. DIN - Deutsche Normen (German Standards)
DIN 1213 Catch Basin Frames and Gratings
DIN 1229 Manhole Covers, Step Irons and Accessories
1.5 DESIGN REQUIREMENTS
A. Verity and report discrepancies between drawings and site
Verify and check all dimensions on site in relation to products prior to

manufacture of any such elements. It is the responsibility of the Contractor to
report discrepancies beforehand.
B. All materials indicated in the drawings are subject to submittal & approval.
Installation may only proceed once approval for a sample has been obtained
as set out in Section 01 3300-Submittal, Division 1.
C. Coordinate installation with adjoining materials. Ensure correct level of

installation, alignment with patterns and obtain approval for all locations
individually
__________________________________________________________________________________________________
D. Paving patterns, landscape elements and other design elements take
preference over positions of manhole covers, gullies, drains and
appurtenances. It is the responsibility of the Contractor to coordinated all
elements accordingly and obtain approval therefore. Manhole covers and all
other utility covers or openings should be aligned or integrated with patterns
or design layouts and positioned accordingly or as instructed by Engineer.
E. Ensure all elements are properly aligned in the horizontal as well as the
vertical planes. Where elements are installed in planting areas, soft
landscape areas or against slopes – shall follow grades and be installed in
such a manned to be at least visually obtrusive to the surroundings. The
Contractor is responsible to consider each position individually, obtain
approval therefore. No additional payments shall be made for adjustments
and integrations for individual elements into the landscape.
F. Position all utilities so that no conflict will arise with tree and other planting
positions. Planting locations take preference over location of utilities and
gullies unless approval for specific location is obtained from Engineer
beforehand.
G. It is the responsibility of the Contractor to adjust, position, align and locate

elements as instructed on site. No additional payments shall be made for
adjustments or making good of surrounding areas.
H. All elements are to be manufactured/cast with a special architectural finish or

pattern – related to traditional Saudi Arabian patterns protruding or engraved.
Coordinate all requirements with Engineer.
1.6 QUALITY ASSURANCE
The Contractor shall be responsible for the quality of all materials and
workmanship and shall comply with SECTION 01 45 00, "QUALITY
CONTROL".
1.7 SUBMITTALS
A. The Contractor shall submit for approval manufacturer's catalogue data

detailing all items to be furnished under this section including certification that
castings comply with cited standards.
B. The Contractor shall submit samples for approval if required by the Engineer.
C. The Contractor shall submit all finishing coatings for selection and approval
and provide necessary samples therefore.
1.8 WARRANTY
All covers, frames and elements to be coated with matt epoxy coating, as
approved by the Engineer and carry at least a 10 year written durability and
protection warranty.
__________________________________________________________________________________________________
PART 2 - PRODUCTS
2.1 GENERAL
A. All goods and products covered by these specifications shall be, when
available, from an In-Kingdom manufacturer. Procurement of all goods and
products manufactured Out-Of-Kingdom must be approved by the Engineer.
B. Proprietary products considered by the Contractor to meet this specification

shall be submitted to the Engineer for approval prior to incorporation into the
permanent Works.
C. Covers/gratings and frames shall be grey cast iron or ductile iron castings, or
shall be laser cut metal sheeting. Grey cast iron shall conform to or exceed
the requirement of either ASTM A 48 Class 30 Or BS 1452 grade 220.Ductile
iron shall conform to or exceed the requirements of either ASTM 536 grade
80-55-06 or BS 2789 grade 600/3.
D. The bearing surfaces of frames and covers shall be machined to ensure that
the covers will seat firmly in the frame without rocking or rattling. For square
and rectangular manhole covers a rubber gasket is permitted in lieu of
machining.
E. Unless otherwise specified the castings shall have priming coat of Zinc
Silicate 75 micron as per SSPC-SP6 Or SP10.Two finish coats of coal tar
epoxy each 100 microns thick, shall also be applied.
2.2 COVER TYPES
The type of cover/grating and frame shall be as specified by the local utility
authority or as defined below:
A. For systems other than Waste Water and Storm Drainage Systems.
1. Heavy Duty: Cover/grating and frame shall meet grade A

requirements of BS 497 Appendix A.
Test load for: Grey Iron is at least 350 kN transmitted through a

300mm diameter bearing block for covers and through a 300 x 235
mm block for gratings.
Test load for: Ductile Iron is at least 350 kN transmitted through a

Cover/grating and frame shall be rated grade A if it is capable of

bearing loads up to 11.5 tonnes.
Heavy-duty covers/gratings and frames shall be used on all roads

where vehicle movement is expected and elsewhere as specifically
required on Contract Drawings.
2. Medium Duty: Cover/gratings and frames shall meet grade B

requirements of BS 497 Appendix A.
__________________________________________________________________________________________________
Test load for: Grey Iron is at least 150 kN transmitted through a
mm block for gratings .

300mm diameter bearing block for Covers and through a 300 x 235
Covers and frames shall be rated grade B if they are capable of

bearing wheel loads up to 5.0 tonnes. Medium duty covers and frames
shall be used on all sidewalks, footways, verges and domestic
accesses subject to vehicular traffic and where specified on the
Contract Drawings.
3. Light Duty: Cover and frame shall meet Grade C requirements of

BS497 Appendix A.
Test load for: Grey Iron is at least 10 kN transmitted through a 300mm

diameter bearing block

300mm diameter bearing block
Light duty covers and frames shall be used on all footways, verges
and domestic accesses not subject to vehicular traffic and where
specified on the Contract Drawings.
4. All tests shall be performed by the manufacturer.
B. For Waste Water and Storm Drainage Systems.
Manhole Frames and Covers: All frames for manholes and inspection
chambers shall be of grey cast iron conforming to DIN 1229 or equivalent.
Unless shown otherwise on the Drawings, frames shall have a circular base
with minimum bearing area of 2300 cm2, a height of 16cm and a minimum
clear circular opening 60cm in diameter. Covers shall have prising slots and
lifting holes with locking device of non-corroding material. The minimum width
of bearing area between the cover and frame shall be 30mm.
The gap between cover and frame shall be sealed by a rubber ring or similar
approved method.
The word "SANITARY" for waste water sewers and "STORM" for storm
sewers in both Arabic and English shall be incorporated in the manhole cover
The covers shall be recessed for asphalt infill or stone in-lay work, which will
be provided by the Contractor to blend it with the surrounding surfaces.
Catchbasin Frames and Grates: Unless otherwise indicated, all catchbasin

frames and grates shall be cast iron Class 'C' (25 ton test load) conforming to
DIN 1213 or equivalent. The types of grates specified for different locations
shall be as indicated on the Drawings.
__________________________________________________________________________________________________
2.3 SPECIAL REQUIREMENTS
A. Sealed or locked covers and frames sizes and details shall be in accordance
with Contract Drawings,
Sealing - may be either single or double pattern - and the minimum depth of
penetration of the cover sealing flange(s) into the frame shall be 10mm.
Locking - Locking shall not nullify the seal.Where locking devices can be
rendered ineffective by corrosion, they shall be suitably protected.If the
locking device utilises a bolt connection, this shall be Stainless Steel.
B. Recessed covers shall receive in-fill material specified by the manufacturer to

meet the required design loads.
C. Glass reinforced plastic (GRP) sub-frames and seal plates shall be

specifically designed to be compatible for use with cover-manufacture’s
products and used only per special request on design drawings.
D. All covers and manholes are to be cast with a special casting finishing of a
Saudi-style pattern – (see typical pattern on drawing LA/PL-D 9501). The
typical pattern of the tree grid needs to be refined and adapted for use on all
other covers. The design shall be a skid preventing with a protrusions of
approx 5mm. Final design may be altered if required and will need to be
approved by the Engineer. All casting to be done to the highest possible
quality as selected by Engineer. Alternatively all elements to be laser cut and
combined from solid sheets to required pattern and design.
E. Inscriptions, manhole cover surfaces (protruding skid preventing pattern),

lifting devices, and provision for gas detection on manhole covers shall be as
shown on Contract Drawings and/or according to the requirements of the
utility agencies responsible for the respective utility and its associated frames,
covers, gratings etc.
F. Where required, covers shall be given specified treatment such as stone in-
lay work to blend the cover surface with the surrounding surfaces.
G. The internal surface of covers and frames of waste water manholes shall be
sandblasted and protected with epoxy coating.
H. All manhole covers for all utilities (Storm drainage, sanitary system, potable
water, telecommunication, medium and low voltage) shall be installed in
recessed type.
2.4 TYPES OF CASTINGS
The Consultant must allow for any of the following methods for castings. The
Engineer reserves the right to select any of the methods below in order to
obtain best possible results. The Contractor may be requested to submit
samples from each of the methods in order to determine best results. No
additional payment shall be made for type of method selected.
A. LOST FOAM
__________________________________________________________________________________________________
A metal mould is used to produce foam patterns. Foam patterns are invested
in sand. Molten metal is poured on to the foam patterns through gating. The
foam evaporates and is replaced by metal.
B. SAND CASTING.
Treated sand is moulded around a wood or metal pattern. The mould halves
are opened and the pattern is removed. Metal is poured into the cavity. The
mould is broken and the casting is removed.
C. RESIN SHELL MOULDING
Resin-coated sand is poured onto hot metal patterns, curing into shell-like
mould halves .These are removed from the pattern and .assembled with or
without cores. Metal is poured into the resulting cavities. Moulds are broken to
remove castings.
D. V-PROCESS CASTING
Sand is "Vacuum-packed" around pattern halves. The pattern is removed and

metal is poured into the cavity. The vacuum is released and the casting is
removed.
PART 3 - EXECUTION
3.1 INSTALLATION
A. The Contractor shall install the cover and frame strictly in accordance with the
manufacturers instructions and recommendations, and the requirements of
the utility ministry or utility authority, or to details shown on the Contract
Drawings.
B. Covers/gratings and frames shall not be subjected to traffic loads until after
the elapse of an adequate curing time for the bedding and haunching
material.
C. All covers shall be bedded and levelled to prevent rocking and lateral
movement of the frame.
END OF SECTION
__________________________________________________________________________________________________
SECTION 33 40 00
STORM WATER UTILITIES
PART 1 - GENERAL
1.1 DESCRIPTION
A. General :
1. Furnish all labor, materials, tools, equipment, and services for all
storm drainage system as indicated, in accordance with provisions of
the Contract Documents.
2. Completely co-ordinate with work of all other trades.
supplementary or miscellaneous items, appurtenances and devices
incidental to or necessary for a sound, secure and complete
installation.
5. The work will include connection with city network.
B. Related Work Specified Elsewhere :
1. Section 31 23 00: Excavation and Fill.
2. Section 31 23 16.13: Trenching.
3. Section 03 00 00: Concrete
4. Section 03 30 00: Cast-in-Place Concrete
5. Section 03 40 00 Precast Concrete

level of quality for materials and products. The Contractor may propose
alternative codes and standards provided they give an equivalent degree of
quality as the referenced codes and standards and are submitted for
Engineer’s review in advance of their use.
A. SASO - Saudi Arabian Standards Organization,

Latest Issue:
B. ASTM - American Society For Testing And

Materials, Latest Issue
A 47 Malleable Iron Castings.
A 48 Grey iron Castings.
__________________________________________________________________________________________________
C 78 Precast Reinforced Concrete Manhole
Sections.
1.3 SUBMITTAL
The Contractor shall submit to the Employer the following items for review
before commencing work:
A. Shop drawings shall be submitted in accordance with Specification.
B. Manufacturer's test certificates and certificate of compliance stating that the

material used and construction of pipes, fittings and accessories conform to
all requirements of this Specification.
C. Catalogue data for all pipes, fittings and accessories showing illustrations and
schedule of parts to facilitate assembly and disassembly.
D. Samples of materials as required by the Employer.
E. Joint detail drawings and joint assembly procedures, including connections to

manholes, catch pits, rodding eyes, etc.
F. Manufacturer recommended specification for transporting handling, loading,

unloading, stock piling and storage of materials.
A. All products shall be delivered in manufacturers' original protective packaging.
B. All products shall be inspected at time of delivery for damage and for
compliance with specifications.
C. Any products that are found to be damaged or not in accordance with the
specifications shall immediately be removed from the site and replaced.
Repairs shall not be undertaken before the Employer's review of Contractor's
proposed action.
D. All products shall be handled and stored as recommended by manufacturer to

prevent damage and deterioration.
E. The Contractor shall supply handling equipment such as lifting beams,

reinforced canvas slings, protective padding, struts, cradles, etc., required to
handle the products without damaging hardware of linings and coatings.
F. Each pipe unit shall be site stored, stacked and handled into the final location
in such manner and by such means, that afford total protection against
damage. The manufacturer's recommendations shall be taken as the
minimum requirement. All site storage areas shall be shaded.
G. Products shall be protected against damage and the ambient conditions both
during transport, site storage and immediately up to the time the products are
installed. Precautions shall be taken to protect the product from mechanical
damage and the effects of sunlight and heat, until the backfilling operations
have been completed.
__________________________________________________________________________________________________
H. Site stacking of pipe work shall be such that the pipe-work will not deform or
be damaged in any way through storage or retrieval.
I. Full consideration shall be given to safety aspects when locating, planning

and constructing pipe stacking areas, and whilst stacking pipes.
PART 2 - PRODUCTS
2.1 GENERAL
All goods and products covered by these specifications shall be procured,

when available from Kingdom of Saudi Arabia manufacturer. Procurement of
all goods and products manufactured out-of-Kingdom of Saudi Arabia shall be
approved by the Employer.
2.2 CAST-IN-PLACE REINFORCED CONCRETE CHANNELS, BOX

CULVERTS, CATCH BASINS AND MANHOLES
Cast-in-place reinforced concrete channels, box culverts, catch basins and

manholes shall be constructed as shown on the Contract Drawings and
according to Division 3 Specification.
2.3 PRECAST REINFORCED CONCRETE CATCH BASINS AND MANHOLES
Precast reinforced concrete catch basins and manholes shall be constructed

as shown on the Contract Drawing. Precast concrete sections shall conform
to ASTM C 478.
2.4 MANHOLE COVERS AND FRAMES
Manhole covers and frames shall be as shown on the Contract Drawings and
as specified in Section 33 3913- Manhole Covers and Frames.
2.5 CURB OUTLET GULLIES
Curb outlet gullies shall be as shown on the Contract Drawings and shall be
manufactured from cast iron to conform to ASTM A 48, Class 30 or better.
2.6 GRATINGS AND FRAMES
Gratings and frames shall be as shown on the Contract Drawings and as

specified in Guideline Specification Section 33 3913, Manhole Covers and
Frames.
2.7 PIPE LINES
A. GRP Pipes & Fittings

__________________________________________________________________________________________________
Glass Reinforced Plastic (GRP) flexible corrosion resistant pipe system shall
be used for underground storm drainage system. It Consists of a
Thermosetting Chemical resistant polyester resin, Fiberglass Reinforcements
and fine Silica sand aggregates to BS 5480 / AWWA C-950. GRP pipes shall
have the following properties:
Properties:
Pressure Class (KPa) PN 6
Stiffness Class (N/m²) SN 10000
For handling GRP pipes, fittings and rubber ring gaskets, instructions of the
manufacturer shall be strictly adhered to GRP pipes and fittings shall be
suitably wedged or braced to prevent damage during shipment and
transportation and rubber rings gaskets and lubricants shall be packed in
suitable containers.
The allowable stack height is 2.5 meters or as per manufacturer’s

specification. When storing the pipes directly on ground, the ground shall be
free of stones and materials causing any damage.
While lifting, the supports shall be pliabe straps or ropes and shall not be
steel cables or chains unless sufficient padding is provided to protect pipes
surfaces. Pipes shall never be dropped.
B. UPVC Pipes and Pipe Fittings:
Pipes: Unplasticized polyvinyl chloride (UPVC), if required, shall conform to

the requirements of ASTM D 1785.
Pipe Fittings: Unplasticized polyvinyl chloride (UPVC), shall match to that of

pipe and conforming to ASTM D 1785, socket-type
Jointing System:
Welded joints using solvent cement conforming to ASTM D 2564.
Flexible Joints: Flexible joints using Flex-Seal couplings shall be provided in

piping to service manhole. Stainless steel clamping bonds, shear rings and
components shall be made from marine grade 300 Series stainless steel to
BS 9570: part 1:1983. Synthetic elastomeric rubber conforming to the
requirements of BS 2494D: 1990.
2.8 RODDING EYES, CLEANOUTS AND INSPECTION CHAMBERS
Rodding eyes, cleanouts and inspection chambers shall be constructed as

shown on the Contract Drawings.
2.9 AGGREGATE FILL FOR SUBSOIL DRAINS
__________________________________________________________________________________________________
Aggregate fill for subsoil drains shall consist of crushed or uncrushed gravel,
crushed stone or a combination of the two and shall be of clean hard
uncoated particles graded uniformly from 10 to 25 mm.
2.10 NO-FINES CONCRETE FILL
Membrane filter material shall be of non-woven approximately 70%

polypropylene and 30% polyethylene, 0.70 mm thick with a pore size of 80
microns. The tensile strength under uniform applied stress to be not less than
7500 N/m. The membrane filter capacity shall be rated in accordance with
ASTM F 317.
2.11 STORM WATER CHANNEL/SWALES
A storm drainage channel shall be constructed as shown on the drawings.

Scour protection shall be provided at the locations identified during the
detailed shop drawings process. It shall be constructed to a uniform gradient
as shown on drawings, except that where services or other obstructions
prevent this, the channel gradient may vary. In such situations a permeable
path shall be maintained to provide groundwater drainage at the uniform
gradient.
2.14.1 PAINTING
All steel work including support pipe etc., shall be protected by epoxy coating.
All preparation of the metal surfaces, grit blasting, washing, and application of
the epoxy primer and coating, whether carried out at the factory or on site,
shall be in accordance with the manufacturer’s recommendations and to the
Engineer’s approval.
PART 3 - EXECUTION
3.1 INSPECTION
The Contractor shall inspect all products for damage immediately before
installation. Any products that are found to be damaged or not in accordance
with the specifications shall immediately be removed from the site and
replaced. Repairs shall not be undertaken without the Employer's review of
Contractor's proposed action.
3.2 GENERAL
All products shall be installed strictly in accordance with manufacturer's

instructions.
3.3 CHANNELS, BOX CULVERTS, CATCH BASINS AND MANHOLES
A. Structure excavation and backfilling shall be in accordance with Specification

Section 31 2300- Excavation and Fill.
B. Concrete reinforcement shall be in accordance with Specification Section 03

2000-Concrete Reinforcing.
__________________________________________________________________________________________________
C. Cast-in-place concrete shall be in accordance with Specification Section 03
3000, Cast-in-place concrete.
3.4 STORM DRAINAGE SYSTEM TESTING
A. Testing shall be carried out from manhole to manhole. Branch drains not
exceeding 10 m long connected to a main drain between manholes shall be
tested as one system with the main drain. Branch drains exceeding 10 m
long shall be tested separately. Pipes shall be tested both before backfilling
and after backfilling has been completed.
B. Pipes, shall be tested by one of the following methods :
1. Water Test:
A Hydrostatic test pressure of 1200 mm head of water above the crown of the
pipe shall be applied at the high end but not more than 6000 mm head at the
low end by means of a standpipe. A period of one (1) hour shall be allowed
for absorption. The loss of water over a period of thirty (30) minutes shall be
measured by adding water from a measuring vessel at regular intervals of ten
(10) minutes and logging the quantity of water required to maintain the
original level in the standpipe. The average quantity of water added for pipes
up to and including 300 mm nominal diameter shall not exceed 0.06 1/h per
100 meters per millimeter diameter of nominal diameter. For drains exceeding
300 mm nominal diameter the average quantity of water added shall not
exceed 0.12 1/h per 100 meters per millimeter of nominal diameter.
2. Air Test:
The length of drain under test shall be tightly plugged and air pumped in until
a pressure of 100 mm water column is indicated in a U-tube connected to the
system. At this pressure, all pipes shall be checked with soap solution to
detect any leakage. If any leaks are found, the air pressure shall be released
and the leaks eliminated, the testing procedure shall then be repeated again
from the beginning until no leaks occur. The air pressure shall then be
increased until a pressure of 100 mm water column is achieved. After
allowing time for stabilization the air pressure shall not fall to less than 75 mm
water column during a period of 5 minutes without pumping.
END OF SECTION
__________________________________________________________________________________________________
SECTION 40 63 43
SCADA / PLC / RTU SYSTEM
PART 1 GENERAL
1.01 RELATED SECTIONS
A. - Quality Control.
B. – Product Delivery Requirements.
C. – Product Storage and Handling Requirements.
D. – Guideline Specification for Central Control.
E. – Grounding and Bonding.
F. – Electrical Identification.
G. – Conductors and Cables.
H. – Wiring Connections.
I. – Communication Circuits.
1.02 REFERENCES
A. IEC 61511 – Functional Safety-Safety Instrumented systems for the process industry
sector.
B. IEEE 610 Series – Standard Software Glossaries.
C. NFPA 70 - National Electrical Code; National Fire Protection Association; 2005.
1.03 SYSTEM DESCRIPTION
A. The SCADA/PLC system architecture shall be distributed technology.
1. Distributed Architecture - this shall allow the system to perform control and
monitoring functions to equipment that are distributed throughout the system.
2. The system shall be layered into three layers and contain a field layer (the level
that contains all of the field level controllers, and application specific controllers), a
Supervisory layer (this is the layer that connects all of the field layers), and an
enterprise layer (this is the layer that connects all of the supervisory layers).
B. The PLC's shall be provided in hot standby configuration.
C. The system shall utilize distributed PLC software and set points to be updated globally
from the head end.
D. The HMI located in the plant rooms shall be connected to the plant PLC and
communicating with CCR via OPC Link.
E. The SCADA/PLC system shall monitor and control the following systems and sub
systems:
a. Control of Bar and Band Screen systems.
b. Control of the Media Filters in the Pre-treatment section.
c. Control of all pumps and equipment in the RO Section.
_____________________________________________________________________________________________________
d. Monitor all process field devices and equipments.
e. Control the Chemical Dosing systems.
f. Control the Post Treatment system.
g. Provide information storage and trending for minimum 7 days for all points.
h. Issue alarms for all plants.
i. Continually calculate the overall system efficiency.
j. Generate Daily, Monthly and Annual reports.
1.04 SCOPE OF WORK
A. Provide an industrial grade fully redundant SCADA/PLC system to monitor, operate
and control the facility to Command and control room.
B. This scope includes the following:
SCADA/PLC system located in the plant Control room and distributed field PLCs near
the plant equipment, as indicated on the drawings.
C. The system shall include hardware, software, control cabling, conduits, etc.
D. Hire the services of a qualified systems integrator to carry out the work. The systems
integrator shall submit the controls system design for review by Engineer. Note that a
minimum of one month shall be allowed for the review of this documentation.
E. The systems integrator shall be responsible for the design and shall ensure the system
is supplied, installed, tested and commissioned by the Contractor as per the system
integrators design documentation.
F. The system integrator shall be retained by the contractor to be a part of the contractor's
planning, installation and start up team.
G. Based on the Sequence of Operation for the plant controls, integrate and automate
open protocol control components available on the open market and in compliance with
the specifications.
H. Distributed Plant Control system designed by the Systems Integrator.
I. The I/O points, wiring diagrams and system architecture for communication between
PLC's and other devices including the remote PLCs are the responsibility of the
Systems Integrator.
K. Coordinate and provide oversight of the installing contractor's planning, installation and
startup of the final control system.
L. Coordinate with sub system manufacturers, such as the Pretreatment, RO and Post
treatment system manufacturers, in order to ensure seamless integration between all
systems.
1.05 SUBMITTALS
A. See Administrative Requirements, for submittal procedures.
B. Certificates: Certify that products of this section meet or exceed specified
_____________________________________________________________________________________________________
requirements.
C. Indicate dimensions, description of materials and finishes, general construction,
specific modifications, component connections, anchorage methods, hardware, and
installation procedures, including specific requirements indicated.
D. All vendor drawings, product datasheets, Specifications, list of manufacturers of all
control system components, Functional and Design details of software and hardware
methodology, drawings and documents, electronic files etc.
E. Control diagrams: Use at least one individual sheet for each major system.
1. System flow diagram with sensing, control and interlock devices.
2. Internal control panel layouts, control panel cover layouts, pneumatic connections
inside control panels with tubing color-coding cross-reference chart.
3. Internal control panel layouts, control panel cover layouts, electrical connections
inside control panels with wiring color-coding cross-reference chart.
4. Ladder-type wiring diagrams showing interlock, monitoring and control wiring to
and from equipment, including control systems equipment.
5. Communications wiring schematic drawings indicating interconnections between
equipment and other peripherals.
6. List of sensing, control and software points including connected control device(s)
and connected devices.
7. Written or flow-charted sequences of control.
8. Each field device is identified and its function is also specified. Control valves,
open/closed valves, flowmeters and other devices are included.
F. Descriptive data and sequence of operations of operating, user and application
software including complete operator's manual and programmer's manual tailored to
this project.
G. Warranty: Submit manufacturer warranty and ensure that forms have been completed
in Employer name and registered with manufacturer.
1.06 QUALITY ASSURANCE
A. Manufacturer Qualifications: Company specializing in manufacturing products
specified in this section, with not less than three years of documented experience.
B. Installer Qualifications: Company specializing in performing the work of this section
with minimum 5 years of experience.
C. Perform design under direct supervision of a Professional Engineer experienced in
design of this Work.
1.07 PRE-INSTALLATION MEETING
A. Convene one week before starting work of this section.
1.08 WARRANTY
A. See Section 01780 - Closeout Submittals, for additional warranty requirements.
B. Correct defective Work within a one year period after Date of Substantial Completion.
_____________________________________________________________________________________________________
1.09 FACTORY TESTING
A. General
1. Complete SCADA-PLC equipment and their components/devices shall be
tested at the factory in accordance with the latest approved manufacturing
codes and standards. The Contractor shall notify the Engineer in writing not
less than 30 days prior to the scheduled starting date of the factory tests.
2. The Employer reserves the right of deputing their representative for
witnessing the factory testing.
3. Upon completion of factory tests, and before shipment of the SCADA-PLC
equipment, the Contractor shall submit 5 certified copies of test reports not
later than 10 days after the completion of all factory tests for review and
approval by the Engineer.
1.10 SERVICE CONDITIONS
A. All the SCADA-PLC equipment and their components and devices installed indoors
shall be suitable for the following service conditions:
1. Ambient Air Temperature
a) Maximum of 40°C.
b) Minimum of 0°C.
c) Average temperature, measured over a period of 1 month, shall be at a
maximum of 35°C.
2. Relative Humidity (Average Value)
a) For a period of 24 hours, shall not exceed 95%.
b) For a period of 1 month, shall not exceed 90%.
B. All the SCADA-PLC equipment and their components and devices installed outdoor
shall be suitable for the following service conditions:
1. Ambient Air Temperature
a) Maximum of 50°C.
b) Minimum of 0°C, unless a lower temperature is specified in the Contract
Drawings.
c) Average temperature, measured over a period of 1 month, shall be at a
maximum of 45°C.
2. Altitude shall be less than 1000 m, unless a higher altitude is specified on
the Contract Drawings/Documents.
3. Average Value of the Relative Humidity
a) For a period of 24 hours, shall not exceed 95%.
b) For a period of 1 month, shall not exceed 90%.
4. Relative humidity may be temporarily 100%.
_____________________________________________________________________________________________________
5. a) All the outdoor PLCs, instrument transmitter’s enclosure should be
weather and corrosion protected i.e. IP67/NEMAX 4x
1.11 DELIVERY, HANDLING AND STORAGE
A. The Contractor shall deliver, handle and store equipment and material units in
accordance with related sections, as well as the following requirements:
1. Materials and equipment shall be delivered to the site originally packed,
securely wrapped and labeled by manufacturer in unopened containers.
Protect materials during delivery to comply with manufacturer’s direction.
2. Materials, products and equipment shall be stored at job site in a dry, clean,
ventilated or temperature controlled environment and/or according to
manufacturer’s instructions.
3. Damage or distortion of the materials shall be avoided during handling and
shipment or transportation.
4. The Contractor shall be responsible for any damage to the materials or
equipment during storage, handling and transportation. The proposed use
of any repaired material or equipment shall be subject to approval by the
Engineer. Any material or equipment, whether repaired or replaced, shall
be at no additional cost to the Employer.
PART 2 PRODUCTS
2.01 PLC
A. General
1. PLCs shall provide high speed processing of data and information.
2. PLCs shall be configured in hot standby configuration.
3. PLCs shall be capable of continuing to work independently in the event that
communications with the head end is lost.
4. PLCs shall be provided with a 30 minute un-interruptible power supply. The power
for the PLC shall be provided from an essential distribution board. The PLC power
feed shall be from an independent breaker located within this panel. The PLC
shall be able to report mains power failure back to the main PLC.
5. The processor module shall contain the microprocessor that performs control
functions and computations, as well as memory to store the program and data.
6. Provide a minimum of 20% spare capacity on the I/O modules.
7. The PLCs shall have a separate communication module.
8. PLCs shall support Plug and Play technology.
9. Communication protocols shall be - Ethernet, Ethernet IP, Device Net, Modbus,
Profibus.
10. PLCs shall be capable of being programmed via ladder diagrams.
_____________________________________________________________________________________________________
11. Redundant PLCs shall be linked with redundant fiber optic cable.
12. PLCs shall be sized for a minimum 35,000 points.
B. PLC Operator Interface

1. The following features shall be included for the PLC panels.
a. Panels shall have NEMA 12 and 4X ratings. Each 24 VDC panel is also UL
listed Class 1 Division 2, CUL, and CE approved to meet the demands of
harsh work environments.
b. Panel shall withstand operating temperatures of 0º to 50°C. Its durable
faceplate allows for quick and easy clean up in water wash down
environments.
c. Panel shall support various input/output devices such as push buttons, pilot
lights, ASCII display/entry, alarming, and trending.
d. Both static and dynamic bitmap graphics shall be supported
e. Panel shall come standard with 4 Mbytes of application memory which makes
it the perfect solution for more sophisticated applications.
f. The battery-backed real time clock shall be available for up-to-the-second time
display as well as alarm stamping.
g. Auxiliary printer port shall allow screen images to be sent to a graphic printer.
2. External Interface
a. Provide both a modem and a web enabled connection in the control panel to
allow remote PLC access through remote connection for monitoring, control,
reprogramming, and troubleshooting. These features shall be password
protect similar to the computers.
C. Cabinet for the PLC Racks
1. Control Cabinet shall be provided for the PLC racks and associated I/O modules.
The PLC and all I/O Cabinet enclosures shall be NEMA 4X rating compliant.
2. The cabinet shall be constructed of minimum 16 gage powder coated steel.
3. The cabinet shall house the power module, IO modules, communication module,
etc.
4. The cabinet shall be ventilated.
D. Power Supply, Distribution and I/O Marshalling
1. All the necessary Power distribution fuses and circuit breakers would be provided
a. All the necessary Power Distribution terminals shall be provided
b. All common equipment's, ducts, terminal strips shall have 20% spare capacity
c. Power wiring and Signal wiring shall be segregated.
d. All the necessary marshalling terminals shall be provided.
e. Marshalling Terminals would be either Din Rail or G rail mounting type
_____________________________________________________________________________________________________
f. Marshalling terminals shall be fused wherever necessary.
g. Each I/O card shall be provided with a separate MCB
E. CPU
1. The PLC selected is to be of modular type and high performance CPU 364 is
based on the Intel 386 EX processor for fast computation and high through put.
They handle 4096 I/O and start at 240K memory.
2. Each CPU shall contain: A minimum Intel 80188 or Intel 80386EX microprocessor
operating at speeds no less than 10 MHz up to 25MHz as the main processing
element, memory mounted on the board, and a dedicated VLSI Instruction
Sequencer Coprocessor (ISCP - Boolean Coprocessor) for performing Boolean
operations, and interfaces to a serial port and the system bus.
3. Each CPU shall contain a real-time calendar and clock that can be accessed by
the user program. This Time of Day clock and calendar shall be battery-backed
and maintain seven time functions: Year (2 digits), Month, Day of Month, Hour,
Minute, Second, and Day of week.
4. Each CPU shall execute Boolean functions at a rate of 0.3 microseconds per
instruction or faster. Each CPU shall be capable of controlling up to 49 I/O slots in
the basic configuration and up to 79 I/O slots in the advanced. The modular CPU
shall be able to provide special functions such as High-Speed Counter function,
Axis Positioning function, and Local Area Networking function.
5. The ethernet port shall support simultaneous communications for programming,
PLC-to-PLC exchanges through programming, and Host/SCADA communications
from PCs.
6. The control system shall utilize industry standards, such as Ethernet TCP/IP.
F. Plant PLC (
1. Configuration: Redundant (Hot Standby)
2. I/O discrete points: minimum 35,000.
3. Processor speed: minimum 1.8 GHz.
4. Memory: min. 64 Mb.
5. User Flash Memory: minimum 64 Mb.
6. Built-in Ports: minimum 2 serial (RS-232 and RS-485) and 1 Ethernet (Auto
10/100, RJ 45).
7. Web based Data Monitoring: minimum 16 web server and FTP connections
combined.
2.02 HUMAN MACHINE INTERFACE (HMI)
A. General scope
1. This specification covers the technical requirements for a Microsoft Windows
based Monitoring and Control system. The Monitoring and Control System shall
exchange data in the form of discrete and analog values from I/O devices and/or
control devices such as programmable, computer numerical controllers. The
Monitoring and Control System shall perform graphical display, alarming, logical
_____________________________________________________________________________________________________
functions, analysis, data handling operations and can communicate with external
systems over a network.
2. Provide hot standby redundant servers.
3. Standard of Acceptance - GE Fanuc Complicity.
B. Employer/Server
1. The Monitoring and Control System shall support distributed architecture including
Human Machine Interfaces, Data Servers, and Viewers (Employer). Each of these
components shall work in conjunction with the others using industry standard
Ethernet networks.
2. The HMI shall support true Employer server architecture. HMI Servers shall poll
and collect data from devices. This data is to be seamlessly shared among other
HMI Servers and to Viewers without requiring the duplication of data values in
another node. HMI Viewers shall act as Employer to the HMI Servers, seamlessly
receiving their data.
3. In a true Employer server environment, data is to be configured once. The HMI
shall support one time configuration of data points. For example, points to be
polled from a device shall be configured once on that server and other Servers or
Viewers need only reference that data item to use it for their applications.
4. Alarms shall be configured once and served across multiple HMI Servers and
Viewers.
5. HMI Viewers shall be able to simultaneously access data from one or more HMI
Servers. Data from multiple Servers may be used within the same graphic screen.
Viewers shall require only a valid TCP/IP connection to the Server to obtain this
data. This TCP/IP link may typically be across a local area Ethernet network
(LAN) although it may be across a wide area network (WAN) and make use of
telephone lines, radio, and/or satellite links.
C. Human Machine Interface Servers (HMI)
1. The HMI Server software shall be configurable to provide for the monitoring and
control of all points, loops, and systems through graphic display screens and hard
copy (printer output) reports. These shall include but not be limited to:
a. Parameter Displays for signal control
b. Control Loop Status Displays
c. Real Time and Historical Data Trend Displays
d. Event Displays and Log Reports
e. Alarm Displays and Log Reports
f. Equipment Diagnostic Displays and Reports
2. HMI Servers shall be capable of operating independently but shall be configurable
to share data with other HMI Servers or Enterprise Server systems.
3. Enterprise server
a. Enterprise Servers system shall be capable of consolidating data from HMI
_____________________________________________________________________________________________________
Servers without the need for reconfiguring point values. Servers shall provide
a broad view of information within a facility and shall be capable of supporting
host or database applications such as SPC and Production Tracking. In
addition, Enterprise Servers shall be capable of supplying data services to
networked viewers.
4. Viewers
a. Viewer Systems shall provide occasional system users with easy access to
plant floor data using the same graphical user interface as Enterprise and HMI
Servers.
b. Viewers shall be capable of both displaying and modifying data.
5. Computer Platforms
a. The computer platform for HMI servers shall be a PC compatible personal
computer running Windows XP professional.
b. The HMI shall be capable of running on Symmetric Multi-Processor Windows
NT operating systems.
6. Real time data management
a. The software shall provide a real time, distributed, memory resident database
of current process data values. These data ("point" or "tag") values may be
from definable device points representing the value of a physical data
collection item on a resource, or viPLCal points representing values calculated
from one or more device point values used in a mathematical expression.
7. Math and function support
a. The following math and logic capabilities are required.
1) Event Driven Math and Logic
2) Visual Basic compliant scripting language support
3) Logical operators (and, or, compares, etc.)
4) Alarm Status
5) Timers
6) Four Function Math (+, -, /, *)
7) Exponential and Logarithmic
8) Statistics (average, mean, min, max, median, etc.)
9) Trigonometric (sine, cosine, etc.)
10) Bit manipulation
11) String functions
12) Conversions (BCD, ASCII, etc.)
b. Expressions using the above math functions shall be supported in the point
configurator.
D. Data sharing
1. Point values shall be stored, retrieved and manipulated across one or more
_____________________________________________________________________________________________________
computers using the software's distributed architecture. Data integrity must be
automatically and continuously ensured.
2. Writing of custom software shall not be required to provide simple data sharing
among HMI Servers, Enterprise Servers and or Viewers. Viewers shall simply
"connect" to Servers to obtain data. Enterprise Servers shall have configurable
support for collecting data from HMI Servers.
3. Application program interfaces shall be published and available to permit users to
write custom software to support interfacing the HMI and Enterprise Servers to
other computer systems and applications. To ensure that these "API's" provide
adequate support for device data collection, it is recommended that the HMI
supplier shall use these API's in the implementation of the HMI itself.
4. The HMI shall also support data sharing using DDE. In this mode, the HMI acts as
the "server" and applications such as Microsoft Excel act as the "Employer".
5. Data collection methods
a. Data collection methods shall including scheduled polling, on-change,
unsolicited, timed interval, “on demand”, triggered reads, and array support,
among others. Engineering Unit conversions on collected data and reverse
engineering units’ conversions for setpoints are required.
b. HMI Servers shall have configurable support for obtaining data from supported
plant floor devices.
c. Application program interfaces shall be published and available to permit
users to write custom software to support additional devices for data
collection. To ensure that these "API's" provide adequate support for device
data collection, it is recommended that the HMI supplier shall use these API's
in the implementation of the HMI itself.
d. The HMI shall also support data collection from DDE servers using both the
DDE and Advance DDE protocol standards. In this mode, the HMI operates as
a Employer. This capability permits the use of third party software to extended
data collection support.
e. The HMI shall also support data collection from OPC servers. In this mode,
the HMI operates as a Employer. This capability permits the use of third party
OPC servers to extended data collection support.
6. Required data types
a. The following Data Types shall be supported:
1) Global
2) Floating point
3) Analog (Signed and Unsigned)
4) Discrete
5) String
6) Arrays
7) Structures
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E. Dynamic Measurement systems
1. The HMI shall have the capability to dynamically switch between measurement
systems such as English and Metric. The HMI shall also support the ability for the
user to define their own measurement systems as well.
F. Real time value and alarm display table
1. The HMI shall have the ability to select and display a table of points in a separate
window without the need for configuring graphic screens. The values of the points
shall update dynamically along with a time stamp that indicates when the value
changed. In addition, points that meet their alarm criteria shall be displayed in a
different color.
2. Double clicking on a displayed point shall bring up configuration information on the
point including its description and alarm information. Points with Read/Write
capabilities shall be able to be set from this table.
3. By using Microsoft standard user interface guidelines, the HMI shall allow the user
to highlight a point and right mouse click. A pop-up menu shall allow the user to
open a window and trend the point without the need of a pre-configured a graphics
screen.
G. Point cross reference
1. The HMI shall provide the ability to cross-reference where points are used within
the HMI. The cross-reference listing shall include areas such as -
a. Point Configuration
b. Events and Actions
c. Database Logging
d. Scripts
2. The ability to print out the point cross-reference information shall be provided to
assist in documenting the configuration of the system.
H. Application modules
1. The Monitoring and Control System shall be implemented in a modular fashion
with a "base" module and one or more "option" modules. Use of option modules
shall require the use of the base module. Multiple option modules may be
combined with the base module to provide additional functionality.
I. Graphical user interface/status monitoring
1. The Graphical User Interface shall provide a set of tools for graphically
representing process status. A graphic editor shall be provided to enable creation
of graphic screens to represent current process information.
2. For ease of use, the editor shall include cut & paste as well as drag & drop support
within a single window and among multiple windows and shall include undo/redo
support. Support for grouping and ungrouping sets of objects and for readily
editing them while grouped are to be included. Object alignment and spacing tools
are required so those objects can be properly arranged on the screen.
3. The editor shall include a utility or tool for determining which points are referenced
in a screen, which objects reference them, and which points are not currently
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defined or known to the software. This tool shall also include provision to search
and replace point names - for both single objects and groups of objects.
4. A test animation capability shall display the screen currently being developed in
the runtime environment for rapid prototyping and testing.
5. The editor software shall include the ability to Create/Edit Points from within the
Editor. It shall also be possible to browse the network to locate computers and
projects for available points. The editing package shall include a Wizard / Symbol
/ Object Library to permit the inclusion of pre-developed or third party graphic
objects. The editing package shall allow Objects/Wizards to be created with the
native graphics, scripting language, and added to the Library.
6. A procedure editor shall be included to control setpoints and to perform window
management. The graphic editor shall include a scripting expression editor to
develop application logic.
7. Graphic objects on these screens can be linked by name to actual device and via
PLC data through the distributed point database. Objects on the graphics screens
can be configured with animation features, causing them to change color and/or
position. Text information can be printed to the screen alerting personnel to
current point status. Objects shall be dynamically scalable - both horizontally and
vertically.
8. The software shall support the following dynamic attributes:
a. Annunciation, movement, blink, rotation, and fill (uni-directional and bi-
directional)
b. Gradient fill
c. Object border animation
d. Object visibility
e. Transfer tags for screen transfer or popup windows
f. Procedure tags to invoke user defined scripts/programs
g. Object and or application help screens
h. Alarm information
i. Trends charts
j. Setpoint tags for point value changes
k. Animated frames that can include other graphic objects
l. Zoom to Best Fit, Resize Window to Zoom
m. Automatic font scaling when changing window sizes
n. 1.5 Million Colors
9. Graphic objects shall include:

a. Imported metafile objects
b. Embedded OLE, including ActiveX objects, sound, video, clip art,
spreadsheets, etc.
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c. SPC charts
d. Trend charts
e. Historical Data displays
f. Alarm displays
g. Arcs
h. Lines
i. Circles
j. Ellipses
k. Lines
l. Polylines
m. Polygons
n. Rectangles
o. Text strings
p. Buttons
10. Tag types shall include:
a. constant - downloads constants to a point
b. variable - allows operator input of desired value
c. ramp - downloads values in configured increments
d. slide - increment/decrement of point values
e. toggle - sets digital points to opposite state
11. Graphics screens shall support a Visual Basic compliant scripting language. Data
items and variables can be manipulated by the screen scripting to provide
additional functionality in dynamically controlling screen characteristics.
12. The graphical editor and viewer shall be capable of being an ActiveX container. It
shall be capable of using ActiveX objects provided with the HMI package or third
party ActiveX controls supplied by others.
13. The graphical user interface shall support ActiveX "methods" to allow the user to
interact with ActiveX control objects. Interaction may be through the association of
a method to
14. A button or object, which the operator initiates, or methods may be used by the
Visual Basic compliant scripting language for advanced functionality and additional
control of the ActiveX components.
J. Alarming
1. The software shall provide alarm annunciation and routing capabilities. The alarm
text associated with each alarm shall be user configurable.
2. Alarms are to be applied as follows:
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3. Digital Points - the alarm generating condition (0 or 1) shall be selectable.
4. Analog Points - the alarm generating conditions shall be evaluated based on alarm
criteria selected:
a. Absolute - There shall be two levels of high alarming, HI-2 and HI-1, and two
levels of low alarming, LO-1 and LO-2. HI-1 and LO-1 are also known as
warning alarms. For high alarming, an alarm shall be generated when the
point value reaches or exceeds the value specified for HI-1 or HI-2. For low
alarming, an alarm shall be generated when the point value reaches or falls
below the value specified for LO-1 or LO-2.
b. Deviation - Alarm limits for deviation alarms shall be given in positive values.
The HI-2 and HI-1 alarms shall be generated when the difference between the
current point value and the Deviation Point value is positive and reaches or
exceeds the specified limits. The LO-1 and LO-2 alarms shall be generated
when the difference between the current point value and the Deviation Point
value is negative and the absolute value of the difference reaches or exceeds
the specified limits.
c. Rate of Change - Rate of Change alarms shall be provided to detect either a
faster or slower than expected change in the value of a point.
d. Duration - The Alarm Display shall include total time in Alarm State.
5. Alarms shall be configurable to be filtered and asynchronously sent to users based
on user role and scope of responsibilities. Alarms shall be configurable with
respective priorities, divided into classes, and color-coded for display. There shall
be user-defined logging criteria, user-defined acknowledgment and deletion
criteria, user-specific textual messages and operator help text. The alarm list can
be toggled between dynamic and static display and quickly filtered to limit the
current view to a particular alarm set of interest.
6. The system shall support "alarm blocking". Users shall be able to define an alarm
hierarchy and block the generation of "lower level" alarms if a "higher level" alarm
is present. This allows for operators to concentrate on primary causes rather than
receive all the resulting secondary problems. For example, if a conveyor stops
then all machines feeding it would also stop. The operator needs to determine why
the conveyor stopped - the operator does not need to see the other alarms. In this
example, fixing the conveyor shall fix those alarms as well.
7. The system shall provide for an automatic routing of configured alarm messages to
display type pagers. The routing shall be configurable as to personnel or pager ID
receiving the message. It shall be possible to upgrade the paging system to
support dual outputs - allowing messages to be sent to local pagers, or to a dial-up
paging system.
K. Data Logging
1. Data collected by the Monitoring and Control System shall be logged into a
relational database to support historical reporting and analysis. The system shall
support multiple SQL compatible databases and/or formats. Configurable logging
of points, alarms, and events shall be supported without forcing the application
developer to understanding database internals. Custom application software must
not be required to log data. Configuration of the logging characteristics of a point
shall automatically configure the database that shall store the data. A variety of
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database management systems shall be available for use.
2. Point and alarm data is to be logged upon a "trigger" event. The following triggers
for logging point and alarm data are required.
a. Point Data - Alarm Data
b. At time of day - on generation.
c. On Time Interval - On Reset
d. On Point Upgrade - On Acknowledgement.
e. On Event - On Deletion
f. Gated based on logical expression
3. Point attributes, which shall be available for logging, include
a. Point Value
b. Previous Value
c. Raw Value
d. Alarm State
e. Resource
f. Time Last Logged
g. Engineering units
4. The logging module shall support the logging of multiple point attributes into a
single record based on a single trigger. The logging module shall also support
logging multiple points and their attributes to a single. The logging module shall
support the simultaneous logging of multiple tables of data consisting of
combinations of single points, multiple points, alarms, and events. This supports
the creation of custom database tables unique to an application.
5. Through configuration alone, the logging utility shall support "store and forward" to
selected database management products. Data shall be buffered on the node
collecting it and automatically forwarded to the node where it is to be logged.
During a communications outage between the two nodes, the data collection node
shall continue to buffer data. Upon restoration of communications, the data
collection node shall automatically forward the buffered data to the logging node
for storage.
6. User configurable database maintenance actions, which are executed
automatically, based on database size or number of records shall be supported.
Examples of these actions include exporting data to a file then purging the records
from the database. No custom software shall be required to implement this
support.
L. DDE Employer and server interface
1. The HMI must support a DDE interface in both Employer and server modes. In the
server mode, DDE aware applications (Employer) such as Microsoft Excel shall be
able to access data managed by the Monitoring and Control System. The DDE
Employer interface support the use of third party applications to monitor, analyze,
report, and modify point data.
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2. Required Services for the HMI server support include:
a. Request Point Configuration Data (e.g. alarm limits, engineering units’ labels)
b. Request Point On-Change (DDE Peek)
c. Request Point Update (DDE Poke)
3. In the Employer mode, DDE server applications such as device communications
drivers shall be able to act as a source of data to the HMI, for both reading and
writing of data down to factory floor devices or external systems. For maximum
flexibility in selecting third party servers and for maximum software performance,
the HMI must support both the DDE and Advance DDE protocols.
M. OPC Employer & server interface
1. The HMI must support an OPC interface in both Employer and server modes. In
the server mode, OPC aware applications (Employers) shall be able to access
data managed by the HMI. The OPC Employer interface shall support the use of
third party OPC Device Communication Servers. The OPC Server interface shall
allow for point information collected and maintained by the HMI to be sent to OPC
applications requesting the data.
N. Application development
1. Application development should be done in the context of a "project". A given
system shall support concurrent application development and execution of multiple
projects. All the data related to a project including communication ports, field
devices, alarms, users, and graphic screens is stored in a project folder. Project
folders shall be easily transportable from system to system. Configuration of a
project shall be fully dynamic so that objects may be added to or modified within
the project without requiring a system restart.
2. System shall be furnished with application development tools for configuring
projects. Utility should provide for interactive fill-in-the-blank transactions for
configuring individual items as well as a Configuration Wizard which guides a
developer through the entire process.
3. To support rapid configuration of large systems, an import/export utility should be
provided to allow for external management and replication of configuration data.
This external file format shall be .CSV format to facilitate the use of standard tools
such as MS Excel and MS Access.
4. An interactive Graphics Editor package is required to develop screen layouts and
to animate a given application.
5. In cases where standard software functions do not support a given requirement, a
set of documented application programming interfaces (API) shall be available for
developers. APIs shall be C language or Visual Basic.
O. Data trending
1. The trending module shall be capable of supporting one or more embedded trends
within the runtime graphics user interface. The following types of trends shall be
supported:
a. Trends with Multiple Y Axes
b. Trends with Multiple X Axes
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c. Trends with multiple time periods
d. Reference curves
e. XY Plots
2. The trending option shall support display of an unlimited number of pens on a
single trend chart. Each pen shall display either dynamically updating data or
provide seamless access to historical values based on user request. In addition,
user shall be able to compare data from different time periods.
3. Trending shall support the creation and re-display of files with reference data from
the currently displayed trend.
4. Users shall be able to analyze trend data by scrolling through time, changing the
range for point displays, zooming into an area of the trend and selecting a new
time period to display.
5. Printing of trend charts is required.
6. Trend layout shall be highly configurable including colors, tick marks, legends, title,
and fonts. The update rate for data being displayed from log files shall be
configurable. The data being trended shall be configurable. This configuration
must be modifiable at runtime without requiring a development system or license.
7. Trend data can be supplied from multiple sources including current point data,
data from .CSV files, and data logged to a database. Data displayed by the trend
manager shall support time-based or on-change based sampling.
8. Trending shall support the display of array points. Arrays can be interpreted as
independent variables or as a time series of a single variable. The latter case
supports buffering of data in high speed sampling applications.
9. The ability to select any numeric value or values being displayed on a graphic
screen and quick rending the values shall be provided. There shall be no need to
have pre-configured graphic screens created to display the quick trends.
P. Statistical process control
1. Data collected though the Monitoring and Control System shall be accessible by a
Statistical Process Control Module. This includes data from plant floor devices,
manual data entry, custom applications, and flat files. SPC Charts/Reports shall
be provided as ActiveX objects, which can be dropped into graphic screens. The
software shall support an unlimited number of quality characteristics or sub-
groups.
2. The quantity of data displayed in SPC charts shall be user configurable and shall
be updated dynamically as new data is collected. SPC ActiveX objects shall allow
the user to dynamically switch between a chart and report view of the data without
the need to reconfigure screens. Users shall be able to scroll through data that is
not initially displayed on a chart. Standard Charts/Reports shall include:
a. Xbar & Range
b. Xbar & Sigma
c. X Individual
d. Histograms
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3. Software shall support the following control checks where "N" is configurable. Each
may be separately enabled or disabled.
a. Any one subgroup beyond upper or lower limits
b. N subgroups on the same side of the center line
c. Trend of N consecutive subgroups in a row up or down
d. N subgroups in a row alternating up and down
e. Sets of Subgroups in a row within one, two or three standard deviation
4. All SPC Out of Control (OOC) conditions shall be capable of being processed by
the Monitoring and Control System to:
5. Change the color of a graphic object to red or flashing
6. Sounding an audio alarm
7. Logging the OOC condition to a device or file
8. Send an alarm message to a user or another process
9. Individual Quality Characteristics are configurable based on the following
parameters:
a. Enable or disabled
b. Subgroup Size and Interval
c. Center Line, Upper and Lower Control Limits
d. Control Limit Recalculation Type (Manual, Automatic)
e. Control Checks and Alarming
10. Configuration information shall be centralized on server node and support SPC
charts operating on viewer nodes. All nodes displaying an SPC chart must have
the same control limits.
11. Users shall be able to dynamically modify control chart configuration parameters
through the user interface. In addition, they shall be able to delete outliners (points
that are out of reasonable range) prior to recalculation of control limits.
12. SPC charts may be embedded in graphic display screens as ActiveX objects to
provide seamless integration among applications.
Q. Equipment control
1. The HMI shall provide an Equipment Control module which includes the capability
configure logic and schedule events based on the following criteria:
2. Time of day
3. Time Interval
4. Production event
5. Point change
6. Alarm Generation
7. In response to configured events, the system shall invoke configurable actions that
include:
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8. Log Event
9. Acknowledge Alarms
10. Enable / Disable an Alarm
11. Recipe Upload / Download
12. Execute a Script
13. Set a Point Value
14. Copy a Point Value
15. Execute a Procedure
16. Scripts shall be modular and re-usable. Scripts shall be in a Visual Basic compliant
language.
17. An event editor shall be included to permits users to configure, monitor and debug
applications. Users shall be able to monitor the progress of control programs and
18. Dynamically modify their operating characteristics. The event editor shall at least
support these debug tools:
19. Run in Single Step Mode
20. Start/Stop Scripts
21. Set Break Points
22. Step into or Over Sub-Scripts
23. Watch variables change
24. Control programs shall have access to all of the application programming
interfaces (API's) within other Monitoring and Control applications such as DDE
interfaces, equipment/device interfaces, production tracking, and system alarming
and logging.
R. Recipe management
1. A module that is capable of monitoring and managing equipment recipes shall be
available. The Recipe module shall support both batch and discrete part
processing requirements. The Recipe module shall support dynamic configuration
of recipe information.
2. The Recipe management module shall support the creation and management of
device independent recipe data for production processes. Configuration data shall
be stored in recipe groups to simplify information management. Within a group,
recipe parameters should only have to be entered one time to minimize duplicate
data entry.
3. Parameter values shall be supported for each recipe. The module shall support
the concept of device independence. This shall permit the configuration of a
recipe a single time yet also permit downloading that same recipe to different
devices, i.e. different
4. Programmable controller models or manufacturers. This device independent
support no longer requires the maintenance of separate recipes for the various
pieces of production equipment in the facility.
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5. There shall be a dedicated user interface utility. The utility shall support the
display of recipes, parameters and the mapping of parameters to devices. Ideally,
this display shall support a spreadsheet-like interface for ease of use and to help
minimize user training. Like a spreadsheet, the information display formatting shall
be user configurable. The interface shall follow the Microsoft Windows look & feel
and include tools such as copy/cut/paste.
6. Overall, the user interface shall support the ability to:
7. Create and manage recipe parameters, recipes, and maps side-by-side in a
spreadsheet format.
8. Import and export recipe groups from/to CSV format files.
9. Archive recipe groups.
10. Automatically reconcile recipe groups to accommodate changes in the group's
structure and layout.
11. Compare recipes.
12. Validate recipe information.
13. Manually upload recipes.
14. Manually review/modify parameters and download recipes.
15. Create recipe parameter files, to support automatic upload and download of
recipes.
16. Identify a Batch ID for recipe downloads.
17. For maximum flexibility, the Recipe management module shall also support a
graphic user interface. Recipe objects should be implemented as OCX controls
that may be embedded in graphic screens. These objects shall let a run-time user:
18. Manually upload recipes.
19. Manually review/modify parameters then download recipes.
20. To support the development of sophisticated applications, the Recipe
management module shall support an interface to the HMI's scripting capabilities.
This scripting interface support shall include the ability to:
21. Automatically upload and download recipes based on system events, such as
point changes from a shop floor device.
22. Import and export recipe groups from/to CSV format files.
23. The module shall support a wide range of data types including:
24. Signed integers
25. Unsigned integers
26. Digital/Boolean values
27. Real numbers
28. Text strings
S. Calendar based control
1. The HMI shall provide for calendar based control operations through a self-
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contained graphic users interface. The HMI shall allow you to dynamically create,
maintain, and execute a calendar schedule of manufacturing events and
corresponding actions. For example, a system shall allow the user to perform
such actions as turn on lights, heat, and equipment based on a schedule, which
they configure and maintain through simple point and click actions.
2. Configuration of the calendar-based control shall allow the user to define different
types of days - production, weekend, holidays, to conform to 4 day or 5 day work
weeks, etc. Users shall then be able to configure manufacturing control events
they want to occur on a particular type of day and the time they should occur.
Association of days on the calendar with a particular type of day shall be through a
point and click interface. The graphic user interface for the calendar-based control
shall allow the user to dynamically change or override the established schedule.
3. The graphics interface for the calendar-based control shall be available on both
Servers and Viewers.
T. Historical data display
1. The HMI option shall provide for the examination of data through enhanced
database logging functions, historical data viewing, data summarization, and
modification and recalculation of data. It shall be possible to summarize data over
configured time intervals and then this summarization in a graphics screen through
an ActiveX control. It shall be possible to edit and modify the historical data trough
the ActiveX control embedded in the graphics screen. The user shall also be able
to enter comments to further document the data. After modifying data, it shall be
possible to initiate the recalculation of the historical data to update summarization.
Summarization values shall be able to be sent to an HMI point.
U. Integration APIs
1. The HMI shall have a set of open interface APIs (Application Program Interfaces).
The APIs shall include:
a. Point Management API - Allows third party programs to be interfaced to the
HMI and pass point data to and from the HMI in real time fashion.
b. Alarm Management API - shall allow alarm information to be passed to and
from the API.
c. Logon API - shall allow the user to create their own custom logon dialog
boxes.
d. Device Communication Toolkit - shall allow the user to construct
communication modules to third party devices with published protocols.
V. Marquee driver
1. The HMI shall have the ability to send alarm information and messages to multi-
line marquee display devices. The marquee driver shall be fully configurable. No
custom coding shall be required to retrieve alarm or message information. It shall
be possible to determine which set of HMI alarms you want to send to the actual
marquee device.
a. Marquee configuration shall include:
b. Marquee Types - All marquee devices that use the same header, footer,
message wrap, empty message, and attributes belong to the same Marquee
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Type.
c. Marquee Ports - The PC communication port or the network communication
port to which one or more serial marquee devices are connected. If more than
one device is on a port, the header and/or footer information (from the
Marquee Type) shall indicate which device on which the message is to be
displayed.
d. Marquee Devices - The ability to assign a Marquee ID, Marquee Type,
Marquee Port, header, footer, empty message, and display time for each
marquee device within a project shall be provided. The option of associating
sets of marquees into Marquee Groups shall be provided.
2. Marquee Messages - For each Marquee message, it shall be possible to assign a
message ID, Alarm ID, alarm state, message header, message footer, message
text, the marquees on which to display the message, the attributes associated with
the message, and any HMI point values to be displayed with the message.
W. SMS notification of alarms
1. The HMI shall provide the ability to send process alarms to cell phones. The
messaging capabilities shall be designed on a Employer / server architecture of to
avoid duplication of configuration information.
2. Messaging features shall include:
a. On line configuration of users and phone numbers.
b. Enable or disable users from receiving messages.
c. Escalation of messages.
d. Filtering of messages based on point groupings, alarm classes, or alarm IDs.
e. Dynamic on-line configuration changes.
f. A scripting interface for automatically sending messages, changing a user's
phone number, or disabling a message.
g. Customizable messages.
h. Configuration templates for fast setups.
i. Support of distribution lists.
X. Report manager
1. The HMI shall provide ASCII based reporting without the need for a relational
database. The user shall be able to pre-configure the reports they want produced
on a timed or event basis.
2. Design of reports shall be performed through a dedicated report editor. The editor
shall have intuitive point and click features and the ability to browse the HMI's point
database for inclusion in the report templates. It shall be possible before final
installation for reports to be tested in accelerated time mode to verify your design.
This shall be accomplished through a design validator and report previewer. The
user shall be able to simulate the events causing values to record and use the
report previewer to view the resulting reports.
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3. Report generation shall be possible based off a timed schedule or process events.
The report manager shall provide a dedicated scheduler that allows users record
values on a timed basis. In addition, the scheduler shall monitor process
conditions and prevent unnecessary reports from being produced. User's reports
shall be automatically archived and printed without operator intervention.
4. A dedicated report viewer shall be provided to allow users to retrieve electronically
stored reports easily by using simple queries. The report viewer shall allow the
user to display multiple reports simultaneously for accurate comparison.
5. Report Manager features shall include:
a. Unattended background reporting is provided by a built-in scheduler. This
shall provide for the execution of periodic, daily, weekly, monthly, and yearly
reports. In addition, the report manager shall monitor events and trigger a
report based on an event.
b. Report Manager shall maintain its own historical database within the reports
being generated. For example, minimum, maximum, average, standard
deviation, and total values are stored as the reports are generated.
c. The Report Designer shall use point and click methods for easy report
template generation. An integrated point browser shall display all HMI points
for quick and easy inclusion.
d. A report-sectioning feature shall enable the creation of complex reports in an
easy fashion. Summary reports that require data from previous reports shall
be built by standard functions.
e. Calculation functions, e.g., add, subtract, divide and multiply shall be
performed within the report.
f. The duration between events shall be tracked and calculations performed on
the duration.
g. Page numbering (with footer and header section) shall be provided.
h. Individual printer selection per report shall be provided. Single line printing
shall be provided.
i. An integrated report viewer shall be provided. The integrated report viewer
shall provide quick access to archived report files. Reports can be compared
easily inside the report viewer.
j. The report manager shall allow values to be entered after the report has been
generated, e.g., laboratory data or values that were (I/O) off-line when the
report was made.
k. The report manager shall provide synchronization flag that can be set to
signify report completion. This flag can be used to reset totalizers.
l. The report files shall be stored in ASCII text files for easy access by any third
party package.
m. Date, time and decimal separator shall be internationalized.
n. Support for the graphical character set shall be provided.
Y. Maintenance Software
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1. Developing a custom built complete maintenance management for the small to the
plant facility. The software shall be very user friendly and easy to learn. It shall
combine purchase functionality and a single user application and contains
standard CMMS features such as Demand maintenance and Preventive
Maintenance work order scheduling, Vendor, Purchasing, Inventory, Labour Craft,
Employee, Reports and Graph modules.
2.03 REDUNDANCY - HOT STANDBY
A. The switchover shall be automatic if no operator intervention is required. Redundancy
applies to both hardware and software, and implies no loss of continuity during the
transfer of control between primary (active) and redundant (backup) components.
Redundant systems reduce single points of failure, preventing loss of functionality.
1. PLC
2. PLC LAN or serial connections to server
3. Computer networks
4. Computer
B. Each level of redundancy provides a failover system that allows continuous system
activity with no loss of data. The following sections briefly describe each level.
1. PLC Redundancy
a. The HMI shall support PLC redundancy. PLC redundancy lets control transfer
from a primary programmable controller to a redundant one in case of failure.
When the primary PLC comes back on line, control can be transferred from
the redundant PLC back to the primary with minimal loss of data. The
redundancy can be synchronous or independent. Synchronous systems
coordinate control and handling of data between CPUs of the active and
backup units, while in independent systems each PLC acts like an active unit
and is not constrained by the others.
2. Cabling Redundancy
a. The HMI shall support Cabling Redundancy. Cabling redundancy involves
separate physical connections to the same device. The devices can be on a
LAN or may require serial connections. Redundant cabling provides an
alternate communication path to the device if the association with the host
computer is lost due to failure of the primary path. The implementation of
cable redundancy with respect to host monitoring/control systems differs with
the device protocol involved.
3. Server Redundancy
a. The HMI shall support Server Redundancy. Server redundancy involves a
primary factory monitoring server and a redundant "Hot Standby" server. The
redundant server is essentially a mirror image of the primary server, running
alternate monitoring/control processes and applications. Data collection is
performed via independent or shared network paths to the same devices,
depending on the protocol. The characteristics of the selected
communications protocol(s) determine the details of the configuration.
b. Upon detection of failure of the primary server, the secondary server can
assume control of data collection, alarm functions, applications, and allow
_____________________________________________________________________________________________________
user access with minimal loss of continuity. When the primary server comes
back on line, control can be transferred back, and the secondary server shall
resume its backup role.
4. Computer Network Redundancy
a. The HMI shall support Computer Network Redundancy. Computer network
redundancy is similar to cabling redundancy, except it covers computer to
computer communications rather than computer to programmable controller.
Computer network redundancy provides an alternate network path in case of
failure of the primary network.
5. System monitoring
a. The HMI shall provide system monitoring to allow the user to monitor the most
important part of the system - the computer. System monitoring shall monitor
both the HMI processes as well as key Windows NT operating system and
network parameters. System monitoring shall be able to monitor the status of
the computer the HMI is running on as well as other NT computers on the
network. System monitoring shall allow for key HMI parameters and statistics
such as alarm frequency, device communications, data collection and
throughput, inter-process communications, data logging, point management,
and user registration to be monitored and recorded. System monitored
information can be alarmed on.
6. WEB capabilities
a. The HMI shall have the capabilities of sending and receiving point based
information from standard HTML pages. In addition, point information shall be
capable of driving animated ActiveX graphic objects within the HTML web
pages.
b. The HMI shall also support Thin Employer technology to enable graphic
screens to be sent to standard web browsers without the need for the user to
create HTML pages. The resulting web based graphic viewers shall be
capable of viewing the graphic screens of the HMI. The web viewers shall
support the ability to perform setpoints back to the supporting server.
2.04 UPS SYSTEM

A. System supplied shall be backed up by a UPS with 30 min back up capacity for the
PLC system and network accessories
B. The offered UPS system shall have capacity and shall be designed for critical part of
the work is stored on control system or servers. The UPS shall be ideally suited for
protecting PLC based control system and shall have a wide range of input voltage
variations through continuous voltage regulation without using the battery. This ensures
that the protected system is not shut down unnecessarily due to voltage fluctuations.
UPS also features Advanced Battery Management, which prolongs battery life by 50%.
C. UPS shall accommodate several advanced communication features, which make it the
perfect choices to protect networks.
2.05 LAN AND PROTOCOLS
A. The following is a summary matrix of the Lan and Protocols within the scope:
_____________________________________________________________________________________________________
1. Layer: Between PLC and PLC
a. Physical Media: Twisted Pair Wire
1) Protocol: Open as noted above
(a) Carrier: RS 485
(1) Speed: Min 9600 bps
2. Layer: Between PLCs
a. Physical Media: Fiber Optic
(a) Carrier: TCP/IP on Ethernet
(1) Speed: 100 Mbps
3. Layer: Between Main Plant and CCR
a. Physical Media: Fiber Optic
(a) Carrier: TCP/IP on Ethernet
(1) Speed: 10/100 Mbps
B. All wiring shall be in accordance with IEE wiring regulations but not in contradiction with
Local Authorities requirements and the same shall be properly supported. The wiring
and tubing exposed and in equipment rooms shall run parallel to or at right angles to
the building structure. All piping and wiring within enclosures shall be neatly bundled
and anchored to prevent obstruction to devices and terminals. All line voltage wiring, all
wiring exposed, and all wiring in equipment rooms shall be installed in rigid galvanized
conduit in accordance to the electrical specifications. All electronic wiring shall be #18
AWG minimum and shielded. All wiring in the central control room shall be installed in
conduit.
C. Provide a minimum 450mm long coil of wire at each device termination.

D. The Contractor shall provide all sensing, control, and wiring for all devices following
unless shown or specified elsewhere.
E. This Contractor shall enter all computer data into the related computers including all
graphics, control programs, initial approved parameters and settings, and English
descriptors. This contractor shall maintain copies of all data file and application
software for reload use in the event of a system crash or memory failure. One copy
shall be delivered to the Owner during training sessions, and one copy shall be
archived in the contractor's local software vault.
2.06 FIBER OPTIC CABLE AND ADAPTORS
A. Fiber Optic Backbone Cable: 8-fiber, Single mode OS-2 type, complying with TIA-
492AAAB; covered with orange cable jacket and complying with relevant portions of
and addenda to latest edition of TIA/EIA-568.
1. In locations other than in plenums, provide NFPA 70 type OFNR nonconductive-
riser-rated or type OFNP nonconductive-plenum-rated cable.
_____________________________________________________________________________________________________
2. In plenums, provide NFPA 70 type OFNP nonconductive-plenum-rated cable.
3. Testing: Furnish factory reel tests.
B. Fiber Optic Horizontal Cable: Single fiber 8 cores, Single mode (OS-1 Type),
complying with TIA-492AAAB; covered with orange single jacket and complying with
relevant portions of and addenda to latest edition of TIA/EIA-568.
1. In locations other than in plenums, provide NFPA 70 type OFN nonconductive
general purpose, OFNR nonconductive-riser-rated, or type OFNP nonconductive-
plenum-rated cable.
2. In plenums, provide NFPA 70 type OFNP nonconductive-plenum-rated cable.
3. Testing: Furnish factory reel tests.
C. Fiber Optic Adapters and Connectors: Duplex SC, push-on-push-off type, single mode
adaptors with zirconia ceramic alignment sleeves; complying with relevant parts and
addenda to latest edition of TIA/EIA-568 and with maximum attenuation of 0.3 dB at
1300 nm with less than 0.2 dB change after 500 mating cycles when tested in
accordance with TIA-455-21.
D. Fiber Optic Connectors: ST/SC type, bayonet twist-on-off, Single mode adaptors with
metallic alignment sleeves; maximum attenuation of 0.3 dB at 1300 nm with less than
0.2 dB change after 500 mating cycles when tested in accordance with TIA-455-21.
2.06 MEDIA CONVERTOR & OPTICAL DISTRIBUTION FRAME:

The media convertor is built-in inside the same housing of PLC. The fiber optic cable
shall be terminated inside the Optical distribution frame (ODF) or fiber optic patch panel
which is located inside the IT rack of telecom room. The ODF will be connected to the
Media Convertor through fiber optic patch cords and the media convertor will connect to
the PLC Ethernet link by the UTP patch cord.
2.07. SERVER CONFIGURATION:

Typical minimum server configuration shall be as follows, Detailed specification shall be
finalized by PLC,SCADA vendor.
► 2.4 GHZ each processor (Quad Core )
► Minimum 2 Processors
► 8GB Main memory (RAM) for all servers
► 216 GB memory Hard disk drive for each server minimum
► Hard Disk Drive in RAID-1/RAID-5 configuration with dedicated RAID controller
► CD R/W drive
► 24” TFT color monitor
► Keyboard & Mouse
► Dual 10/100/1000Mbps Ethernet ports
► redundant power supply
► redundant fan
► Sound Card and Speakers
2.08. PLC Panel Air Conditioning:

_____________________________________________________________________________________________________
For PLC panels typical minimum specifications for air-conditioning system shall be
► Wall mounted/Panel Mounted Cooling Units
► Make: RITTAL or Equivalent
► Mounting: Vertical Panel mounted
► Maximum allowable PLC panel inside (cabinet internal) temperature: Vendor to Confirm
► Internal Heat Load: Vendor to Confirm
► Cooling Output: Vendor to Confirm
► Cooling: Closed Loop Cooling
► Enclosure of air conditioner: NEMA 4X
► Enclosure Material: Stainless Steel
► Size: Vendor to Confirm
► Power Supply: 220V AC, 60 Hz/ 380 V AC , 60 Hz
► Refrigerant: CFC Free
► UL listing required
► Panel air conditioner shall include microprocessor based programmable temperature
management, digital display and remote alarm capability.
2.09 Asset Management System:
Asset management will be used to provide Integrated Solutions that Maximize the
Equipment and Process Availability. Asset management is Real Time Monitoring of the
health of Equipment/ Instruments.
Asset management will have following features.
► Capacity to diagnose Faults.

► Integration between Control Systems and Maintenance Management.
► Central Tool for Configuration of Devices.
► Intelligent Technology for Predictive Maintenance.
► Integrated access to Datasheets, Manuals, Drawings,
► Description, Alarms...
An online and centralized automation asset management system, PRM shall help both
operators and maintenance personnel prevent downtime, and reduce maintenance
costs.
► Automatically acquires device events (e.g. alarms) in real-time, twenty-four hours per
Day, and saves them in the database. Thus the operating status of field devices can be
monitored continuously.
► Uses intelligent field networks such as HART. Performs automatic device recognition
and registration (Plug & Play), monitors device status, displays device events (e.g.
alarms), allows tuning of device parameters, and performs device diagnosis. With asset
management and intelligent field devices, operators and maintenance personnel can
monitor the condition of plant assets remotely.
► The display color of device icons shall change depending on the device status. This shall
provide an easy-to-understand overview of the device operating status.
► Allows not only devices with field communication capability but also conventional
Devices to be registered together for centralized device management.
The Contractor (PLC, SCADA Vendor) shall integrate Waste water Pumping Station
SCADA with Asset Management Software for real time monitoring of equipment life
cycle.
_____________________________________________________________________________________________________
2.10 Vibration monitoring System:
The measurement of Vibration levels shall be carried out on the Bearing housings of the
machinery in both Horizontal & Vertical planes (X – Y planes).
The Vibration Monitoring System shall as a minimum consists of Sensors with low noise
cables of 10 meters length in SS flexible conduits, Local terminal box / Junction boxes ,
necessary per-amplifier/ electronics mounted in local weather –proof boxes , Vibration
monitors, Monitor Racks, Power supplies, integrating units, Signal conditioning devices,
sensor-mounting accessories, interconnecting cables, calibration equipment, Panel/s
..etc..
Sensors shall be Velometer / Accelerometer type & selected based on the service
requirement / parameters w.r.t machine Speed and the Vibration ranges, for each of the
Machine. The Project-specific details of various machines shall be provided by vendor
However, the typical machine data / parameters are indicated below for which the
Sensors & other monitoring equipment shall be
a. For Pumps : RPM = Varies from 300 ( for certain CWPs ) / 1500 ( for
ECWPs/ACWP/DMCWP ) / upto 6000 ( for certain BFPs ) & Vibration Range = 0 to 15 /
25 / 35 mms per sec – Peak
The Sensors with mounting accessories shall be mounted on Bearing housing of the
Machine, in Horizontal and Vertical directions. Weatherproof housing shall be provided
for these sensors and shall be suitable for field conditions of the pumping station.
_____________________________________________________________________________________________________
PART 3- EXECUTION
3.01 GENERAL
A. The Contractor shall provide all materials, equipment, and labor as deemed
necessary to show proper execution of the work.
B. All installation details, write-up on handling of the equipment/materials, instruction
manuals and latest revised approved Drawings and Documents furnished by the
Contractor or manufacturer shall be available at site prior to installation of the
SCADA-PLC equipment. These details shall be reviewed by the Employer’s
representative. The details and instructions furnished in these documents shall be
followed carefully during installation of the equipment at site.
C. All equipment/materials moved to the installation site shall be inspected for damage
or deterioration during storage.
D. The Contractor shall verify all the tag numbers and nameplates for the equipment
and device numbers with the details specified on the Contract
Drawings/Documents.
E. The Contractor shall also provide the equipment manufacturer’s services of a
competent and experienced Engineer to supervise the installation of the SCADA-
PLC equipment, the field tests, initial operation, and instruct and train the
Employer’s personnel in the correct installation, operation, service, and
maintenance of the equipment.
F. After the installation is completed and properly adjusted, the Contractor shall
conduct operating tests. The various equipment and systems shall be demonstrated
to operate in accordance with the requirements of this Specification and the other
relevant codes and standards. Tests shall be performed in the presence of the
Employer’s representative. The Contractor shall provide electric power, instruments,
special tools, safety gears, and personnel necessary for performing the various
tests.
G. For easy, smooth, safe operation and maintenance of the SCADA-PLC equipment,
the manufacturer or vendor of SCADA-PLC equipment shall give training to the
Employer appointed representatives during start-up, testing and commissioning.
3.02 INSTALLATION OF SCADA AND PLC EQUIPMENT
A. The installation of SCADA-PLC equipment including PLCs, interface Cabinets,

protective relays, control system, laying of cables, etc. All the SCADA-PLC
equipment shall be factory assembled and tested in accordance with manufacturer’s
recommended practice, latest revision of relevant standards and codes, and as per
the approved Contract Drawings/Documents.
B. The Contractor shall be responsible in installing the SCADA-PLC equipment
including protection and control systems, and shall include all related work on
related systems, whether existing or new, to provide satisfactory interfaces and
overall integrated systems.
C. The Contractor shall install all the field indoor and outdoor SCADA-PLC equipment
at the designated locations, as specified on the Contract Drawings/Documents.
_____________________________________________________________________________________________________
D. The Contractor shall be fully responsible for the complete installation of SCADA-
PLC equipment, loading the software, and starting up the PLC and LAN system as
per the Contract Drawings.
E. Laying and routing of power and control cables of SCADA-PLC system shall be
either through underground ducts or through cable trays or in conduits, as specified
on the Contract Drawings/Documents. SCADA equipment installed shall be suitable
in the service conditions, as specified in par. 1.10.
F. Data communication cables shall maintain a minimum separation of 75 mm from
any AC power cables. Fiber optic cables are excluded from this requirement.
G. The Contractor shall verify that the identification tags are attached to each SCADA-
PLC equipment and relevant components/devices bearing its equipment/device
number in accordance with the Contract Drawings/Documents.
H. Grounding connections shall be made, as indicated on the Contract Drawings, and
connected up to the nearest grounding bus or network
3.03 TESTING AND COMMISSONING
A. General
1. The Contractor shall carry out all site tests in accordance with approved test
procedure to ensure that the SCADA-PLC equipment, components and
devices comply with this Specification and operational requirements. All tests
shall be subject to witnessing by the Employer’s representatives.
2. At least 4 weeks prior to scheduled tests, the Contractor shall submit to the
Engineer an outline of the plan and procedures to be used in performing the
site inspection and site tests. This outline shall include a brief description of
the test equipment, connection diagrams, proposed tests and procedures, test
sheets, calculations, reference drawings and minimum/maximum test and
performance values in conformance with applicable standards which shall be
used to determine conformance with the specification and acceptability of the
SCADA-PLC equipment and installation.
3. All testing equipment shall be calibrated by approved authorities and
calibration certificate shall be provided to the Engineer for review and
approval.
4. Upon completion of installation and prior to final acceptance, each component
of each system shall be tested to the complete satisfaction of the Engineer.
The Contractor shall provide all test instrumentation, equipment and
accessories necessary for demonstration and putting the equipment into
operation. Before commissioning, the Contractor shall submit all necessary
calculations of instruments and components to the Engineer for approval.
5. Upon completion of all testing, the Contractor shall submit 5 copies of a
certified report attesting that each test has been performed in accordance with
the approved test procedures. The report for each test shall include the name
of the person in-charge of the test and the date of performance. All factory and
field test reports shall be included in Operation and Maintenance Manuals.
_____________________________________________________________________________________________________
6. In the event any problems are encountered during testing, including damage
of the equipment or failure of testing criteria or injuries to persons, the
Contractor shall be held fully responsible for the same.
END OF SECTION
_____________________________________________________________________________________________________
SECTION 41 22 13.13
OVERHEAD TRAVELING CRANE
PART -1 GENERAL
1.01. DESCRIPTION:
A. Work under this section shall include supply and installation of overhead single
girder bridge crane as shown on Drawings and specified herein. The crane
shall have a capacity of 3 tons unless otherwise specified on the drawings.
B. Overhead single girder bridge crane shall be designed and manufactured,

generally, in accordance with BS 422 Class II and FEM Group 1A/2 for indoor
duty, alternatively American Class "C".
1.02 APPLICABLE CODES AND STANDARDS:
A. ASTM - American Society for Testing and Materials
A 36 Structural Steel
A 307 Carbon Steel Externally Threaded Standard Fasteners
A 325 High-Strength Bolts for Structural Steel Joints
A 441 High-Strength Low Alloy structural Manganese Vanadium Steel
B. CMAA 70 Electrical Overhead Traveling Cranes
C. HMI 100 Electric Wire Rope Hoists
D. ICBO Uniform Building Code (UBC)
E. NEMA ICS 6 Enclosures for Industrial Controls and Systems
F. NFPA 70 National Electric Code
G. SASO – Saudi Arabian Standards Organization
H. SASO 977/1997 – Safe use of cranes – Part 2: Mobile cranes..
I. BS - British Standards
BS 466 Crane Technology.
BS 2573 Rules, Part 1 – Structures and Part 2 – Mechanisms.
_________________________________________________________________________________________________
Riyadh Township-Site 1 41 2213.13 Page 1 of 8
1.03 SUBMITTALS:
1. Connection diagrams and outline drawings.
2. Manufacturer's data.
3. Operations and Maintenance Manuals.
4. Certificates of Compliance: For material and strength for wire ropes and
hooks.
5. Test Reports.
6. List of Spare Parts and Special Tools.
1.04 TRANSPORTATION, HANDLING AND STORAGE:
Shipping container(s) shall be provided as specified in the purchase order with

suitable supports and lifting eyes, the location of which shall be clearly
identified.
The manufacturer shall provide recommendations for on-site storage and

handling.
1.05 WARRANTY:
Submit 2 copies of written guarantee signed by the manufacturer, installer and

contractor, agreeing to replace defective material and workmanship within 5
years of date of substantial handing over.
1.06 QUALITY ASSURANCE:
A. Quality Control:
1. The manufacturer shall provide and maintain a quality program that

provides the necessary degree of assurance that the delivered items will
conform to the purchase document requirements.
2. The manufacturer is responsible for ensuring that:
a. Each item provided conforms to the specified dimensional, material

and functional requirements.
b. Required conformance verifications are performed in the prescribed

manner.
c. Certification and labeling is as specified.
d. Quality control certification performed during fabrication is verifiable

and traceable to the item after fabrication.
_________________________________________________________________________________________________
PART –2 PRODUCTS
2.01 OVERHEAD BRIDGE CRANE:
A. Provide a complete package overhead single beam bridge crane,

electrically operated as specified herein, assembled and erected, proof
load and tested.
B. Service Conditions: Operating conditions climate conditions and structural

design requirements shall be as indicated or required.
C. The crane shall operate in the area as indicated on the drawings with the
span and length of travel as noted here or on Drawings.
D. The crane shall be erected in a building, and careful arrangements made

to do so. Erection of the crane and down shop steelwork, and completion
of all the related works shall be responsibility of the Contractor. The long
travel bar insulated conductors and supports are also to be erected,
suitable holes having been drilled in the steelwork by Contractor, to details
supplied by the crane manufacturer.
E. The crane shall be designed and manufactured, generally, in accordance

with BS 422 Class II and FEM Group 1A/2 for indoor duty, alternatively
American Class "C". Details are typical. Manufacturers may put forward
their standard designs, provided they meet the overall requirements
specified.
F. Construction: The crane shall be of the single girder construction. Each

beam shall be suitably braced and plated to facilitate accurate supporting
wheel alignment and connection.
G. Hoist Unit: The hoist unit shall be of the electric wire rope type, designed
and manufactured according to the standards issued by the Federation of
American or European Manufacturers and in full compliance with the
relevant standards. The hoisting motor shall be fan-cooled and housed
inside the hoisting barrel.
It shall be a high quality conical brake motor designed especially for crane
duty, including Class F insulation and protection to 1P55/DIN 40050. The
helical gearing to run in an oil bath and to be made of heat-treated
quenched and tempered steel.
H. Long Travel Drives: The cranes shall be supported on single flanged cast
steel rail wheels, one driven and one trailing each bogie. The drive shall
be transmitted from the gearbox via a totally enclosed pinion and spar
gear.
I. Control Equipment: Shall be fitted to the main beam of the crane and shall
be IP54/IP55 mild steel panel enclosure housing the control equipment:
_________________________________________________________________________________________________
Control Contactor
Mechanical and Electrical interlocked pairs of reversing contactors
Timers as required
HRC fuses
DIN rail mounted terminations
J. Pendant Control: The cranes shall be controlled by means of a low voltage

(50V) push-button pendant suspended from a trolley running in a
galvanized steel track secured across the full span of the crane bridge.
This system shall provide complete mobility of the operating position of the
pendant controller, irrespective of the crane hook position.
K. Finish: Prior to fabrication, all untreated crane steelwork shall be shot

blasted and painted suitable for use in the climatic conditions of Saudi
Arabia. Any paintwork damaged during transport, shipping and erection
shall be made good on site. "Touch-up" primer and topcoat complete with
paint brushes shall be supplied for this purpose.
L. Tropicalization: The cranes shall be adequately tropicalized to combat the

varying climatic conditions existing at site.
M. Design Requirements:
1. The crane shall be the manufacturer's standard design for the service
specified. Standard replacement parts shall be readily available.
2. The crane shall be designed and fabricated in accordance with the

requirements of this Specification. Compliance with all stated
requirements is considered to be mandatory.
3. Electrical equipment and components shall be furnished as required.
4. The crane shall be supplied and guaranteed with the items listed
below:
a. Complete package overhead crane with hoists, trolleys and

runway conductors with hanger clamps, assembled and erected,
proof load and tested. Conductors for the trolley and crane shall
be the totally enclosed festooned runway type.
b. Provide crane machinery and control apparatus, including motors

and motor controllers. Pendant controller for all motions as
required shall be supplied and guaranteed. Electrical controls
and interlocks, including all conduits, wiring and connections
between motors and controllers and the equipment are required
for operation from 380 volts, 3 phase, 60 Hertz power supply.
Phase loss protection shall be provided. Phase loss protection
shall be provided. All runway electric conductors shall be copper.
All conduits and fittings shall be galvanized steel.
c. All components and appurtenances for crane's safe operation

_________________________________________________________________________________________________
and maintenance required by OSHA Regulations and American
National Standard Institute or equivalent.
d. Complete painting as required.
e. Supervision by experienced and qualified technical

representative during erection, complete installation, start-up
and preliminary testing of the crane.
f. Where required for installation, maintenance or servicing of the

equipment, special tools shall be provided. A complete itemized
list of all special tools included with equipment shall be
furnished. Special tools shall be permanently marked with
equipment designation and function shall be mounted in a fitted
lockable steel tool box.
g. Submit a complete spare parts listing for the equipment which

shall cross-reference all assigned part numbers back to the
original manufacturer's part numbers. Make a notation of
quantities of these items recommended and/or required for
continuous operation during one normal overhaul cycle. The
spare part lists shall include cross sectional or assembly type
drawings, part numbers, materials and estimated delivery lead
times.
h. Furnish complete lubrication instructions for the crane, including

types and grades of lubricants to be used. Lubricants used shall
be suitable for the full crane of operating temperature as
specified.
i. The Contractor shall provide main runway supporting girders,

bridge end stops and erection, installation, and testing labor of
the steelwork. The main runway girders and electric power
supply shall be designed by the Contractor.
M. Mobile crane and local labor required for the erection of the Overhead
Crane shall be provided by the Contractor. A qualified Owner's
Representative shall also be made available to fully supervise and assist
in the erection of the crane. He must also carry out proof loads and testing,
and provide certification. Test weights must be provided as required.
N. Crane shall be fitted with end stops in addition to over travel limit switches.
O. Crane to use standard interchangeable parts, wherever possible.
P. Crane will operate under 46o C maximum outside air temperature. Safety
hooks are required on crane and long travel buffers if necessary with
travel limit switches for the overhead travelling crane.
Q. The crane rails shall be provided with removable end-stops and jointing
facilities which will permit a returned extension of the travel length in both
directions.
_________________________________________________________________________________________________
R. Festooned cables shall take into account the ultimate travel length.
S. Inspection and Tests:
1. The manufacturer's responsibility is to control the quality of the crane

and all components.
2. The Contractor/Owner's Representative reserves the right to inspect

the crane for workmanship and compliance to this specification.
3. The crane shall be shop pre-assembled. All critical dimensions shall

be verified, and all motions shall be tested using the crane's own
controls and wiring, by the manufacturer, prior to shipment. All motors
and controls shall be operated at the specified voltage.
4. Upon satisfactory performance and acceptance for shipment at the

manufacturer's facility, the crane shall be dismantled only to the
extent necessary for packing and shipping. All components shall be
match marked to facilitate field assembly.
5. Crane shall be inspected for condition and preliminary acceptability

upon receipt and tested for performance capabilities after installation
in accordance with ANSI Standards (or equivalent). Technical
supervision during erection, assembling, and testing shall be provided
by the manufacturer.
T. Identification, Painting and Handling:
1. Manufacturer's Data Plate: A nameplate of 1808 chrome-nickel alloy

(stainless) steel, 1.5 mm thick shall be attached securely to each
crane at a location approved by the Owner's Representative. The
following information shall appear on this nameplate and shall be
formed by die-stamping, etching or by raised letters:
Manufacturer's name
Manufacturer's serial number
Year of manufacture
Manufacturer's size and type number
Purchaser's order and mark numbers
2. Painting and Protective Coating:
All hot rolled and/or cast parts shall be sand blasted to SSPC-SP4 or
equal, other components shall be power brushed and solvent
cleaned.
Finish paint shall be manufacturer's standard product as selected and

approved by the Contracting Officer.
_________________________________________________________________________________________________
Other surfaces subject to corrosion in operation, transmit or storage
shall be coated with a suitable corrosion prevention agent or paint
where appropriate.
2. 02. CRANE TECHNICAL SPECIFICATIONS:
A. 3-Ton capacity or as specified in the drawings, single girder bridge cranes

which shall provide the maximum height of lift over the whole area within
the designed long and cross travel motions as indicated on Drawing.
B. All of the cranes and hoists shall be provided with full down and cross
room insulated electric supply bars and festoon cables with insulated
pickup bars. The down room steelwork shall be drilled to suit the supply
insulators from details supplied by the crane makers. An isolating switch
shall be provided with each crane and a locking switch with two individual
keys shall be provided at the pendant controls to prevent unauthorized
use. The cranes shall be erected by the manufacturer or manufacturer's
authorized representative hired by the Contractor. After erection, required
tests shall be carried out by the Contractor in the presence of the
Contracting Officer.
C. Design Criteria:
1. Hoist Load : 3 tons.
2. Lifting ( Load height) : As shown on the drawings.
3. Hoisting Speed (Main) : 6/1.44 MPM 14.4/3.6 KW, Dual

Speed
4. Cross Traverse Speed : 24/6 MPM 2.04/0.51 KW, Dual Speed
5. Long Travel Speed : 40/10 MPM 2 x 0.30/0.07 KW, Dual

Speed
6. Control : Detachable mobile pendant
7. Current Supply : 380 Volts, 3 Ph, 60 Hz.
8. Span : As shown on Drawings.
9. Runway length as indicated in the drawings.
10. Crane must be suitable for indoor use in temperatures of 46oC.
11. Fixed pendant control.
12. End carriage must be provided with guiding rollers.
_________________________________________________________________________________________________
13. The crane unit shall be provided with a control cabinet and insulator.
The cabinet shall include time overload relay, etc.
14. The drive units shall be equipped with flanged required cage disc
brake motors which are totally enclosed.
15. Contact controlled limit switches shall be provided for all crane
movements.
PART –3 EXECUTION
3.1 INSTALLATION:
A. General:
1. Installation shall be in accordance with CMAA 70, and manufacturer's

published instructions.
B. Field Tests:
1. Performance Test: After the cranes have been installed, the contractor
shall conduct a witnessed performance test to demonstrate compliance
with the specifications.
2. Functional Operation: The crane shall be tested at an overload of 125

percent of rate load through all motions. All locking and safety devices
shall be tested for their intended functions. Visual inspection shall be made
for proper installation, alignment and lubrication.
--- END OF SECTION ---
_________________________________________________________________________________________________

33 05 61 Concrete Manholes

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What are the different types of manholes and chambers covered in this specification?

What are the different types of manholes and chambers covered in this specification?

What standards and references are cited for materials and construction?

What standards and references are cited for materials and construction?

SECTION 33 05 61

1.1 DESCRIPTION OF WORK

A. This Section covers the furnishing and installation of manholes, valve

1.2 SECTION INCLUDES

A. Precast Concrete Manholes

B. Cast-in-place Concrete Manholes and Chambers

C. Precast Concrete Catch basins

D. Precast Concrete Sewage Wet Wells

E. Cast-in-place Sewage Wet Wells

F. Precast Concrete Valve Chambers

G. Installation of Covers/Gratings and Frames

1.3 RELATED SECTIONS

A. Section 01 3200 Construction Progress

B. Section 01 3300 Submittal Procedures

C. Section 01 4500 Quality Control

E. Section 01 6000 Product Requirements

A. The referred codes and standards are intended to provide an acceptable

C. SASO Saudi Arabian Standards Organization

1. SASO 412 Methods of Test for Cast Iron Covers

2. SASO 413 Cast Iron Manhole Covers

2. BS 4164 Coal Tar Based Hot Applied Coating Materials

1. NACE No. 2 - SSPC SP10Near- White Metal Blast Cleaning

2. NACE No. 3 - SSPC SP6 Commercial Blast Cleaning

ASTM A Standard Specification for Carbon Structural

ASTM A Standard Specification for Steel Wire, Plain,

5. ASTM A36M Standard Specification for Carbon Structural

7. ASTM A74 Standard Specification for Cast Iron Soil Pipe

8. ASTM A82 Standard Specification for Steel Wire, Plain,

10. ASTM A185 Standard Specification for Steel Welded Wire

11 ASTM A193M Standard Specification for Alloy-Steel and

12 ASTM A194M Standard Specification for Carbon and Alloy

15. ASTM A283M Standard Specification for Low and

17. ASTM A395M Standard Specification for Ferritic Ductile Iron

21. ASTM A497M Standard Specification for Steel Welded Wire

22. ASTM A536 Standard Specification for Ductile Iron Castings

23. ASTM A569 Standard Specification for Steel, Carbon (0.15

25. ASTM A576 Standard Specification for Steel Bars, Carbon,

26. ASTM A615 Standard Specification for Deformed and Plain

27. ASTM A635M Standard Specification for Steel, Sheet and

28. ASTM A659M Standard Specification for Commercial Steel

32. ASTM A1012 Standard Specification for Seamless and

34. ASTM B127 Standard Specification for Nickel-Copper Alloy

36. ASTM C33 Standard Specification for Concrete Aggregates

37. ASTM C76M Standard Specification for Reinforced

38. ASTM C94M Standard Specification for Ready-Mixed

40. ASTM C425 Standard Specification for Compression Joints

41. ASTM C443M Standard Specification for Joints for Circular

43. ASTM C564 Standard Specification for Rubber Gaskets for

Standard Specification for Vitrified Clay Pipe,

45. ASTM D1149 Standard Test Method for Rubber

47. ASTM D1784 Standard Specification for Rigid Poly(Vinyl

50. ASTM D2241 Standard Specification for Poly (Vinyl

55. ASTM D2657 Standard Practice for Heat Fusion Joining

56. ASTM D2729 Standard Specification for Poly (Vinyl

57. ASTM D2751 Standard Specification for Acrylonitrile-