Vol III (B) Technical Specification For Mech Work

Uchchhal,Songadh and Nizar Lift Irrigation Scheme
FOR OFFICE USE ONLY CONTRACT No.
GOVERNMENT OF GUJARAT
NARMADA, WATER RESOURCES, WATER SUPPLY
& KALPSAR DEPARTMENT
TENDER PAPERS FOR
Cost Put to Tender: Rs. 849,59,28,124.23
NAME OF WORK: Ukai Reservior based Uchchhal,

Songadh and Nizar taluka, Di.Tapi ,lift Irrigation
Scheme.
VOLUME – III(B) (TECHNICAL SPECIFICATION FOR MECHNICAL

WORKS)
Date of Downloading Up to Dt.25-01-2019 to 25-02-2019,

18.00 Hrs
Date of online Submission Up to Dt.25-01-2019 to 25-02-2019,
18.00 Hrs
Date of Submission of Tender Fee, Up to Dt.01-03-2019, 18.00 Hrs
EMD & Other Documents(Physical)
Date Pre-Bid Conference Dt.02-02-2019, 12.00 Hrs
Date of opening of PQ Bid Dt.26-02-2019, 12.00 Hrs
OFFICE OF THE SUPERINTENDING ENGINEER

UKAI CIRCLE (CIVIL), UKAI
TALUKA-SONGADH, DIST. TAPI, PHONE: 02624-233270
Geo- Designs & Research (P.) Ltd.

GOVERNMENT OF GUJARAT
NARMADA, WATER RESOURCES, WATER SUPPLY
& KALPSAR DEPARTMENT
Tender Cost Time limit for the

Name of the Work
(In Crores) Work
Ukai Reservior based Uchchhal, Songadh 849.59 Time Limit 36 months
and Nizar taluka, Di.Tapi ,lift Irrigation for Construction and 10
Scheme years for Operation &
Engineering, Procurement and Construction Maintenance after
(E.P.C) contract for construction of Intake commissioning
well with pumping station in Ukai reservoir
near Village Selude and Naraanpura for
Uchchhal, near High level Canal for
Songadh and near village Nevele for Nizar
including supplying and laying M.S pipeline
of various dia for UL1 & UL2, UL3 for
Uchchhal, Motatarpada and Medha line for
Songadh and NL1.NL2, (Left side of Tapi
river),NR1 and NR2 (right side of Tapi river)
of size is varying from 2200 mm to 900 mm
and thickness 15 mm to 7 mm respectively
and for DI pipe dia 800 mm to 250 mm
including designing, providing, lowering &
laying underground pipeline distribution
network in command area with allied work
etc. complete including operation and
maintenance of commissioned project for 10
year
VOLUME III (B): TECHNICAL SPECIFICATION FOR MECHANICAL WORK

VOLUME – I PRE – QUALIFICATION BID AND TECHNICAL DATA-SHEETS

FOR CIVIL, MECHANICAL, ELECTRICAL AND
INSTRUMENTATION WORKS
VOLUME – II CONDITIONS OF CONTRACT
VOLUME – III(A) TECHNICAL SPECIFICATIONS FOR CIVIL WORKS
VOLUME – III(B) TECHNICAL SPECIFICATIONS FOR MECHANICAL WORKS
VOLUME – III(C) TECHNICAL SPECIFICATIONS FOR ELECTRICAL WORKS
VOLUME – III(D) TECHNICAL SPECIFICATIONS FOR INSTRUMENTATION

WORKS
VOLUME – III(E) DRAWINGS
VOLUME – III(F) TECHNICAL BID
VOLUME – III(G) OPERATION & MAINTENANCE – SCOPE & SPECIFICATIONS
VOLUME – IV PRICE BID

Table of Contents
1 GENERAL ..................................................................................................................................................... 4
1.1 ACCOMPANIMENT TO BID ............................................................................................................. 4
1.2 INTENT ................................................................................................................................................ 4
1.3 INTERPRETATION OF PROJECT DOCUMENTS ........................................................................... 4
1.4 SCOPE OF Specification ...................................................................................................................... 5
1.5 AMBIENT CONDITION ..................................................................................................................... 6
1.6 RATING ............................................................................................................................................... 6
1.7 REGULATIONS AND STANDARDS ................................................................................................ 6
1.8 LIST OF APPLICABLE INDIAN STANDARD AND CODE OF PRACTICE .................................. 7
1.9 MATERIAL AND EQUIPMENT ...................................................................................................... 12
1.10 MANUFACTURERS ......................................................................................................................... 12
1.11 INSPECTION AND TESTING .......................................................................................................... 13
1.12 RECTIFICATION AND TAKING OVER ......................................................................................... 15
1.13 COMPLETION CERTIFICATE......................................................................................................... 15
1.14 PRICE DETAILS ................................................................................................................................ 16
1.15 TEST CERTIFICATES ...................................................................................................................... 16
1.16 INSTRUCTION MANUAL ................................................................................................................ 16
1.17 AS BUILT DRAWINGS .................................................................................................................... 16
1.18 SPARE PARTS ................................................................................................................................... 17
1.19 COMMISSIONING SPARES............................................................................................................. 17
1.20 Packing and Preservation .................................................................................................................... 18
1.21 PAINTING .......................................................................................................................................... 18
2 VERTICAL TURBINE PUMPS (VT PUMPS) ........................................................................................... 18
2.1 SCOPE ................................................................................................................................................ 18
2.2 CODES & STANDARDS ................................................................................................................... 19
2.3 DESIGN FEATURES ......................................................................................................................... 19
2.4 FEATURES OF CONSTRUCTION ................................................................................................... 21
2.5 TESTS AND INSPECTION ............................................................................................................... 24
2.6 VISUAL INSPECTION ...................................................................................................................... 26
2.7 WELDING .......................................................................................................................................... 27
2.8 DRAWINGS / DOCUMENTS ........................................................................................................... 27
2.9 NAME PLATE ................................................................................................................................... 27
3 SUBMERGED CENTRIFUGAL PUMP-MOTOR SETS (SCF PUMPS)................................................... 28
3.1 TECHNICAL SPECIFICATIONS ..................................................................................................... 28
3.2 INSTALLATION ................................................................................................................................ 28
3.3 PUMP DESIGN .................................................................................................................................. 29
a) Speed: Speed is required to be decided on achievable efficiency of pump. ................ 29
3.4 MOTOR DESIGN: ............................................................................................................................. 30
4 SLUICE VALVES / GATE VALVES ......................................................................................................... 34
4.1 DESIGN FEATURES ......................................................................................................................... 34
4.2 FEATURES OF CONSTRUCTION ................................................................................................... 34
4.3 REQUIREMENT FOR VALVES ....................................................................................................... 37
4.4 INSPECTION AND PERFORMANCE TESTS ................................................................................. 37
4.5 TESTS FOR VALVE .......................................................................................................................... 38
4.6 CLEANING ........................................................................................................................................ 39
4.7 PAINTING .......................................................................................................................................... 39
4.8 TECHNICAL PARTICULARS .......................................................................................................... 39
4.9 HANDWHEEL ................................................................................................................................... 39
4.11 MATERIAL OF CONSTRUCTION .................................................................................................. 40
4.12 NOMINAL PRESSURES ................................................................................................................... 40
4.13 TEMPERATURE RATINGS ............................................................................................................. 40
4.14 BODY ENDS ...................................................................................................................................... 40
4.15 BEARINGS ......................................................................................................................................... 41
4.16 MATERIALS ...................................................................................................................................... 41
4.17 OPERATION ...................................................................................................................................... 41
4.18 DIRECTION FOR OPERATION ....................................................................................................... 41
5 DUAL PLATE CHECK VALVES (NON RETURN VALVES) ................................................................ 42

5.1 DESIGN REQUIREMENTS FOR DUEL PLATE CHECK VALVES (DPCV) ............................... 42
5.2 CLEANING ........................................................................................................................................ 43
5.3 PAINTING .......................................................................................................................................... 43
5.5 MATERIAL OF CONSTRUCTION .................................................................................................. 43
6 BUTTERFLY VALVES .............................................................................................................................. 44
6.1 SCOPE OF WORK ............................................................................................................................. 44
6.2 REFERENCE ...................................................................................................................................... 45
6.3 TERMINOLOGY AND DEFINITION .............................................................................................. 45
6.4 VALVE - END CONNECTION ......................................................................................................... 45
6.5 SERVICE APPLICATION ................................................................................................................. 45
6.6 NOMINAL PRESSURE ..................................................................................................................... 45
6.7 PRESSURE / TEMPERATURE RATING ......................................................................................... 46
6.8 BODY ENDS ...................................................................................................................................... 46
6.9 FACE TO FACE DIMENSIONS ....................................................................................................... 47
6.10 BODIES .............................................................................................................................................. 47
6.11 DISC AND SHAFT ............................................................................................................................ 47
6.12 SEATING AND LININGS ................................................................................................................. 47
6.13 BEARINGS ......................................................................................................................................... 48
6.14 MATERIALS ...................................................................................................................................... 48
6.15 OPERATION ...................................................................................................................................... 48
6.16 TESTING ............................................................................................................................................ 49
6.18 FIXING OF VALVES ........................................................................................................................ 52
7 AIR VALVE ................................................................................................................................................. 53
7.1 TYPE OF AIR VALVE ...................................................................................................................... 53
7.2 JOINTING MATERIAL ..................................................................................................................... 55
7.3 BALL .................................................................................................................................................. 55
7.4 HIGH PRESSURE ORIFICE.............................................................................................................. 56
7.5 INSPECTION AND TESTING AT MANUFACTURER’S WORKS ............................................... 57
8 Pressure Reducing Valve .............................................................................................................................. 58
8.1 Testing................................................................................................................................................. 58
8.2 Marking ............................................................................................................................................... 59
9 EXPANSION BELLOW .............................................................................................................................. 59
9.1 GENERAL .......................................................................................................................................... 59
9.2 OPERATING PRINCIPLES ............................................................................................................... 59
9.3 TESTING ............................................................................................................................................ 59
10 ELECTRICALLY OPERATED TRAVELLING CRANE AND HOIST ............................................... 62
10.1 CRANE & HOIST .............................................................................................................................. 62
10.2 ELECTRICALLY OPERATED HOIST ............................................................................................. 65
10.3 ELECTRICAL REQUIREMENTS..................................................................................................... 67
10.4 PENDANT CONTROL ...................................................................................................................... 68
10.5 TESTING AND INSPECTION AT MANUFACTURER'S WORKS ................................................ 68
10.6 TESTS AT SITE ................................................................................................................................. 68
11 Location : Pump house ........................................................................................................................ 69
11. WALL THIMBLE MOUNTED C. I. SLUICE GATES ..................................................................... 71
11.1 SPECIFICATION ............................................................................................................................... 71
11.2 APPLICATION .................................................................................................................................. 71
11.3 SALIENT FEATURES: ...................................................................................................................... 71
11.4 SHOP TESTING PARAMETERS: .................................................................................................... 73
11.5 STANDARD PAINTING: .................................................................................................................. 73
11.6 MATERIAL OF CONSTRUCTION: ................................................................................................. 73
12 PIPES AND SPECIALS .......................................................................................................................... 74
12.1 GENERAL .......................................................................................................................................... 74
13 MS ERW (ELECTRIC RESISTANCE WELDED) PIPES ................................................................ 76
13.1 SCOPE ................................................................................................................................................ 76
13.2 CODES AND STANDARDS ............................................................................................................. 76
13.3 GENERAL .......................................................................................................................................... 78
13.4 MANUFACTURING .......................................................................................................................... 78
13.5 DESIGNATION.................................................................................................................................. 78
13.6 DIMENSIONS .................................................................................................................................... 79

13.7 CHEMICAL COMPOSITION ............................................................................................................ 79

13.8 PRODUCT ANALYSIS ..................................................................................................................... 79
13.9 TEST ON PIPES / TUBES ................................................................................................................. 79
13.10 COATING........................................................................................................................................... 80
13.11 INFORMATION TO BE SUPPLIED BY THE PURCHASER WHILE PLACING ORDER .......... 80
13.12 MARKING.......................................................................................................................................... 81
13.13 PROTECTION AND PACKING........................................................................................................ 81
14 INSTALLATION, TESTING AND COMMISSIONING ...................................................................... 82
14.1 ERECTION - GENERAL ................................................................................................................... 82
14.2 LEVELING AND GROUTING OF MACHINERY .......................................................................... 83
14.3 RECORDS, PROCEDURES AND REPORTS .................................................................................. 84
14.4 GENERAL PREPARATIONS BEFORE COMPLETION OF THE PLANT .................................... 85
14.5 COMPLETION OF ERECTION ........................................................................................................ 86
14.6 PRE-COMMISSIONING ................................................................................................................... 88
14.7 COMMISSIONING ............................................................................................................................ 91
15 INSPECTION AND TESTING AT MANUFACTURER’S PREMISES ............................................... 93
15.1 GENERAL .......................................................................................................................................... 93
15.2 INSPECTION AND TESTS ............................................................................................................... 96
16 T ECHNICAL SPECIFICATION OF MOTORS ................................................................................. 100
16.1 H T MOTORS ................................................................................................................................... 100
17 INSPECTION AND TESTING AT MANUFACTURER’S PREMISES ............................................. 108
17.1 QUALITY ASSURANCE PLAN, TESTING & INSPECTION OF MOTOR ................................. 108
17.2 GENERAL CONDITIONS ............................................................................................................... 109
17.3 ROUTINE TEST............................................................................................................................... 110
17.4 TYPE TEST ...................................................................................................................................... 111
18 SURGE CONTROL SYSTEM FOR PUMPING MAIN ...................................................................... 122
18.1 ACCEPTED CONTROL SYSTEM.................................................................................................. 122
18.2 WATER HAMMER CONTROL ...................................................................................................... 123
18.3 SURGE CONTROL SYSTEM - REQUIREMENTS ....................................................................... 124
19 FIRE FIGHTING SYSTEM .................................................................................................................. 125
ABBREVIATION .............................................................................................................................................. 132
20 DATASHEET ....................................................................................................................................... 134

Uchchal,Songadh and Nizar Lift Irrigation Scheme
1 GENERAL
These General Mechanical and Electrical Technical Specifications are meant to

amplify the specifications and General Conditions of Contract. If any
discrepancy is noticed between these conditions, General Conditions of
contract, specifications, Bills of Quantities and Drawings the most stringent of
the above shall apply.
All electrical & mechanical installations shall be of high quality, safe, durable,
complete and fully operational including all necessary items, spares and
accessories whether or not specified in detail. All electrical & mechanical work
shall be completed in accordance with the regulations and standards to the
satisfaction of the inspection agency authorized by owners. The general
provisions, special provisions and general requirements apply to all sections of
this specification.
The contractor shall be fully responsible for the maintenance of electrical,

mechanical & other installations till the entire work covered by this contract is
satisfactorily completed by him and handed over to the owner.
1.1 ACCOMPANIMENT TO BID
The Contractor will attach to the bid, at the time of submission technical
schedules provided by BID documents.
1.2 INTENT
It is the intention of the specification and drawings to design, supply, and

installation, testing and commissioning and ready for use for continuous
dependable and satisfactory operation.
1.3 INTERPRETATION OF PROJECT DOCUMENTS
The specifications and price schedule shall be considered as part of this

contract and any work or material shown on price schedule and not called for
4
in the specification or vice versa shall be executed as if specifically called in for

both. The drawings indicate the extent and general arrangement of the
machineries, equipments, apparatus, fixtures, controlling switches, wiring
system etc. and are essentially diagrammatic. The drawings indicate the points
of termination of conduit runs and broadly suggest the routes to be followed.
Machinery and equipment shall be installed as indicated on the drawings.
However, any minor changes found essential to coordinate the installations of
this work with other services shall be made without any additional cost to the
owner. The drawings are for the guidance of the contractor. Exact locations
distances and levels will be governed by the building. The contractor shall
examine all civil, structural, mechanical and electrical drawings before starting
the work and report to the Department any discrepancies which in his opinion
appear on them and get them clarified.
1.4 SCOPE OF Specification
These specifications cover design, manufacture, factory testing, supply,

delivery to site, unloading. handling and storage to site, complete installation
including cement concrete foundation wherever necessary, final checkup,
painting, performance testing and commissioning of pumping machinery and
related electrical equipments and accessories to be supplied under these
specifications on turnkey basis, to achieve a guaranteed co-ordinate
commercial operation of the same to the entire satisfaction of the department.
Any item of work, either supply and/or erection of material/machinery which

have not been specifically mentioned in this specification and drawing but are
necessary to complete the work for trouble free, efficient operation and
guaranteed performance of the entire plant offered shall be deemed as included
within the scope of this specification and shall be provided by contractor
without any extra cost to the client.
The following mechanical and electrical equipments are to be covered under

this contract.
a) Vertical Turbine (VT) Pumps & Motors
b) Pipes and Fittings
c) Valves - (i) Sluice / Gate / Butterfly valves (b) Non Return Valves (c) Air
Valves / Air Cushion Valves / Zero Velocity Valves
5
d) E.O.T. Crane of required capacity

e) Expansion Bellows
f) De-watering Pumps
g) Trash Racks / Screens at in-let to the water sump
h) Low voltage switch gear and control gear
i) Distribution board
j) Power and control cables
k) Lighting system
l) Earthing
1.5 AMBIENT CONDITION
The equipments are to be operated in tropical climate with high ambient

temperature up to 50o C. So the equipment shall be so designed that it will be
suitable to operate under tropical climate with high humidity, dust and fungus
condition.
1.6 RATING
Rating of all items shall be appropriate for the condition on the particular site
on which the items will be used.
The rating of all electrical equipments / components shall be for three phase
415 V, 50 Hz AC supply with the following variations:
a. Voltage variation +/- 10%
b. Frequency variation +/- 5%
c. Combined variation +/- 10%
The rating shall be as per manufacture's printed literature and drawings and
as per latest Indian Standards, IE rules and Power supply authority conditions
for power supply prevailing at the location.
1.7 REGULATIONS AND STANDARDS
The installation shall conform in all respects to Indian Standard Code of

Practice for pumping machinery and electrical equipment installations. It shall
6
also be in conformity with the current Indian Electricity rules, Indian

Electricity Act, National Electrical code and Regulations of the local Electrical
Supply Authority in so far as these become applicable to the installation.
Wherever these specifications call for a higher standard of material and /or
workmanship than those required by act of the above regulations, then these
specifications shall take precedence over the said regulations and standard. In
general, the material, equipment and workmanship not covered by the above
shall conform to the relevant Indian Standards.
The electrical installation work shall follow codes of the Indian standard
specifications and Rules (within the best meaning of the same) under this
contract.
The machinery, equipment, component and material shall conform to the latest
revision of the following standards:
1.8 LIST OF APPLICABLE INDIAN STANDARD AND CODE OF PRACTICE
SR. STANDARD NO. TITLE

NO.
1. IS – 5 Colors for ready mixed paints and enamels.
2. IS – 104 Ready mixed paint, brushing, zinc chrome, priming.
3. IS – 158 Ready mixed paint, brushing, bituminous, black,
lead free, acid, alkali and head resisting.
4. IS – 325 Three phase induction motors.
5. IS – 335 New insulating oils.
6. IS – 375 Marking and arrangement for switch gear, Bus bars
main connection and auxiliary wiring.
7. IS – 613 Specification for copper rods and bars for electrical
purpose
8. IS – 694 PVC insulated cables for working voltage up to and
including 1100 V.
9. IS – 722 AC Electricity meters
10. IS – 732 (part I) Code of practice for electrical wiring installations
11. IS – 807 Code of practice for design, manufacture, erection
and testing (structural portion) of cranes and hoists
12. IS – 816 Code of practice for use of metal arc welding for
general construction in mild steel
7
13. IS – 900 Code of practice for installation and maintenance of

induction motors.
14. IS – 1239 Mild steel tubes, tubular and other wrought steel
fittings
15. IS – 1248 (Part I & Direct acting indicating analogue electrical
II) measuring instrument and their accessories.
16. IS – 1271 Electrical insulation classifies by thermal stability
17. IS – 1520 Horizontal split casing centrifugal pump for clear,
cold and fresh water
18. IS – 1554 (Part I & II) PVC insulated electrical cables (heavy duty)
19. IS – 1651 Stationary cells and batteries, lead acid type (with
tubular positive plates)
20. IS – 1710 Vertical turbine pumps for clear, cold, freshwater.
21. IS – 1866 Insulating oil in service, code of practice for
maintenance and supervision of.
22. IS – 2026 (Part Ito V) Power Transformers
23. IS – 2062 Steel for general structural purposes.
24. IS – 2071 (Part I to High voltage testing method
Ill)
25. IS – 2099 Bushings for alternating voltage above 1000 V.
26. IS – 2121 (Part l to Conductors aid earth wire accessories for overhead
lV) power lines.
27. IIS – 2147 Degrees of protection provided by enclosures for low
voltage switchgear and control gear
28. IS – 2253 Designation for types of construction and mounting
arrangements of rotating electrical machines.
29. IS – 2309 Code of practice for the protection of buildings and
allied structures against lightning.
30. IS – 2486 (Part I) Metal fittings for overhead power lines with a
nominal voltage greater than 1000 volts.
31. IS – 2544 Porcelain post insulators for systems with nominal
voltage greater than 1000 volts.
32. IS – 2551 Danger notice plates.
33. IS – 2629 Recommended practice for hot dip galvanizing on
iron and steel.
34. IS – 2633 Hot dip galvanizing
8
35. IS – 2667 Fittings for rigid steel conduits for electrical wiring.
36. IS – 2675 Enclosed distributions fuse boards and cutouts for
voltage not exceeding 1000 volts.
37. IS – 2705 (Part I to Current transformers
IV)
38. IS – 2834 Shunt capacitors for power systems.
39. IS – 3043 Code of practice for Earthing
40. IS – 3070 (Part I & Lightning Arrestors for AC system.
III)
41. IS – 3156 (Part I & Voltage transformers
IV)
42. IS – 3177 Code of practice for electric overhead traveling
cranes and gantry cranes other than steel work
cranes
43. IS – 3427 Metal enclosed switch gear and control gear for
voltage above 1000 v but not exceeding 11000 v.
44. IS – 3452 Toggle switches
45. IS – 3589 Seamless or Electrically welded steel pipe
46. IS – 3624 Vacuum and pressure gauges
47. IS – 3637 Buchholz relay
48. IS – 3639 Fittings and accessories
49. IS – 3835 Aluminized steel core wire for Aluminum
conductors (ACSR)
50. IS – 3938 Electric wire rope hoists
51. IS – 3961 (Part II) Recommended current ratings for cables
52. IS – 4029 Guide for testing three phase induction motors
53. IS – 4064 Switch fuse unit
54. IS – 4137 Code of practice for heavy duty electric overhead
traveling cranes including special service machines
for use in steel work.
55. IS – 4237 General requirements for switch gear and control
for voltage not exceeding 1000 volts.
56. IS – 4691 Degree of protection provided by enclosures for
rotating electrical machinery.
57. IS – 4722 Rotating electrical machines.
58. IS – 4728 Terminal marking and direction of rotation for
9
rotating electrical machinery.

59. IS – 4759 Hot dip galvanizing
60. IS – 4889 Method of determination of efficiency of rotating
electrical machines.
61. IS – 5504 Spiral welded pipe
62. IS – 5039 Distributions pillars for voltage not exceeding 1000
v.
63. IS – 5082 Wrought aluminum and aluminum alloy bars, rods,
tubes and sections for electrical purposes.
64. IS – 5216 Guide for safety procedures and practices in
electrical work.
65. IS – 5312 Swing type Non return valve
66. IS – 5578 Guide for marking of insulated conductor.
67. IS – 5831 PVC insulation and sheath of electric cables.
68. IS – 6005 Code of practice for phosphate of iron and steel.
69. IS – 6346 Specification for PVC insulated cables for electricity
supply
70. IS – 6362 Designation of methods of cooling of rotating
electrical machine.
71. IS – 6474 Polyethylene insulation and sheath for electric
cables
72. IS – 6511 Range of preferred safe working loads for cranes,
lifting appliances and related excavators equipment.
73. IS – 6595 Horizontal centrifugal pump for clear, cold and
fresh water
74. IS – 6600 Loading of oil immersed transformer
75. IS – 6792 Method for determination of Electric strength of
insulating oils
76. IS – 6875 Control switches for voltage up to and (part I to III)
including 1000 V AC and1200 VDC
77. IS – 7098 (Part I & II) Cross linked polyethylene insulated PVCs Sheathed
cables for working voltages from 3.3 KV up to and
including 33 KV
78. IS – 7421 Bushings for </= 1000 V
79. IS – 7538 Three Phase squirrel cage indications motor for
centrifugal pumps for agricultural application.
10
80. IS – 8061 Code of practice for design, installation and

maintenance of service lines up to and including
650 v.
81. IS – 8084 Inter connecting Bus bars for A.C. voltage above
1KV Up to and including 36 KV.
82. IS – 8130 Conductors for insulated electric cables and fixable
cords.
83. IS – 8197 Terminal marking for electrical measuring
instruments and their accessories
84. IS – 8309 Compression type tubular terminal ends for
aluminum conductors of insulated cables.
85. IS – 8923 Warning symbol for dangerous voltage
86. IS – 9046 AC contractors of voltage above 1000 V up to and
including 11 KV.
87. IS – 9137 Code of acceptance test for CF pumps
88. IS – 9224 Low voltage fuses.
89. IS – 10001 Performance requirements for constant speed
compression ignition (diesel) engines for general
purposes (up to 20 KW)
90. IS – 10028 Code of practice for selection installation (Part I to
III) and maintenance of transformers.
91. IS – 10234 Pipeline Welding
92. IS – 10418 Specification for drums of electric cables
93. IS – 10748 Hot-Rolled steel strip
94. IS – 10810 Methods for test for cables
95. IS – 11346 Testing of agricultural pump
96. IS – 12661 High voltage motor starter (D.O.L)
97. IS – 12672 Internal fuses and internal overpressure
disconnections for shunt capacitors
98. IS – 12776 Galvanized strand for Earthling
99. IIS – 13095 Wafer type butterfly valve size from 40 mm to 2000
mm
100. IS – 13118 High Voltage AC circuit Breakers.
101. IS – 13349 Cast iron single faced thimble mounted sluice gates
102. IS – 13947 (Part I to Low voltage switchgear and control gear
V)
11
103. IS – 14845 Air Relief Valves

104. IS – 14846 Non rising stem type sluice valve size from 50 mm
to 1200 mm
105. IS – SP: 30-1984 National Electrical code.
106. ASME (Section –ix) Non Destructive Test
107. API 1104 Pipeline Works
108. AWWA C 512 Air Relief Valves
1.9 MATERIAL AND EQUIPMENT
All material and equipment shall conform to the relevant Indian standards and
shall be of the approved make and design. The contractor shall be responsible
for the safe custody of all the materials and shall insure them against theft,
damage by fire, earthquake etc. A list of items of materials and equipment
together with sample of each shall be submitted to the Engineer-In-Charge
within 15 days of the award of the contract. Any item which is proposed as a
substitute shall be accompanied by all technical detail giving sizes, particulars
of materials and the manufacturer's name and shall be submitted along with
the bid offer. At the time of the submission of proposed substitute the
contractor shall state the credit, if any due to the client’s. In the event, the
substitution is approved all changes and substitutions shall be requested in
with detail justifications and approvals obtained in writing from the Engineer-
In-Charge. Decision of Engineer-In-Charge in the matter shall be final.
All materials of the same kind of service shall be identical and made by the
same manufactures. Any deviation to this rule shall be got approved from the
Engineer-In-Charge. Top priority shall be given to the products that have a
permanent agent providing spare parts and maintenance facilities in the same
city where the project is situated.
1.10MANUFACTURERS
Where manufacturers are furnished specific instructions relating to the
materials used in this job, covering points not specifically mentioned in these
documents, these instructions shall be followed in all cases.
12
Where manufacturer's names and/or catalogue numbers are given this is an

indication of the quality standards and performance required.
Where interfacing occurs, equipment shall be mutually compatible in all
respects.
1.11INSPECTION AND TESTING
The Engineer-In-Charge reserves the right to inspect and test at

manufacturer's works at all reasonable times during manufacture of items
included in this contract. Tests on site of completed works shall demonstrate
among other things.
a) That all items operate efficiently and quietly to meet the specified
requirements.
b) That all circuits are correctly fused and protected and that all protective
devices are properly coordinated.
c) That all non current carrying metal work is properly and safely grounded in
accordance with the specifications.
d) While testing any machineries/equipments at manufacturers/contractor's
place the Engineer-In-Charge shall reserve the right to check/calibrate all the
measuring devices.
The contractor shall provide all necessary instruments and labor for testing
and shall make adequate records of test procedures and readings and shall
repeat any tests requested by the Engineer-In-Charge and shall provide test
certificates signed by a properly authorized person. Such test certificates shall
cover all works.
If tests fail to demonstrate the satisfactory nature of the installation or any
part thereof then no claims for the extra cost of modifications, replacements or
retesting will be considered. The Engineer-In-Charge decision as to what
constitutes a satisfactory test shall be final.
The above general requirements as to testing shall be read in conjunction with
any particular requirements specified elsewhere.
e) All materials, components and equipments covered in this specification shall
be procured, manufactured, erected, commissioned and tested at all the stage
as per comprehensive quality assurance programmed drawn in with IS -
9000A.
This is however, not intended to form a comprehensive programmed as it is the
contractor's responsibility to draw up and implement such programmed duly
13
approved by the Engineer-In-Charge. The detailed quality plans for

manufacture and field activities should be drawn up by the Contractors
separately in the prescribed format and signed by TPI will be submitted to
Engineer-In-Charge for his approval.
f) Manufacturing quality plan will detail out for all components and equipments,
various test/inspection be carried out as per the requirements of specification
and standard mentioned there in quality practices and procedures followed.
Contractor's quality control organization, the relevant reference documents
and standards, acceptance norms, inspection documents raised etc. during all
stages of material procurement, manufacture, assembly and final testing /
performance testing.
g) Field quality plans will detail out for all the equipments the quality practices
and procedure etc to be followed by contractor's site quality control
organization, during various stages of site activities from receipt of materials /
equipments at site.
h) The Contractors shall also furnish along with the quality plan copies of the
reference documents/ plant standards / acceptance norms/test and
inspection procedure etc as referred in them. These quality plans and reference
documents / standards etc shall be subject to Engineer-In-Charge approval,
without which manufacture shall not proceed. These approved documents
shall form a part of the contract. In these approved quality plans, owner shall
identify customer hold points(CHP), test/checks which shall be carried out in
presence of TPI and the Engineer-In-Charge or his representative beyond
which work shall not proceed without approval of Engineer-In-Charge in
writing.
All deviations to these specifications, approved quality plan and applicable
standards must be documented and referred to Engineer-In-Charge or his
representative along with technical justification for approval.
i) No materials/ equipments shall be dispatched from the manufacturer's works
before the same is either accepted subsequent to pre-dispatch final inspection
(including verification records of all previous test/inspection) by Engineer-In-
Charge or his representative or such pre-dispatch final inspection is waived by
the Engineer-In-Charge.
All material used or supplied shall be backed up by valid material certificate
and test reports. These certificates and reports shall indicate the hit numbers
or other such acceptable identification numbers of the material they purport to
14
certify. The material certified shall also have the identification details stamped
on it.
j) All material used for equipment construction including casting and forging etc
shall be of tested quality as per relevant codes/standards. Details of results of
the test conducted to determine the main properties, chemical analysis and
details of treatment procedure recommended and actually it shall be recorded
on certificates. Tests shall be carried out as per applicable materials standard
agreed details.
k) No welding shall be carried out on iron component for repair or whatsoever
purposes.
All the sub vendors proposed by the contractor for procurement of major
bought out items including castings, forging, semi finished and finished
components/equipment-(list of which shall be drawn by the contractor,
submitted to and finalize by the Engineer-In-Charge shall be subject to
Engineer-In-Charge’s approval.
l) The contractor shall undertake an inspection, testing programming during
manufacture in his work that of his sub contractor's to ensure the mechanical
accuracy of components, compliance with drawing conformance to functional
and performance requirements acceptability of all materials, parts and
equipments correlation of its identity with test certificate shall carry out all
test/inspection required establish that the items/equipments conform
requirements of this specification and the relay codes/standards specified in
this specification in addition to carrying out tests as per the approval.
1.12RECTIFICATION AND TAKING OVER

The contractor shall carry out all rectifications, repairs or adjustment work
found necessary during performance testing, commissioning and trail run.
On successful commissioning and trial run and on carrying out the
rectification work, the Engineer-In-Charge will take over the installation either
wholly or in part as the case may be. Unless otherwise specified, the work,
material and accessories shall confirm to the latest applicable Indian standard.
1.13COMPLETION CERTIFICATE
On completion of the electrical and mechanical installation (or an extension to
an installation) a certificate shall be furnished by the contractor countersigned
by the licensed supervisor, under whose direct supervision the installation was
carried out. This certificate shall be in the prescribed form as required by the
15
local authority. The contractor shall be responsible for getting the installation
inspected and approved by the local concerned authorities.
1.14PRICE DETAILS
At anytime and at the request of the Engineer-In-Charge, the contractor shall

provide details or break up of costs and prices of any part or parts of the work.
1.15TEST CERTIFICATES
The contractor shall submit valid test certificates for all the electrical and
mechanical plant, equipment material/system. These shall be issued by a
Government recognized inspection office certifying that all equipments,
materials, construction and functions are in agreement with the requirements
of these specifications and accepted standards.
1.16INSTRUCTION MANUAL
The contractor shall prepare instruction manuals in English, on operation,

preventive maintenance and repairs of pumping machinery, mechanical and
electrical equipments supplied and submit 5 copies of the same to the
Engineer-In-Charge at the time of handing over.
1.17AS BUILT DRAWINGS
At the completion of work and before issue of certificate of virtual completion

the contractor shall submit to the Engineer-In-Charge layout drawing drawn at
appropriate scale indicating the complete electrical and mechanical system "As
Installed" These drawings must provide:
a) Run, location and size of conduits. Inspection, junction and pull boxes.
b) Number and size of conductors in each conduit.
c) Location and rating of sockets and switches containing the light and power
outlets.
d) Location and details of distribution boards switch gear and other
particulars.
16
e) A complete wiring diagram as installed and scheduled drawings showing all

connections in the complete electrical system.
f) Location of outlets, junction boxes, sizes of various conduits for telephone,
clock system, fire alarm, sound system and all other extra low voltage
system.
g) Location of all earthing stations, route and size of all earthing conductors,
manholes etc.
h) Route and particulars of all cables.
i) Pumping machinery dimensional layout drawings in pump house.
j) EOT and EOH with electrical hoist drawings.
k) Pumps dimensional drawings, cross sectional drawings, foundation
drawings, supply location, Valves dimensional cross sectional drawings
complete with details.
1.18SPARE PARTS
The Contractor shall indicate and include, in the supply all the necessary
commissioning spares, mandatory spares and recommended spares in the
schedule of spare parts. The Engineer-In-Charge reserves the right to finalize
the exact quantities of the spare parts and effect price adjustment on the basis
of the rates quoted by the Contractor. The spare ordered by Engineer-In-
Charge shall be delivered at the site at agreed delivery schedule.
1.19COMMISSIONING SPARES
a) It will be the responsibility of the Contractor to draw and furnish a list of all
commissioning spares required for successful commissioning of the equipment
covered under the contract. Such list shall be furnished by the contractor
within four months of the date of LOA, separately for all equipments and shall
be reviewed by Engineer-In-Charge and discussed for mutual agreement. The
commissioning spares will be so identified as to allow the trial operation not to
suffer for want of commissioning spares. The identification of commissioning
spare will not in any way relieve the vendor any of its responsibilities of
satisfactory performance under the provisions of other condition of contract.
All the commissioning spares shall be deemed to be included in scope of the
contractor as a part of the respective equipment package at no extra cost to
owner.
17
b) All such identified spares shall be supplied by contractor at least two months
before the schedule date of commencement of trial operation of the respective
package. Such spare shall be received and stored.
1.20Packing and Preservation
a) Each spares shall be clearly marked or labeled on the outside of the packing
with its description. When, more than one spare-part is packed in a single
case, a general description of the contents shall be shown on the outside of
such case and a detailed list enclosed. All cases, containers and other
packages must be suitably marked and numbered for the purposes of
identification.
b) All cases, containers or packages are liable to be opened for such examination
as may be reasonable by the engineer.
c) In case of equipment supplied with grease/lubricants from imported origin, the
supplier shall clearly indicate the indigenous equivalent of the
grease/lubricant and source of supply so as to enable to owner to procure
these items from indigenous sources. Necessary initial filling of lubricating oil,
grease etc. shall be arranged by the contractor with no extra cost to client.
1.21PAINTING
All metallic surfaces equipment and components shall first be thoroughly

cleaned, degreased and phosphate and then be given two coats of zinc primer
and in then the surface shall be coated, painted with approved shade of paint.
The resulting coating shall be uniform and smooth and shall adhere perfectly
to the surface.
2 VERTICAL TURBINE PUMPS (VT PUMPS)

2.1 SCOPE
The pumps shall be designed in such a way that it shall be lift the water up to design
head by single pump operation in case of less water demand
This specification covers the design, performance, manufacturing, construction

features, testing, delivery, installation and commissioning of vertical turbine
pumps at Pumping Station with suction strainer, bell mouth, column
18
assembly, discharge elbow, motor stool, thrust bearing, (in pump or in motor
or in pump and motor as per pump manufacturers) non reversing device etc.
2.2 CODES & STANDARDS
The design, manufacturing, performance of vertical turbine pumps shall

comply to all currently applicable statutes, regulations and safety codes in the
locality where the equipment will be installed. The equipment shall conform to
IS 1710 (latest edition) or International Standard, whichever is better. The
performance test shall be carried out as per IS 10981 Class - B.
2.3 DESIGN FEATURES

The vertical turbine pump shall be capable of developing the specified
required total flow & head at duty point at 50 Hz (rated frequency) for
continuous operation.
a) The pumps will be required to work satisfactorily in the entire operating
range, while operating in solo as well as in any combination for parallel
operation. The pumps of a particular category shall be identical & shall be
suitable for parallel operation with equal load sharing. Components of
identical pumps shall be interchangeable.
b) The pump characteristics shall be of stable nature and such that efficiency
is fairly constant for the operation under varying water levels as specified.
The best efficiency point of pump should be near to specified duty point.
c) The head capacity curve should be continuously rising towards shut off with
highest at shut off. The pump curve should be of non overloading type. The
pump-set should be designed to operate up to a period of 5 minutes at shut
off head without causing any damage to pump set. The shut-off head should
not be less than 115 % of the total head of the pump.
d) NPSH required by pumps offered should be lesser by at least 0.5 M than

NPSH available at any point of operation in the entire range with solo and
parallel operation.
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e) The pumps shall be suitable for nonstop continuous 24 hour’s operation

without interruptions. However, the actual hours of operation per day shall
be as per the approved design report of the system.
f) The impeller adjustment shall be such that the impeller runs free in any
installed condition despite extension of line shaft (caused by hydraulic down
thrust, the weight of shafting and weight of impellers).
g) The rating of the motor, driving the pump, shall have the power sufficient to
drive the pump throughout the entire range of head capacity curve.
h) Necessary lifting arrangement on equipment shall be provided for easy

handling of the Pumps & Motors.
i) The pump shall be designed considering raw water above 500 NTU. The
pump shall be lubricated by external forced water lubrication system as
specified irrespective of site conditions. Also, strainer of suitable size to
allow pump to operate in flood water condition on monsoon must be
provided.
j) The velocity of vibration shall be limited to 3.0 mm/sec at the thrust

bearing. The noise level measured at pump, motor & discharge head shall be
limited to 85 db at a distance of 1.86 meters. The pump discharge head
shall be of MS fabricated or CI construction & suitably reinforced to
withstand all types of static dynamic loads, torsion loads etc. & design shall
be rugged to limit vibrations within acceptable limits. The pump discharge
head/ motor stool shall be suitable to accommodate thrust bearing with
cooling arrangement & contain stuffing box with mechanical seal. A
sufficient opening should be provided between adjacent pump-sets so as to
have easy access & working on thrust bearing & stuffing box.
k) The Thrust Bearing shall be of heavy duty tilting pad type. The bearing shall
be designed to withstand all the loads under normal operation & shut off &
shall be suitable for reverse rotation. The bearing should be oil lubricated
type and shall be provided with an oil level indicator & a local as well as
remote temperature measuring and indication arrangement. The Thrust
Bearing shall have water cooling system preferably in the oil bath or
alternatively through a suitable cooling water jacketing arrangement. The
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following shall be provided as minimum requirement. (a) Temperature probe

suitable for dial type thermometer. (b) RTD for use with temperature
scanner with an indication/ annunciation/ tripping protections in the PLC
panel.
l) The Cooling Water supply for the thrust bearing shall be of clean water and
may be taken from a tapping from pump discharge line with a suitable
replaceable water filtering arrangement. The life of thrust bearing shall not
be less than 75,000 hours of operation.
m) The Clearance between strainer & sump bottom, between adjacent pumps,
as well as clearance from side walls should be such that the vortex free
operation is ensured. Static balancing test shall be carried out.
n) The line shaft bearing shall be having a forced water lubrication system. A
suitable overhead tank, forced water lubrication water pumps and necessary
filtering arrangements shall be provided for this purpose.
2.4 FEATURES OF CONSTRUCTION
a) GENERAL
i. Pumps shall be of vertical turbine type complete with bowl and column
assemblies, suction strainer, bell mouth, discharge elbow, motor stool,
thrust bearing etc.
ii. Suction strainer shall be designed with a net opening area not less than 4
times the area at suction bell mouth diameter. Pump shall work
satisfactorily even when strainer gets clogged up to 50%.
iii. The bowl assembly shall consist of a rotating impeller/ impellers housed
in a stationery bowl/ bowls having fixed guide vanes. The bowl/ bows
shall also include the housing of the pump shaft bearing.
iv. The column assembly shall consist of a column pipe/ pipes to convey the
liquid handled from bowl assembly to column assemblies and shaft
bearings, discharge elbow.
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v. Generally, the VT pump discharge shall be located in the discharge head

and shall be taken out from the upper side of the supporting floor of the
discharge head, unless otherwise specified.
vi. The Successful bidder /Contractor has to carry out CFD (Computational
Fluid Dynamics) analysis of pump sump house through pump
manufacturer to predict the flow characteristics and shall satisfy to owner
for vortex free flow for Pump house.
b) SUCTION STRAINER
i. Each pump shall be provided with a suitable suction strainer to prevent

entry of foreign materials and debris which can damage the pump. The
strainer shall be fabricated from SS 304. The net opening area of the
strainer shall be at least 4 times the area at suction diameter of the bell
mouth. It shall be designed such that, it will cause minimum choking or
clogging.
c) BOWLS
i. The bowls shall be of Cast Steel material and shall be free from blow holes
and other detrimental defects. The surface shall be smooth.
ii. The bowl assembly shall be equipped with replaceable wearing rings.
Liquid passage shall be smooth finished and the bowl shall contain bushes to
serve as bearings for the impeller shaft.
iii. The pump shall be painted from inside and outside with anti corrosive
primer and epoxy based paint.
d) IMPELLER
i. The impeller shall be of S.S. CF8M, Semi open or enclosed type and shall
be properly balanced dynamically. The impeller shall be properly
machined, with finished liquid passages. They shall be adjustable
vertically by means of an adjusting nut in the head assembly.
22
ii. Impeller shall be securely fastened to the impeller shaft with keys, and
lock-nuts.
iii. To avoid any internal resonance, the number of vanes on diffuser shall not
be equal to or be a multiple or number of vanes on the impeller.
e) IMPELLER SHAFT
i. The impeller shaft shall be made of hardened stainless steel SS-410. It

shall have a surface finish between 0.75 microns or less. The butting faces
of the shaft shall be machined square to the axis and the shaft ends &
shall be chamfered on the edges.
ii. The shaft shall be straight and the shaft deflection shall be within 0.125
mm (total dial indicator reading) for maximum 3 meter length of the shaft.
f) LINE SHAFT
i. The size of the shaft shall be calculated on the basis of maximum

combined shear stress. This shall not exceed 30% of the elastic limit, in
tension or 18% of the ultimate tensile strength.
ii. The design of the shaft shall also take into consideration the critical speed
of the shaft which shall not coincide with the operating speed.
iii. The shaft shall be furnished with interchangeable sections having a

nominal length equal to column pipe length. The maximum permissible
error in the axial alignment of the coupling axis with the axis of the shaft
shall be 0.05 mm in 150 mm.
iv. Shaft shall be provided with shrunk or snug fitted shaft sleeves of
compatible wear/ corrosion resistant material precision ground and
polished where pass through bearings.
g) LINE SHAFT COUPLING
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Couplings shall be designed with a minimum safety factor of 1.5 times the
shaft factor.
h) LINE SHAFT BEARINGS
Bearings shall be of thordon type integral with replaceable sleeves of metallic

material with suitable securing arrangement in the bearing housing.
Lubrication shall be by a external forced water lubrication system.
i) COLUMN PIPE
i. The standard lengths of the column pipe shall be maximum 2.5 meters.
The column pipe shall be of welded flanged design.
ii. The velocity of water in column pipe shall not exceed 2.5 M/Sec at rated
discharge.
iii. The size of column pipe shall be such that friction loss will be limited to
0.5 m for every 10 m length of column.
j) DRIVER
Driver shall be coupled through flexible or rigid coupling to the head shaft.
k) THRUST BEARING
Pump design with single thrust bearing at motor top or separate thrust bearing
for pump and motor. In case the thrust bearing is located in the pump, the
coupling shall be flexible type in such case.
2.5 TESTS AND INSPECTION
a) PRE –MANUFACTURING INSPECTION / DOCUMENTS
i. Pump manufacturer will submit - (i) Test setup and test procedure (ii)
Details of instrumentation along with their least counts and calibration
certificates before commencing manufacturing/testing as per IS 10981CL
B.
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ii. Engineer In-charge will depute his representative to inspect the test setup.
iii. Only after finalization/ acceptance of test setup and test procedures, the
manufacturer will commence manufacturing/testing.
b) HYDROSTATIC TEST
i. A standard hydrostatic test shall be conducted on all pump columns;

discharge elbow and bowl assemblies at 1.5 times the maximum discharge
pressure of the pump or twice the rated pressure, whichever is higher.
ii. The hydrostatic test shall be conducted for a minimum duration of 30
minutes.
c) PERFORMANCE TEST
Performance Test will be carried out as per IS 10981 (Class B). Performance
test at rated speed shall be conducted at manufacturer’s works in presence of
third party inspection agency appointed by department / TPI or Engineer-in-
charge representatives for all pumps with one type tested job motor. No
negative tolerance on bowl efficiency, overall pump efficiency as well as
capacity & head will be permitted.
The performance test shall include determination of head, discharge, power &
efficiency over the entire range from shut off to full valve open condition. At
least 6 different readings need to be taken in addition to shut off & duty point.
The minimum submergence test shall be carried out at manufacturer’s work

i.e. the value of minimum submergence available at site should be simulated (i.e.
water level above impeller eye) & it should be demonstrated that the pumps run
satisfactory & without any vibrations or cavitations or any other harmful effects at
this level. At least one pump of each type will be subjected to minimum
submergence test.
All the instruments used for testing should be calibrated & latest available
calibration certificates are to be submitted before testing. Also the test set up & test
procedure shall be submitted for Engineer’s approval before testing.
The vibrations & noise levels shall be recorded at manufacturer’s works.
25
d) STANDARD RUNNING TEST
i. Bowl assemblies shall be given running test over the full operating range,
covering from free discharge with delivery valve fully open to the shut off
head. The duration of tests shall be minimum one hour. A minimum of six
readings apart from duty point and shut off readings shall be taken for
plotting the performance curves.
ii. The pump shall be tested for parallel operation at site. The pumps should
work satisfactorily in parallel operation with equal load sharing. The
velocity of vibrations shall be limited to 3.0 mm/sec at motor non driving
bearing top & noise level should not exceed 85 db at a distance of 1.86
meters.
e) Impeller shall be dynamically balanced at rated or reduced speed as per

ISO standard. However the bidders should furnish the co-relation of accuracy and
limits of unbalance.
f) Necessary test certificates of the above tests shall be furnished for the
purchaser’s approval.
g) Pump bowls shall be offered for Dye penetration test and if found defective,
it shall be rejected and destroyed to avoid reuse. The pump impellers shall
be offered for Dye penetration test as per approved procedure. Ultrasonic
test of impeller shaft shall be carried out along with above test.
2.6 VISUAL INSPECTION
Pumps shall be offered for the purchaser’s visual inspection before dispatch.
Pump components shall not be painted before inspection. After the inspection, test
certificate shall be furnished. Inspection for critical dimensions of components like
shafts diameter, wall thickness of column pipes; flange thickness etc. will be
witnessed.
Inspection of verification of metallurgy of various components shall be done by
reviewing the certificates of the metallurgical tests carried out by the manufacturer.
26
2.7 WELDING
All welding and related operation shall be done as per code. Welders shall be
qualified as per codes. All welding procedures shall be submitted for approval.
2.8 DRAWINGS / DOCUMENTS
The following drawings shall be submitted by the manufacturer.

a) Preliminary outlined GA (general arrangement) & dimensional drawings,
showing details of pump, motor, civil foundation, clearances, minimum
submergence, etc.
b) Performance curves for capacity v/s head, efficiency, and KW requirement
shall be furnished. The capacity range shall be zero flow to maximum flow.
c) Typical cross sectional (CS) drawing showing constructional details with
the complete bill of material, bill of quantity (BOM & BOQ) & relevant
standards. Catalogues of all the components with part number shall be
furnished.
d) Pump House General Arrangements drawing of all the pumps with
dimensional details.
e) Test reports for chemical analysis of material of construction (MOC) of
major components like impellers shafts bowl assembly etc.
f) Performance test reports and curves for similar model of pumps with a list
of installations.
g) O & M manual & spare part list.
h) Start up & shut down instructions.
i) Quality Assurance Plan (QAP) to be submitted for approval prior to the
manufacturing.
j) Dimensional similarity / interchangeability certificates shall be submitted
so as to ensure interchangeability of components.
2.9 NAME PLATE
Each pump shall be provided with a stainless steel name plate of the
manufacturer, indicating minimum following details.
(a) Rated capacity in M³/hr
(b) Total head in MWC
(c) Speed in RPM.
27
(d) Rated Power in KW at 50 Hz.

(e) Test pressure
(f) Make & Model number
(g) Manufacturer’s serial number
(h) Weight of equipment
(i) Material of bowl.
(j) Material of impeller & shaft
(k) Details of Thrust Bearings with grade of lubricants
3 SUBMERGED CENTRIFUGAL PUMP-MOTOR SETS

(SCF PUMPS)
3.1 TECHNICAL SPECIFICATIONS
a) The pump set shall be of compact unitary construction. The pump casing
shall be of high efficiency, volute casing or bowl type with the impeller
mounted directly onto the extended solid motor shaft (without any
couplings). The pump design shall be suitable for water sump de-watering
purpose. Pump shall be suitable to handle Mud, debris etc. Pump shall be
of Non-clog design. Maximum solids handling capacity of the pump shall be
provided accordingly.
b) The pump is to be mounted directly in submerged condition in to the water

storage area. It may suck up silt, clay, pebbles etc. Hence it should be of
appropriate reliable & robust design.
3.2 INSTALLATION
a) The pumps shall be suitable for portable installation either horizontal or

vertical & shall be interchangeable between these modes throughout their
working life time. The pump will be discharging water through vertical
column pipes.
b) The pump shall be offered with vertical column discharge with or without
any bottom supporting arrangement. Bottom anchoring with auto coupling
type or horizontal axis pump suitable to the requirement may be provided.
c) The scope of works shall be inclusive of the Pump-motor sets with Discharge
/ Column Pipes and necessary supporting arrangements at the top floor.
28
d) To "fish out" a Vertically Installed Submerged pump-set (even if a chain has

not been attached to the lifting hook prior to the pump-set being lowered)
the pump should have a self centering lifting hook. Its design should be
such that the lifting chain's hook can be engaged to the pump's lifting hook
without the need for man to enter the wet sump to engage the same.
3.3 PUMP DESIGN
a) Speed: Speed is required to be decided on achievable efficiency of pump.
b) The pump shall be capable of developing the required total head at rated
capacity for its continuous operation. Pumps of particular category shall be
identical and shall be suitable for parallel operation.
c) The head capacity curve shall be continuously rising towards shut off with
the highest at shut off. The shut off head shall be at least 115% of the
specified duty point head. The Impeller shall be of high efficiency Multi
Channel Enclosed type (except for Specific Speeds ≥ 90 where Semi Open
Impellers shall be allowable).
d) Suction Strainer: Provision of a suction strainer shall be dependent on the

material to be handled by the pump.
e) The pump set shall be suitable for starting with delivery valve open as well
as closed at any operating point. The motor should also start accordingly.
The pump set shall be capable of withstanding the accidental rotation in
reverse direction.
f) Fully filled up & Stamped Data Sheets as per attached format shall be
submitted along with the Technical Bid.
g) Pump shall be vertical single shaft machine having a common shaft for
pump and motor
h) A filter / screen arrangement is to be provided at the inlet of the incoming

water, i.e. at the source of water to enter in to the water storage area.
However, the Pump shall be suitably designed to handle the silt / mud /
sand / debris / grass / any other foreign material, which is likely to come
along with the water.
i) Pump-motor unit shall be provided with suitable lowering and lifting

arrangements
29
j) The Pump-motor unit shall be supplied with a suitable and sufficiently long
copper cable for a direct connection with the electric power / control panel
without any joints when the pump-motor unit is installed inside the water.
k) The Characteristic curves of the Pump Head, Efficiency, BKW and the
NPSHR against the Discharge Flow Rate shall be furnished by Pump-motor
Vendor.
l) The Pump-motor unit shall be of water proof design suitable for total
submergence in the water and compatible to operate normally against the
minimum, maximum and normal water levels in the water storage area &
for continuous operation.
m) The Pump-motor unit shall be provided with a suitable moisture sensing

arrangement so that the pump-motor unit shall be electrically tripped when
moisture is sensed.
n) There shall be a suitable provision like: Thermister Relay / any other for
tripping of the unit against pump over load / motor overheating.
o) The Pump-motor unit shall be provided with the necessary supporting

arrangement at the top of the well and the flanged discharge bend at the
outlet for further connecting with the expansion elbows etc. Apart from
this, the pump vendor shall provide any other auxiliary / accessories that
are required for his design of pumps for smooth, safe and efficient operation
and it will be included in their offer of the pump-set.
3.4 MOTOR DESIGN:
(I) TYPE OF MOTOR
a) The motor shall be of Squirrel Cage, Induction type, Air Filled, yet suitable
for the actual, maximum water immersion in to the water & also suitable
for S1 duty. It may be rated for LT - 415 Volt (±10%), 3 phase, 50 Hz (±5%)
or HT AC electric supply as suitable. Its winding should be of Class “F”
insulation * (withstanding winding hot spot temperature of up to 185°C)
while the nominal temp rise of winding hotspot should not exceed that of
class “B”.
b) It should be wound using Dual Coated, Super Enameled; Copper wire with
high temperature index as per IS: 4800 Part-13. PVC / Poly Propylene /
30
Poly Ethylene insulation for winding wires shall not be allowed. Motor’s
Insulation should be Vacuum Varnish Impregnated & Oven Baked to
ensure Moisture Impervious & Mechanically Robust insulation. Dip or Pour
type Air Dry Varnishing shall not be allowed.
(II) MOTOR RATING
The Motor Rating should be higher of the following two criteria:
a) 10% margin on Maximum Power consumption through out the range of

performance at 50 Hz (Including voltage and frequency variation) OR
b) 15 % more Brake Kilowatt Power ( BKW ) consumed at duty point at 50 Hz

(Including voltage and frequency variation) .
(III) ROTOR OF MOTOR
The Motor’s Rotor shall be of Dual Cage Copper Bar Brazed type to assure
following:
a) Long Corrosion free Service life (in presence of high moisture inevitable in
submerged motors. Aluminum corrodes much faster than Copper)
b) Ease of Onsite Repairing & beneficial Fly Wheel type Inertial effect (as
compared to aluminum rotor, copper rotor is heavy) which reduces
detrimental effects of water hammer
c) Better Motor Efficiency & Cooler Operating Temperature
(IV) MOTOR COOLING:
To restrict the Dead Water Level (in case of Vertical Installation) in the Sump to
1m, Medium sized, Vertical pumps (≥55kW) should have a Cooling Jacket – i.e.
motor cooling is accomplished by circulation of pumped water between the
motor casing & the jacket shell - this jacket shell is fed by cold water from the
pump casing & discharges its heated water back into the sump (in case of Wet
Installation) or Pump casing (in case of Dry Installation) by integrally cast
ducts. There should not be any pipes, hoses, etc for this circulation.
(V) MOTOR PROTECTION:
Thermal Overload Protectors (Bi Metallic Over Load Relays) should be

embedded in each phase of the stator winding to detect overheating & trip the
31
motor from the control panel in the event of the temperature exceeding the safe
operating limit (above 130C).
To detect primary Mechanical Seal’s Leakage a Moisture Sensor shall be

provided in intermediately Oil Chamber (& not in the Motor casing or
elsewhere) – this shall detect water mixing in oil by mode of increased leakage
current from the moisture sensor.
(VI) CABLES:
a) A watertight Cable Junction Box sealed from the motor shall be

provided for the motor power and signaling cables.
b) The cable shall be brought directly out of the submerged motor without
joints, and shall be of sufficient length, minimum 10 m to be terminated
in an IP 68 junction box (in the scope of electrical contractor) outside
adjacent to the wet well & above the HFL. They shall be sized in
accordance with the electricity utility regulations and BS 7671.
c) It should have Power as well as Control Cables of Dual Sheathed EPRS

/ PVC Armored type with Copper Core of required size as per detail
engineering. However the Cross Section of the cable shall be ample
enough to ensure a Voltage Drop of not more than 2% at actual site
conditions.
(VII) SHAFT & BEARINGS:
a) The Solid Shaft shall be supported by heavy duty Ball or Roller bearings
with a minimum L10 life of 75,000 hours in accordance with BS 5512.
The bearings should be Permanently Greased with Premium Quality,
High Temperature, Long Life Grease thereby obviating the need of re-
lubrication for upto L10 life of the bearings. The bearing should be of
Metric Series & not Imperial ones.
b) Oil Lubricated bearings shall not be allowed.
c) In case the motor is to be driven via a VFD, atleast one of the bearings
(DE or NDE) should be Current Insulated to prevent “electric fluting
damage” caused by Harmonics.
(VIII) STUFFING BOX / OIL CHAMBER:

32
a) The pressurized entry of water into the motor (from the pump’s
volute/Bowl casing) should be prevented by Two separate mechanical
seals in mounted in a Tandem mode within an oil chamber.
b) The Primary (Inboard) seal should always be of Silicon Carbide or

Tungsten Carbide faces to withstand erosive wear due to any silt
particles.
c) The Secondary (Outboard) seal should be of Carbon v/s Cast Chrome

Molybdenum Steel or Silicon Carbide or Tungsten Carbide – i.e.
Thermally Unstable materials like Alumina/ Aluminum Oxide shall not
be allowed.
(IX) TESTING:
a) The pumpsets shall be tested in accordance with ISO 9906, IS 10981, IS

5120 (Tolerance Class 2); with or without VFD as per the provision in
the tender specifications.
b) The Flow shall be measured by full Bore Electro-Magnetic or Ultrasonic

Flow Meters (of 0.5% or less accuracy class.)
c) The Testing shall include the following:
(A) Motor Routine Tests at Pump manufacture place:
1. IR
2. HV
3. No Load Amperes, Vibration, Noise Levels, etc.
Note: Job pump shall be tested with job motor.
(B) Pump Performance Test:
In accordance with IS 5120 / ISO 9906, Grade 2-5% / ISO 2548-5%

shall include measurements of Head, Discharge, Motor Input at least 6
different points to plot the Actual Performance Curves
(C) All the Extra Charges for such Testing shall be borne by the Contractor.
It is clarified that, in case of Field Testing Failure; Engineer-In-Charge /
TPI reserves the right to detain the pumps in their custody until the
33
contractor replaces the failed pumps with new pumps which shall again
be subjected to Re-Testing. No extra charges shall be allowed by owner
to the contractor.
(D) Pump testing should be carried our preferably with VFD or without VFD
as per the provision of the tender. Incase the pump sets are to be used
with VFD then the testing has to be conducted compulsorily with VFD
(to ascertain compatibility with VFD)
4 SLUICE VALVES / GATE VALVES
4.1 DESIGN FEATURES
All the valves above or equal to the size of 300 mm nominal bore shall be gear
operated.
It is a general requirement that the valves in the pump house shall be Sluice /
Gate / Butterfly Valves & shall be motorized and are of ductile iron (DI) body
construction and valves in the field pipe lines shall be Sluice / Gate / Butterfly
Valves & shall be manually operated (through a suitable gear box mechanism
in case of valves above 300 mm NB) & are of ductile iron construction unless
otherwise stated.
The valves shall be free from sharp projections, which are likely to catch and
hold stringy materials.
Valves shall close with clockwise rotation of the hand wheel. The direction of
closing and opening shall be marked on the hand wheel.
The stuffing box gland shall be of one-piece design.
4.2 FEATURES OF CONSTRUCTION
The pump house valves shall be preferably with a mechanical & electrical
indication of valve position and an indication of the valve percentage opening.
34
The valves for the field pipeline shall be manually operated. The valves shall be
provided with a valve position locking arrangement (mechanical type).
Sluice / Gate Valves shall be provided with back seating arrangement.
Renewable body and wedge ring shall be provided.
Valve shall be of double flanged type. Holes drilling and flange thickness of
valve flange and mating companion flanges shall generally conform to the
standard IS 1538-1976.
The valves shall be completely overhauled before placing in position.
Necessary joining materials viz. bolts, nuts, washers, packing etc. shall be
provided by the contractor at his cost. The valves and associated piping shall
be fixed so as to have axis perfectly horizontal. The Valves and associated
piping shall be supported on RCC pedestals and the associated piping shall be
shall be secured with suitable clamping arrangement. For an easy access to
the valves’ manual operating wheel/ handle, necessary approach with
operator’s standing space shall be provided for all the valves of the pump
house and of the field pipelines.
If required the contractor shall also carry out drilling of holes of appropriate
diameter in flanges in required numbers.
A hand wheel shall be provided for emergency operation. The hand wheel drive
shall be mechanically independent.
The valve design shall take care of the pressure drop across the valve disc in
case of partial opening of the valve and shall take care of the erosion and
cavitations effect on the body and disc during such operation.
Valve(s) subjected to back pressure shall have the valve seat, disc and the
operator suitably designed to ensure trouble-free operation.
Valve body shall be of Ductile Iron (DI) material with flanged ends in pump
house.
35
The shaft diameter shall take into consideration, the maximum torque required
for the valve operation, the maximum differential pressure across the valve
disc when the valve is closed and the shock load due to accidental closure of
the valve disc.
The disc shall be designed for maximum differential pressure across the valve
as well as the shock load due to accidental closure of the valve. Disc design
shall offer minimum head loss. Disc shall also offer minimum resistance to
flow. Disc shape shall be contoured.
Valve seats shall be of a design that permits removal and replacement at site
and shall be securely clamped on the body or disc of the valve.
Seat material shall be suitable for the operating conditions and handling fluid
and may be suitably reinforced, if required.
The seat design shall permit easy removal for replacement purposes without
the need for removing the valve from the line. No deposited or welded seat
rings permitted.
The valve bearings shall be of 'self lubricated' type and shall not have any
harmful effect due to handling fluid.
Adjustable thrust bearing(s) shall be provided to hold the valve disc securely in
the center of the valve seat.
Operator (mechanical or electrical actuator) shall be used for opening, closing,

controlling or holding the valve disc at the intermediate positions as and when
required. Operator sizing shall be done on the basis of the maximum torque
requirement of the valve for seating/ unseating/ controlling/ holding the disc
at the intermediate positions and the time required for valve operation.
Irrespective of whether the valve is operated by a power actuator or not, each

Sluice Valve / Gate / Butterfly Valve shall be provided with a hand wheel for
manual operation. The hand wheel and associated gearing arrangement shall
be designed to limit the maximum manual effort to around twenty (20) kg for
valve operation. Valves located at inaccessible position, shall be provided with
36
extension spindle and floor stand or hand lever/ round chain to facilitate
manual operation.
Valve to be operated through gearing arrangements and/ or by power actuator,

shall be provided with adjustable mechanical stop limiting device to prevent
over travel of the valve disc in ‘open’ or ‘closed’ position.
4.3 REQUIREMENT FOR VALVES
The valves shall satisfy the following requirements.

Size : As per Data-sheet
Body test pressure : As per Data-sheet
Seat pressure : As per Data-sheet
MATERIAL OF CONSTRUCTION (MOC)

Body (Pump House) : Ductile Iron - DI
Body (Field Valves) : Ductile Iron - DI
Spindle : Stainless steel SS410.
Operation (Pump House Valves) : Motorized controlling operation through
Electric Actuator (only ON / OFF operation
is
not acceptable)
Operation (Field Pipeline Valves) : Manual operation through a suitable gear
box
Application : Raw Water
Material test certificate shall be furnished.
4.4 INSPECTION AND PERFORMANCE TESTS
Manufacturer shall conduct all tests and stage inspections required to ensure
that the equipment offered by him conform to the specification requirement.
Test certificates for all shop tests shall be furnished to Engineer-In-Charge for
approval.
The Engineer-In-Charge or his Representative shall witness the tests.
37
The Contractor shall arrange for inspection of valves at manufacturer’s

premises and shall arrange for testing of valves for body test pressure and seat
test pressure of all the valves to be supplied in presence of Engineer-In-Charge
in line with the approved Quality Assurance Plan.
Defects noted during inspection, test and operation of valves shall be rectified
by the contractor at his own cost without any extra claim to the entire
satisfaction of the Engineer-In-Charge.
4.5 TESTS FOR VALVE
(a) MATERIAL TEST
Material to be used for the valve components shall be of tested quality.

Chemical analysis and mechanical tests on materials to be used shall be done
as per relevant standard.
(b) NON-DESTRUCTIVE TEST
Valve body and disc shall be subjected to Non-Destructive Testing (NDT).

Components subjected to NDT and shall be stamped for identification.
(c) HYDROSTATIC TEST
Each valve body shall be subjected to hydrostatic test as specified. For valves
subjected to back pressure condition, leakage test shall be carried out on both
sides of the disc.
(d) PERFORMANCE TEST
Each valve complete with operating device shall be shop operated at least three
(3) times from fully closed to fully open conditions and reverse, hold at
intermediate positions under no flow condition, to prove the workability of the
assembly.
(e) TESTS AT SITE
38
Performance of the valves shall be tested at site at actual working condition.
4.6 CLEANING
Prior to factory inspection, all manufacturing waste such as metal chips debris
and all other foreign matter shall be removed from interior of valve. All mill
scale, rust, oil, grease, chalk and all other deleterious material shall be
removed from the interior and exterior surfaces.
4.7 PAINTING
Valves shall first be given two coats of zinc base primer after completely
cleaning the surface and then it shall be coated with three coats of epoxy
paint. The resulting coating shall be uniform and smooth and shall adhere
perfectly to the surface.
4.8 TECHNICAL PARTICULARS
a. Applicable standard :IS - 14846-2000 / API 600/603/ BS 1414

b. Application : Raw Water
c. Liquid data : Specific Gravity 1.0 kg
d. Type : Double flanged
e. Hand wheel : Required for operation
f. Bolts & nuts : Carbon steel
g. Body test pressure : As per Data Sheet
h. Seat test pressure : As per Data Sheet
i. Connection : To be provided on pipeline in between
pump discharge and the common header
j. Flange thickness & holes : As per IS: 1538 (latest)
4.9 HANDWHEEL
A hand wheel shall be provided for emergency operation. The hand wheel drive
shall be mechanically independent of the motor drive and any gearing should
be such as to permit emergency manual operation in a reasonable time.
39
4.10TESTS AND INSPECTION
All valves shall hydrostatically tested by the manufacturer before dispatch. The
pressure shall be obtained without any significant hydraulic shock. Testing
shall be carried on before application of paint or other similar treatment unless
otherwise agreed between the purchaser and the manufacturer. There shall be
no air entrapped within the part of the valves subjected to test pressure.
Valve shall be offered by vendor for visual inspection before shipment. Valves
shall be tested as per the relevant standards.
The hydrostatic testing shall be witnessed by the purchaser or his

representative / TPI.
4.11MATERIAL OF CONSTRUCTION
All sluice valves at the pump-house shall be of body Ductile Iron, Spindle SS.
All valves shall be supplied with matching companion flanges with necessary
bolts, nuts and gaskets.
4.12NOMINAL PRESSURES
Valve shall be designated by nominal pressure (PN) defined as the maximum

permissible working pressure (MPa) at 20 deg. C temperature as under:
PN 0.25, PN 0.6, PN 1.0, PN 1.6 & PN 2.5
4.13TEMPERATURE RATINGS
All valves shall be suitable for continuous use at their PN designation within
the temperature range of –10 0 c to 65 0 c.
4.14BODY ENDS
40
Flanges shall be at right angles to the axis of the bore and concentric with the
bore. Flanges shall be drilled unless otherwise specified and bolt holes shall be
off centers.
4.15BEARINGS
The bearings shall be suitable for the maximum loads imposed during service.
4.16 MATERIALS
This standard is based on materials specified in IS unless otherwise agreed;

the materials shall be of a grade equivalent to those given in IS or superior.
Other material may be used as per agreement between the manufacturer and
the purchaser.
4.17 OPERATION
All valves shall be capable of operated at a differential pressure across the

wedge. Worm gear or any other suitable type of operator can be used.
4.18DIRECTION FOR OPERATION
Unless otherwise specified, manually operated valves shall be closed by

turning hand wheel in a clockwise direction when facing the hand wheel.
All operating device shall be provided with suitable stops to prevent movement
of the shaft beyond the limit corresponding to the fully closed position of the
disc.
All operating device shall be packed with grease for life time operation.
Operating device shall be totally enclosed and weather proof for general
application.
Operating device shall be self locking type. Valve shall be capable of being
locked in at any intermediate positions.
41
The operating device hand-wheels shall be marked ‘CLOSE’ or ‘SHUT’ to

indicate the direction of closer. The operating device shall be provided with
arrangement to indicate the valve position.
The manufacturer shall issue a test certificate confirming that the valves have
been tested in accordance with this standard and stating the actual pressures
and medium
used in the test.
5 DUAL PLATE CHECK VALVES (NON RETURN

VALVES)
5.1 DESIGN REQUIREMENTS FOR DUEL PLATE CHECK VALVES (DPCV)
a) The design and manufacture of the valves shall comply with all currently
applicable statutes, regulations and safety codes in the locality where the
equipment will be installed. Nothing in this specification shall relieve the
contractor of this responsibility.
b) The non-return valves shall be of Dual Plate Check Valve (DPCV) type
design. It shall be free from sharp projections.
c) The valves shall be designed for minimum head loss
d) The valves shall have flanged ends. Flange confirming to IS: 1538.
e) The valve shall be suitable for mounting on a horizontal pipeline and flow
direction shall be clearly embossed on the valve body.
f) Valves shall possess high speed closing characteristics and be designed for
minimum slam condition when closing.
g) Dual plate check valves shall conform to API 594. They shall have metal to
metal sealing. The spring action shall optimize the equal closing rates of
each plate especially when the friction coefficients are uneven due to one
plate resting upon one another. The plates shall not drag on the seat while
opening. The plates shall not vibrate under full or partial flow condition.
42
h) In case of the nozzle check valve, the disc shall be correctly positioned at all
times to achieve fully non-slam closure. The spring shall be fully shielded
from the flow stream by the central flow diffuser.
i) Sealing shall be metal to metal. The disc shall be stable and shall not
vibrate under full or partial load conditions. The pressure designation of the
valve shall be as per the Data Sheet.
5.2 CLEANING
Prior to factory inspection, all manufacturing waste such as metal chips debris
and all other foreign matter shall be removed from interior of valve. All mill
scale, rust, oil, grease, chalk and all other deleterious material shall be
5.3 PAINTING
cleaning the surface and then it shall be coated with three coats of coal tar
epoxy paint. The resulting coating shall be uniform and smooth and shall
adhere perfectly to the surface.
5.4 TESTS AND INSPECTION
Valves shall be manufactured and tested as per the relevant standards, i.e. as
per API 594 / 598 (with PN rating as per Data Sheet), with its latest revisions.
Valves shall be offered for visual inspection and dimensional checks.
The hydrostatic and water tightness testing shall be witnessed by the

purchaser Manufacturer/ contractor shall submit the manufacturing quality
assurance plan of the valve to TPI and get approval of Engineer-In-Charge
before manufacturing.
5.5 MATERIAL OF CONSTRUCTION
TECHNICAL PARTICULAR
43
SR.
DESCRIPTION PARTICULARS
NO.
1 Standard API 594 / 598

2 Size As per Data-sheet
3 Working pressure As per Data-sheet
4 Type Duel Plate Check Valves (DPCV)
5 Ends Flanged, with companion flanges, nut,
bolt, gaskets.
6 Other requirements Liquid handled – Raw Water
7 Body Ductile Iron – DI
8 Bolts, studs & nuts Carbon steel IS 1367 class 4.5
9 Body test As per standard
10 Seat test As per standard
11 Face to face dimension As per standard
12 Companion flanges and Required as per IS 1538 (table IV & VI)
erection hardware
6 BUTTERFLY VALVES
Butterfly valves shall be with flanged ends & confirm with IS: 13095 / 1991 (or
latest). It is a general requirement that the BFVs near Pump House shall be
motorized & are of Ductile Iron (DI) body and BFVs on field pipe lines shall be
manually operated (through a suitable gear box mechanism) & are of ductile
iron construction unless otherwise stated. Fabricated valve shall not be
allowed and paid.
6.1 SCOPE OF WORK
This standard cover double flanged ductile iron valves for general purpose.
Valves covered under this standard are manually or electrically operated. It
covers valves of nominal pressure designations up to and including 2.5 MP
with ends flanged in accordance with appropriate table (IV & VI) of IS 1538
44
(latest). Mating / companion flanges shall also be drilled and having thickness
as per IS 1538.
6.2 REFERENCE
The Indian standards are necessary adjuncts to this standard.
6.3 TERMINOLOGY AND DEFINITION
Terminology and definition covered in IS: 13095 are generally applicable.
6.4 VALVE - END CONNECTION

Double flanged valve
A valve having flanged ends for connection to pipe flanges by individual
bolting.
6.5 SERVICE APPLICATION
(a) Valves shall be suitable for one or more of the following applications.
(i) Tight shut off - A valve having no visible leakage on the disc in closed
position under test conditions.
(ii) Regulating - A valve intended for regulating purpose and which may
have a clearance between the disc and the body in close position.
(iii) Low leakage - A valve which has specified maximum leakage rate on the
disc in the closed position.
(b) Vacuum Condition

Where valves are to be used under vacuum conditions, the detailed design
provision shall be mutually agreed between the purchaser and the
manufacturer.
6.6 NOMINAL PRESSURE
45
Valve shall be designated by nominal pressure (PN) defined as the maximum

permissible working pressure (MPa) at 20 0 C temperatures as follows:
PN 0.25, PN0.6, PN1.0, PN 1.6, PN 2.0 & PN 2.5
6.7 PRESSURE / TEMPERATURE RATING
Maximum permissible gauge working pressure and operating temperatures

shall be in accordance with standard IS: 13159 (Part I): 1991 except that
restriction on temperature may be placed by the manufacturer on valves in
accordance with this standard by reason of valve type, trim materials or other
factors. However, all valves shall be suitable for continuous use at their PN
designation within the temperature range of –10 0 C to 65 0 C.
6.8 BODY ENDS
a) Double Flanged Body Ends
Valve shall be of double flanged type. Holes drilling and flange thickness of
valve flange and mating companion flanges shall conform to the standard
IS 1538-1976. Flanges as per any other specific requirements of the
purchaser may also be given as agreed to between the manufacturer and
the purchaser or as per IS: 13159 (part I): 1991.
Flanges shall be at right angles to the axis of the bore and concentric with
the bore. Flanges shall be drilled unless otherwise specified and bolt holes
shall be off centers. Tapped by the design of the valve
b) Wafer Body ends (where ever applicable)

i. Body ends shall be capable of being fitted between the pipe flanges
complying with the requirements of flange drilling.
ii. The joint faces shall be at right angles to the axis of the bore and
concentric with the bore.
iii. Holes may be provided, where required by the design, for the passage of
the bolts securing the flanges and the valve. Where through bolting is
not practicable due to the presence of valve shaft, bearing housing,
tapped holes may be provided for individual bolting of each flange.
46
6.9 FACE TO FACE DIMENSIONS
Face to face dimensions of double flanged and wafer types of valve shall be as
per standard. Face to face dimensions are exclusive of the sealing gaskets at
both ends. The manufacturer shall ensure that adequate space will be
available between valve flanges for bolting when flanged valve with short body
face to face or wafer type face to face are manufactured. Tolerance on face to
face dimension shall be as follow
Face to face Dimension of the Valve (mm) Tolerance (mm)

Over Up to and Including
0 250 +2
250 500 +3
500 800 +4
800 1,000 +5
1,000 2,400 +6
6.10BODIES
Bodies end ports shall be circular and the numerical valves of the diameter
shall be as close as possible to the valve of DN.
6.11DISC AND SHAFT
The disc and shaft shall be designed to withstand the maximum pressure
differential across the valve in either direction of flow. The shaft may be of one
piece design or in two pieces separately attached to the disc. Any means of
attachment between the shaft and the disc shall be such as to preclude
components becoming loose in service.
6.12SEATING AND LININGS
47
Non-integral seating, and lining where used, and their means of attachment
shall be such as to preclude their becoming loose in service.
6.13BEARINGS
The bearings shall be suitable for the maximum loads imposed by the shaft
during testing and in service for valves DN 350 and above, a bearing shall be
provided to take the axial thrust; spring retaining clips (cir-clips) shall not be
used as thrust bearing suitable sealing shall be provided for the shaft where it
passes outside the pressure containing en closer.
6.14MATERIALS
This standard is based on materials specified in relevant IS. The materials

shall be of a grade equivalent to those given in datasheet or superior.
6.15OPERATION
a) Manual Operation
All valves shall be capable of operated at a differential pressure across the disc
as marked on the valve. Lever, worm-gear/ traveling nut type or any other
suitable type of operator can be used.
Direction for Operation
Unless otherwise, specified manually operated valves shall be closed by

turning hand wheel or lever in a clockwise direction when facing the hand
wheel or lever. The design of lever when fitted shall be such that the lever may
only be assembled to the valve so that it is parallel to the direction of flow
when the valve is open.
All gear traveling nut operators shall be provided with suitable stops to prevent
movement of the shaft beyond the limit corresponding to the fully closed
position of the disc.
48
All gear traveling nut operators shall be packed with grease for life time
operation. Gear / traveling nut operators shall be totally enclosed and weather
proof for general application. For special applications such as marine,
submerged service, etc. the purchaser may specify special enclosure.
All gear/traveling nut operators shall be self-locking type. All leaver operated
valve shall be capable of being locked at least three intermediate position.
The operating hand-wheels shall be marked ‘CLOSE’ or ‘SHUT’ to indicate the

direction of closer.
The operator shall be provided with arrangement to indicate the disc position.
6.16TESTING
All valves shall hydrostatically tested by the manufacturer before dispatch as

directed by Engineer-In-Charge. The pressure shall be obtained without any
significant hydraulic shock. Testing shall be carried on before application of
paint or other similar treatment. There shall be no air entrapped within the
part of the valves subjected to test pressure.
a) Performance Testing
Each valve shall be shop operated from fully closed to fully open position and
reverse, under no pressure and no flow condition to demonstrate that the
complete assembly is workable.
b) Body Test
Completely assembled valve shall be tested as follows:
The body ends shall be blanked so that the valve is subjected to the full
pressure in all directions include by the test pressure water. Valves may be
tested in any suitable manner as directed by Engineer-In-Charge. The valve
disc shall be in slightly open position and pressure equivalent to 1.5 times the
maximum permissible working pressure shall be applied with water. The
duration of this test shall be as per standard.
49
c) Seat Test
The seating surface of the valve shall be cleaned unless a surface treatment
forms an integral part of the design or the use of a temporary surface
treatment has been agreed between the manufacturer and the purchaser to
avoid the possibility of damage under the condition of the test.
NOMINAL MINIMUM TEST DURATIOIN

DIA IN MINUTES
MM BODY SEAT TEST WHEN APPLICABLE
TEST
Up to and 0.25 0.25

including 50
65 to 150 1.00 1.00
200 to 300 2.00 2.00
350 to 1000 5.00 2.00
1200 to 5.00 3.00

2000
d) Each valve shall be shop tested for leaks in close position. The test shall be
conducted with the body flanges in a horizontal position. Pressure shall be
applied to the upstream end of the valve, the downstream being open to
atmosphere. The duration of test shall be as per Table above. There shall be no
indication of leakage past the valve disc during test and valves shall be drop
tight. Seat test shall be carried out in both the direction of valve if agreed
between the manufacturer and the purchaser. The seat pressure applied on
upstream side shall be equivalent to 1.1 times the maximum permissible
working pressure at 20 0 c and shall be applied with water.
e) For regulating type valves seat test shall not be applicable.
f) Disc Strength Test
The test shall be conducted with the body flanges in horizontal position. The
test pressure shall be 1.5 times the maximum permissible pressure at 20° C
With disc in closed position; hydro test pressure shall be applied to the lower
face of the disc for duration as per table-3. There shall be no damage to the
valve disc nor shall any part of valve or disc be permanently deformed by the
50
test. The purpose of this test is to provide evidence of the adequacy and
structural integrity of disc and body. Any leakage past the seat shall not be the
criteria for rejection of the valve (Sampling test sample as per IS 2500).
g) Maximum permissible leakage shall be as given in Table in Para 6.17.
When specified by the purchaser, the manufacturer shall issue a test

certificate confirming that the valves have been tested in accordance with this
standard and stating the actual pressures and medium used in the test.
VALVE TYPE LEAKAGE RATE
Tight shut-of No visible leakage for duration of test
Low leakage 0.1 mm2 / s X DN (sec 5)
Regulating Not specified (outside the scope of this

standard)
INSPECTION
The Engineer-In-Charge or his authorized representative shall have access to

the manufacturer’s works at all reasonable times to inspect assembled valve at
factory. The contractor has to make necessary arrangements for testing
facilities of the valves as per the relevant IS at factory.
WITNESSING OF TESTS
The contractor should witness the tests.
MARKING
Marking shall be cast integral on the body or on a plate securely attached to

the body. The markings shall be in accordance with IS: 9866 - 1981.
PREPARATION FOR DISPATCH

51
(a) Valve shall be complete in all respect when dispatched. Each valve shall
be drained, cleaned, prepared and suitable protected with 2 coats of red
oxide on un-machined surfaces and rust preventive coats on machined
and flanged surfaces for dispatch in such a way as to minimize the
possibility of damage and deterioration during transit and storage.
Painting other than specified on the finished valve shall be as per the
agreement between the manufacturer and the purchaser.
(b) Disc shall be unseated when dispatched, but care shall be taken to
ensure that there is no risk of damage to the disc.
(c) When specified, the body ends shall be suitably sealed to exclude foreign
matter during transit and storage.
(d) Components shipped unattached shall be adequately protected and
identified to permit correct field assembly.
6.18FIXING OF VALVES
Loading at store and unloading at site of works shall be done carefully using
suitable mechanical handling devices such as crane, chain pulley etc. The
arrangement of housing the valves shall be with chambers and stable and firm
foundations. The chamber and top roof cover with removable lid shall be
provided so that it shall be possible to remove or replace or recondition the
valves seats and to remove the parts without removing the valves from the pipe
work. For this suitable flange adapters may be provided.
Valves used on pipeline shall be straight through type and non-checkable.

Each valve or its operation equipment shall bear an approved name plate
stating its function. All operation spindles, gears and head stocks shall be
provided with adequate points for lubrication.
BYPASS ARRANGEMENT
Each Butterfly Valve shall be provided with by-pass arrangement of Sluice

Valve.
52
7 AIR VALVE
7.1 TYPE OF AIR VALVE
a) Single Acting Air Valve
Single acting air valve shall be of S2 type (with large orifice), with isolating
sluice valve confirming to IS 14845 – 2000 & AWWA C 512 and shall be having
an outlet of large capacity for admission and release of bulk volume of air
during emptying and filling of the pipeline.
The ball sealed orifice shall always remain open while air is exhausting and is
immediately closed when Water rises in the chamber, lifts the ball and seals
the orifice. It shall also ensure that there are no recesses or pockets,
sheltering, escaping air for the large orifice (low pressure) ball to drop into
when the valve open. Turbulent air at the time of filling of pipe shall not
circulate in such cavities and cause the ball to blown into when the valve is
open. Turbulent air at the time of filling of pipe shall not circulate in such
cavities and cause the ball to blown into the discharging air streams, blowing
the valve shut prematurely.
The cone angle of the lower pressure chamber shall be such that even at the
critical velocity of all air escape at 300 m/sec. The total impact force on the
ball is less than the suction force on the angular area between the ball and the
cone. The design of the valve should be such as to allow maximum free air
discharge at various pressure differentials
.
The low pressure cover shall be massive and designed to withstand full
operating thrust in working Conditions.
The seat ring shall be held securely in place under the low pressure cover by a
joint support ring to prevent it from sagging when the ball is not sealing the
orifice.
The valve body, the orifice cover, cowl of the air valves shall be made of cast
iron as per IS: 210 grade FG 260.
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TECHNICAL PARTICULARS (DATA SHEET)
SR. DESCRIPTION PARTICULARS
1. Type and Design : Single Air Valve (Large orifice)

2. Size : As per Design or Data-sheet
3. Working pressure : As per Data-sheet
4. Body : Ductile Iron
5. Floats : SS – AISI 304, to withstand pressure
6. Site Ring : EPDM Rubber
7. Testing required : Visual and Dimensional check. Testing shall
be carried out as per IS: 14845
b) Double Acting Kinetic Air Valve General
Double acting kinetic Air valve with isolation valve confirming to IS: 14845 –
2000, AWWA C 512, having one outlet of large capacity for admission and
release of bulk volume of air during emptying and filling of the pipeline and
another having small outlet for escape of smaller quantities of trapped air.
The ball sealed orifice shall always remain open while air is exhausting and is
immediately closed when Water rises in the chamber, lifts the ball and seals
the orifice. It shall also ensure that there are no recesses or pockets,
sheltering, escaping air for the large orifice (low pressure) ball to drop into
when the valve open. Turbulent air at the time of filling of pipe shall not
circulate in such cavities and cause the ball to blown into when the valve is
open. Turbulent air at the time of filling of pipe shall not circulate in such
cavities and cause the ball to blown into the discharging air streams, blowing
the valve shut prematurely.
The cone angle of the lower pressure chamber shall be such that even at the
critical velocity of all air escape at 300 m/sec. The total impact force on the
ball is less than the suction force on the angular area between the ball and the
cone. The design of the valve should be such as to allow maximum free air
discharge at various pressure differentials..
The low pressure cover shall be massive and designed to withstand full
operating thrust in working Conditions.
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The seat ring shall be held securely in place under the low pressure cover by a
joint support ring to prevent it from sagging when the ball is not sealing the
orifice.
The valve body, the orifice cover, cowl of the air valves shall be made of ductile
iron as per IS: 1865 grade 500/7.
7.2 JOINTING MATERIAL
Each valve shall be supplied with all necessary joints on all the flanges of valve
supplied under this Contract including those flanges which will be jointed to
pipe system. The lengths of bolts shall be assumed to be suitable for jointing
MS pipes.
The cost of all jointing material supplied under the contract shall be inclusive
of rates. Joint ring shall be of flat section at least 3 mm thick. It shall be of
rubber in accordance with IS: 638 Or its latest edition (specification for rubber
and insertion jointing) of hardness proven in practice so as to form a water
tight joint and use of jointing paste shall not be allowed. Bolt holes shall be
drilled according to centre lines. Bolt heads and nuts shall be hexagonal and
shall confirm to IS: 1363 (Specification for black hexagonal bolts, nuts and
black hexagonal Screws).
7.3 BALL
The ball of large orifice shall bear a calculated mathematical relation with inlet
diameter of the valve (i.e. the average cross section area of escaping air stream)
so that it will result in the ball being blow shut by a stream of water but held
down by a stream of air. The buoyancy of the floats shall be such that it will
ensure effective sealing of large orifice even at low pressures.
The weight of floats of the same size and type shall not differ by more than 2%.
The SS material used in the manufacture of floats shall be suitable for
perfectly sitting on the large orifice. The float provided in high pressure
chamber, manufactured from SS, shall be also being suitable for seating on the
small orifice.
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7.4 HIGH PRESSURE ORIFICE
The high pressure orifice and the high pressure chamber shall be so designed
that the orifice is effectively sealed in working condition by float.
The material of the orifice shall be gunmetal. The orifice shall be of size not
less than 3 mm and tapering to 100 mm suitable to release accumulated air
within the pipe. The profile of the orifice shall be carefully chosen to avoid
damage to the float surface. The orifice shall be protected by a suitable plug of
stainless steel.
VALVE FLANGE
All valve flanges shall be designed to withstand the stresses to which they
would be subjected under hydraulic tests. Flanges shall be machined flat. The
flanges shall be drilled in accordance with IS: 1538 (Specification of CI fittings
for pressure pipes for water etc.). All flanges shall be supplied with matching
companion flanges, nuts, bolts and gaskets. The matching flanges shall have
drilling of holes and flange thickness as per the valve flanges.
CLEANING
Prior to the factory inspection, all manufacturing waste such as metal chips,
debris and all other foreign material shall be removed from interior of valve. All
mill scale, rust, oil, grease, chalk and all other deleterious material shall be
paint. The resulting coating shall be Uniform and smooth and shall adhere
Valves used in pipes carrying water, the inside coating shall not contain any
constituent soluble in water or any ingredient which could import any taste to
the water.
56
PAINTING
paint. The resulting coating shall be uniform and smooth and shall adhere
7.5 INSPECTION AND TESTING AT MANUFACTURER’S WORKS
All valves shall be offered for visual inspection and dimensional check and
performance testing. Valves shall be tested as per IS: 14845.
DOCUMENTS / DRAWINGS TO BE SUBMITTED
Following documents / drawings shall be submitted

(a) Preliminary outline dimensional drawings.
(b) Typical cross section drawings with bill of material and material of
construction and necessary supports for mountings.
(c) Flow v/s head loss curve for valves.
(d) List of spares
7.6 TECHNICAL PARTICULARS
(1) Type and Design : Temper proof Double acting kinetic air
Valve with Isolation valve
(2) Size : As per Data-sheet
(3) Working pressure : As per Data-sheet
(4) Body :
a) Field Valves : Ductile Iron
b) Pump-house Valves : Ductile Iron
(5) Spindles : SS
(6) Floats : SS (AISI 304) to withstand high
pressure
(7) Connecting Ends : Flanged flat face ends. Holes Drilled
Conforming to IS: 1538
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(8) Testing required : Visual and Dimensional check.

Testing shall be carried out as
stipulated for standard kinetic air valve
8 Pressure Reducing Valve

Pressure reducing valve shall confirm to IS 9739:1981 Reaffirmed 2007, Body
and component ball be designed to provide ample resistance to distortion
under maximum working pressure.
The design of the valve shall be such that in calc of failure of any part or the
valve, it shall be capable of maintaining a continuous flow of water to the
system.
All valve shall be so constructed and installed as to permit repair or removal of
parts without breaking a pipeline or removing the valve from the pipeline.
TECHNICAL PARTICULARS (DATA SHEET)
1. Size : As per Design or Data-sheet

2. Working pressure : As per Desing
3. Body : Ductile Iron
4. Diaphragm cover and spring chamber : Cast Iron
5. Body seat ring, adjustable screw and valve item : Chromium steel
6. Tommy bar : Mild steel
7. Diaphragm and valve disc : Synthetic rubber
8. Gasket : Compressed asbestos fibre
9. Fasteners : Steel
10. Springs : Carbon steel
11. Strainer screen : Stainless steel
8.1 Testing
All valves shall hydrostatically tested by the manufacturer before dispatch as

directed by Engineer-In-Charge. All performance requirement related tests shall be
carried out as per IS: 9739:1981.
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8.2 Marking
All valves shall be marked with the ISI certification mark.
9 EXPANSION BELLOW
9.1 GENERAL
SS Expansion joint shall be a metallic flexible connector fabricated of plies of

metal to provide stress relief in piping systems due to thermal, mechanical and
other movements. It provides flexibility and concurrent movements.
a) Compensate, Lateral, Axial, Torsion and Angular movements.

b) Low movement forces
c) Reduced fatigue factor
d) Reduced heat loss
9.2 OPERATING PRINCIPLES
SS Expansion Joints are flexible, reinforced bellows which are used in piping
systems to meet the following major needs
a) To protect piping by absorbing any difference in dimension due to

temperature variation or line movement.
b) It shall be protect equipment such as supports & anchors, pumps & valves
etc, other equipment.
c) It shall be useful for simple connection of misaligned pipes.
d) Movement Accommodation:
Expansion and contraction, as well as rapid movements (dynamic stresses),

are absorbed by multidirectional and often simultaneous deflections:
9.3 TESTING
An SS Expansion joint is assessed on every vital performance criterion:-

a. UTS
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b. Radiographic test
c. Liquid Penetration test
d. Deflection
e. Heat build-up
f. Life Cycle Test with load
g. Vacuum test
h. Hydraulic test
i. Stiffness test
j. Vibration test.
DESIGN
SS Expansion Joint by the user should be based on the following points.
MECHANICAL DATA
a) All Bellows shall have IS: 2062 plate flanges. The hole-drilling dimension
shall be as per IS: 1538 to match with the pump outlet flange or valve
flange as the case may be, however, selection of the flange thickness as
per IS: 6392, Table 17 for PN 1.6 & IS: 6392 Table 23 for PN 2.5 may be
done for these M. S. flanges of the expansion bellows.
b) All Bellows shall be hydro tested, by our internal inspection department at
24 kg/sq. cm pressure For PN 1.6 & 37.5 kg/sq. cm for PN 2.5.
c) M.O.C. of Bellows element and liner shall be SA 240 TP 304.
d) M.O.C. of Tie Rods & Nuts shall be IS 1367.
e) M.O.C. of Weld ends & Lugs shall be IS 2062.
Piping Stress Analysis for the piping system where the Expansion Joint is to be
fitted can be provided by the contractor on specified data.
ACCESSORIES AND INSTALLATION
a) ACCESSORIES
i) CONTROL UNITS
The Control Unit assembly, consisting of two or more control rods & stretcher
plates are placed according to SS Expansion Joints from flange to flange. This
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minimizes possible damage of the SS Expansion Joint caused by excessive

motion of the bolt line, due to failure of anchor or equipment, it also absorbs
static pressure thrust developed at the joint and limits the extension and
compression movements, if required to prevent damage to the main equipment
without hampering its basic need. Inadequate support of pipelines, incorrect
anchoring, and considerable temperature variations may cause many
abnormal movements. As such undesirable and destructive movements can
effectively be encountered by using control units.
ii) PROTECTIVE SHIELDS / COVER

The Protective Shields/Cover should be used on the SS Expansion Joint that
carries high temperature. It protects the environment in the event of leakage/
splash & protects the SS Expansion Joint from fire during a flash fire.
iii) INTERNAL SLEEVES

A device which minimizes contact between the inner surface of the bellow &
the liquid flowing it, so as to protect the inner surface from corrosion and to
ensure that no foreign materials remain on the corrugation.
iv) COMPANSION/ COUNTER FLANGES

Companion/ Counter Flanges for the pipeline for which the SS Expansion
Joint is to be fitted can also be supplied with the SS Expansion Joint, if
required.
b) INSTALLATION OF ACCESSORIES
i) INSTALLATION
Piping sections where SS Expansion Joints are accommodated should be
anchored properly to take care of stresses/ Reaction forces due to internal
pressure.
Taking into consideration the above, solid & belting anchor points should be
selected particularly where change in direction of piping elbows are near to the
pump etc.
ii) ANCHORING POINTS
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An SS Expansion Joint must always be installed between two anchoring points

(fixed supports). If it is not possible to install anchoring points (support points),
stabilizing devices must be used.
iii) BUCKLING
In order to avoid pipe buckling, guide collars must be provided regularly along
the pipe length. A guide collar must also be provided on either side of the SS
Expansion Joint. Maximum service life depends on careful and correct
installation. Transport Expansion Joints to area of installation in packed
condition. Flange face of companion flanges in pipeline should be smooth and
without any sharp edges. For large size of Expansion Joints installed in
horizontal ducts, lifting lugs welded to flanges should be used to hoist joint in
position. Joints should only be fitted after all work on the pipeline and flanges
have been complete and anchors and supports have been established. This is
to avoid any accidental damage due to welding splatter or sharp objects and to
ensure that the joints are not overstressed.
The bolts on the flanges must be tightened evenly. Uneven tightening may lead
to hazardous leakage. Faulty fitting may lead to failure of the expansion joints.
10 ELECTRICALLY OPERATED TRAVELLING CRANE

AND HOIST
10.1CRANE & HOIST
(a) GENERAL DESIGN REQUIREMENTS
All mechanical equipment shall be simple and robust design, easy for erection,
inspection, adjustment painting and dismantling. Fastenings shall be to hold
the parts in place under all specification conditions of service. Steel castings,
steel forged wrought steel wheels and sheaves shall be anchored properly. All
shaft loads shall be transmitted through suitable keys, splices or pins and not
by press. Wherever practicable, machinery shall be mounted on self-
supporting steel frames or bedplates or on structural steel supports. All
working parts shall be accessible for servicing. The crane travel shall be by
hand and hoist shall be motor driven. The capacity of and lift as per design of
pumping station.
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The crane shall be guaranteed by the manufacturer of accepted modern design

free from inherent design in either workmanship or materials; and to safely
fully handle its rated load without any deflection in its structure or
mechanism. All material shall be the best of their kinds. Any part proved
defective within one year from date of erection testing at site shall be replaced
free of charge by supplier.
(b) CRANE STRUCTURE
The crane structure shall conform to IS: 807 latest edition and shall be
designed to withstand stresses arising from simultaneous travel of the rated
load of the crane along the bridge and the travel along the track and to
withstand the effect any possible combination of forces due to the loads, live
loads, local bending, inertia force, earthquake in the area as specified, with
adequate factor of safety. The bridge structure of the crane shall be of single
girder construction to safely carry full rated load of the crane without undue
vertical or lateral deflection or vibration. Girder shall be connected to the top
and side of each truck in such a manner that skewing will be prevented. The
trolley supporting rails shall be laid on top of bridge and steel rail stops shall
be provided at end of the bridge. Trolley stops should be spring type to reduce
shock and impact on the structure. All joints in the tension zone of the girder
shall be radio graphically tested and test certificate furnished for approval
before dispatch of the crane.
Each bridge end truck (crane has two end trucks) shall consist of two channels
connected to from a ring box section. Trucks shall be so designed that the
loading is equally distributed to each channel.
(c) TROLLEY
Trolley shall consist of a welded frame of structural steel sections adequately

braced to resist vertical, lateral and torsion strains, and properly machined to
receive the hoisting drums, wheels, axles etc. All the mechanical equipment
shall be mounted on machined pads. These pads shall be permanently welded
to the supporting structures after final alignments. Trolley frame shall be
provided with safety stops, jacking pads, equipment covers and hand railing as
63
required. The trolley wheel bearings shall have heavy-duty roller bearings
antifriction type. Wherever bearing caps are provided they shall be provided
with fittings for adequate lubrication. On the bottom of the trolley frame, on
each side, a double end spring bumper shall be provided to engage stops at
each end of the bridge.
(d) WHEEL AND AXLES
Wheel and axles shall be stationary type and made from steel and ground to
size to receive the inner race of the roller bearings. Axles shall be prevented
from turning or working endwise by means of a key plate fitting into a milled
slot in the end of the axle and bolted to the end trucks. Wheels shall generally
conform to IS: 3177. Wheel shall be double flanged type for end trucks. They
shall be accurately machined to suit the rail on which they are to operate.
Axles & shafts shall be made of high strength low alloy steel.
All bearings shall be of antifriction type of adequate capacity. Due allowance

shall be made for impact and side thrusts. Truck and trolley wheels shall be
provided with roller bearings. Other bearings may be ball bearings. Bearings
shall be made of steel.
All gears shall conform to relevant Indian Standard and also to IS: 3177
straight spur and helical gears shall normally be used for all motions. Gear
boxes shall generally conform to IS: 3177. Gear shall be cut from forged steel
blanks.
Adequate provision shall be made for proper lubrication of all gears, bearings
and pulley. Bearings shall be designed for grease lubrication of all gears,
bearings and pulley. Bearings shall be designed for gear lubrication by grease
gun.
Each trolley shall move over the inside of the bottom flange of the I-beam. The
gear pulley assembly should be so located that there is no fouling with the
bridge drive pulley and shaft. The trolley shall be spur gear type.
(e) RUNWAY RAILS
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The contractor along with the crane shall furnish suitable runway rails of
adequate size. The erection of runway rails is also included in Contractor's
scope. The runway lengths of the rails will be as indicated in the Technical
Data Sheets. However, these lengths are tentative only and the actual length of
rails will be determined at a later date depending on the final dimensions of the
building. Bridge stops will be provided at each end of the rails. The contractor
shall provide all clamps and fittings necessary for fixing the rails.
(f) LADDERS
The contractor shall be provided with necessary access from operating floor to
gantry girder level.
10.2ELECTRICALLY OPERATED HOIST
a) DESIGN REQUIREMENTS
Electric hoists shall be complete with hoisting motor, wire rope drum, wire
rope, hook necessary gearing, sheaves electromagnetic brakes for hoisting.
Weather and dust-proof push button station, connector panel creep speed
arrangement all wiring, flexible trailing cable, limit switches, travel stops, ear-
thing terminals and other accessories to meet the full requirements of the
Engineer-In-Charge. The Engineer-In-Charge will provide electric supply at one
point in pump house.
The hoist will be required to operate in the local climatic conditions. All the
parts of the hoist and trolley shall be designed to withstand such atmospheric
conditions without any deterioration.
b) FEATURES OF CONSTRUCTION
All though, this is an EOT crane, there shall be an optional provision of

manually operating through a chain drive, from the pump-house floor. The
hoist shall have the following requirements:
i) DRUMS
65
Rope drums shall be MS seamless type, as per ASTM 106, Gr. B made out of
tested quality of plates. Drums shall be machine grooved right and left with
grooves of a proper shape for the rope used. Grooving shall be of proper length
to handle all rope needed to make the required lift plus the two dead laps at
each anchor point, without overlapping. Drum shall be flanged at both the
ends. Flanges shall project above the rope by a distance not less than two-rope
diameter.
ii) SHEAVES
Rope sheaves shall be rolled steel. Grooves shall be machined to the proper
shape for the rope used. Sheaves shall be equipped with anti-friction type
bearings. Sheaves shall be fully guarded so that the rope cannot come off.
iii) GEARS
Gears shall be from solid forged steel blanks or shall be of stress-relieved
welded steel construction or built-up from steel billets and welded together to
form a one-piece gear section.
iv) BEARINGS
All anti-friction bearings are to be of standard make & interchangeable with
corresponding other standard sizes of the bearings. Bearings shall have a
minimum life expectancy of 40,000 hours and may be ball, roller, or removable
bronze-bushing type except that motor bearings shall be of the ball or roller
type.
v) ROTATING AND STATIONARY SHAFTS

Shafts and axles shall have ample strength and rigidity and adequate bearing
surfaces for their duties.
vi) LUBRICATION
A centralized grease lubrication unit with hand operated grease pump shall be
provided for anti-friction bearings.
vii) HOIST ROPE

Hoist ropes shall be extra flexible, improved plough steel rope with a well
lubricated hemp core and having six strands of 37 wires per strand with an
ultimate tensile strength of 160/175 kg/sq. mm. The rope shall be fastened to
66
the drum with an attachment having strength equal to that of the rope. The
rope shall be of sufficient length so that two full laps shall remain on the drum
at the extreme low position of the hook. Reverse bends or cross bends are to be
avoided. The breaking loads for the hoist ropes shall not be less than six times
the calculated load in the ropes at the drum, based on rated load on hooks,
plus the weight of the bottom block, plus the weight of rope. Wire slings with
U-blots (2 nos.) shall be supplied with the hoist hook.
viii) HOOKS
Hooks shall be solid, forged, heat treated alloy steel of rugged construction of
the single hook type and provided with a standard depress type safety latch.
They shall have swivels and operate on ball or roller thrust bearings with
hardened races. Lock to prevent hooks from swiveling shall be furnished.
ix) BRAKES
Hoisting motors shall be equipped with electrically released, spring set,
friction, shoe type brakes having torque capable of holding 125% of the full
rated hook load. Brakes shall apply when either the motor controller or the
main power switch is in "OFF" position, or in the event of power failure.
Breaker should be equally effective in both the direction of rotation.
10.3ELECTRICAL REQUIREMENTS
Drive motor shall be as per IS: 325 and companion specification enclosed.
Motor shall be designed for frequent reversal, braking and acceleration. Pullout
torque shall be 2.15 times the rated torque. Pendant control switch, controllers
and resistors, controls, electrical protective devices, cables and conductors,
earthling guards etc. shall be as per IS: 3938. Limit switches shall be provided
for over-hoisting and over-lowering and of two extreme ends of trolley travel.
Control gear such as switch fuse, contactors, and relays shall be mounted in
separate wall mounted panel in pump house.
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10.4PENDANT CONTROL
Pendant controls shall be provided with the pendant, which can be operated
from a convenient position on the operating floor. The control push buttons
shall be of spring returning type and shall be of reputed make subject to
owner's approval. The pedant switch box shall be capable of withstanding
rough handling. The mass of the pendant shall be supported independently of
the electric cable by means of chain or wire rope and the pendant shall be
effectively earthed.
10.5TESTING AND INSPECTION AT MANUFACTURER'S WORKS
The manufacturer shall conduct in presence of Engineer-In-Charge all tests

required to ensure that the equipment furnished shall conform to the
requirements of the specification and in compliance with the requirements of
the applicable codes.
Hook shall be tested in line with IS: 1875. Besides chemical and mechanical
tests, proof load test (at 125 % rated load) deflection test shall be conducted.
Suitable NDE (e.g. UT and DPT) shall be carried out before and after loads test.
Welds shall be subjected to suitable NDE e.g. RT/UT or DPE/MPE.
Prior to dispatch, the crane shall be assembled and subjected to check for
deflecting span, load, alignment, no load and full load & overload tests.
10.6TESTS AT SITE
After assembly and erection at site, the crane shall be subjected to

commissioning tests as laid down in the Indian Standards IS: 3177 and IS:
3832 including deflection and overload test.
The contractor’s authorized representative at site shall submit the reports on

the tests to client. The contractor shall furnish all test gadgets and instrument
necessary for conducting tests at site.
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PERFORMANCE GUARANTEE
The equipment shall guarantee to meet the performance requirements by the

specification and rectification shall be carried out until satisfactory results are
obtained before clearance for dispatch to site.
ACCEPTANCE
After erection crane, the owner will test all crane operation and controls to
determine that crane performance is satisfactory. Acceptance can take only if
crane perform to the entire satisfaction of Engineer-In-Charge. The supplier
shall depute to site his engineer to supervise the installation and instruct the
owner in operation and maintenance.
TECHNICAL DATA TO BE SUBMITTED WITH PROPOSAL
Following technical information shall be furnished with the proposal.

a. General arrangement drawings of the HOT crane with EOH showing
overall dimensions and clearance required.
b. A write up on the crane controls along with the drawing indicating
power and control schemes.
c. Calculations supporting motor horsepower selection for hoisting cross
travel and long travel motions.
d. Calculation for selecting rope size, no. of falls and F.O.S. (Factor of
Safety)
e. Calculation for selection of brake along with manufacturers brake
selection charts/catalogues.
f. List of vendors for bought out items.
g. Details of manufacturing and test facilities as available with the
manufacturer.
h. Experience list about the supply of similar cranes.
10.7TECHNICAL PARTICULARS
11 Location : Pump house
2 Crane rail support : R.C.C. brackets
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[A] ELECTRICALLY OPERATED TRAVELLING (EOT) CRANE
3 Quantity : 1 no. per pump-house

4 Span : As per Pump house size
5 Run way length : As per Pump house size
6 Operating floor : Pump house floor
level
7 Test load : 125% of rated load of
pumps, motor and
Accessories.
[B] TRAVELLING TROLLEY
8 Trolley type : Spur gear type

9 Wheels : Rim toughened, heat
treated forged steel
10 Shaft : High strength low
alloy Steel
11 Gears : From steel blanks
12 Frame : Rolled steel
13 Load chain : Alloy steel
[C] ELECTRICALLY OPERATED HOIST
14 Type of hoist : Spur geared, electrically

Operated
15 Capacity : As per Data Sheet
16 Lift : As per Data Sheet
17 Hoist drive : Electric motor
18 Gearing : Totally enclosed
19 Break : Electrically released spring
Set or friction disc type type
20 Drum : Steel plates
21 Sheaves : Rolled steel
22 Bearing : Anti friction roller bearing
23 Wire rope : 6 Strands - 7 wires
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24 Motor : Variable speed motor.

25 Control : Pendant
26 Creep speed control : As per requirement
27 Hook Approach : 0.5 Mtr.
28 Lifting speed : As per requirement
29 Ladder : Required for servicing
Crane & hoist
11. WALL THIMBLE MOUNTED C. I. SLUICE GATES
11.1 SPECIFICATION
These gates are made generally as per IS: 13349-1992.
11.2 APPLICATION
Wall thimble mounted Sluice gates are used either for isolation of flow from a
sump / chamber to a closed conduit or to another sump / chamber or for isolation of
flow from a conduit to a sump / chamber. Standard sluice gates have to be
modified to make them suitable for modulation application and hence standard
sluice gates should not be used for modulation application.
11.3 SALIENT FEATURES:
The salient features of the offered sluice gates are as mentioned underneath.
a) Flange back frame gate suitable for mounting on the face of a Cast iron
Wall thimble using studs and with a gasket between gate frame and wall
thimble flange.
b) Wall thimble to have cross section “F” and depth of 150 mm for the gate
size up to and including 600 mm and depth of 300 mm for the gate size
above 600 mm unless until specified otherwise. Gates having square /
rectangular opening are to be provided with thimble having square/
rectangular opening aperture with square/ rectangular flange for gate
frame mounting.
c) Square/Rectangular shaped natural rubber Gasket with predrilled holes
for positioning in between machined face of wall thimble flange and frame
flange.
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d) Open top frame provided with short length extension guides to support ½
vertical height of the slide when the slide is in full open position.
e) Frame specially designed to permit front access for tightening of thimble
mounting nuts so as to enable mounting of gates side by side or near
corners.
f) Rigid shutter is designed to withstand the applicable water head. Shutter
to be provided with cast Integral pocket to house the stem-connecting
block, which connects the spindle to the shutter for up and down
operation.
g) Seat facing fitted on machined Dovetail grooves of frame and shutter-using
counter sunk screws for better fitments.
h) The type of bottom closing offered i.e. conventional bottom closing shall be
as mentioned in price schedule attached. In case of conventional closure
gates, metal to metal sealing arrangement shall be provided around four
sides of opening.
i) Adjustable Center type individual side wedging arrangement for gates
meant for seating water head application and adjustable type individual
side as well as top & bottom wedging arrangement for gates meant for
unseating water head application.
j) Adjustable Channel type stems guide brackets in requisite quantity to
prevent buckling of spindle in event of over-closing of gate.
k) Rising stem / spindle to suit the distance between centerline of gate
opening and top of operating platform as stated below in price schedule.
The spindle is provided with square / trapezoidal threading with the
threaded length being approximately 400mm more than the height of
waterway opening.
l) Spindle couplings to connect multiple stem / spindles in case the
maximum length of one-piece
m) Stem / spindle exceed 4.5 to 5 meters resulting into provision of more
than one stem / spindle.
n) Provision of safety stop nut on spindle to prevent the chances of over-
closing of gate, which may otherwise damage either the spindle or the
lifting platform.
o) Lift mechanism mounted on separate platform above gate frame so that
gate operating thrust comes on to the platform.
p) Operation of gates by means of manual lift mechanism comprising of Pillar
mounted geared gate operating mechanism suitable for opening / closing
72
of gate by a single person with an effort not exceeding 18 kg on the hand

wheel / crank handle.
11.4 SHOP TESTING PARAMETERS:
a) Leakage test at operating pressure for gate leakage performance.

b) Movement test for checking interference free movement of complete
assembly.
c) Seat clearance check for checking clearance between mating sealing faces.
d) Positive Material Identification test for all material other than cast iron.
11.5 STANDARD PAINTING:
a) Surface preparation: Blast clean or Ground to near white metal finish.

b) Priming: 1 coat of red oxide primer before and after shop testing. Total
priming thickness shall be 75 Microns.
c) Finish painting for gate assembly: 2 coats of Coal Tar Epoxy paint for gate
assembly. Total paint thickness inclusive of priming 250 microns.
d) Finish painting for headstock: gray epoxy paint. Total paint thickness
inclusive of priming shall be 150 microns.
11.6 MATERIAL OF CONSTRUCTION:
The materials of construction of important components of gates will be as

under:
a) Frame & Shutter CI IS: 210 Gr. FG 260
b) Wall Thimble CI IS: 210 Gr. FG 260
c) Seating Faces & Counter Sunk Fixing Leaded Tin Bronze IS: 318, Type
LTB-2.
d) Wedging Device (with LTB-2 Linings) CI IS: 210 Gr. FG 260
e) Stem, Stem Extension & Coupling Stainless Steel ASTM A276 type 304
f) Stem Nut: Stainless Steel ASTM A743 CF: 8
g) Fasteners, Anchor Bolt, Studs & Nuts: Stainless Steel ASTM A276 type
304
h) Lifting Mechanism, Pillar and Head Stock: CI IS: 210 Gr. FG 200
i) Stem Guide: CI IS: 210 Gr. FG 200
j) Stem Guide Bracket: Structural steel
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k) Lift Nut: Leaded Tin Bronze IS: 318 Type LTB-2

l) Painting: Epoxy
12 PIPES AND SPECIALS
12.1 GENERAL
a) The scope of work is to manufacture & supply pipes, which shall be in

conformity with IS: 3589 – 2000 (latest) & IS 5504 (latest) from M. S. Plates
conforming to IS: 2062 -1999 or hot rolled steel coils conforming to IS:
10748-2004 of required sizes with internal lining of solvent free Food-grade
Epoxy (confirming to BS-6920) and external coating of 3 Layer Poly
Ethylene (3 LPE) - confirming to DIN 30672 or any other appropriate
standard. The Dry Film Thickness (DFT) of internal epoxy lining shall be
minimum 406 micron and total thickness of external 3 LPE coating shall be
3.7 mm on body of pipe and 3.3 mm on weld joint.
The M. S. Pipes, manufactured at the factory shall be provided with bevel ends.
After the final inspection of the pipe, the pipe bevel ends on both the sides
shall be coved with suitable protectors such that the pipe ends does not get
damaged during transportation, loading and unloading work. Also, varnishing
will be carried out at the inside and outside of the pipe cut back portion to
avoid the corrosion of the un- coated metal during storage period. The
varnishing can be removed after wards at the time of the welding and field joint
coating. The spiders on both ends of the pipe shall be of adequate size and
stiffness to keep the pipe in circularity during handling and storage. It will not
be less than 80 mm OD pipe. The spider pipe shall be a heavy duty pipe with
at least 6 mm wall thickness. If possible, the pipe vender shall avoid the
welding of the spider pipe with the main pipe and adopt some other means for
this purpose as it damages the internal surface of the pipe metal.
All the Piping Work in side of the Pump House shall be externally coated with
Zinc Rich Primer & suitable Epoxy Paint (Total DFT 200 microns). All the
piping work out side of the Pump House including the pump discharge piping
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and discharge header shall be externally coated with 3 LPE coating of 3.7 mm
DFT on body of pipe and 3.3 mm on weld joint.
The pipes shall be of uniform bore and straight in axis.
The flanges of the straight pipes shall be square to the axis of the pipe. The
faces of the flange shall be parallel. The bolt holes circle shall be concentric
with the bore and bolt holes equally spaced. In straight pipes, the bolt holes in
one flange shall be located in line with those in other.
The faces of the flanges of the fittings shall be square to the directional axes.
The holes shall be located symmetrically off the center line. The intersecting
axes of the tees shall be perpendicular to each other.
The bolt holes on flanged pipes and fittings shall be drilled with the help of
drilling jig. The blank flanges are to be machined and drilled.
All nuts and bolts used for jointing the pipes and fittings shall be of hot dipped
galvanized.
The approximate quantity for the pipe and fittings shall be furnished in
schedule of quantity.
The quantity of pipes is for tender purpose only. So during ordering of pipes &
fittings, Contractor has to measure the actual quantities required as per
execution of the site & prior approval should be taken from Engineer-In-
Charges / client.
The Pump discharge pipe lines in the pump house, shall be provided with
necessary air venting arrangement like, air valves or ball valves (manually
operated) of adequate size & rating for venting of air during start-up of the
pumps.
The reducers shall be prepared by conical bending of M S Plates in either

single piece (with one long seam weld joint) or half round pieces (with 2 nos. of
long seam weld joints). The minimum length of reducers shall be at least equal
to or more than the major diameter of the pipes to be connected. At Shop, the
testing of the welding joints shall be carried out by UT and Die Penetrating
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Testing to ensure the soundness of the weld joints. After installing the
Reducers at site, selected portion Radiographic Testing of site weld joint shall
be carried out after Weld Visual Inspection. Required pre-heating shall be done
while welding of field joints on the pipe to ensure that there is no moisture
present. One complete field joint at every 500 meters shall be checked with
100% radiographic examination over and above 10% radiography of each field
joint. Coil joint weld seam should not be failed at any time during testing. The
LCM of ultra-sonic thickness gauge must be 0.01 mm at pipe manufacturing
unit.
Sr. No. Description Particulars

1 Plates / HR coil IS:2062, Gr, E 250 BR / IS : 10748
Gr. III Fe 410
2 Welding & Electrodes ASME-SECT-IX, IS-7310, IS:7307,
IS:814, IS:3613, IS:6419, IS:7280
3 Inside Food Grade Epoxy IS : 3589
/ Outside Epoxy Coating
4 Fabrication & IS : 3589 and / or IS: 5504
Manufacturing of Pipe
13 MS ERW (ELECTRIC RESISTANCE WELDED) PIPES
13.1 SCOPE
This specification covers design, approval of documents, manufacture, Inspection,

delivery at site, storage at site, installation, testing and commissioning of MS ERW
Pipes and all kinds of Fittings. The Scope generally covers the requirements for
welded, plain ended, bevel ended or screwed ended black or galvanized steel tubes
or pipes, which are intended to be used for water supply.
13.2 CODES AND STANDARDS
Following Indian standards with latest revision will be applicable for MS ERW Pipes.
The design, manufacture & installation of the pipes shall comply with all currently
applicable statutes, regulations and safety codes in the locality where pipes are to be
manufactured / installed.
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Sr. No. Code Ref. No. Description

1. IS: 1239 (Part- Steel Tubes, Tubulars and other Wrought Steel Fittings
1) - Part-1 – Steel Tubes
2. IS: 1239 (Part- Steel Tubes, Tubulars and other Wrought Steel Fittings
2) - Part-2 – Steel Fittings
3. IS: 3589 Steel Pipes for Water & Sewage
Note:
IS: 1239 will be applicable for the Steel Tubes of sizes from 6 mm Nominal Bore (Nb)
to 150 mm Nominal Bore (Nb)
IS: 3589 will be applicable for the Steel Pipes of sizes from out side diameter 168.3
mm to 2540 mm
However, as a general industrial practice, the MS pipes shall be manufactured up to

500 mm pipe diameter with ERW process. Hence, this specification covers the MS
ERW Pipes of sizes from 6 mm to 500 mm pipe diameters in conjunction with above
referred standards.
Following Indian Standards shall also be applicable as additional reference to the

pipe manufacturing standards as listed above.
Sr.No. Code Ref. No. Description

1. IS: 228 Method of chemical analysis of steels
2. IS: 1608 Method of tensile testing of steel products
3. IS: 2328 Method for flattening test on metallic tubes
4. IS: 2329 Method of bend test on metallic tubes
5. IS: 3803 (Part- Method for elongation conversions for steels
1)
6. IS: 12278 Method of ring tensile test on metallic tubes
7. IS: 4711 Method for sampling of steel pipes, tubes and fittings
8. IS: 4736 Hot-dip Zinc coating on Mild Steel tubes
9. IS: 513 Cold rolled low carbon steel sheets and strips
10. IS: 10748 Hot rolled steel strips for welded tubes and pipes
11. IS: 1387 General requirements for supply of metallurgical
materials
12. IS: 4740 Code of practice for packaging of steel tubes
13. IS: 554 Pipe threads, where pressure-tight joints are made on
the threads – Dimensions, Tolerance and Designations
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14. IS: 8999 Gauging practice for pipe threads, where pressure tight
joints are required on the threads
13.3 GENERAL
The pipes shall be generally designated as MS Black Pipe manufactured without any
subsequent surface treatment or MS Galvanized Pipes as the case may be. The size will be
either designated by nominal bore (NB) denoting the approximate bore of the pipe or by out
side diameter (OD) and thickness of the pipe as the case may be. The plain ended pipes
shall be having cleanly finished ends by normal de-burring process. The plain end pipe shall be
supplied with square cut. The beveled end pipes shall be having finished tube end with a
specified angle and root face as per the details given in the relevant standards. The pipes shall
be cleanly finished and free from injurious defects. The ends shall be free from sharp edges
and burrs.
13.4 MANUFACTURING
The pipes shall be manufactured from plate, sheet or strip, welded continuously by the
passage of an electric current across the abutting edges longitudinally or spirally. The finished
pipes shall not include welds used for joining lengths of the hot or cold, flat rolled strips prior to
tube forming. The external weld bead shall be removed completely. The height of the internal
weld fin shall not be greater than 60% of the specified wall thickness of the pipes. Pipes may
be manufactured in Random or Exact lengths as agreed to between the manufacturer and the
purchaser. The tubes confirming to IS: 1239 shall be reasonably straight. The finished pipes
confirming to IS: 3589 shall not deviate from straightness by more than 0.2 percent of the total
length of the pipe. Checking shall be carried out using a taut Siring or wire from end to end
along the side of the pipe to measure, the greatest deviation.
13.5 DESIGNATION
[1] IS: 1239 - The steel tubes covered under IS: 1239 shall be designated by their nominal bore
and shall be further classified as Light, Medium & Heavy, depending upon their wall thickness.
The welded steel tubes shall be manufactured from hot rolled steel strip for welded tubes
and pipes confirming to IS: 10748 or cold rolled low carbon steel sheets & strips confirming to
IS: 513. For welded tubes, the height of the internal weld fin shall not be greater than 60% of
the specified wall thickness.
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[2] IS: 3589 - The pipes covered under IS: 3589 shall be designated by the method of
manufacture followed by the Grade Number corresponding to the minimum specified tensile
strength in Mega Pascal (MPa) following the symbol Fe. The sizes of the pipes shall be
designated by their outside diameters (OD) in mm and wall thickness (WT) in mm.
As per example: ERW – Fe 410 indicates Electric Resistance Welded (ERW) or Induction
Welded steel pipes having a minimum tensile strength of 410 MPa.
13.6 DIMENSIONS
The dimensions, nominal mass and tolerances in the dimensions and mass shall be as per
the relevant applicable standards.
13.7 CHEMICAL COMPOSITION
The ladle analysis of steel shall be as given in respective standards (IS: 1239 & IS: 3589).
The chemical analysis of steel shall be carried out either by the method specified in IS: 228
and its relevant parts or any other established instrumental / chemical method. In case of
dispute, the procedure given in IS: 228 and its relevant parts shall be the referee method.
However, where the method is not given in IS: 228 and its relevant parts, the referee method
shall be as agreed to between the purchaser and the manufacturer. Where the tubes are
required to be galvanized, the Zinc coating on the tubes shall be in accordance with IS: 4736.
13.8 PRODUCT ANALYSIS
If so agreed between the purchaser and the manufacturer, the product analysis may be carried
out. The permissible variations in the case of product analysis and the limits are as
specified in the respective standards (IS: 1239 & IS: 3589).
13.9 TEST ON PIPES / TUBES

Following tests on the tubes shall be conducted in line with the specifications.
Tensile & Elongation
Bend Test
Flattening Test
HYDRAULIC PRESSURE TEST
[1] IS: 3589 - Each pipe confirming to IS: 3589 shall be hydraulically tested at the
manufacturer's works before the pipe is coated, wrapped and lined.
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The hydraulic test pressure shall be the pressure calculated as per the following
formula:
Where,
2 ST P = Hydraulic Test Pressure in MPa
P = ------ D = Specified Outside Diameter of the Pipe in mm
D T = Specified Thickness of the Tube in mrn
S = Stress - 60% of the Specified Minimum Yield Stress in MPa
Test Pressure : The maximum test pressure shall be limited to 5 MPa, wherever
applicable.
Time : The hydraulic test pressure shall be applied for 5 Seconds.
Additionally, Non Destructive Test may also be carried out as agreed to by the
purchaser and the manufacturer. The method of NDT and the acceptance level shall
be as agreed to between the manufacturer and the purchaser.
[2] IS: 1239 – Each Pipe confirming to IS: 1239 shall be tested for leak tightness as
an in process test at the manufacturer’s works by Hydrostatic Test and additionally
by Eddy Current Test in accordance with the standard. The Hydrostatic Test shall
pressure and time shall as per following details and shall not show any leakage in the
pipe.
Test Pressure : The minimum test pressure shall be at least 5 MPa

Time : The hydraulic test pressure shall be applied for 3 Seconds.
13.10 COATING
Any type of protective coating, if required, may be provided in line with the tender
specifications and as agreed to between the manufacturer and the purchaser. Where
tubes are required to be galvanized, the zinc coating on tubes shall be in accordance
with IS: 4736.
13.11 INFORMATION TO BE SUPPLIED BY THE PURCHASER WHILE

PLACING ORDER
a) The quantity ordered (total tonnage, total length or number of tubes)

b) The number of this standard
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c) The Grade of Steel

d) The outside diameter and thickness or Nominal Bore and Class
e) The length of pipes
f) The end preparation (plain, beveled or screwed ends or special joints)
g) The type of external coating and / or interior lining as per specifications.
h) The steel making processes and de-oxidation procedures
i) The tube making process
j) Delivery condition
k) Ladle analysis
l) Delivery lengths
m) End preparation
13.12 MARKING
Each Pipe shall be having minimum following markings
a) Manufacturer’s Name & Trade Mark

b) Applicable IS Number
c) Pipe Numbering Details
d) Nominal Bore & Class of Pipe (Light, Medium or Heavy) as applicable
e) Outside Diameter, Thickness & Designation as applicable
f) Color Code as applicable
g) BIS Certification Marking
h) Name of Purchaser / Client
i) Name of Project
j) Any other marking as agreed to by Client & Manufacturer
13.13 PROTECTION AND PACKING
Black Tubes, not otherwise protected shall be varnished or suitably painted externally
throughout the length unless ordered unpainted or unvarnished. Where tubes are
bundled for transport, all qualities of tubes shall be packed in accordance with IS:
4740.
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14 INSTALLATION, TESTING AND COMMISSIONING
14.1 ERECTION - GENERAL
a) The Contractor’s staff shall include adequate and competent erection

engineers with proven, suitable, previous experience on similar contracts to
supervise the erection of the Works and sufficient skilled, semi-skilled and
unskilled labor to ensure completion of Works in time. The Contractor shall
not remove any representative, erector or skilled labor from the Site without
prior approval of the Engineer’s Representative.
b) The Contractor shall ensure that no installation or erection work shall
commence until full and unconditionally approved working drawings,
signed and stamped by the Employer are available at Site.
c) The Contractor’s erection staff shall arrive on the Site on dates to be agreed
by the Engineer-In-Charge. Before they proceed to the Site, however, the
Contractor shall first satisfy himself, as necessary, that sufficient plant of
his (or his sub-contractor’s) supply has arrived on Site so that there will be
no delay on this account.
d) One erection engineer who shall be required to be the Contractor’s
representative shall be conversant with the erection and commissioning of
the complete Works. Should there be more than one erector, one shall be in
charge and the Contractor shall inform the Engineer-In-Charge or his
representative in writing which erector is designated as his representative
and is Engineer-In-Charge. Erection engineer is to report to Project
Manager.
e) The Contractor shall be responsible for setting up and erecting the plant to
the line and levels of reference and of the positions, levels dimensions and
alignment, appliances and labor in connection therewith. The checking of
setting out of any line or level by the Engineer-In-Charge or his
representative shall not in any way relieve the Contractor of his
responsibility for the correctness thereof.
f) Erection of Plant shall be phased in such a manner so as not to obstruct
the work being done by other contractors or operating staff who may be
present at the time. Before commencing any erection work, the Contractor
shall check the dimension of structures where the various items of Plants
are to be installed and shall bring any deviations from the required
82
position, lines or dimensions to the notice of the Engineer-In-Charge. Plant

shall be erected in a neat and workmanlike manner on the foundations and
at the locations shown on the approved drawings. Unless otherwise directed
by the Engineer-In-Charge, the Contractor shall adhere strictly to the
aforesaid approved drawings. If any damage is caused by the Contractor
during the course of erection to new or existing Plant or buildings or any
part thereof, the Contractor shall at his cost make good, repair or replace
the damage, promptly and effectively as directed by the Engineer-In-Charge
and to the Engineer-In-Charge satisfaction.
g) The Contractor shall align all equipment and holding down bolts and shall
inform the Engineer-In-Charge before proceeding with grouting-in the items
concerned. The Contractor shall ensure that all equipment is securely held
and remains in correct alignment before, during and after grouting-in.
h) The approval by the Engineer-In-Charge of the Contractor’s proposals for
rigging and hoisting any items of the Plant into final positions shall not
relieve the Contractor from his responsibility for damage to completed
structures, parts or members thereof or other installed equipment. He shall
at his own cost make good, repair or replace any damaged or injured items,
whether structural, electrical, architectural, or of any other description,
promptly and effectively to the satisfaction of the Employer.
i) No Plants or other loads shall be moved across the floors of structures
without first covering the floors with timber of sufficient size so that applied
loads will be transferred to floor beams and girders of steel or concrete. If it
is required to reduce bending stresses and deflection, the beams and
girders shall be provided with temporary supports.
j) During erection of the plant, the Engineer-In-Charge will inspect the
installation from time to time in the presence of the Contractor’s Site
representative to establish conformity with the requirements of the
Specification. Any deviations and deficiencies found or evidence of
unsatisfactory workmanship shall be corrected as instructed by the
Engineer-In-Charge.
14.2 LEVELING AND GROUTING OF MACHINERY
a) He shall undertake sufficiently in advance chipping of any unevenness of

concrete on foundations, anchor bolt pockets, cutouts etc., to achieve
83
uniform level of reference for erection. All concrete surfaces receiving grout
shall be hacked as required to ensure better bonding with grouting.
b) Contractor shall undertake the inspection of all components to be erected
sufficiently in advance to check their soundness and conformity to drawings
and the inspection records shall be signed by the Engineer-In-Charge as
approval for undertaking the installation of the components. Any damage,
shortfalls etc. shall be made good to the satisfaction of the Engineer-In-
Charge.
c) All grout for equipment shall be carried out using non-shrinkable
continuous grout materials with suitable frame work of at least 12mm
thickness. Surfaces to receive the grout shall be hacked and roughened and
laitance shall be removed by wire brushing or blast of air. Concrete surface
shall be blown off by compressed air before commencing grouting. Grouting
shall be done in one continuous operation from one side such that grout
flows in a single wave until grout reaches all confined spaces with no air
pockets and air form all confined spaces is expelled. A hydro static head of
150 mm shall be maintained during grouting operations. All grouting shall
be carried out in the presence of the Engineer-In-Charge representative. All
lines and levels shall be checked up after grout is set. Block outs shall be
closed using cement concrete of the same grade as that of the parent
structure.
14.3 RECORDS, PROCEDURES AND REPORTS
a) The Contractor shall maintain records pertaining to the quality of

installation/erection work and inspection, testing, compliance with all
technical requirements in respect of all his works as described in the
previous paragraphs. The reporting formats shall be in the approved
formats. The Contractor shall submit such records duly signed by TPI to
the Engineer-In-Charge after the completion of any particular work before
submitting the bill of supply/progress of work. Such report shall comprise
shop inspection reports, shop testing reports, material test reports, based
on which dispatch clearances are provided, all the quality control reports of
welding, erection and alignment records.
b) All the above mentioned records shall be submitted in the final form duly
countersigned by the Engineer-In-Charge or his representative attesting
conformity to specifications and his approval of installation, and duly
84
incorporating all the additions, alternations, and information as required by

the Engineer-In-Charge on the basis of preliminary reports giving the
progress of the work. Such records notwithstanding, any records
submitted earlier with bill of supply/progress etc., shall be duly bound and
submitted to the Engineer-In-Charge in six copies by the Contractor on his
notification of the mechanical completion of erection.
14.4 GENERAL PREPARATIONS BEFORE COMPLETION OF THE PLANT
a) The following documents should be completed in accordance with the

Contract schedule before completion of erection. The Engineer-In-Charge
and the Contractor shall preserve and control these documents in a safe
and appropriate place on Site in order the both parties personnel can make
use of them at any time.
b) TECHNICAL DOCUMENTS
i) Operation and Maintenance manual
ii) Design documents including the Contractor’s design data, drawings and
Specifications.
iii) Tools and test equipment list
iv) Spare parts list
v) Lubricant list
c) PROCEDURES
i) Mechanical testing procedure
ii) Electrical testing procedure
iii) Instrumentation testing procedure
iv) Detailed Pre-commissioning and Commissioning procedure
v) Detailed Performance Test procedure
d) GENERAL AND COORDINATION DOCUMENTS

i) Detailed organization charts for Pre-commissioning and Commissioning
showing lines of authorities and responsibility, and functions of all key
personnel.
ii) The job description of the members of the team.
iii) The scheduled dates of assignment of each member to Pre-
commissioning and Commissioning Organization.
85
iv) A detailed schedule showing the time sequence which the Contractor
anticipates to follow for the various steps in Completion of Erection, Pre-
commissioning and Commissioning of each unit and equipment.
v) The regulations for safety, hygiene and discipline.
vi) The practical organization of the relationship (meetings, reports, etc.)
between the Contractor and the Employer at the phases of Pre-
commissioning and Commissioning.
vii) Emergency communication route.
e) MANPOWER
Required manpower shall be provided as agreed between the Contractor and
the Engineer-In-Charge a Manpower Mobilization Plan which shall include
the number and qualifications of the operator and maintenance personnel to
be furnished by the Contractor for the Plant.
14.5 COMPLETION OF ERECTION
a) The completion of Plant under erection by the Contractor shall be

deemed to occur, if all the units of the Plant are structurally and
mechanically complete and will include among other such
responsibilities the following:
b) Plant in the Scope of the Contract has been erected, installed and
grouted as per specifications.
c) Installation checks are completed and approved by the Engineer-In-
Charge.
d) The erected Plants are totally ready for commissioning checks.
e) At the stage of completion of erection, the Contractor shall ensure that
all the physical, aesthetic and workmanship aspects are totally complete
and the Plant is fit and sound to undergo tests on completion and
subsequent pre-commissioning checks.
f) Upon achieving the completion as described above, the Contractor shall
notify the Engineer-In-Charge by a written notice intimating completion
of erection and notify the Engineer-In-Charge for inspection. The
Engineer-In-Charge or his representative shall proceed with the
inspection of such units within 14 days of such a notice.
g) The Engineer-In-Charge shall certify completion when there are no
defaults in the Works or the Engineer-In-Charge shall inform the
86
Contractor list of deficiencies for rectification hereinafter referred as

Punch list and the Contractor shall complete the rectification work
within a jointly agreed period before pre-commissioning activities and
obtain the Engineer-In-Charge’s acceptance or approval of the same
before proceeding with the same.
h) The Engineer-In-Charge may inform the Contractor that the works are
accepted with the ‘Punch’ list (items which do not hamper operability,
safety or maintainability) and allow the Contractors to proceed with the
pre-commissioning checks when the Contractor under-takes to complete
such outstanding works within an agreed time during defects liability
period. Taking over shall be based on rectification of all deficiencies as
advised by Punch lists.
i) The erection period indicated by the Contractor would be deemed to
cover all the activities up to Completion as stipulated in previous
paragraphs, notice of completion by the Contractor, inspection by the
Engineer-In-Charge for Completion, and Contractor rectification of all
deficiencies as noticed by the deficiency/Punch list, and acceptance by
the Engineer-In-Charge of such rectification’s, prior to Tests on
Completion.
j) Minor defects, which, in the opinion of Engineer-In-Charge, do not
hamper operability and maintainability, will not be taken into account
for deciding Mechanical Completion. Such defects shall be rectified
concurrent to commissioning checks before Tests on Completion.
However, the Engineer-In-Charge’s decision in this regard is final.
k) The commissioning period as notified by the Contractor shall be deemed
to occur beyond the date of Completion and shall include all periods of
pre-commissioning, trials and Tests on completion.
l) It is in the Contractor’s interest to offer the section/units / systems,
progressively under identified milestones within overall erection period,
duly completed for rectification of any deficiencies pointed out by the
Engineer-In-Charge and to achieve Mechanical Completion before
undertaking the tests on Completion within the specified erection
period. The Engineer-In-Charge also reserves the right to withhold the
cost as estimated to be equivalent to the rectification of deficiencies
pointed out to the Contractor until such a time such deficiencies are
rectified to the satisfaction of the Engineer-In-Charge.
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14.6 PRE-COMMISSIONING
a) After the Completion of erection, Pre-commissioning activities listed

below shall be carried out to make the Plant ready for Commissioning.
All instruments, materials and provisions necessary for conducting site
tests shall be provided by the Contractor at his own cost.
b) Upon completion of erection of each piece of equipment, facility or
discrete part of the plant, mechanical checks and tests shall be carried
out according to the Contractor’s check list. The mechanical checks and
tests shall be to establish that:
c) The Plant is erected in accordance with the Contractor’s construction
drawings, pipe work drawings, instrument diagrams, etc. issued for the
Plant.
d) The materials are installed and mechanically function in accordance
with the Contract and Applicable codes as listed in the Contract are
followed for Materials and workmanship.
e) Items such as painting, thermal insulation and final clean-up which do
not materially affect the operation or safety of the Plant will be excluded.
All these items shall be listed and completed after Pre-commissioning or
commissioning at the discretion of the Contractor, but before
acceptance.
f) The Contractor shall prepare and maintain at site test forms and
records which shall include:
i. Description of type of test or check,
ii. Date and times of test or check,
iii. Identification of equipment and facilities,
iv. Test pressure, test data and results, including remarks, if any,
v. Signature of the Contractor’s personnel attesting to data recorded, if
any.
g) Checks, tests and records thereof shall be carried out by the
Contractors construction forces.
h) Engineer-In-Charge or his representative shall attend such check and
test wherever the Engineer-In-Charge’s or his representative’s witness or
attesting of the check or test is required. For this purpose, the
Contractor shall keep the Engineer-In-Charge informed of a day-to-day
test plan schedule. The test plan schedule may be revised from time to
time to reflect the actual progress of the work and test.
88
i) Any item, if found incomplete or requiring repair or adjustment, it shall

be marked as such on the test records and then reported by the
Contractor to the Engineer-In-Charge and the Contractor’s personnel in
charge of the relevant construction area.
j) Checking procedures shall be repeated until all the items on the check
list are cleared.
k) A complete set of test records shall be handed over to the Engineer-In-
Charge on completion.
l) The tests on the different Mechanical and Electrical equipment shall
include but not limited to:
Pumps, Piping and Valves
i) Complete piping installation shall be subjected to hydrostatic test at
a pressure of 1.5 times the shut off pressure of pump or twice the
working pressure of pump whichever is higher to test the soundness
of the joints. Provision of the necessary pumps, gauges, blank
flanges, tappings etc. for carrying out these tests shall be included in
the Contract.
ii) Leakage tests shall be carried out on all erected pipe work, pumps
and valves immediately after erection and where possible before
being built in.
iii) Operating tests shall be conducted on valves.
iv) The pump set shall be tested for performance. The vibration and
noise levels shall be checked to be within the specified.
v) The pump shall be tested throughout the operating range with all
working (excluding stand-by) for all the pumps. No negative tolerance
shall be permitted on any parameters visibly head, discharge and
efficiency. All the pumps will be tested for efficiency at duty point
after installation.
m) PUMP MOTORS
Condition of winding insulation be tested and insulation values shall be
restored to required level by suitable heating arrangements locally.
n) CRANES
The crane and lifting tackle shall be tested for the safe working load at factory.
The Contractor shall arrange the test load. Deflection and speed tests shall also
be conducted at site with load in presence of Engineer in- charge.
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o) INSTRUMENTATION
The tests on the instrumentation equipment shall include but shall not be
limited to :
i) All cables shall be tested for polarity, continuity and insulation resistance.
The common mode DC voltage at each signal input terminal shall be measured
and recorded.
ii) The pre-commissioning tests on the various main categories of plant shall
be as listed below:
A) The resistance of each electronic loop shall be measured
B) Electronic equipment shall have been energized for at least 24 hours
before testing begins
C) The zero setting of each display instrument including any local
indicator on or associated with a transmitter shall be checked
D) The correct calibration of each item in each control or monitoring loop
shall be checked by the introduction of appropriate signal at each source, at five
cardinals points of the range for increasing and decreasing signals
p) The following tests methods shall be used:

i) Pressure operated devices – dead weight testers or portable calibrators
ii) Level operated devices – actual level variation or simulation thereof.
Instrument zero reading shall be checked against a bench mark.
iii) For controlling devices, the Contractor shall demonstrate the correct
operation of the loop including the regulating devices. Each automatic
controller shall be set to the appropriate estimated values of the terms. It will be
optimized during the plant start-up. Each control valve shall be optimized during
the plant start-up. Each control valve shall be checked by operation of the
manual control on the associated controller and the correct stroking verified.
Valve positioners, electro-pneumatic converters and gauges shall be checked
during these tests.
iv) All systems shall be checked for “fail-safe” operation.
v) Initiating devices not covered by the foregoing e.g. plant stop/start
controls shall be checked in conjunction with the testing of the associated
switchgear and machine.
q) The Contractor shall also demonstrate the data transfer as per data transfer
schedule between Pumping Stations.
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14.7 COMMISSIONING
a) After the completion of Pre-commissioning activities the final checks and

preparations necessary for start-up of the plant shall be carried out. The
Contractor shall submit to the Engineer-In-Charge a written notice of
mechanical completion which shall include:
i. Identity of a part of the Plant considered mechanically complete
ii. A copy of all relevant completed test reports
iii. The date on which the completion of the tests was achieved
iv. Check list and
v. A request for issuance of a Mechanical Completion Certificate in respect
of that part.
b) Within fourteen (14) days from the date of receipt of the Contractor’s written
notice, the Engineer-In-Charge shall:
i. In the case of acceptance, issue a Mechanical Completion Certificate.
ii. In the case of objection, submit a rejection statement setting forth
remaining items to be completed or defects or deficiencies to be corrected before
Mechanical Completion status can be accepted. When the Engineer-In-Charge
rejects the Contractor’s notice, the Contractor shall take any necessary action to
complete or correct the items marked and give the Engineer-In-Charge a second
Notice of Mechanical Completion.
c) Commissioning activities of the Plant listed below shall be carried out to
enable the start-up and operation after the issuance of a Mechanical
Completion Certificate by the Engineer-In-Charge. Procedures are
described as below:
i. Commissioning Procedure shall be carried out in a methodical
sequence as follows
A) Warming up,
B) Start-up,
C) Initial running,
D) Operability adjustment,
E) Stable operation
F) Final adjustment
d) At all stages of commissioning sequence, the plant shall be operated at
optimum Plant conditions. To ensure this, the Contractor may make
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minor adjustment to the conditions indicated in the Operation and

Maintenance Manual as necessary.
e) The Contractor shall check the operating conditions of the plant by
constantly monitoring operating data.
f) The Contractor shall specify for each discrete part of the plant the
operational data to be recorded and the manner in which the data is to
be taken.
g) All the operating data shall be recorded by the Engineer-In-Charge on
the forms to be mutually agreed. A copy of the operating log and
analytical data from initial operation through to the completion of
Performance Test shall be made available by the Engineer-In-Charge to
the Contractor for evaluation.
b) UPVC Pipe: UPVC shall be confirming to IS 4985:2000. The system shall be
highly resilient, tough and durable with high tensile strength and high impact
strength. It shall be free from problems caused by scale formation, rusting,
weathering and chemical action, and lasting for a life time. The pipes shall be
virtually immune to attack by bacteria, fungi and other microorganisms or insects.
The pipes shall be non-conductive and immune to galvanic and electrolytic
corrosion. The PVC piping system shall be corrosion resistant to a great extent,
so much that they can be buried in alkaline or acidic soils or installed in over-the
ground environments, with no paint or special coating.
The pipes shall be inert to most chemicals and can resist attacks from most
chemicals at moderate temperatures.
The interior walls of the pipes and fittings shall have a mirror smooth finish
ensuring high flow rates and low frictional losses.
The pipes shall be free from rusting, pitting or scale formation so that there is no
particle deposition and the inner bore of the pipe remains undiminished
throughout the life of the system.
Jointing shall be done with the special solvent which ensures 100 % leak proof joints.
The PVC pipes shall be relatively more flexible and shall have adequate tensile
strength and even burst strength to withstand the operating pressures encountered
in most service conditions, with the acceptable range of temperature for the system.
c) D.I. (Ductile Iron) Pipe : D.I. pipes shall be confirming to the IS – 8329:2000.
DI shall be of required pressure class according to the operating pressure. The pipes
used will be either with push on joints (Rubber Gasket Joints) or Flanged joints.
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Pipes should be manufactured according to the preferred pressure class as per the
final design. The pipes shall be coated with bitumen and have factory provided
cement mortar lining in the inside as per the IS 8329.
The pipes will be supplied in standard length of 5.50 and 6.00 meters length with
suitably rounded or chamfered ends. Each pipe of the push on joint variety will also be
supplied with a rubber EPDM gasket.
The pipes will be subjected to following tests for acceptance:
 Visual and dimensional check as per Clause 13 and 15 of IS 8329
 Mechanical Test as per Clause 10 of IS 8329
 Hydrostatic Test as per Clause 11 of IS 8329
The test reports for the rubber gaskets shall be as per acceptance tests of the IS
5832.
The following types of DI fittings shall be manufactured and tested in accordance with
IS: 9523 or BS 4772.
 Flanged socket
 Flanged spigot
 Double socket bends (90degrees, 45degrees 22 /12degrees, 11 ¼degrees)
 Double socket branch flanged tee
 All socket tee
 Double socket taper
 All flanged tee
 All flanged taper
All the DI fittings shall be supplied with one rubber ring for each socket. The rubber
ring shall conform to IS: 12820 and IS: 5382. Flanged fittings shall be supplied with
one rubber gasket per flange and the required number of nuts and bolts.
15 INSPECTION AND TESTING AT MANUFACTURER’S

PREMISES
15.1 GENERAL
a) All inspection and testing shall be carried out in accordance with the
Specification and in absence of Specification relevant Indian Standard or
internationally approved equivalent standard.
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b) The Contractor shall carry out at the place of manufacture tests of the
Plant /Equipment at any part of the Works.
c) The Engineer-In-Charge shall be entitled to attend the aforesaid
inspection and/or tests by his own duly authorized and designated
representatives.
d) The Engineer-In-Charge and his duly authorized representative shall
have access to the Contractor’s premises at all suitable times to inspect
and examine the material and workmanship of the mechanical and
electrical plant and equipment during its manufacture there. If part of
the plant and equipment is being manufactured on other premises, the
Contractor shall obtain permission for the Engineer-In-Charge or his
duly authorized representative, to inspect as if the plant and equipment
was manufactured on the Contractors own premises. Testing (including
testing for chemical analysis and physical properties) shall be carried out
by the Contractor and certificates submitted to the Engineer-In-Charge’s
representative who will have the right to witness or inspect the above
mentioned inspection /testing at any stage desired by him.
e) The procedure for the testing and inspection to be carried out during or
following the manufacture of the materials to ensure the quality and
workmanship of the materials and to further ensure that they conform to
the Contract in whatever place they are specified shall be as described
below.
i. The Contractor shall give the Engineer-In-Charge at least 10 clear
days notice in writing of the date and the place at which any plant or
equipment will be ready for inspection/testing as provided in the
Contract. The Engineer-In-Charge or his duly authorized
representative shall thereupon at his discretion notify the Contractor
of his intention either to release such part of the plant and equipment
upon receipt of works tests certificates or of his intention to inspect.
The Engineer-In-Charge shall then give notice in writing to the
Contractor, and attend at the place so named the said plant and
equipment which will be ready for inspection and/or testing. As and
when any plant shall have passed the tests referred to in this section,
the Engineer-In-Charge’s representative shall issue to the Contractor
a notification to that effect.
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ii. The Contractor shall forward to the Engineer-In-Charge 3 duly

certified copies of the test certificates and characteristics performance
curves for all equipment.
iii. If the Engineer-In-Charge’s representative(s) fails to attend the
inspection and/or test, or if it is agreed between the parties that the
Engineer-In-Charge’s representative(s) shall not do so, then the
contractor may proceed with the inspection and/or test in the
absence of the Engineer-In-Charge’s Representative and provide the
Engineer-In-Charge with a certified report of the results thereof as
per (ii) above.
iv. If any materials or any part of the works fails to pass any inspection /
test, the Contractor shall either rectify or replace such materials or
part of the works and shall repeat the inspection and/or test upon
giving a notice as per (i) above. Any fault or shortcoming found during
any inspection or test shall be rectified to the satisfaction of the
Engineer-In-Charge before proceeding with further inspection of
wiring of that item. Any circuit previously tested, which may have
been affected by the rectification work, shall be re-tested.
v. Where the plant and equipment is a composite unit of several
individual pieces manufactured in different places, it shall be
assembled and tested as one complete working unit, at the maker’s
works.
vi. Neither the execution of a inspection test of materials or any part of
the works, nor the attendance by the Engineer-In-Charge’s
representative(s), nor the issue of any test certificate shall relieve the
Contractor from his responsibilities under the Contract.
vii. The test equipment, meters, instruments etc., used for testing shall
be calibrated at recognized test laboratories at regular intervals and
valid certificates shall be made available to the Engineer-In-Charge’s
representatives at the time of testing. The calibrating instrument
used as standards shall be traceable to National/International
standards. Calibration certificates or test instruments shall be
produced from a recognized/Laboratory for the Engineer-In-Charge’s
consent in advance of testing and if necessary instruments shall be
recalibrated or substituted before the commencement of the test.
viii. The Contractor shall not pack for shipment any part of the plant until
he has obtained from the Engineer-In-Charge or his authorized
95
representative his written approval to the release of such part for

shipment after any tests required by the contract have been
completed to the Engineer-In-Charge’s satisfaction.
ix. The following Testing shall be carried out for all the equipment as
applicable.
A) Visual Inspection.
B) Material Certificates for all the specified material shall be
furnished.
C) Welding Qualifications
D) Dimension Checking
E) Stage Inspections (in process inspection)
F) Dynamic balancing for all rotating parts
G) Hydrostatic / Leak testing for all pressure parts, Pneumatic Leak
Test wherever applicable
H) Operation check
I) Liquid Penetration Tests & Magnetic Particle Tests (for machined
surfaces of pressure parts).
J) Ultrasonic test for forging materials viz.,
Plates of thickness 20mm and above for pressed / formed parts
such as heads, etc.
Plates, flanges and bars of thickness / dia 40mm and above used for fabrication
of pressure and load bearing members and rotating parts
K) Radiographic testing for all butt welded parts, as per applicable
codes.
L) Hardness tests for all Hardened surfaces.
f) The Contractor shall maintain proper identification of all materials used,
along with reports for all internal / stage inspection work carried out, based
on the specific job requirement and or based on the datasheets /
drawings / specifications.
15.2 INSPECTION AND TESTS
(i) PUMP
a) All pumps shall undergo witness performance tests at the pump

manufacturer’s Works at full load full speed with one of the type tested
job motor.
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b) Minimum submergence test shall be undertaken for one pump to verify

that the pumps meet the minimum submergence committed.
c) A standard hydrostatic test shall be conducted on all pump columns;
discharge elbow and bowl assemblies at 1.5 times the maximum
discharge pressure of the pump or twice the rated pressure, whichever is
higher. The hydrostatic test shall be conducted for a minimum duration
of 30 minutes.
d) Impeller and pump rotating assembly shall be dynamically balanced as
per ISO 1940 / Gr. 6.3 at rated speed or reduced speed.
e) Standard running test shall be conducted as per BS 5316 Part 2 Class B
/ ISO 3555 / IS: 10981 Class - B at the rated speed at manufacturer’s
works to measure the capacity, total head, efficiency and power.
However, no negative tolerance shall be permitted on the tested
pump efficiency. Pump efficiency shall be more than guaranteed pump
efficiency at rated speed at duty point given by agency. Coating /
painting shall not be applied on the impeller and casing prior to testing.
These tests shall form the basis for pump acceptance except for vibration
and noise. The pump shall be tested over a range comprising shut off
head to maximum flow. Minimum six readings (apart from duty point
and shut off) approximately equidistant shall be taken for plotting the
performance curve. The following formula shall be taken for computing
the power input to the pump:
Power input to the Pump in kW: QxH

367.2 x p
Where, Q = Discharge in M3/hr

H = Total head in mwc
p = Efficiency of pump.
If the vibration, noise level readings taken during performance test show
higher than that permitted, vendor shall guarantee to show that the
values shall be maintained at site after erection. Any cost of rectification
needed on this count shall be borne by the Contractor.
f) The contractor shall carry out performance test of pumps at site to
prove the committed guaranteed parameters in the presence of Engineer
in – charge / his authorized representative. All necessary calibrated
instruments required for measurement of discharge, head, power etc. to
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be arranged by the contractor. Pumps not meeting min guaranteed

parameters shall not be accepted till required parameters are achieved
in performance testing.
The test procedure is to be submitted by the contractor in advance for
approval of Engineer-In–Charge.
(ii) VALVES
a) There shall be no visible evidence of structural damage to any of the

valve component during testing.
b) Motorized valves shall be tested with their actuators, with a differential
head equivalent to their maximum working pressure, to prove that the
actuators are capable of opening and closing the valves under maximum
unbalanced head condition within the specified opening or closing
period.
c) Sluice valves for isolation purpose shall be offered for open end test.
TEST FOR VALVES

A) The following test shall be carried out for butterfly valves:
a) Seat leakage test at rated pressure.
b) Body hydrostatic test at 1.5 times the rated pressure.
c) Disc strength test at body test pressure.
d) Valve operation.
e) 15  opening and closing test.
B) The following test shall be carried out for sluice valves:
a) Seat leakage test at rated pressure
b) Hydrostatic test at 1.5 times the rated pressure
c) Valve operation with and without actuator
C) The following test shall be carried out for Non Return valves:
a) Seat leakage test at rated pressure
b) Body hydrostatic test at 1.5 times rated pressure
c) Operation
(iii) PIPE WORK:

a) Testing of pipes and fitting shall be carried out in accordance with
relevant Indian Standard and internationally approved standard. Pipes
shall be hydrostatically tested for 1.5 times the rated pressure.
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b) Agency will maintain the registers and all record during pipe
manufacturing work and get certified by respective authorities like
department / TPI.
c) For all inspection works, transportation, lodging & boarding for all the
representative engineers from respective authorities shall be arranged by
the agency.
d) Pipe manufacturing registers shall be maintained & data shall be posted
in soft form in to the computer by agency.
e) 3 LPE material testing shall be carried out at pipe manufacture’s lab
during PQT and it will also be carried out at an independent government
approved lab, i.e. GIRDA, CIPET etc. the frequency of test shall be as
decided by the Engineer-In-Charge.
f) Agency shall prepare a planning preferably in the form of Bar chart and
review progress of actual work v/s target from time to time and take
corrective actions for timely completion.
g) The agency shall have a field laboratory for various field related testing
work will all the equipment.
h) Agency will arrange ‘C’ value testing after fully commissioning of the
project of this, then will submit a procedure to department /TPI for
review & approval.
i) Back log for internal and external coating of field joints shall be not more
than 10 weld joints on pipe line, i.e. agency shall complete coating work
after 10 weld joints are completed; otherwise without completing the
coating on pipe, further welding on pipeline shall not be allowed. This
will be a ‘HOLD’ point for site activities.
j) Authorized engineer of agency shall remain present during pipe
manufacturing as well accompany to the representatives of engineer in-
charge during inspection work at manufacturing site / test lab.
(iv) E.O.T. CRANE
The cranes shall be completely assembled in the Contractor’s or

subcontractor’s Works and shall be subjected to the tests as specified in
IS 807/IS 3177 or relevant internationally approved standard. The
Contractor shall provide the test weights.
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16 T ECHNICAL SPECIFICATION OF MOTORS
16.1 H T MOTORS
1. GENERAL:
The specification covers the design, manufacture, performance testing at
manufactures works, supply, delivery, storage at site; erection, testing and
commissioning of Squirrel cage induction motors complete with
instrumentation controls and safety devices, equipment for the cooling water
system, lubricating system oil, water piping with valves, fitting and other
accessories at each pumping station as detailed in the Schedule of
Requirements and as described in the various sub sections of the
specifications. The scope of supply shall include spares for 5 years of operation
of the pumping station, special tools and testing devices, all parts accessories
etc. which are essential for construction, operation and maintenance of all the
motors even though these are nor individually or specifically stated or
enumerated. Corresponding components of all the motors and associated
equipment and spares shall be of the same material, dimensions and finish
and shall be interchangeable.
The motor shall perfectly match in respect of speed, runaway speed, moment of
inertia, overload capacities, couplings and any other requirement with that of
pump.
2. STANDARDS
Sr.
Standard Description
No.
1 IS/ IEC 60034 Squirrel cage induction motors
2. IS 4691 Type of enclosures
3. IS 900 Code of practice for installation and maintenance of induction
motors
4. IS 6362 Method of cooling
5. IS 4029 Testing of induction motors
6. IS 2223 Dimensions of flange mounted as induction motors
7. IS 2253 Designations for types of construction and mounting
8. IS 2254 Designations of vertical shaft motors for pumps
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9. IS:4722 Rotating electrical machines

10. IS:4728:1975 Terminal marking and direction of rotation for rotating electrical
machinery.
11 IS:6362:1995 Designation of methods of cooling for rotating electrical machines.
12. IS:7816: 1975 Guide for testing insulation resistance of rotating machines.
13. IS:12065: 1987 Permissible limits of noise level for rotating electrical machines.
15. IS:4889: 1968 Method of determination of efficiency of rotating electrical
machines.
16. IS:12802:1989 Temperature rise measurement of rotating electrical machines.
17. IS:12824 Types of duty and classes of rating for rotating electrical
:1989 machines.
3. PERFORMANCE AND CHARACTERISTICS
a) Motors shall be suitable for satisfactory and efficient operation of pumps

for application and duty assigned. The rating of the motor shall be such
that it should not get over loaded when the pump would be delivering high
discharge due to water level in the sump at its highest level.
b) Motors shall be capable of satisfactory operation at full load at a supply
voltage of 80%of the rated voltage for 5 minutes, commencing from hot
conditions.
c) Motors shall be capable of developing the rated full load torque even the
supply voltage drops to 70% of the rated voltage. Such operation is
envisaged for a period of one second. The pull out torque of the motor to
meet this requirement shall be at least 205% of full load torque.
d) The locked rotor current of the motors shall not exceed 550% of full load
current inclusive of 20% tolerance.
e) The motor vibration shall be within the limit specified in IS: 4729 and IS:
325 - 1978. The permissible noise level shall not exceed the stipulations
laid down in IEC 34-9. The motor shall be designed to withstand 120% of
rated speed for two minutes without any mechanical damage.
f) Motors shall start satisfactorily and capable of giving rated output without
reduction in the expected life span when operated continuously under
following supply conditions.
Variation in supply voltage: +/- 10%
Variation in supply frequency: +/- 5%
Combined voltage and frequency variation: +/-10%
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The locked rotor withstand time under hot condition at 110% rated voltage
shall be more than the starting time at 80% voltage by at least two
seconds or 15% of the accelerating time whichever is greater.
g) Dropping efficiency from 100% load to 60% load is acceptable if the lowest
measured efficiency at 60% load is above minimum guaranteed value
given by the bidder in the data sheet.
h) The rating of motor shall be 10% margin of the maximum power required
by the pump over the entire operating range from shut off to run out flow
(or 15% on duty point, whichever is higher). Motors shall be provided with
eye bolts, lugs or other means to facilitate safe lifting.
i) All motors shall be so designed that the maximum inrush currents, and
locked rotor and pull out torques developed by them at highest voltage
and frequency limits do not endanger the motor and the driven
equipment.
J) Induction motors shall be designed to be capable of withstanding the
voltage and torque stresses developed due to the difference between the
motor residual voltage and incoming supply voltage equal to 150% of the
rated motor voltage during changeover of buses.
k) Motor not meeting min guaranteed parameters shall not be accepted till
required parameters are achieved in performance testing.
4. STATOR WINDING AND INSULATION
a) Motor winding shall be of proven high quality and reliability. For HT

motors the insulation system of stator winding shall be of the epoxy type.
b) Stator coils and rotor bars shall be tight fit in their slots. Any stator slot
packing used for winding of HT motors shall comprise of material
impregnated with a conducting medium and shall be compatible with the
system of stress control.
c) All winding overhangs and leads shall be adequately supported, braced
and blocked.
d) Case winding and all joints shall be designed to give an adequate safety
factor on the fatigue due to thermal and mechanical stresses, taking into
account the specified starting and running conditions. All electrical joints
and connections shall be of brazed or welded construction.
e) Motors shall be given power house treatment. This comprises an
additional treatment to the winding over and above the normal specified
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treatment. After the coils are placed in slots and all connections have been
made, the entire motor assembly shall be impregnated by completely
submerging in suitable insulating compound or varnish followed by proper
baking. At least three such submersions and baking shall be applied to
the assembly, class of insulation ‘F’. Motor winding shall be given a
further treatment with epoxy paint to withstand atmospheric conditions,
polluted by hydrogen sulphide.
f) The slot and overhang insulation of windings of HT shall also be based
essentially on mica. Windings of HT shall be provided with stress control
and corona protection. The anti corona protection shall be adequately
earthed and be resistant to damage due to abrasion or vibration.
g) All windings insulation shall be non hygroscopic, oil resistant to flame
propagation. All windings shall be impregnated and suitably processed to
effectively seal them to prevent deterioration from adverse environmental
conditions at site.
h) Temperature rises shall not exceed the values for insulation equivalent to
class B. More than 60°C to 75°C. These temperature rises are acceptable
for an ambient temperature of 50°C.
i) The motor construction shall be suitable for easy disassembly and
reassembly. The enclosure shall be study and shall permit easy removal of
any part of the motor for inspection and repair.
j) The rotor bars shall not be insulated in the slot portion between the iron
core lamination and the bars.
k) Motor shall be closed air circuit air cooled (without external cooling fan)
machine mounted heat exchanger (CACA/CACW) and the degree of
protection shall be IP 55, and duty cycle S1 as per IS: 325: 1978, IS: 6362
& IS: 4691.
l) The cooling fans shall be capable of being connected for rotation in either
direction or due care for cooling etc.
m) Motor shall be provided with PT 100 grade and terminals shall be brought
in separate RTD box.
5. CONSTRUCTIONAL FEATURES
a) Motor and its components (such as stator, rotors, end shields, terminal
boxes, bearings and heat exchangers) shall be designed to be readily
interchangeable as integral units for the same design and rating.
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b) All nonmetallic components used shall be of resistant to flame

propagation.
c) The motor construction shall be suitable for easy disassembly and
reassembly. The enclosure shall be sturdy and shall permit easy removal
of any part of the motor for inspection and repair.
d) Motor shall be provided with eye bolts, lugs or other means to facilitate
safe lifting.
e) Vertical motor shall be flange mounted type provided with thrust bearing.
f) All enclosures shall be designed to provide an effective sealing between the
primary and secondary air circuits. All totally enclosed type of motors
shall have suitable means of breathing
6. BEARINGS
a) Motors shall have anti friction tilting pad type bearings of oil lubricated
ball or roller type. Unless otherwise agreed the bearing shall be selected to
give a minimum i.e. 75000 hours at rated operating conditions.
b) Greased ball / roller / thrust bearings shall be of reputed make subject to
the Owner’s approval. The life expectancy of the bearings shall be stated.
c) Bearings shall be adequate to absorb axial thrust in either direction
produce by the motor itself or due to shaft expansion. Motor bearings
exposed to high temperature (i.e. motors for hot oil pumps) shall have
adequate provisions for cooling of bearings. Bearings shall have steel /
brass cages. Bearings with polyamide cages shall not be acceptable.
d) The bearings shall be so constructed that the loss of lubricating fluid is
kept to a minimum shall be possible without any dismantling operation.
e) The bearings shall prevent dirt and water from getting into the motor.
Bearing lubricant shall not find access to motor windings. Bearings shall
be capable of grease injection from outside without removal of covers. The
bearing boxes shall be provided with labyrinth seals, to prevent loss of
grease or entry of dust or moisture. When grease nipples are provided,
these shall be associated, where necessary, with appropriately located
relief devices which ensure passage of grease through the bearings.
f) The bearings shall permit running of the motor in either direction of
rotation.
g) The bearings are oil lubricated, a drain plug shall be provided for draining
residual oil and oil level sight gauge shall be provided to show precise oil
104
level required for stand-still and running conditions.

h) Unless otherwise approved, bearing lubricating system shall be such that
no external forced oil or water is necessary to maintain the required oil
supply or keep bearing temperature within design limits.
i) Lubricants shall be selected for prolonged storage and normal use of the
motors in tropical climate and shall contain corrosion and oxidation
inhibitors. Grease shall have suitable bleeding characteristics to minimize
setting.
j) Safety measures for bearing temperature for tripping to be added. (High
temperature).
7. NO. OF STARTS
Continuous duty motors shall be suitable for two starts in succession and
three equally spread starts in an hour under the specified conditions of load,
torque and inertia, with the motor initially at its normal running temperature.
8. TORQUE REQUIREMENTS
a) The accelerating torque at any speed with the lowest starting voltage shall
be at least 10% of rated full load torque of the motor.
b) The pull out torque at rated voltage shall not be less than 205% of the full
load torque.
9. STARTING TIME
a) For motors with stating time up to 20 seconds at minimum permissible

voltage during starting, the locked rotor withstand time under hot
condition at highest voltage limit shall be at least 2.5 seconds more than
stating time.
b) For motors with starting time more than 20 seconds but not exceeding 45
seconds at minimum permissible voltage during starting, the locked rotor
withstand time under hot condition at highest voltage limit shall be at
least 5 seconds more than the starting time.
c) For motors with starting time more than 45 seconds at minimum
permissible starting voltage, the locked rotor withstand time under hot
conditions at highest voltage limit shall be more than the starting time by
105
at least 10% of the starting time.
10. TERMINAL BOX
a) Terminal box shall be of weather proof construction designed for indoor

service, to eliminate entry of dust and water, gaskets of approved make
shall be provided at cover joints and between box and motor frame.
b) Terminal box shall be suitable for single compression cable jointing kit.
The terminal box shall be suitable for top and bottom entry of cables.
c) Unless otherwise approved, the terminal box shall be capable of being
turned through 360 in steps of 90.
d) The terminals shall be of the stud type with necessary plain washers,
spring washers and check-nuts. They shall be substantially designed for
the current carrying capacity and shall ensure ample phase to phase and
phase to ground clearances. Suitable cable jointing kit shall be supplied
by the motor vendor/ EPC agency to match Owner’s cable.
11. ROTOR
a) The rotor shall be of squirrel cage type, dynamically balanced to provide a

low vibration level and a long service life to the bearings. The accepted
values of peak to peak vibration amplitudes for a motor at a rated voltage
and speed on a machine surface bed plate with the motor levelled and with
a half key or coupling fitted shall not exceed those given in IS: 4729. The
shaft ends shall be provided with a suitably threaded hole or holes to
facilitate the assembly or removal of couplings and bearing races.
b) The rotor bars shall not be insulated in the slot portion between the iron
core laminations for squirrel cage motors.
c) Rotor will be made up of electrical steel followed by environmental
protection coating for anti corrosion.
d) All motor rotors shall be dynamically balanced. Rotors shall be so
designed as to keep the combined critical speeds with the driven
equipment away from the running speed by at least 20%.
12. PAINT AND FINISH
a) Motor external parts shall be finished and painted to produce a neat and
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durable surface which would prevent rusting and corrosion. The

equipment shall be thoroughly degreased, all rust, sharp edges and scale
removed and treated with one coat of zinc epoxy primer and two coats of
Epoxy paints.
b) The motor fan shall also be painted to withstand corrosion.
13. ANTI-CONDENSATION HEATERS AND TEMPERATURE DETECTORS
a) All motors shall be provided with 240 volt anti condensation heaters, sized
and located so as to prevent condensation of moisture during shut down
period. The heater shall remain "ON" when the motor is not in service, and
shall not cause damage to the windings.
b) At least twelve simplex or six duplex resistance type embedded
temperature defectors for the stator winding each having D.C. resistance
of 100 at 0°C embedded in the stator winding at locations where highest
temperature may be expected and at bearings. The material of the RTD
shall be platinum. Temperature Detectors detector leads, external to the
slot shall be provided with a protective covering. These RTDS shall be
wired to PLC controls for monitoring temperature rise.
c) The heater leads shall be brought out to a separate terminal box of the
same specification and grade of protection as the main power terminal box
excepting that the nickel plated brass glands provided shall be suitable for
2 core 4 Sq. mm aluminum conductor, armoured cable.
d) A warning label with indelible red inscription shall be provided on the
motor main terminal box & space heater terminal box to indicate that
isolation of the power line alone is not sufficient and that the heater
supply should also be isolated before carrying out any work on the motor.
Motor supplied shall be complete with all double compression cable
glands, crimp type cable lugs.
e) Motor supplied shall be complete with all double compression cable
glands, crimp type cable lugs.
14. NOISE LEVEL
The permissible noise level shall not exceed the stipulations laid down in IEC
34-9. & IS: 12065.
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15. MOTOR VIBRATION
Motor vibrations shall be within the limits of IS: 4729 unless otherwise
specified for the driven equipment. The vibrations as measured at motor
bearings shall be within the limits specified in IS: 12075/BS: 4999 Part ‐ 142.
Motor shall also be capable of withstanding the vibration produced by the
driven equipment.
16. NAME PLATE
Each motor shall have a nameplate displaying all the particulars specified in
relevant standards. In addition, the nameplate shall indicate identification,
number of bearings used for motor and recommended lubricant indicating
required quantity of lubricant and interval at which the bearings are to be
lubricated.
Name plate shall be made of 2 mm thick stainless steel with the relevant
details embossed on it in English.
17. ACCESSORIES
Two independent earthing points shall be provided on opposite sides of the

motor, for bolted connection of the Owner’s earthing conductors. These
earthing points shall be in addition to earthing stud provided in the terminal
box.
17 INSPECTION AND TESTING AT MANUFACTURER’S

PREMISES
17.1 QUALITY ASSURANCE PLAN, TESTING & INSPECTION OF MOTOR
a) The general QA requirement is attached; the vendor is advised to go

through the same before submitting the bid.
b) All tests shall be conducted as per relevant IS/IEC/IEEE standards
c) Quality Assurance plan shall be submitted by the bidder along with the
108
vendor documents for the approval.
17.2 GENERAL CONDITIONS
a) OEM (Original equipment manufacturer) shall have ISO certification

b) All the tests are to be carried out in the presence of any authorized represen
tative of the client and third party as per direction of Engineer of Contract.
c) The contractor shall have to offer stage inspection during manufacturing
process where required by the client / final inspection on completion of
manufacturing for Routine test & type test inspection.
d) Routine test shall be performed by manufacturer on all equipments (100%)
in presence of EPC agency/ contractor, client and TPA and minimum one
motor to be type tested.
e) The proposed date of stage/ final inspection shall be informed to Owner
FIFTEEN days in advance.
f) The contractor shall submit the following during commencement period.
A) Name of raw material as well as bought out accessories and the names
of sub suppliers selected from those furnished after award of work.
B) The contractor shall submit the routine/ type test certificate of bought
out items & raw materials at the time of routine testing of the fully
assembled equipment.
C) List of standards; according to which the raw materials are tested, list of
tests normally carried out on raw materials in presence of contractor’s
representative, copies of test certificates.
D) Type test certificates of the raw material and bought out accessories.
g) Instruments
A) The manufacturer should keep the precise and accurate measuring
instruments
B) The periodical calibration should be carried out of all the instruments
/equipment used for the measurement during tests and for assessing the
various properties of the material and accessories.
C) The proper record of the same should be maintained during
manufacturing stage and shall be shown to the inspecting officer on demand.
D)
All the measuring instruments used in inspection and testing shall be properly
calibrated and sealed once in a year with tag of competent authority.
h) Equipment offered shall have all Type Test Certificates from accredited
laboratory (accredited based on ISO/IEC Guide 25 / 17025 or EN 45001 by the
109
National Accrediting Body of the country where laboratory is located), as per IEC/
IS /technical specification.
i) The type test conducted shall be on similar equipment and on similar
capacity.
j) Equipment not type tested in the last five years, type tests need to be
performed without any extra cost. The purchaser may select the transformer for
type tests randomly.
k) The acceptance of any quantity of equipment shall in no way relieve the
vendor of his responsibility for meeting all the requirements at this specification
& shall not prevent subsequent rejection, if such equipment are later, found to be
defective.
l) EPC agency shall arrange for commissioning test at site by the OEM/ OEM
approved agency confirm equipment are healthy at site & test result at site are
same & committed figures are achieved.
m) Four sets of certified type tests reports shall be submitted for approval prior
to dispatch of the equipment. The equipment shall be dispatched only when all
the required acceptance & routine tests have been carried out & the test reports
have been approved by the client & TPA.
n) Certificates shall be clearly identified by serial or reference number where
possible to the material being certified and shall include information required by
the relevant reference standard or specification clause
p) Job pump of each type shall be tested with job motor and shall be witnessed
by client’s representative.
q) Soft stater shall be tested with job motor & Job pump to check that Starting
current of motor shall be as per the value given during bid evaluation. In case
this type of testing not done during factory test, agency shall be responsible to
prove the starting current value during commissioning stage. Any dispute
between pump/motor/ soft starter shall be resolve by the agency.
17.3 ROUTINE TEST
a. Insulation resistance test before & after HV test

b. High voltage test
c. Reduced voltage running up test at no load to check the ability of motor to
run up to full.
d. No load running of the motor and measurements of currents and voltages on
all three phases.
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d. Locked rotor test at suitable voltage.

e. Testing of accessories/auxiliaries for correct functioning.
f. Vibration test.
g. Noise Level test.
17.4 TYPE TEST
Measurement of stator resistance and rotor resistance of motor.

a. No load running of motor and reading of voltage, current, power and speed.
b. Open circuit voltage ration on motors.
c. Reduced voltage running up test at no load to check the ability of motor to
run up to full
d. Speed on no load in each direction of rotation with 1/√3 of the line voltage
applied to the motor.
e. Locked rotor reading of voltage, current, power input and torque of motors.
f. Full load reading of voltage, current, power input at 125%, 110%,100%, duty
point, 75%, 60%, 50 % load
g. Temperature rise test.
h. Momentary over load test
i. Insulation resistance test with before and after the high voltage test.
j. High voltage test
k. IP 55 test as per applicable standard.
MOTOR ACCEPTANCE AFTER TEST
Motor not meeting min guaranteed parameters shall not be accepted till
required
Parameters are achieved in performance testing.
Though the motors shall be accepted on the basis of the satisfactory results of
the tests at the works, it shall not absolve the vendor from liability regarding
the proper functioning of the motor coupled to the driven equipment at site.
L.T. MOTORS
1. GENERAL
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The specification covers the design, manufacture, testing at manufactures

works, supply, delivery, storage at site; erection, testing and commissioning of
Squirrel cage induction motors complete with instrumentation controls and
safety devices, equipment , lubricating system oil.
The scope of supply shall include spares for 5 years of operation of the
pumping station, special tools and testing devices, all parts accessories etc.
which are essential for construction, operation and maintenance of all the
motors even though these are nor individually or specifically stated or
enumerated.
Corresponding components of all the motors and associated equipment and

spares shall be of the same material, dimensions and finish and shall be
interchangeable.
The motor shall perfectly match in respect of speed, runaway speed, moment of
inertia overload capacities, couplings and any other requirement with that of
pump
2. STANDARDS
Sr.
Standard Description
No.
1 IS 12615-2011 Squirrel cage induction motors
2 IS 12615 Energy efficient induction motors- three phase squirrel cage
3 IS 4691 Type of enclosures
4 IS 900 Code of practice for installation and maintenance of induction
motors
5 IS 6362 Method of cooling
6 IS 4029 Testing of induction motors
7 IS 2223 Dimensions of flange mounted as induction motors
8 IS 2253 Designations for types of construction and mounting
9 IS 2254 Designations of vertical shaft motors for pumps
10 IS:4722 Rotating electrical machines
11 IS:4728:1975 Terminal marking and direction of rotation for rotating electrical
machinery.
12 IS:6362:1995 Designation of methods of cooling for rotating electrical
machines.
112
13 IS:7816:1975 Guide for testing insulation resistance of rotating machines.

14 IS:12065:1987, Permissible limits of noise level for rotating electrical machines.
IEC60034-9
15 IS:12075:1987 Mechanical vibrations of rotating electrical machines
16 IEC 60034-14 Mechanical vibrations of rotating electrical machines
17 IS:4889:1968 Method of determination of efficiency of rotating electrical
machines.
18 IS:12802:1989 Temperature rise measurement of rotating electrical machines.
19 IS:12824:1989 Types of duty and classes of rating for rotating electrical
machines
3. TECHNICAL PARAMETERS
Sr.
Description Technical Parameter
No.
1 Motor Rating As per the requirement of Pump.
2 Type of motors 3 Phase Induction Motor, TEFC
3 Quantity
4 Motor duty Continuous, S1
5 Application Standard IS 12615-2011
6 Motor Energy efficiency EFF2 as per IS- 12615 (94%)
class
7 Design Temperature 50 Deg C amb.
8 Rated Speed Contractor to specify
9 Supply voltage & frequency
Conditions
Voltage : 415 V + 10%
Frequency : 50 Hz + 5%
Combined V & F Variation + 10%
10 Insulation class Class F and temperature rise as per class B
11 Starting Method Star Delta up to 50 kW
Soft Starter for Above 50 kW
12 Cable termination details Al conductor, XLPE / PVC insulated,
armored 6.6 kV grade cable
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13 Cable termination box class IP 55

protection
14 Space heater 230 V
10 Bearing temperature Required
sensing
15 Winding temp. sensing 6 Nos. required for each motor
16 Earthing conductor GI strip as per the sizes specified
4. DESIGN CRITERIA
4.1 Rating & Temperature rise
a) All motors shall be of continuous rated type
b) The motors shall be designed for maximum ambient temperature of 50 C;
with the temperature rise of the stator winding by resistance method over
the ambient air temperature no exceeding 70C for both class B and class
F insulation.
c) In case of continuous operation at extreme supply voltage variation limits,
the temperature rise limits as specified above shall not exceed by more
than 10 C for motors of output up to and including 200 KW.±10%
d) Each motor shall be assigned a maximum continuous rating (MCR)
corresponding to this temperature rise.
e) Wherever the basis for motors ratings are not specified in the
corresponding mechanical specification sections, maximum continuous
motor ratings shall be at least 10% above the maximum load demand of
the driven equipment under entire operating range as specified elsewhere
including voltage and frequency variation.
f) The rated supply voltage, voltage & frequency variations in the supply are
mentioned elsewhere. Motors shall be capable of delivering its maximum
continuous rating with supply variations. The motor can start
satisfactorily under the extreme conditions.
g) All motors shall be so designed that the maximum inrush currents, and
locked rotor and pull out torques developed by them at highest voltage and
frequency limits do not endanger the motor and the driven equipment.
i) Induction motors shall be designed to be capable of withstanding the
voltage and torque stresses developed due to the difference between the
motor residual voltage and incoming supply voltage equal to 150% of the
rated motor voltage during changeover of buses.
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J) The voltages at all motors during start up shall be maintained at a value

which ensures that there is sufficient accelerating torque developed by the
motor to give a safe run up time.
k) The maximum system transient impedance shall be used in calculating
voltage drops relating to motor starting, restarting and re-acceleration
requirements.
l) During starting or re-acceleration of a motor, either individually or in a
group, the voltage dip at the motor terminals shall not vary more than
15% from rated voltage when started direct on line under the worst
operating scenario i.e. largest motor started with minimum number of
power sources and minimum fault level.
5. TORQUE REQUIREMENTS
a) The accelerating torque at any speed with the lowest starting voltage shall
be at least 10% of rated full load torque of the motor.
b). The pull out torque at rated voltage shall not be less than 205% of the full
load torque.
6. NO. OF STARTS
Continuous duty motors shall be suitable for two starts in succession and
three equally spread starts in an hour under the specified conditions of load,
torque and inertia, with the motor initially at its normal running temperature.
7. STARTING CURRENT
The ratio of starting Current/rated current (MCR corresponding to the

specified temperature rises) shall not exceed 6 .In case of DOL starter. But
with soft starter it shall be between 2 to 3 times.
8. STARTING TIME
a. For motors with stating time up to 20 seconds at minimum permissible

voltage during starting, the locked rotor withstand time under hot
condition at highest voltage limit shall be at least 2.5 seconds more than
stating time.
b. For motors with starting time more than 20 seconds but not exceeding 45
seconds at minimum permissible voltage during starting, the locked rotor
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withstand time under hot condition at highest voltage limit shall be at

least 5 seconds more than the starting time.
c. For motors with starting time more than 45 seconds at minimum
permissible starting voltage, the locked rotor withstand time under hot
conditions at highest voltage limit shall be more than the starting time by
at least 10% of the starting time.
9. CONTROL
All the motors shall be suitable for control through circuit breaker / MCCB as
specified.
10. ENCLOSURE AND METHOD OF COOLING
The motors shall be of totally enclosed closed Fan Cooled, (TEFC).

11. VIBRATION LEVEL & NOISE LEVEL
The vibrations as measured at motor bearings shall be within the limits specified in IEC:
60034-14, IS: 12075. The motor shall also be capable of withstanding the vibration
produced by the driven equipment. The Noise levels shall comply with IEC:60034-9, IS:
12065.
12. CONSTRUCTIONAL FEATURES
a) Motor and its components (such as stator, rotors, end shields, terminal
boxes, bearings and heat exchangers) shall be designed to be readily
interchangeable as integral units for the same design and rating.
b) All nonmetallic components used shall be of resistant to flame
propagation.
c) All enclosures shall be designed to provide an effective sealing between
the primary and secondary air circuits. All totally enclosed type of
motors shall have suitable means of breathing and of drainage to
prevent accumulation of from condensation. Drain holes diameter shall
not exceed 6mm.
d) The cooling fans shall be capable of being connected for rotation in
either direction or due care for cooling etc., especially where identical
motors are to be provided for opposite direction of rotation, such as for a
pair of conveyor without replacing or removal of fans or any other parts.
116
e) Motors shall preferably be capable of being connected for rotation in

either direction with due care for cooling etc., specially where identical
motors are to be provided for opposite direction of rotation, such as for a
pair of conveyor without replacing or removal of fans or any other parts.
f) All heavy parts of the motors shall be provided with necessary
arrangement: such as lifting lugs/eye bolts for lifting or handing during
erection or overhaul.
g) All motor rotors shall be dynamically balanced. Rotors shall be so
designed as to keep the combined critical speeds with the driven
equipment away from the running speed by at least 20%.
h) Space heaters or internal electric heaters shall be provided on motors
rated above 30 KW to maintain the windings in a dry condition during
periods of standstill. The heaters shall be suitable for use on 240 volts,
50Hz AC Supply. Space heater shall remain ON when motor is in
operation
j) Temperature Detectors
At least six nos. of simplex or duplex platinum resistance type embedded

temperature detectors, evenly distributed around the stator, shall be provided
for all HT motors. These shall be located at locations where high temperatures
are expected during operation. Resistance of the temperature detector at 0 C
shall be one hundred (100) ohms. Temperature detector and detector lead
insulation class shall be the same as stator winding insulation call. Detector
leads, external to the slot shall be provided with a protective covering. These
RTDS shall be wired to PLC controls for monitoring temperature rise.
13. WINDING AND INSULATION
a) Winding insulation shall be of class B or better for LT AC motors. It

shall be of proven high quality and reliability.
b) All windings insulation shall be non-hygroscopic, oil-resistant and
resistant to flame propagation. All windings shall be impregnated and
suitably processed to effectively seal them to prevent deterioration from
adverse environmental conditions at site.
c) All winding overhangs and leads shall be adequately supported, braced
and blocked.
117
d) Cage windings and all joints shall be designed to give an adequate safety
factor on the fatigue due to thermal and mechanical stresses, taking
into account the specified starting and running conditions. All electrical
joints and connections shall be of brazed or welded construction.
14. BEARINGS
a) Bearings shall be of roller type, except where motor speed and shaft
loading dictate otherwise. Vertical motors shall normally have rolling
type guide and thrust bearings. The latter may however be of Kings bury
tilting pad type where heavy axial loads are to be supported.
b) Temperature of lubricating oil as it leaves the bearing shall be not
exceeding 71 C.
c) Bearing shall comply with the relevant Indian or International
Standards. The bearings housing shall be correctly packed with lithium
based grease at the time of assembly. Construction shall be such that
the bearings can be dismantled without risk of damage.
15. TERMINAL BOXES AND ASSOCIATED FITTINGS
a) The cable boxes and terminations shall be designed to enable easy

disconnection and replacement of cables. Leads from terminals to the
windings shall be adequately sized and braced to withstand the heating
and forces produced by maximum fault current.
b) Terminals shall be suitable for receiving aluminum conductor
XLPE/PVC insulated cables. Motor shall be supplied with compression
type tinned brass cable glands and Crimping type tinned copper lugs for
the termination of cable. The termination lugs shall conform to DIN
46329.
c) Clearance between the lugs/bare live parts of different phases and
between lugs/bare live parts and earth shall be as per relevant
standard. The terminal boxes shall be capable of withstanding a system
fault level. A suitable provision of releasing the pressure developed
during faults shall be made. Terminal boxes shall be suitable for top
and bottom entry of cables.
d) LT motor terminal box shall be capable of being turned through 360 in
step of 90C.
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16. EARTHING TERMINALS
Two independent earthing points shall be provided in accordance with IS:

3043, on opposite sides of the motor for bolted connection.
17. RATING PLATE
In addition to the requirements as called for in relevant IS, the rating plating
plate shall indicate the following:
a) Maximum continuous rating in KW and corresponding temperature rise,
as applicable for cooling medium temperature as specified.
b) Bearing identification numbers (in case of ball/roller bearing and
recommended lubricant.)
18. PAINT & FINISH
a) All external parts shall be finished and painted to produce a neat and
durable surface which would prevent rusting and corrosion. The
equipment shall be thoroughly degreased, and sharp edges and scales
removed and treated with one coat of primer and two coats of enamel
paint shade no 631 as per IS:5 for indoor motors and shade no. 632 as
per IS: 5 for outdoor motor. Motor fans shall also be painted to
withstand corrosion.
b) All fasteners used in the construction of the equipment shall be either of
corrosion resistant material or heavy cadmium plate. Current carrying
fasteners shall be either of stainless steel or high tensile brass or
copper.
19. PRE COMMISSIONING TEST OF PUMP & MOTOR:
The test shall be carried out as per IS: 9137 code of acceptance test of pump
Class C, in general and as started below in particular.
The purpose of the field test is not to ensure whether pump performance as
regards parameter i.e. H, Q & power etc. within acceptance limit as per IS:
119
9137. The purpose is to ensure that the pump performance is generally

acceptable or otherwise.
Final acceptance shall be as per following criteria.

i) As regards H/Q characteristic for acceptance it shall be checked
whether motor is not getting overloaded within the specified head range.
ii) Flow measurement shall be taken by the flow meter to be provided by
contractor.
iii) The head shall be measured with calibrated pressure gauge of accuracy
1% or better. At least 3 pressure gauges shall be got calibrated from two
different institutions with prior approval of the Engineer in charge. The
calibration shall be point to point and not mere for percentage error. The
gauge shall be fitted at suitable place from the discharge nozzle. It may
be noted that pressure gauge shall be installed at least 2 times diameter
away from discharge nozzle and delivery valve be placed at least four
times diameter away from discharge nozzle. Such conditions shall be
simulated at site condition and no allowance for this deficiency shall be
considered. The decision of Engineer in Charge shall be final.
iv) The input power to motor shall be measured by 2 wattmeter method.
The watt meters shall be of Laboratory grade having accuracy of min.
0.5% and these should be digital type.
v) The speed shall be measured by non-contact tachometer with digital
display calibrated. The field test shall be taken with entire head range in
such a manner that it would cover at least 6 points (i.e. duty point, 2
above duty points, 2 below duty point and shut off). The guarantee for
head and discharge shall deem to be fulfilled as per clause.
The field performance test at site is absolutely essential as above (i) to (v) and
the manufacturer shall also be asked to attend the same.
20. PRE COMMISSIONING CHECKS & TEST OF HT MOTOR:
1. Check IR & PI value. If require improve IR & PI by drying out to obtain

the required insulation resistance values. Approval of the drying
methods shall be obtained from Owner before applying heat.
2. Align motor with the pump
3. Check cable connection at motor phase, neutral side & Circuit breaker
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side and space heater connection .

4. Check motor earthing at two places and measure earth resistance
5. Set winding & air temperature gauges for alarm & trip set value are as
per OEM recommendation & simulate the values.
6. Carry out DC simulation test of the breaker. See that breaker trips by
operating all relays one by one.
7. Test motor protection relay by secondary injection relay test set & see
that settings are done as per recommendation.
8. Switch on DC supply at motor beaker keeping breaker in racked out
position. See that space heater becomes “on”. Measure current taken by
the space heater circuit. & note down for future reference.
9. Run motor in decoupled condition, check direction of rotation, it should
be as required for the pump. Note down no load current in
decoupled, vibration on motor bearings in decoupled condition.
10. Stop motor, Coupled motor with Pump. Give start kick & check
direction of rotation.
11. Run pump motor set with discharge valve in closed position. Observe &
note down no load current in coupled condition, vibration at all the
bearings for future reference.
12. Run motor on load opening pump discharge valve note down no load
current in coupled condition, vibration at all the bearings for future
reference.
13. Each Pump- motor set is to run separately continuously for 72 hours at
full load and temperature of various parts including winding, bearing
etc. are to be observed. And measurement of discharge at rated head is
to be measured.
21. PRE COMMISSIONING CHECKS & TEST OF LT MOTOR:
1. Check IR & PI value. If require improve IR & PI by drying out to obtain

the required insulation resistance values. Approval of the drying
methods shall be obtained from Owner before applying heat.
2. Align motor with the pump
3. Check cable connection at motor phase , neutral side & Circuit breaker
side and space heater connection
4. Check motor earthing at two places and measure earth resistance
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5. Set winding & air temperature gauges for alarm & trip set value are as
per OEM recommendation & simulate the values.
6. Carry out DC simulation test of the breaker. See that breaker trips by
operating all relays one by one.
7. Test motor protection relay by secondary injection relay test set & see
that settings are done as per recommendation.
8. Switch on DC supply at motor beaker keeping breaker in racked out
position. See that space heater becomes “on”. Measure current taken by
the space heater circuit. & note down for future reference.
9. Run motor in decoupled condition, check direction of rotation, it should
be as required for the pump. Note down no load current in decoupled,
vibration on motor bearings in decoupled condition.
10. Stop motor, Coupled motor with Pump. Give start kick & check
direction of rotation
11. Run pump motor set with discharge valve in closed position. Observe &
note down no load current in coupled condition, vibration at all the
bearings for future reference.
12. Run motor on load opening pump discharge valve note down no load
current in coupled condition, vibration at all the bearings for future
reference.
13. Each Pump- motor set is to run separately continuously for 72 hours at
full load and temperature of various parts including winding, bearing
etc. are to be observed. And measurement of discharge at rated head is
to be measure
18 SURGE CONTROL SYSTEM FOR PUMPING MAIN

18.1 ACCEPTED CONTROL SYSTEM
(a) Following types of control systems are only accepted for control of water
hammer pressures in the pumping mains. a) Zero Velocity Valves and Air
Cushion Valves (only for pumping main).
(b) The manufacturer of these systems must have previous experience of
manufacturing such systems and must produce test results on at least
two systems manufactured and installed by him with diameter of the
main not less than 1200 mm. In case of on way surge tanks, the valves
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used should be of reputed accepted make with proper opening

characteristics.
(c) The agency has to submit the design of surge protection device and get
approved by owner’s engineer.
18.2 WATER HAMMER CONTROL

a) SPECIFICATION FOR WATER HAMMER CONTROL DEVICE
WITH ZERO VELOCITY VALVE AND AIR CUSHION VALVE
The valve has an outer fabricated casing ('Main Body') in which a 'Central Rod'
is held by struts. A 'Stationary Central Dome' creates an annular streamlined
passage for smooth flow of water. Closing Disc is mounted on 'Central Rod'.
Disc is held in closed position by a number of 'Stainless Steel Springs' (as per
AISI 304). Two 'Anti Rotation Guides' are provided on the edge of 'Central Disc'
with minimum resistance to flow. 'Anti Rotation Guide' is claded with Stainless
Steel Strip (as per AISI304) and 'Guide Fork' with brass liners. A 'Bypass' with
a 'Valve' connects upstream and downstream sides of valve. A 'Man Hole' is
provided on 'Outlet' cone of main body, for maintenance and replacement of
spring (if required) without removing the valve from line. The 'Outer Shell',
'Dome' & 'Disc' are fabricated out of MS plates as per IS: 2062. A stainless steel
sleeve (as per AISI 304) is fitted on 'Central Shaft' and moves in brass bush in
'Disc' for free movement. The Valve will be painted in Zinc Rich Epoxy Paint
from inside and food grade epoxy from outside both in min two layers with total
thickness of 406 microns.
b) SPECIFICATION FOR AIR CUSHION VALVE
The valve consists of a 'Main Body' and 'Top Housing'. On the side of main
body, two 'Air Inlet Valves' loaded with a light spring are fitted. The 'Inlet' is
protected by a cover. The 'Top Housing' has an opening for air escape. A spring
loaded 'Poppet' with a brass seat and Neoprene 'Sealing Ring' covers the top of
the opening. The spring pressure on the valve is adjustable by a screw (S.S. as
per AISI-304). The 'Housing' has a tapered outlet, the opening of which is
adjustable by a tapered plug and Screw (SS as per AISI-304). The outlet is
protected by a cover. On its lower side a cage holding a ball float is fitted. 'Main
Body', 'Top Flange', are fabricated from MS (as per IS:2062/I.S.1239). The 'Top
Housing' is made from high grade cast iron. Main body, float ball and air inlet
flange are hydraulically pressure tested. Stems of valves are in stainless steel
123
(as per AISI-304), and work in 'Brass Bushes'. Sealing rings are of good quality
rubber and seats are of brass The Valve will be painted in Zinc Rich Epoxy
Paint from inside and food grade epoxy from outside both in min two layers
with total thickness of 406 microns.
All branched outlets including outlets for Air valves will be with compensation
pads (Dia of Main / For branch Dia ratio greater than 3). Diameter of
compensation pad will not be less than 1.75 times the O.D. of the branched
outlet. Plate thickness for pads will be same that of the main.
For outlets with above ratio less than three, then the joints will be of plate
reinforcement type.
All branched outlets including air valve, tees will be provided with one ½” BSP
coupling duly plugged for measurement of pressure in due course. The closing
plug will be in Stainless Steel (AISI 304 or equivalent) with Hex. Head and will
be provided with copper washer for sealing.
All flanges will be drilled as per IS: 1538. Thickness of all flanges will be as per
relevant IS.
Thickness of pipes Strength of steel pipes is verified to check effect of positive

and negative pressures during transients due to power failure and surge
protection devices shall be provided to avoid any damage to the pipeline
integrity, shape and structure.
18.3 SURGE CONTROL SYSTEM - REQUIREMENTS
a) The requirements given are tentative. The contractor, after award of

contract, must carry out the surge analysis based on the longitudinal
section, Pump and Motor characteristics of the selected pumps by the
contractor.
b) During detailed engineering, based on the Surge Control System’

selected by the contractor, following information must be submitted.
For design of surge control system following limits will be adhered to
(The surge pressures will be estimated after all working pumps at
designed discharge, trip simultaneously)
124
i. Maximum upsurge anywhere in the system will not exceed 10.0 kgf/sq.cm
or 1.2 times the Normal Working Pressure at manifold whichever is lower.
Beyond half the length of pipeline, the limit will be 6.0 kgf/sq.cm or 1.5
times the Normal Working Pressure at mid length.
ii. The lowest pressure (Minimum Down surge) anywhere in the system will
not be lower than (-) 0.4 kgf/sq.cm (i.e @ 0.6 kgf/sq.cm above absolute
zero) (Only 50% of the installed air valves can be assumed as operative for
this condition.).
iii. The contractor will submit Surge analysis without any control system to
ascertain the requirement of surge control system and the results along
with details will be submitted during detailed engineering in case of award
of contract.
19 FIRE FIGHTING SYSTEM

This specification is intended to cover design, engineering supply, test and
inspection at works, delivery at site, properly packed for transportation, erection,
testing, commissioning, performance demonstration at site and handing over to
Owner of Fire Protection System as indicated in the scope of work and as required for
reliable and effective Fire Protection of the Project.
The specification also includes the supply of recommended spares for 2 (two) years
trouble-free operation of the system and special tools and tackles.
This specification also makes it obligatory for the contractor for arrangement and
obtaining necessary clearance / approval from all statutory authorities or
authority approved by TAC.
It is not the intent to completely specify all the details of design and construction
herein. Nevertheless, the equipment and installation shall conform to high standard
of engineering design and workmanship in all respect and shall be capable on
performing continuous satisfactory operation and acceptable to the Owner as well as
the various statutory authorities. In case of any violation of the above by the
Contractor, the Owner reserves the right to change/ reject/ modify any equipment /
system during the detail engineering stage of the contract.
Wherever a material or article is specified or described by the name of a particular

brand, manufacturer or vendor the specific item mentioned shall be understood as
125
established type function and quality desired Other manufacturer’s product may be
considered provided sufficient information is furnished to allow the OWNER to
determine that the product proposed are equivalent to those brand.
1. GENERAL INFORMATION
a) The entire system shall be designed and engineered by the Bidder based on
the basic design guidelines furnished in the specification, various codes /
standards, bidder’s experience and also as per good engineering practice.
b) Before quoting the bidder may visit the site and acquaint himself with the site
conditions and the scope of work of the fire protection system as specified in
this specification.
2. SCOPE OF SUPPLY
Scope of Supply & Work (Services)
a. The equipment and items to be furnished under the scope of this contract
are outline therein-after. Any additional equipment, material, services which
are not specifically mentioned but required to make the system complete
and acceptable & shall be deemed to be included in the scope.
b. Supply, installation, testing, commissioning, handing over to OWNER the

complete fire protection system as per specification and as per latest Norms.
c. Transportation to site, unloading and intermediate storage at site, complete

work of erection including final grouting, testing and commissioning and
putting into operation of entire fire protection system.
d. Supply, installation, testing & commissioning of fire pump, jockey pump,

electric control panel etc. as per schedule of work & specification.
e. Supply, installation, testing & commissioning of complete set of piping,

valves, fittings, specialties, instruments elect. Panel, cabling etc as required
for the complete Fire Fighting System.
f. All bolts, foundation bolts, nuts, gaskets, packing, pipe hangers, support /
thrust block etc. as needed for complete erection & commissioning of system
shall be provided. The cost of the same shall be considered in the piping
126
rate. No extra / separate payment will be made for this. Supply of all
consumable materials required to complete erection of the system.
g. Supply, installation, testing, commissioning of complete cabling for motors,

from control panel including earthing cable etc.
h. Supply and application of primer and final painting as per specifications.
i. Supply, laying and testing of cables from motor to panel including

earthing of motor & panel.
j. Supply of various drawings, data, test reports, test certificates, operation

and maintenance manual as necessary.
k. First fill of all fuel and lubricants at no extra cost.
l. All spare parts and tools and tackles as per specification.
m. All final dressing of foundations, grouting of equipment and patch work

during and after erection.
n. Excavation for laying of underground piping, back filling, dressing,

compacting, watering, carting away of surplus earth up to 500 Mt.
o. Hydro Testing for the complete system.
p. Carrying out 10% radiography of weld joints of piping, hydro testing of

piping loop.
q. Submission and obtain necessary approval of relevant drawings, schemes

and documents from local / fire authorities / TAC and also obtain all
necessary permissions and NOC for execution of work as well as getting final
approvals from the concerned fire officers along with relevant “NOC”. No
extra payment shall be made on account of getting the approval. The
contractor shall also take care of any other requirement. The cost incurred
for covering complete scope of work specified above shall be included in
various items of schedule of works. No extra payment shall be given for
covering anything of the above scope of works.
3. HYDRANT SYSTEM
127
Hydrant type fire protection system shall be laid in the form of ring mains having
adequate network so that water at recommended pressure and flow rate is made
available at all hydrant points.
Contractor shall provide external hydrants. Hydrants shall have instantaneous

type female outlets of 63mm dia.
Contractor shall provide each external hydrant with 15m long no percolating
controlled percolation RRL hose pipe with gunmetal male and female instantaneous
type couplings machine wound with GI wire (hose to IS:636 / IS:8423 type
certification), gun metal branch pipe with nozzle to IS 903.
Contractor shall provide standard fire hose reels of 25 mm dia high pressure
flexible hose 36 m long with gunmetal nozzle, wall mounted on a circular hose reel of
heavy duty mild steel construction having cast iron brackets. Hose reel shall be
connected directly to the wet riser with an isolating valve. Hose reel shall conform to
IS: 884.
Contractor shall provide hose cabinet shall be provided for all internal and
external fire hydrants. Hose cabinets shall be fabricated from 16 guage MS powder
coated sheet of fully welded construction with hinged double front door partially
glazed (4 mm glass panel) with locking arrangement, stove enameled fire red paint
(shade No. 536 of IS:5) with “FIRE HOSE” written on it prominently. Cabinet surfaces
in contact with the walls shall not be powder coated but instead given two coats of
anti-corrosive bitumastic paint. Pipelines of the hydrant system shall be
charged with pressured water up to the hydrant valves.
When any of the hydrant valves in the system is opened, the water pressure in the
corresponding water pipeline shall fall rapidly. Under such situation, pressure in the
water main shall decrease further and impulse from pressure switch shall start the
fire pump. Through the local control panel located in the Fire Water Pump house. If
this pump is not started due to any fault, the water pressure in the pipeline shall
further drop and the impulse from another pressure switch shall start the diesel
engine driven stand by pump.
4. HVW SPRAY SYSTEM
HVW Spray System is envisaged for transformers in the switchyard.
a) General
128
Each of these transformers shall be surrounded with pipe rings having spray
nozzles and quartzoid bulb detectors. The pipe ring with spray nozzles shall be
connected to the downstream side of a pressure operated Deluge Valve. The upstream
side shall be connected to the Pump in Pump House.
The QB detector network shall always be under pressurized conditions. This shall
be achieved through a connection from upstream side of DV. In case of fire these
detectors shall explode at a predetermined temperature thereby releasing the
pressure from the downstream side of DV. This shall open the deluge valve and
simultaneously start the Pump. Thus water shall be sprayed on the equipment
under fire.
Start signal to the pump shall be given through a pressure switch – which shall
sense drop in pressure upto a preset value, in the header and accordingly issue a
signal to the control cum annunciation panel for starting the pump. Provision for
local/remote- manual operation of the system shall also be provided.
Annunciation for DV open shall be displayed on Fire Alarm panel.
b) Design Criteria
i. The system shall consist of water supply system, suitable number of spray
nozzles, deluge valve, strainers, pipes and necessary valves. Wet type
detection shall be provided for actuating the Deluge system.
ii. Design discharge density for HVW Spray system shall be 10.2 lpm/ sq.m
as per the rules of water spray system of Tariff Advisory Committee (TAC).
iii. Minimum water pressure at the farthest and / or highest projector on the
equipment protected shall be 3.5 kg/cm2. However water pressure at any
point shall not exceed 5 kg/cm2.
iv. The automatic actuation of the deluge valve shall be by means of

Quartzoid bulb detectors of 79 deg. C type.
v. An isolation valve shall be provided at upstream of each of the deluge

valve. The size shall be same as that of the deluge valve.
vi. An isolation valve will be provided on the downstream of deluge valve, so

that this valve can be kept closed and can be operated manually, if there
is any malfunction of deluge valves.
129
vii. Water motor gong shall form part of accessories to be provided with deluge
valve.
viii. A strainer ('Y' type) shall be provided at upstream of deluge valve.
ix. Pressure gauges at both upstream and downstream of deluge valves, and
in the detector pipe network shall be provided.
x. Pressure switches shall be provided in spray and QB detector piping to

exhibit "FIRE" and "SPRAY ON" annunciations and as well as for interlock.
xi. All Spray pipe mains/ pipe lines shall be routed above ground on RCC
pedestals. Road, Rail or pipe trench crossing shall be through RCC Hume
pipes duly covered with coating and wrapping as per specification. Hume
pipe for road crossing shall be NP3 class and that for rail crossing shall be
NP4.
xii. Facility for remote actuation of deluge valves, through a push-button shall
be provided. Local control panel for each deluge valve shall be provided.
5. SPARE PARTS
a) Recommended Spares
The supply of spare parts as necessary and recommended by the

respective manufactures for 2 (two) years of reliable trouble free operation
and maintenance of all equipment for the plant, shall be under the scope of
CONTRACTOR.
6. DRAWING & DOCUMENT
a) Drawing/Documents / Data & Manual to be furnished by CONTRACTOR

after award of contract and get approval from the consultant / architect before
starting the execution.
b) Piping Layout drawings along with hydraulics for each individual

system/equipment and get approval from consultant / architect
c) Any other drawings deemed necessary by OWNER / CONSULTANT.
d) Performance test curves and test certificates for all equipment.
e) Write-up operation, control and monitoring of the fire protection system.
130
f) Two copies Instruction manuals for operation, maintenance, overhaul

and replacement of parts of various equipment.
7. PAINTING & COATING
a) Over ground Piping
Piping to be laid over ground shall be supported on pipe rack / supports.

Rack/ support details shall have to be approved by Owner.
The entire over ground piping shall be painted with red colour shade No. 536
as per IS: 5.
Surface of over ground pipes except galvanized pipes shall be thoroughly

cleaned of mill scale, rust etc. by wire brushing.
Over ground pipes shall be painted with one coat rich zinc primer& two coat of
Synthetic Enamel paint of approved shade.
b) Underground Pipe Line
Steel pipe lines to be laid in trenches underground shall be protected against

corrosion by means of 4 mm thick anti-corrosive tape Rustech or equivalent
make.
Application:
i) The various layers of materials shall be applied as follows:
Cleaning of exterior steel pipe surface with wire brush such that all rust, mill
scale is removed. - Application of a continuous and uniform primer film with a
dry thickness not less than 25 – 30 microns.
Application of a helicoidally wrapping of a 4 mm thick tape pulled into contact

with the primer with proper tension in order to avoid an excessive penetration
15 mm overlap shall be provided. The application shall be in accordance with
IS: 10221.
ii) Pipe line thus coated and wrapped shall be tested for holiday detection by
means of high voltage holiday detector (10,000 volts). Any defects observed
during such tests shall be suitably rectified.
131
ABBREVIATION
1 ANSI AMERICA NATIONAL STANDARDS
INSTITUTE
2 LOA LETTER OF AWARD
3 BKW BRAKE KILOWATT POWER
4 CI CAST IRON
5 DI DUCTILE IRON
6 NDT NON-DESTRUCTIVE TEST
7 DPCV DUAL PLATE CHECK VALVE
8 MOC MATERIAL OF CONSTRUCTION
9 TEFC TOTALLY ENCLOSED CLOSED FAN COOLED
10 AWWA AMERICAN WATER WORKS ASSOCIATION
132
11 NB NOMINAL BORE
12 PN NOMINAL PRESSURE
13 BIS BUREAU OF INDIAN STANDARDS
133
20 DATASHEET
1. FOR UCHCHHAL:
DATA SHEETS FOR MECHANICAL WORKS - PUMP HOUSE
Sr.
ITEM DESCRIPTION
No.
2 NON RETURN VALVES
3 EXPANSION BELLOWS
4 VERTCAL TURBINE (VT) PUMPS
5 ELECTRICALLY OPERATED OVERHEAD TRAVELING (EOT) CRANES
6 ELECTRIC OPERATED HOIST
7 EXHAUST FANS
8 AIR VALVE
9 M. S. PIPE LINES
10 ELECTRICAL MOTORS – HT & LT
11 BUTTERFLY VALVES (BFV)
134
SLUICE VALVES / GATE VALVES

Sr.
Description Required Specs.
No.
1.1 General Double Flanged
(for water application)
(a) Size Of required size as per pipe diameter
(b) Type Sluice Valve (SV) – Non-rising Spindle Type
or Gate Valve – Rising Spindle Type
(c) Make Furnish during detail engineering
(it shall be of approved vendor list)
(d) Rating PN 2.0
(e) Standard to which (1) IS 14846 : 2000 (for Sluice Valve)
manufactured (2) API – 600 / 603, BS – 1414 (for Gate
Valves)
(3) IS 1538 / 1976, Part IV & VI or standard,
suitable to size (for Flange)
(f) Valve Location (1) In the Pump House
(2) In the Pipe line
1.2 Mode of Operation: Motorised
1.3 Materials of
Construction
(a) Body, Bonnet, Wedge, Ductile Iron as per IS 1865 Gr. 500/7
Stuffing Box & Gland
(b) Stem (Spindle) SS AISI 410
(c) Stem (Spindle) Diameter Furnish during detail engineering
(mm)
(d) Body Seat Ring / Wedge Bronze IS 318, GR LTB 2
Facing Ring & Stem Nut
(e) Gland Packing PTFE impregnated
(f) Bonnet Gasket Rubber IS 638 Type B
(g) Fasteners Carbon Steel IS 1367, CL 4.6 / 4
1.4 Mfg. Quality Assurance To get approved, prior to manufacturing
Plan QAP)
1.5 Testing
(a) Seat Test Pressure (Hydro- As per Standard
test) – Kg/cm2
(b) Body Test Pressure As per Standard
(Hydro-test) – Kg/cm2
1.6 Construction
(a) Gear Arrangement Required
135
Sr.
No.
(b) Thrust bearing Required
arrangement
(c) Back Seat Bush Required
(d) Shoe and Channel Required

arrangement
(f) Opening Indicator Required
(g) Back Seat Bush Bronze IS 318 Gr. LTB2
(h) Shoe and Channel lining Bronze IS 318 Gr. LTB2
1.7 Deviation Deviations (if any), from the above

specifications, clearly. If the deviation is for
betterment in design / performance, then it
will be supported with technical justification.
1.8 Pressure Drop Bidder to Furnish
Calculation
1.9 Paint Valves shall first be given two coats of zinc
base primer after completely cleaning the
surface and then it shall be coated with
three coats of epoxy paint. Valves shall be
painted with Food Grade Epoxy for Internal.
1.10 Weight/ Dimension
(a) Total Weight (kg) of the Furnish during detail engineering
Complete Assembly
(b) Over-all dimensions of the Furnish during detail engineering

complete assembly – L X B
X H (mm)
136
NON – RETURN VALVES (DUEL PLATE CHECK VALVES - DPCV)

Sr.
No.
2.1 General Double Flanged, for water application
(b) Type Duel Plate Check Valve (DPCV), Non Slam,
Spring Action with by-pass arrangement
(d) Rating PN 2.0
(e) Standard to which Design: API – 594
manufactured Testing: API – 598
IS 1538 (for Flange)
(f) Valve Location In the Pump House
2.2 Materials of Construction
(a) Body Ductile Iron as per IS 1865 Gr. 500/7
(b) Plates Cast Steel ASTM A 216 Gr. WCB with 13% Cr.
S.S. overlay (on seating surface only)
(c) Body Seat Ring SS AISI 304 with weld overlay on seating
surface in conjunction with EPDM
(d) Bearing / Washer Teflon / SS AISI 304
(e) Spring SS – AISI 304
(f) Hinge Pin, Stop Pin (1) SS AISI 410
(2) BS 970, Gr. 304
(g) End Cover MS
(h) Bolts & Nuts Carbon Steel IS 1367, Cl. 4.6/4, Hot Dipped
Galvanized
Plan (QAP)
2.4 Testing
(a) Seat Test Pressure (Hydro- As per design code
test) – Kg/cm2
(b) Body Test Pressure (Hydro- As per design code
test) – Kg/cm2
Calculation
137
Sr.
No.
surface and then it shall be coated with three
coats of epoxy paint. Valves shall be painted
with Food Grade Epoxy for Internal.
Complete Assembly

complete assembly
L X B X H (mm)
138
EXPANSION BELLOW
Sr.
No.
01 Make furnish during detail engineering
(As per approved vendor list)
02 Item Corrugation Design Metallic Expansion
Bellow
03 Size(mm) Of required size as per pipe diameter
04 Fluid Raw Water
05 Location Pump Discharge line
06 Pressure Rating (Kg/cm2) 16
07 Temperature 50 deg C
08 End Connection Suitable end connection or Flanged.

Flanges shall be flat faced,
(As per IS 1538)
09 Material of Flange M.S.
10 Material of Bellows Stainless Steel 304
11 Material of Hardware Alloy Steel

(As per IS 1367)
12 Axial expansion (mm) 15 (Min.) to be adjusted with pump &
piping installation requirement
13 Axial compression(mm) 15 (Min.) to be adjusted with pump &
14 Lateral Movement (mm) +/- 1 (Min.) to be adjusted with pump
& Piping installation requirement
15 Hydro-static Test 15 (Min.)
Pressure(Kg/cm2)
16 Mode of Installation Horizontal
17 No. of Tie rods Three no.(120 deg. Orientation)
139
VERTICAL TURBINE (VT) PUMPS

Sr.
No.
1.0 General
(a) Pump Type Vertical turbine
(b) Standard to which Furnish during detail engineering
manufactured
(c) Make Furnish during detail engineering (It shall be
as per approved vendor list)
(d) Model Furnish during detail engineering
(e) Number of stages One or Multistage
(proposed) (Furnish during detail engineering as per
design)
(f) Head – H (at 50 Hz) 90 ( Towards Mirkot & Mogarbara)
130 (Towards Vadpada & Fulumran)
(g) Discharge – Q (at 50 Hz) 4635 (Towards Mirkot)
6070 (Towards Mogarbara)
3311 (Towards Vadpada)
3200 (Towards Fulumran)
(h) Pump Speed – RPM - Furnish during detail engineering as per
At 50 Hz (considered) design
(j) Pump Location On Intake
(k) Type of operation Continuous
(l) Min. Guaranteed Pump 87 % or more (Without negative tolerance)
Efficiency, at 50 Hz at
duty point
(m) Application To pump raw water
(n) Quantity 8 no. (7 w + 1 SB)
2.0 Feature of Construction
(a) Internal element Enclosed impeller / Semi open
(b) Type of lubrication Forced Water lubrication system for shaft
(considered) bearings
(c) Type of sealing Mechanical seal
(d) Type of coupling Direct ( Flexible or Rigid)
(e) Number of stage Furnish during detail engineering as per
design, i.e. Single or Multiple
(f) Column size, diameter, Furnish during detail engineering
length, thickness.
(g) Discharge level with Above floor
respect to floor
3.0 Design Data
(a) Diameter of impeller Furnish during detail engineering
(b) Min, submergence
required. Measured from
bottom of bowl for
cavitations free operation
140
Sr.
No.
of pumps in Furnish during detail engineering
(1) Solo Furnish during detail engineering
(2) Parallel operation.
(c) Delivery Pipe Diameter Furnish during detail engineering
(mm)
(d) Type of thrust bearing Tilting pad type
(e) Thrust bearing make Furnish during detail engineering
(f) Life of Thrust bearing Minimum 75,000 Hrs. of operation
(Hours)
(g) Thrust bearing lubrication Oil-bath lubrication type
4.0 Liquid Data
(a) Liquid handled Raw Water
(b) Specific gravity 1.0
(c) Temperature Ambient up to 500 C.
5.0 Material of Construction
(VT Pump)
(a) Column pipe ERW, M.S. IS 2062, Gr. Fe 410 minimum 14

mm. wall thickness with inside and outside
epoxy painted in maximum 2.5 Mtr. Sections
(b) Suction bell Cast Steel ASTM A 216 Gr. WCB with inside
anti-corrosive coating
(c) Pump casing / Bowl Cast Steel ASTM A 216 Gr. WCB with inside
anti-corrosive coating
(d) Impeller SS - CF8 M
(e) Impeller shaft SS 410
(f) Impeller Guide Piece Cast Steel ASTM A 216 Gr. WCB
(g) Line shaft SS 410
(h) Head shaft SS 410
(i) Shaft coupling SS – CF8 M
(j) Pump-Motor Couplings Furnish during detail engineering
(k) Suction strainer S.S AISI - 304
(l) Shaft sleeves S.S – 316
(m) Hardware in contact with S.S.-304
water
(n) Companion flanges M. S.
(o) Column Flanges Min. thickness as per relevant standard
(p) Motor Stool Furnish during detail engineering
(q) Bolts, Nuts and washers Furnish during detail engineering
(r) Gland Bronze IS: 318 Gr. LTB-2.
(s) Shaft bearing All Thordon Bearings
(t) Base Plate/ Sole plate MS IS: 2062, minimum 60 mm thickness
(u) Discharge Elbow MS IS: 2062, minimum 14 mm wall
141
Sr.
No.
thickness with inside and outside epoxy
paint
6.0 Accessories & Services
Required
(a) Base plate/Sole plate YES
(b) Foundation bolts YES
(c) Suction strainer YES (SS – 304)
(d) Companion flanges YES
(e) Spares parts YES
recommended (Furnish during detail engineering separate
list)
(f) Maintenance tools YES
(Furnish during detail engineering separate
list)
(g) Start-up / essential YES
spares (Furnish during detail engineering separate
list)
(h) Painting YES ( Epoxy )
(j) Pressure Gauge (0 – 20 kg) YES
7.0 Testing
7.1 Hydro-static test YES
7.1.1 Bowl Assembly YES
7.1.2 Pump Column assembly, YES
Discharge head, etc.
7.2 Performance test YES
7.3 Standard running test YES
7.4 Dynamic balancing test YES
7.5 Visual inspection check Required
7.6 Parallel Operation test at Required
site
7.7 Non destructive testing
7.8 a) DP on impeller YES
7.9 b) DP on Bowl YES
8.0 Other
8.1 Maximum Size of Solid - Furnish during detail engineering
passage capacity (mm)
8.2 Hydraulic Test Pressure 1.5 times on shut off or 2 times of duty
point whichever is higher
8.3 Safe operating time at Furnish during detail engineering
shut-off (in min.)
8.4 Weight / Dimension
8.4.1 Total Weight (kg) of the Furnish during detail engineering

Complete Assembly of the
Pump (This includes all
components like,
142
Sr.
No.
Discharge Head Assy.,
Column Pipes / Shaft,
Pump Assy. Etc., but
excluding motor)
8.4.2 Over-all dimensions of the Furnish during detail engineering
discharge head (including
the base plate) – L X B X H
(mm)
8.5 DEVIATION Deviations (if any), from the above
143
DATA SHEETS FOR GUARANTEED PARTICULARS ( UCHCHHAL)

[1] VERTICAL TURBINE (VT) PUMPS
Sr.
Offered
No Required Specs. Unit Required Specs.
Specs.
.
Rated Discharge (Q)(at rated speed
A M3/hr 6117 (P.S. at Shelud)
and at rated frequency, i.e.50Hz)
3335 (P.S. at
Naranpura)
Rated Head Effective (H)(at rated
B Meters 90 m (At Shelud)
speed and at rated frequency,
130 m (At Naranpura)
i.e.50Hz)
Water Horse Power (WHP), at 50 Hz WHP
C 2010 (at Shelud)
1583(at Naranpura)
Pump input KW at rated condition, KW
D 1723 (at Shelud)
at 50 Hz
1357 (at Naranpura)
Pump Efficiency at rated
E %
parameters, at duty point - At 50HZ 87.0
Motor efficiency at rated condition
F %
and steady state temperature 94.0
Input to motor at rated condition, KW
G i.e.50 Hz 1833 (at Shelud)
1443 (at Naranpura)
Overall Efficiency of Pump Motor set
%
H at rate condition 81.78
Maximum NPSH required under Meter
I As per Vendor
operation at:Normal Water Level Meters
Lowest Water Level Design
Minimum Submergence required for
J Meter As per Vendor
safe operation
Design
Notes:
(a) Material certificates of components shall be furnished before inspection of
components.
(b) Bidder to furnish GA drawing indicating overall dimensions, weight, and
height details along with offer.
(c) Bidder to furnish Performance curves for Head V/s Capacity, Efficiency
V/s Capacity and Power (BKW) V/s Capacity.
(d) The capacity range shall be zero flow to maximum flow.
(e) Bidders have to submit performance test reports and, family curves (Head
(H) v/s Discharge
(Q), Efficiency v/s Discharge and Power (P) v/s Discharge (Q) for similar
model of pump.
(f) There shall be a difference of 50 BHN hardness between casing ring and
impller ring.
(g) If the guaranteed, efficiency of pump quoted by the bidders is less than
minimum specified in the tender than the offer of bidder is liable to be rejected.
(h) Bidder to furnish deviations (if any), from the above specifications, clearly.
If the deviation is for betterment in design / performance, then it will be clearly
mentioned with technical justification. (j)
Bidder to furnish guaranteed technical particulars duly filled.
144
ELECTRICALLY OPERATED OVERHEAD TRAVELLING (EOT) CRANES

Sr.
No.
5.1 Make Furnish during detail engineering.
(It shall be as per approved vendor list)
5.2 Applicable Standards IS : 3177
5.3 Capacity (Tones) EOT crane lifting capacity shall be

minimum 20 tons. However the final
selection of crane capacity shall be
appropriately provided for lifting of the
component having height-weight
5.4 Safe working load (Tones) Furnish during detail engineering
5.5 Recommended Rail Sq. Bar. Or Rail – Furnish during detail

engineering details
5.6 Quantity 1 no.
5.7 Class / Duty II / Medium
5.8 Lift (m) 15 meter
5.9 Span (m) 20 meter
5.10 Length of the runway (m) 50 meters is envisaged. However, it will be

as per final approved drawing
5.11 Type of Girder Furnish during detail engineering
5.12 Method of operation / Floor Operated, Through P. B. Station with

VFD VFD
5.13 Drum M. S. Seamless Pipe, as per ASTM 106, Gr.
B.
5.14 Operating speed (loaded)
(a) Hoisting (Main & Aux.) m (Around 2 MPM)

/ min. Furnish during detail engineering
(b) Cross travel – m/min (Around 10 to 12 MPM)
Furnish during detail engineering
(c) Long travel - m/min (Around 10 to 12 MPM)
5.15 Type of hook Solid (forged steel), IS – 3815, with thrust
bearing)
5.16 Hoisting Rope
(a) Diameter (mm) Furnish during detail engineering
(b) Construction Furnish during detail engineering
(c) No. of falls Furnish during detail engineering
(d) Make Furnish during detail engineering

(it shall be of approved make)
5.17 Factor of safety Furnish during detail engineering
145
Sr.
No.
5.18 Description of Brakes
for
(a) Hoisting Furnish during detail engineering
(b) Cross travel motion Furnish during detail engineering
(c ) Long travel motion Furnish during detail engineering
5.18. Motor for hoisting

1
(a) Make Furnish during detail engineering
(b) Type Furnish during detail engineering
(c) Rating Furnish during detail engineering
5.18. Motor for Cross Travel

2
5.18. Motor for Long Travel

3
5.19 Details of brakes for hoist

motion
(a) Make of electromagnetic Furnish during detail engineering
brake
(b) Make of electro hydraulic Furnish during detail engineering
thruster brake
(c) Design holding torque Furnish during detail engineering
5.20 GA drawing indicating Furnish during detail engineering

overall dimensions weight,
height and necessary
details
5.21 MOC & Test Certificate Furnish during detail engineering

will be supported with technical
justification.
146
ELECTRIC OPERATED HOIST
Sr.
No.
6.1 Make Furnish during detail engineering
6.2 Applicable Standards Furnish during detail engineering
6.3 Capacity (Tones) 5 Ton
6.5 Recommended Girder Furnish during detail engineering
6.6 Quantity 1 no.
6.9 Span (m) 50 meter or as per site condition
6.10 Length of the runway (m) As per drawing
6.11 Type of Girder Single Girder
6.12 Method of operation Floor Operated, Through Down Pendant P.

B. Station
B.
6.14 Shaft High Tensile - EN -8
(a) Main Hoist (m / min.) (Around 2 MPM)

bearing)
6.17 Hoisting Rope

6.19 Description of Brakes for
6.20 Motor for hoisting
147
Sr.
No.

motion
(a) Make of electro magnetic Furnish during detail engineering
brake
thruster brake

details

justification.
148
PROPELLER EXHAUST FANS
Sr.
No.
7.1 Make As per approved vendor list
7.2 Applicable Standards IS 2312
7.3 Size (mm) 450
7.4 Capacity (m3/min) 60
7.5 Quantity As per approved civil drawing
7.6 Rating 5
(mm of water static)
7.7 Motor
(a) Make As per approved list
(b) Rating (kW) Furnish during detail engineering
(c ) Total Nos. provided Furnish during detail engineering (It

will be as per approved drawing and
sufficient quantity as per pump house
requirement)
(d) WEIGHT / DIMENTIONS
(i) Total Weight (kg) of the Furnish during detail engineering
Complete Assembly
(ii) Over-all dimensions of the Furnish during detail engineering

complete assembly
(3) L X B X H (mm)
(e) Deviation Deviations (if any), from the above

specifications, clearly. If the deviation
is for betterment in design /
performance, then it will be supported
with technical justification.
149
DOUBLE ORIFICE TAMPER PROOF KINETIC AIR VALVE-

(WITH ISOLATION SLUICE VALVE)
Sr.
No.
1 General
(b) Type Flanged, S. S. Ball, Temper-proof, Kinetic

Air Release Valve with Isolating Valve
(d) Rating PN 1.6
(e) Standard to which IS 14845 : 2000 / AWWA C 512 (for
manufactured valve),
IS 1538 / 1976, Part IV & VI (for Flange)
(f) Application / Location To be fitted on water pipe-line for release
of air
2 Materials of Construction
(a) Body, Cover, Cowl / Auto
Valve etc.
(i) For Pump-house valve Ductile Iron
(SG Iron, IS-1865, Gr. 500/7)
(ii) For Pipeline Valves Ductile Iron
(SG Iron, IS-1865, Gr. 500/7)
(b) Float - HP Orifice SS AISI 304
(c) Float - LP Orifice SS AISI 304
(d) Large Orifice Nitrile Rubber
(e) Small Orifice Bronze IS 318, Gr. LTB 2
3 Accessories Required with isolating Sluice Valve.
4 Mfg. Quality Assurance To get approved, prior to manufacturing
Plan (QAP)
5 TESTING
(a) Seat Test Pressure As per standard
(b) Body Test Pressure (Hydro- As per standard
test) – Kg/cm2
6 Construction
(a) Isolation valve: Furnish during detail engineering
built in or separate (Separate Sluice Valve with same rating &
size of Air Valve is preferred)
(b) Isolation valve: Furnish during detail engineering
Material of Body, Disc &
Spindle
(c) Float ball size Furnish during detail engineering
(Large orifice)
150
Sr.
No.
(d) Float ball size Furnish during detail engineering
(Small orifice)
(e) Isolation valve stem details Furnish during detail engineering
(if built-in)
7 DEVIATION Deviations (if any), from the above
specifications, clearly. If the deviation is
for a betterment in design / performance,
then the it will be with technical
justification.
8 WEIGHT / DIMENTIONS
Complete Assembly
X H (mm)
151
M.S. PIPE LINE
1 Plates / HR coil / Pipe IS:2062, Gr.B Fe 410 /

Manufacturing IS:10748 Gr.III Fe 410 /
IS: 3589-2000 & IS 5504
- of approved make
2 Welding & Electrodes ASME – SECT – IX, IS – 7310, IS – 7307, IS:

814, IS: 3613, IS: 6419, IS: 7280, IS – 9595
Approved Make Electrode
3 Food-grade Epoxy paint, for Shot blasting, followed by application of 406
Inside of pipeline micron Dry Film Thickness (DFT), solvent
free, high build, food-grade epoxy lining,
confirming to AWWA C-210-07/ BS 6920 -
suitable for potable water application as per
specification
4 Epoxy Paint Coating for Shot blasting, followed by supply and
out-side of pipeline For application of primer & suitable epoxy paint,
making total DFT as 200 microns as per
Pump House specifications
5 3LPE for outside of Main External anti-corrosion coating of pipes by

Pipe line using 3 Layer Side Extruded Polyethylene
coating conforming to DIN-30670, 1991,
`Polyethylene Coating for Steel Pipes ‘ and
> DN 100 ≤ DN 2.7
the requirements of specification (3.7 mm
250 mm thickness)
> DN 250 < DN 2.9
500 mm
≥ DN 500 < DN 3.2
800 mm
≥ DN 800 3.7
mm
6 Fabrication & IS: 3589 /IS: 5504
7 Deviation Deviations (if any), from the above
specifications, clearly. If the deviation is for a
betterment in design / performance, then the
it will be with technical justification.
8 Quality Assurance Plan - To get an approval from Client/ Client’s
QAP representative before supply of pipes
152
MOTORS – HT & LT
[A] HT Induction Motors
Sr. Required Specs.

Description
No.
1 Make As per approved vendor list
2 Application To drive VT Pump
4 Type of motor Squirrel cage Induction motor
5 No. of Motor 5 Nos (At Shelud)
5 Nos (At Naranpura)
6 Supply system fault level. 25 kA , 1 Sec (minimum)
7 Supply neutral Resistance earthed
8 Rated voltage 6.6 KV
9 Indicative Rated KW 5370 kW
10 No. of Phases 3 Phase Induction Motor
11 Frequency 50 Hz.
12 Supply condition ± 10% voltage variation
± 5% frequency variation
± 10% combined voltage and frequency
variation
13 Speed Less than 1000 RPM
14 Full load current Furnish during detail engineering
15 No load current Furnish during detail engineering
16. Motor GD SQ. Furnish during detail engineering
17 Load GD SQ. Furnish during detail engineering
18 Duty condition S1 suitable for constant operation
19 Method of starting soft Starter
20 Starting current in % of FLC Furnish during detail engineering
inclusive IS tolerance
21 Starting current with soft Less than 3 times of FLC of motor
starter
22 No of start Two starts in succession and three equally
spread starts in an hour
23 Minimum permissibly voltage 80% Rated Voltage
24 Starting torque in Kg-m at Furnish during detail engineering
minimum permissible voltage
rated voltage
26 Minimum accelerating torque Furnish during detail engineering
at min permissible voltage
27 Starting torque Sufficient starting torque to start the pump
% of full load torque with delivery valve open and when other
pumps are running.
28 Pull out torque Sufficient to bring the motor to normal
% of full load torque speed in minimum time
153
Sr. Required Specs.

Description
No.
29 Class of insulation & temp. Class “F” but Temperature rise restricted to
rise by thermometer that of class “B”
30 Maximum Ambient 50°C.
temperature
31 Location Indoor
32 Hazardous area division N.A.
33 Atmosphere Humid, Dusty at a time
34 Stator Connection Star
35 Direction of rotation Bidirectional
36 a) Type of Cooling CACW/CACA
b) Degree of protection IP – 55
37 Cable Terminal box PSTB type suitable to rotate 90 deg.
50 KA for 0.25 Sec
STC rating of Terminal Box IP 55.
protection class
38 External cable details. Al conductor, XLPE insulated, armoured
6.6 kV (UE) grade Cable
As per design
a) No. of cores. As per design .
b) Size
39 Shaft Solid shaft , Hollow Shaft
40 Type of Couplings Matching with Pump coupling
41 Make of bearings (A) As per approved vendor list
A) Make (B) Furnish during detail engineering
B)Recommended lubrication (C) Furnish during detail engineering
C) Recommended Life Span
in Hr
42 Type of bearings Ball / Roller
43 Colour shade of paint if Grey shade 631 as per IS 5
special
44 Space heater for motors 240 V, 1 Ph., 50Hz., A.C. for winding
required heating
45 Thermistors / RTD’s / For indicating, alarming and trip. ( 6 nos
required min)
46 Bearing temp. Detectors Required for alarm & Trip
47 Winding connections 6 Terminals Required for alarm & Trip
48 Standard to be followed IS 12615-2011, IS/IEC 60034, IS 8225, IS
4889, IS 4772, IS 4029, IS 4691 and other
relevant Indian Standard or equivalent
BSS.
49 Efficiency @ Rated Speed (a, b, c) Minimum 94%
a)Duty point
b) Full Load (d) Furnish during detail engineering
c) 0.75 Load
d) 0.50 Load
50 Power Factor at
a)Duty point Furnish during detail engineering

b) Full Load Furnish during detail engineering
c) 0.75 Load Furnish during detail engineering
d) 0.50 Load Furnish during detail engineering
51 Earthing conductor GI strip
154
[B] LT MOTORS
Sr. Required Specs.

Description
No.
2 Model Furnish during detail engineering
3 Quantity As per process requirement

4 Rated Output kW Confirm as per process requirement
5 Type of motor 3 Phase Induction motor
6 Motor Duty S1 Continuous
7 Frame size Furnish during detail engineering
8 Type of mounting Furnish during detail engineering
9 Rated Voltage Volts / KV 0.415 kV
10 Permissible Voltage variation +10% to -10%

11 Rated Full load Current Amps Furnish during detail engineering
13 Rated Frequency & Variation 50 Hz +5% to -5%
14 Combined V & F Variation +10% to -10%
15 Rated Speed rpm Furnish during detail engineering
16 Applicable Standard IS 12615-2011
17 Motor Energy efficiency class IE3
18 Design Temperature 50 Deg C ambient.
19 Insulation Class Class F
20 Temperature rise as per class B
21 Rated Power Factor
At full Load
At Duty Point Furnish during detail engineering
At 75% Load
At 50 % Load
22 Power Factor at Starting ‐ Furnish during detail engineering
23 Efficiency
At full Load
At 75% Load
At 50 % Load
24 Maximum Ambient 50 deg C
Temperature for Continuous
Operation oC
25 Maximum Temperature Rise 70 deg C
at Full Load oC
26 Starting Method DOL/ Star Delta/ Soft starter
27 Power factor at starting Furnish during detail engineering
28 Starting Current Furnish during detail engineering
29 Starting current at rated
Voltage
DOL Starting Current Amps 6%
Star Delta 3.5 times
Soft Starting Current Amp Not be more than 3 times
155
Sr. Required Specs.

Description
No.
30 Starting torque at rated 80%V 100%V 110%V
Voltage
Starting torque
Pull out torque
Full load torque (Kg m)
Locked rotor torque
31 Starting time at Rated Voltage 80%V 100%V 110%V
With load
Without load with driven
equipment coupled
32 Heating time constant Furnish during detail engineering
Cooling time constant
33 Successive start- Hot & Cold 2 Hot Start, 3 Cold Start
34 Degree of protection IP 55
35 Method of cooling IC 411
35 Fault level with stand capacity 50 KA for 1 Sec
37 Winding connection Delta
38 Paint shed 631 of IS-5
39 Bearings Furnish during detail engineering
Make
Type
Recommended lubrication
Recommended Life Span in Hr
40 Motor Terminal Box
Type Stud Type
Fault current with stand 50 KA for 0.25 Sec
capacity
size To confirm suitable for cable size
41 Space heater: Furnish during detail engineering

Nos, watt, Voltage
42 Winding temperature detector Required
Type
Nos Furnish during detail engineering
43 Bearing temperature detector Required
Type
44 No of grounding terminal
On motor body 2 Nos
On Terminal Box 1 Nos
45 Moment of Inertia Furnish during detail engineering
Pump
Motor
Total
46 Weight in KG Furnish during detail engineering
Stator
Rotor
Total
47 Noise level As per IS12065
48 Vibration Level As per IS 12075
156
BUTTERFLY VALVES
Sr.
No.
(a) Size / Dia, mm Of required size as per pipe diameter
(b) Make Furnish during detail engineering
(c) Rating PN 1.6
(d) Standard to which IS 13095 / 1991 or Latest (for valve),
manufactured IS 1538 (for Flange)
11.2 Mode of Operation: Motorized
11.3 Materials of
Construction
(b) Shaft SS AISI 410
(c) Disc Ductile Iron as per IS 1865 Gr. 500/7
(d) Seat Ring SS AISI 304
(e) Bearing Bush Steel-backed PTFE
(f) Clamping Ring SS AISI 304
(g) Internal Hardware SS AISI 304
(h) External Hardware Carbon Steel IS 1367, CL 4.6 / 4

Plan (QAP)
11.5 Testing
(a) Seat Test Pressure As per Standard
(c ) Disc Strength Test – As per IS 13095
Kg/cm2
betterment in design / performance, then
it will be supported with technical
justification.
Calculation
157
Sr.
No.
painted with Food Grade Epoxy for
Internal.
Complete Assembly
(b) Over-all dimensions of Furnish during detail engineering
the complete assembly –
L X B X H (mm)
11.10 By-pass Valve to Main Required
Valve
General Note:
a) Work allotted EPC agency shall furnish material test certificates of all the
major components during inspection of the equipment.
b) The datasheet given in this chapter of all the components shall be read in
conjunction with the respective Technical Specification of Civil,Electrical &
Instrumentation works (Vol-III-A, B, and C & D) & drawings.
c) Bidder have to confirm guaranteed particular and technical values shall be

equal or better then indicated in the datasheet. However all complete technical
datasheet (to meet tender requirement) shall be filled during detail engineering
by work allotted EPC agency.
158
DATA SHEETS FOR MECHANICAL WORKS - PIPE LINE
Sr.
ITEM DESCRIPTION
No.
2 AIR VALVE
4 M. S. PIPE LINES
SURGE CONTROL DEVICES – ZERO VELOCITY & AIR CUSHION

5
VALVES
6 PRESSURE REDUCING VALVE
159

Sr.
No.
(d) Rating PN 1.0
manufactured (2) API – 600 / 603/6D, BS – 1414 (for Gate
Valves)
(3) IS 1538 / 1976, Part IV & VI or
standard, suitable to size
(for Flange)
(f) Valve Location In the Pipe line
1.2 Mode of Operation: Motorized, Hand Operated
1.3 Materials of
Construction
(mm)
(e) Gland Packing Jute & Hemp (IS 5414) / PTFE
Plan QAP)
1.5 Testing
1.6 Construction
160
Sr.
No.
arrangement

arrangement
(e) Opening Indicator Required
(f) Back Seat Bush Bronze IS 318 Gr. LTB2
(g) Shoe and Channel lining Bronze IS 318 Gr. LTB2

Calculation
Complete Assembly

L X B X H (mm)
161

Sr.
No.
1 General
(b) Type Flanged, S. S. Ball, Temper-proof, Kinetic Air

Release Valve with Isolating Valve
(d) Rating PN 1.0
(e) Standard to which IS 14845 : 2000 / AWWA C 512 (for valve),
manufactured IS 1538 / 1976, Part IV & VI (for Flange)
(f) Application / Location To be fitted on water pipe-line for release of
air
Valve etc.
(SG Iron, IS-1865, Gr. 500/7)
(SG Iron, IS-1865, Gr. 500/7)
Plan (QAP)
5 TESTING
test) – Kg/cm2
6 Construction
Spindle
(Large orifice)
162
Sr.
No.
(Small orifice)
(if built-in)
Complete Assembly
X H (mm)
163
BUTTERFLY VALVES
Sr.
No.
(c) Rating PN 1.6
(d) Standard to which IS 13095 (for valve,
3.2 Mode of Operation: Hand / Gear operated
3.3 Materials of
Construction
Plan (QAP)
3.5 Testing
Kg/cm2
Calculation
164
Sr.
No.
Complete Assembly
L X B X H (mm)
Valve
165
M. S. PIPELINE
Sr.
No.
IS: 3589
- of approved make
2 Welding & Electrodes ASME – SECT – IX, IS – 7310, IS – 7307,

IS: 814, IS: 3613, IS: 6419, IS: 7280, IS –
9595
3 Food-grade Epoxy paint, Shot blasting, followed by application of
for Inside of pipeline 406 micron Dry Film Thickness (DFT),
solvent free, high build, food-grade epoxy
lining, confirming to AWWA C-210-07/
BS 6920 - suitable for potable water
application as per specification
out-side of pipeline For application of primer & suitable epoxy
paint, making total DFT as 200 microns
Pump House as per specifications
5 3LPE for outside of Main External anti-corrosion coating of pipes

Pipe line by using 3 Layer Side Extruded
Polyethylene coating conforming to DIN-
30670, 1991, `Polyethylene Coating for
> DN 100 ≤ 2.7
Steel Pipes ‘ and the requirements of
DN 250 mm specification
> DN 250 < 2.9
DN 500 mm
≥ DN 500 < 3.2
DN 800 mm
≥ DN 800 3.7
mm

justification.
166
SURGE CONTROL DEVICES:

(Zero Velocity and Vacuum Breaker cum Air Cushion Valves)
Sr.
Valve Type Size & Rating
No.
1 Zero Velocity Valve –1 Of required size as per pipe
diameter and rating as per
the design
7 Vacuum Breaker cum Air Cushion Valve - Of required size as per pipe
1 diameter and rating as per
the design
OR
Surge anticipation valve and control system
Sr.
No.
1 Surge Anticipation Valve –1 Pressure Of required size as per
activated hydraulic control valve with hydraulic design and pipe
combination air valve if required
the design
Note: The successful contractor h as to submit detailed design &

calculations. Locat ion of Air Vessels & Surge control
device are to be decided by the successful contractor on
the base of detailed design submitted & got approved
from the department competent authority before
ex ecution. The M ax imum surge pressure to be restricted
shall be less than or equal to 10 kg/cm 2 .
General Note:
conjunction with the respective Technical Specification of Civil, Mechanical,
Electrical & Instrumentation works (Vol-III-A, B, and C & D) & drawings.

167
PRESSURE REDUCING VALVE

Sr.
No.
1 General

(d) Outlet pressure As per design
(e) Standard to which IS 9739: 1981
manufactured
(f) Application / Location To be fitted on water pipe-line to reduce
pressure
2 Materials of Construction As per IS 9739: 1981
Plan (QAP)
4 TESTING AS per standard
Complete Assembly
X H (mm)
168
2. FOR SONGADH:
[A] DATA SHEETS FOR MECHANICAL WORKS - PUMP HOUSE
Sr.
ITEM DESCRIPTION
No.
2 NON RETURN VALVES
3 EXPANSION BELLOWS
7 EXHAUST FANS
8 AIR VALVE
9 M. S. PIPE LINES
169

Sr.
No.
(d) Rating PN 2.0
Valves)
(3) IS 1538 (for Flange)
1.2 Mode of Operation: MOTORISED
1.3 Materials of
Construction
(mm)
Plan QAP)
1.5 Testing
test) – Kg/cm2
1.6 Construction
170
Sr.
No.
arrangement

arrangement

Calculation
Complete Assembly

X H (mm)
171

Sr.
No.
(b) Type Duel Plate Check Valve (DPCV), Non Slam,
Spring Action with by-pass arrangement
(d) Rating PN 2.0
(b) Plates Cast Steel ASTM A 216 Gr. WCB with 13% Cr.
S.S. overlay (on seating surface only)
(c) Body Seat Ring SS AISI 304 with weld overlay on seating
surface in conjunction with EPDM
(4) BS 970, Gr. 304
(g) End Cover MS
Galvanized
Plan (QAP)
2.4 Testing
test) – Kg/cm2
test) – Kg/cm2
Calculation
172
Sr.
No.
Complete Assembly

complete assembly
L X B X H (mm)
173
EXPANSION BELLOW
Sr.
No.
01 Make Furnish during detail engineering
Bellow
04 Fluid Raw Water
08 End Connection Suitable end connection or Flanged.

Flanges shall be flat faced,
(As per IS 1538)

(As per IS 1367)
12 Axial expansion (mm) 15 (Min.) to be adjusted with pump &
13 Axial compression(mm) 15 (Min.) to be adjusted with pump &
14 Lateral Movement (mm) +/- 1 (Min.) to be adjusted with pump
& Piping installation requirement
Pressure(Kg/cm2)
174

Sr.
No.
1.0 General
manufactured
(c) Make Furnish during detail engineering (It shall be
as per approved vendor list)
(e) Number of stages One or Multistage
(proposed) (Furnish during detail engineering as per
design)
(f) Head – H (at 50 Hz) 75 meter (At Ukai)
70 meter (Towards Tarapada)
97 meter (Towards Medha)
(g) Discharge – Q (at 50 Hz) 27140 m3/hr (At Ukai reservoir)
15270 m3/hr (Towards Tarapada)
11091 m3/hr (Towards Medha)
(h) Pump Speed – RPM - Furnish during detail engineering as per
At 50 Hz (considered) design
(j) Pump Location On Water Sump
(l) Min. Guaranteed Pump 87 % or more (Without negative tolerance)
Efficiency, at 50 Hz at
duty point
(n) Quantity 8 no. (7 w + 1 SB)
(c) Type of sealing Mechanical seal
(d) Type of coupling Direct, (flexible or rigid)

(e) Number of stage Furnish during detail engineering as per
design, i.e. Single or Multiple
length, thickness.
(g) Discharge level with Above floor
respect to floor
3.0 Design Data
(b) Min, submergence
required. Measured from
175
Sr.
No.
bottom of bowl for
cavitations free operation
of pumps in Furnish during detail engineering
(4) Solo Furnish during detail engineering
(5) Parallel operation.
(c) Delivery Pipe Diameter Furnish during detail engineering
(mm)
(f) Life of Thrust bearing Minimum 75,000 Hrs. of operation
(Hours)
4.0 Liquid Data
(VT Pump)
(a) Column pipe ERW, M.S. IS 2062, Gr. Fe 410 minimum 14

mm. wall thickness with inside and outside
epoxy painted in maximum 2.5 Mtr. Sections
(b) Suction bell Cast Steel ASTM A 216 Gr. WCB with inside anti-
corrosive coating
(c) Pump casing / Bowl Cast Steel ASTM A 216 Gr. WCB with inside anti-
corrosive coating
(j) Pump-Motor Couplings Pl. furnish details
(k) Suction strainer S.S AISI – 304
water
(n) Companion flanges M.S.
176
Sr.
No.
(u) Discharge Elbow MS IS: 2062, minimum 14 mm wall
thickness with inside and outside epoxy
paint
Required
(e) Spares parts YES
recommended (Furnish during detail engineering separate
list)
(Furnish during detail engineering separate
list)
(g) Start-up / essential YES
spares (Furnish during detail engineering separate
list)
7.0 Testing
7.6 Parallel Operation test at Required
site
8.0 Other
8.2 Hydraulic Test Pressure 1.5 times on shut off or 2 times of duty point
whichever is higher
8.3 Safe operating time at Furnish during detail engineering
shut-off (in min.)

177
Sr.
No.
components like,
Discharge Head Assy.,
Column Pipes / Shaft,
Pump Assy. Etc., but
excluding motor)
discharge head (including
the base plate) – L X B X H
(mm)
8.5 DEVIATION Deviations (if any), from the above
178
DATA SHEETS FOR GUARANTEED PARTICULARS ( SONGADH)
5 [1] VERTICAL TURBINE (VT) PUMPS

Sr.No. Required Specs. Unit Required Specs. OfferedSpecs.
Rated Discharge 27140 m3/hr (At Ukai
A M3/hr
(Q)(at rated speed reservoir)
and at rated 15270 m3/hr (Towards
frequency, i.e.50Hz)
Tarapada)
11091 m3/hr (Towards
Medha)
Rated Head
B Meters 75 meter (At Ukai)
Effective (H)(at 70 meter (Towards
rated speed and at Tarapada)
rated frequency,
97 meter (Towards Medha)
i.e.50Hz)
Water Horse Power WHP 7175 HP (At Ukai)
C (WHP), at 50 Hz 3903 HP (Towards
Tarapada)
3928 HP(Towards Medha)
Pump input KW at KW 6150 KW (At Ukai reservoir)
D
rated condition, at 3345 KW (Towards
50 Hz Tarapada)
3367 KW (Towards Medha)
Pump Efficiency at
E % 87
rated parameters,
at duty point - At
50 HZ
Motor efficiency at
F % 94
rated condition and
steady state
temperature
Input to motor at KW 6543 (At Ukai)
G rated condition, 3539(Towards Tarapada)
i.e.50 Hz
3582 (Towards Medha)
Overall Efficiency of
% 81.78
H Pump Motor set at
rate condition
Maximum NPSH
I As per Vendor Design
required under
operation at:
Normal Water Level Meter
Lowest Water Level Meters
Minimum
J Meter As per Vendor Design
Submergence
required for safe
operation
Notes:
components.
179
(b) Bidder to furnish GA drawing indicating overall dimensions, weight, and height
details along with offer.
(c) Bidder to furnish Performance curves for Head V/s Capacity, Efficiency V/s
Capacity and Power (BKW) V/s Capacity.
(e) Bidders have to submit performance test reports and, family curves (Head (H) v/s
Discharge
(Q), Efficiency v/s Discharge and Power (P) v/s Discharge (Q) for similar model of
pump.
(f) There shall be a difference of 50 BHN hardness between casing ring and impeller
ring.
(g) If the guaranteed, efficiency of pump quoted by the bidders is less than minimum
specified in the tender than the offer of bidder is liable to be rejected.
(h) Bidder to furnish deviations (if any), from the above specifications, clearly. If the
deviation is for betterment in design / performance, then it will be clearly mentioned
(j) Bidder to furnish guaranteed technical particulars duly filled.
180
ELECTRICALLY OPERATED OVERHEAD TRAVELLING (EOT)

CRANES
Sr.
No.
5.3 Capacity (Tones) EOT crane lifting capacity shall be

minimum 20 tons. However the final
selection of crane capacity shall be
appropriately provided for lifting of the
component having height-weight

engineering details
5.6 Quantity 1 no.
5.10 Length of the runway (m) 50 meters is envisaged. However, it will be

as per final approved drawing
5.12 Method of operation

/ Floor Operated, Through P. B. Station with
VFD VFD
B.
(a) Hoisting (Main & Aux.) m (Around 2 MPM)

/ min. Furnish during detail engineering
bearing)
5.16 Hoisting Rope

181
Sr.
No.
for
5.18. Motor for hoisting

1
5.18. Motor for Cross Travel

2
5.18. Motor for Long Travel

3

motion
brake
thruster brake

details

justification.
182
Sr.
No.
6.6 Quantity 1 no.
6.12 Method of operation Floor Operated, Through Down Pendant P.

B. Station
B.

bearing)
6.17 Hoisting Rope


for
183
Sr.
No.

motion
brake
thruster brake

details

justification.
184
Sr.
No.
7.3 Size (mm) 450
7.6 Rating 5
7.7 Motor
(c ) Total Nos. provided Furnish during detail engineering (It

will be as per approved drawing and
sufficient quantity as per pump house
requirement)
(i) Total Weight (kg) of the Furnish during detail engineering
Complete Assembly

complete assembly
(6) L X B X H (mm)

specifications, clearly. If the deviation
is for betterment in design /
performance, then it will be supported
185

Sr.
No.
1 General
(b) Type Flanged, S. S. Ball, Temper-proof, Kinetic

Air Release Valve with Isolating Valve
(d) Rating PN 2.0
(e) Standard to which IS 14845 : 2000 / AWWA C 512 (for
manufactured valve),
IS 1538 / 1976, Part IV & VI (for Flange)
(f) Application / Location To be fitted on water pipe-line for release
of air
Valve etc.
(SG Iron, IS-1865, Gr. 500/7)
(SG Iron, IS-1865, Gr. 500/7)
Bidder to confirm.
Plan (QAP)
5 TESTING
test) – Kg/cm2
6 Construction
Spindle
186
Sr.
No.
(Large orifice)
(Small orifice)
(if built-in)
justification.
Complete Assembly
X H (mm)
187
M.S. PIPE LINE

IS: 3589-2000 & IS 5504
- of approved make

814, IS: 3613, IS: 6419, IS: 7280, IS – 9595
specification

`Polyethylene Coating for Steel Pipes ‘ and
> DN 100 ≤ 2.7
the requirements of specification (3.7 mm
DN 250 mm thickness)
> DN 250 < 2.9
DN 500 mm
≥ DN 500 < 3.2
DN 800 mm
≥ DN 800 3.7
mm
188
MOTORS – HT & LT
Sr. Required Specs.

Description
No.
5 No. of Motor 6 no.
9 Indicative Rated KW 5370 kW
11 Frequency 50 Hz.
± 10% combined voltage and frequency
variation
21 Starting current with soft Less than 3 times of FLC of motor
starter
rated voltage
26 Minimum accelerating torque Furnish during detail engineering
at min permissible voltage
27 Starting torque Sufficient starting torque to start the pump
% of full load torque with delivery valve open and when other
pumps are running.
28 Pull out torque Sufficient to bring the motor to normal
% of full load torque speed in minimum time
189
Sr. Required Specs.

Description
No.
29 Class of insulation & temp. Class “F” but Temperature rise restricted to
rise by thermometer that of class “B”
30 Maximum Ambient 50°C.
temperature
31 Location Indoor
50 KA for 0.25 Sec
STC rating of Terminal Box IP 55.
protection class
38 External cable details. Al conductor, XLPE insulated, armoured
6.6 kV (UE) grade Cable
As per design
a) No. of cores. As per design .
b) Size
41 Make of bearings (D) As per approved vendor list
A) Make (E) Furnish during detail engineering
B)Recommended lubrication (F) Furnish during detail engineering
C) Recommended Life Span
in Hr
42 Type of bearings Ball / Roller
43 Colour shade of paint if Grey shade 631 as per IS 5
special
44 Space heater for motors 240 V, 1 Ph., 50Hz., A.C. for winding
required heating
45 Thermistors / RTD’s / For indicating, alarming and trip. ( 6 nos
required min)
48 Standard to be followed IS 325, 8225, 4889, 4772, 4029, 4691 and
other relevant Indian Standard or
equivalent BSS.
(d) Specify during detail engineering

a)Duty point
b) Full Load
c) 0.75 Load
d) 0.50 Load
50 Power Factor at

d) 0.50 Load Furnish during detail engineering
190
[B] LT MOTORS
Sr. Required Specs.

Description
No.


16 Applicable Standard IS 12615-2011
17 Motor Energy efficiency class IE3
At full Load
At 75% Load
At 50 % Load
23 Efficiency
At full Load
At 75% Load
At 50 % Load
24 Maximum Ambient 50 deg C
Temperature for Continuous
Operation oC
25 Maximum Temperature Rise 70 deg C
at Full Load oC
29 Starting current at rated
Voltage
DOL Starting Current Amps 6%
Star Delta 3.5 times
Not be more than 3 times
191
Sr. Required Specs.

Description
No.
Soft Starting Current Amp
30 Starting torque at rated 80%V 100%V 110%V
Voltage
Starting torque
Pull out torque
Locked rotor torque
With load
equipment coupled
32 Heating time constant Furnish during detail engineering
33 Successive start- Hot & Cold 2 Hot Start, 3 Cold Start
Make
Type
Type Stud Type
Fault current with stand 50 KA for 0.25 Sec
capacity
size To confirm suitable for cable size

Nos, watt, Voltage
Type
Type
On motor body 2 Nos
Pump
Motor
Total
Stator
Rotor
Total
47 Noise level As per IS12065
48 Vibration Level As per IS 12075
192
193
BUTTERFLY VALVES
Sr.
No.
(c) Rating PN 2.0


Plan (QAP)
11.5 Testing
test) – Kg/cm2
(b) Body Test Pressure (Hydro- As per Standard
test) – Kg/cm2
Kg/cm2
betterment in design / performance, then
it will be supported with technical
justification.
Complete Assembly
194
Sr.
No.
complete assembly –
L X B X H (mm)
Valve
2] General Note:
a) Bidder shall furnish material test certificates of all the major components during
inspection of the equipment.
conjunction with the respective Technical Speciation of Civil, Electrical and
Instrumentation works (Vol-III-A, B, and C and D) and drawings.
c) Bidder should not mention or fill e.g "during detail engineering" or "submitted later
on".
d) Mentioned all performance and technical values are equal as per data sheet or
better than
195
DATA SHEETS FOR MECHANICAL WORKS - PIPE LINE
Sr.
ITEM DESCRIPTION
No.
2 AIR VALVE
4 M. S. PIPE LINES
5 UPVC PIPE
6 DI PIPE
SURGE CONTROL DEVICES – ZERO VELOCITY & AIR CUSHION

7
VALVES
196

Sr.
No.
(d) Rating PN 1.0
manufactured (2) API – 600 / 603, BS – 1414 (for Gate
Valves)
(3) IS 1538 / 1976, Part IV & VI or
standard, suitable to size
(for Flange)
1.2 Mode of Operation: Motorized, Hand Operated Valve should be
compatible with Actuator for future
connection with SCADA.
1.3 Materials of
Construction
(mm)
(e) Gland Packing Jute & Hemp (IS 5414) / PTFE
Plan QAP)
1.5 Testing
1.6 Construction
197
Sr.
No.
arrangement

arrangement

Calculation
Complete Assembly

L X B X H (mm)
198

Sr.
No.
1 General

(d) Rating PN 1.0
(f) Application / Location To be fitted on water pipe-line for release of
air
Valve etc.
(SG Iron, IS-1865, Gr. 500/7)
(SG Iron, IS-1865, Gr. 500/7)
Plan (QAP)
5 TESTING
test) – Kg/cm2
6 Construction
Spindle
(Large orifice)
199
Sr.
No.
(Small orifice)
(if built-in)
Complete Assembly
X H (mm)
200
BUTTERFLY VALVES
Sr.
No.
(c) Rating PN 1.6
3.2 Mode of Operation: – Motorised
– Manual Valve should be compatible with
Actuator for future connection with SCADA.
3.3 Materials of
Construction
Plan (QAP)
3.5 Testing
Kg/cm2
Complete Assembly
L X B X H (mm)
Valve
201
M. S. PIPELINE
Sr.
No.
IS: 3589
- of approved make
2 Welding & Electrodes ASME – SECT – IX, IS – 7310, IS – 7307,

IS: 814, IS: 3613, IS: 6419, IS: 7280, IS –
9595
3 Food-grade Epoxy paint, Shot blasting, followed by application of
for Inside of pipeline 406 micron Dry Film Thickness (DFT),
solvent free, high build, food-grade epoxy
lining, confirming to AWWA C-210-07/
BS 6920 - suitable for potable water
application as per specification
out-side of pipeline For application of primer & suitable epoxy
paint, making total DFT as 200 microns
Pump House as per specifications
5 3LPE for outside of Main External anti-corrosion coating of pipes

Pipe line by using 3 Layer Side Extruded
Polyethylene coating conforming to DIN-
30670, 1991, `Polyethylene Coating for
> DN 100 ≤ 2.7 Steel Pipes ‘ and the requirements of
DN 250 mm
specification
> DN 250 < 2.9
DN 500 mm
≥ DN 500 < 3.2
DN 800 mm
≥ DN 800 3.7
mm

justification.
202
uPVC Pipes
Sr.
Description Required Specs. Offered Specs.
No.
1 Pipe material Un-plasticized Poly Vinyl
Chloride - uPVC
2 Medium to be handled Potable Water
3 Required Property of the Non Toxic

Materials of Pipes and
- Bidder to Confirm
Specials
4 Applicable Standards Bidder to mention
(a) Pipe Manufacturing IS: 4985-1988
(b) Pipe Installation IS: 7634 (Part – 3) - 2003
(c ) Pipe Testing IS: 12235 (Part 1 to 11) -

1986
(d) Elastomer Rings IS: 5382 - 1985
5 Class of Pipe Suitable for any one of the

following Working
Pressures in Kg / Cm2
(I) 2.5
(II) 4.0
(III) 6.0
(IV) 10.0
- Bidder to mention the
offered PN Rating of Pipe
as per BOQ
6 Recommended 0° to 49° C
Temperature Range
7 Recommended Safe 100 Kg / Cm2 at 20° C

Working Stress
8 Pipe Diameters - Bidder to mention the

offered Sizes of Pipe as per
BOQ
9 Pipe Wall Thickness - Bidder to mention the
offered wall thickness of
Pipe as per BOQ
10 Quantity of Pipes - Bidder to mention the
offered Quantity of Pipes as
per BOQ
203
DI Pipe
Sr.
No.
1 Pipe material Ductile Iron

- Bidder to Confirm
Specials
(a) Pipe Manufacturing IS: 8329:2000
(b) Pipe Installation IS: 12288:1987
(c ) Pipe Testing IS: 8329:2000

following
(II) K7
(III) K8
(IV) K9
(V) K10
- Bidder to mention
Temperature Range

BOQ
per BOQ
204
Sr.
No.
9 ISI Marking / BIS Required
Certification - Bidder to Confirm
10 Routine Tests Required as per relevant
standard
- Bidder to Confirm
11 Type Test Required as per relevant
standard
- Bidder to Confirm
12 Marking Required as per relevant
standard and Tender
Specifications
- Bidder to Confirm
13 Make of Pipes and Specials Bidder to furnish as per the
approved vendor list
14 Pipe Ends Bidder to mention from
below types
(a) - Plain
(b) - Socketed
(c ) - Threaded
(d) - Flanged
15 Pipe Jointing Bidder to mention from

below types
(a) - Socket & Spigot Flexible
push on joints
(b) -Restrained joint
(c ) -Mechanical
(d) - Flanged
16 DI Pipe Jointing with Shall be by a Flange Joint

other materials‟ pipes / - Bidder to Confirm
fittings / valves etc. (like
metallic)
17 Standard Length of Pipes 4 / 5 /5.5/ 6 meters

- Bidder to mention
18 Pipe Installation Under Ground / Over
Ground
- Bidder to Mention
205
Sr.
No.
19 Anchoring and Supports to Shall be provided as per
Pipes / Fittings and Valves specifications / standards
- Bidder to Confirm
20 Hydraulic Testing of the Shall be carried out as per
Pipes and Fittings specifications and relevant
standards
(a) At Works - Bidder to Confirm
(b) At Site - Bidder to Confirm
21 Surge Conditions Piping work shall be

capable for safe working
with surge condition, which
may occur
- Bidder to Confirm
22 Deviation Bidder to furnish deviations
(if any), from the above
specifications, clearly. If the
deviation is for betterment
in design / performance,
then it will be supported
with a technical justification
23 Quality Assurance Plan - To get an approval from
QAP Client/ Client’s
representative before
manufacture, testing and
supply of the pipes and
fittings

Sr.
No.
1 Zero Velocity Valve –1 Of required size as per pipe
the design
7 Vacuum Breaker cum Air Cushion Valve - Of required size as per pipe
1 diameter and rating as per
the design
OR

Sr.
No.
1 Surge Anticipation Valve –1 Pressure Of required size as per
activated hydraulic control valve with hydraulic design and pipe
combination air valve if required
the design
Note: The su ccessful contractor h as to submit detailed design &

calculations. Location of Air Vessels & Surge Control Device are to
be decided by the successful contractor on the base of detailed
design submitted & got approved f rom the departmen t competent
authority before ex ecution. Th e Max imum surge pressure to be
restricted sh all be less th an or equal to 10 kg/cm 2 .
General Note:
conjunction with the respective Technical Specification of Civil, Mechanical,
Electrical & Instrumentation works (Vol-III-A, B, and C & D) & drawings.


Sr.
No.
1 General

manufactured
pressure
Plan (QAP)
Geo Designs & Rearch Pvt. Ltd.,Vadodara Page 107

Sr.
No.
Complete Assembly
X H (mm)

3. FOR NIZAR:
DATA SHEETS FOR MECHANICAL WORKS - PUMP HOUSE
Sr.
ITEM DESCRIPTION
No.
2 NON RETURN VALVES
3 EXPANSION BELLOWS
7 EXHAUST FANS
8 AIR VALVE
9 M. S. PIPE LINES

Sr.
No.
(b) Type Sluice Valve (SV) – Non-rising Spindle Type or
Gate Valve – Rising Spindle Type
(d) Rating PN 2.0
Valves)
(3) IS 1538 (for Flange)
1.2 Mode of Operation: Motorised
(a) Body, Bonnet, Wedge, Stuffing Ductile Iron as per IS 1865 Gr. 500/7
Box & Gland
(c) Stem (Spindle) Diameter (mm) Furnish during detail engineering
1.4 Mfg. Quality Assurance Plan To get approved, prior to manufacturing
QAP)
1.5 Testing
test) – Kg/cm2
test) – Kg/cm2
1.6 Construction
(b) Thrust bearing arrangement Required

arrangement

Sr.
No.
1.7 Deviation Deviations (if any), from the above specifications,

clearly. If the deviation is for betterment in design
/ performance, then it will be supported with
technical justification.
1.8 Pressure Drop Calculation Bidder to Furnish
1.9 Paint Valves shall first be given two coats of zinc base
primer after completely cleaning the surface and
then it shall be coated with three coats of epoxy
paint. Valves shall be painted with Food Grade
Epoxy for Internal.
Complete Assembly

complete assembly – L X B X H
(mm)

Sr.
No.
(b) Type Duel Plate Check Valve (DPCV), Non Slam, Spring
Action with by-pass arrangement
(d) Rating PN 2.0
(b) Plates Cast Steel ASTM A 216 Gr. WCB with 13% Cr. S.S.
overlay (on seating surface only)
(c) Body Seat Ring SS AISI 304 with weld overlay on seating surface in
conjunction with EPDM
(2) BS 970, Gr. 304
(g) End Cover MS
Galvanized
(QAP)
2.4 Testing
test) – Kg/cm2
test) – Kg/cm2
clearly. If the deviation is for betterment in design /
performance, then it will be supported with
Complete Assembly

Sr.
No.
complete assembly
L X B X H (mm)
2.8 By-pass Valve Required. Bidder to confirm

provision.

EXPANSION BELLOW
Sr.
No.
01 Make Furnish during detail engineering
Bellow
04 Fluid Raw Water
08 End Connection Suitable end connection or Flanged. Flanges

shall be flat faced,
(As per IS 1538)

(As per IS 1367)
12 Axial expansion (mm) 15(Min.) to be adjusted with pump& piping
installation requirement
13 Axial compression(mm) 15(Min.) to be adjusted with pump& piping
installation requirement
14 Lateral Movement (mm) +/- 1(Min.) to be adjusted with pump&
Piping installation requirement
Pressure(Kg/cm2)

Sr.
No.
1.0 General
manufactured
(c) Make Furnish during detail engineering (It shall be as
per approved vendor list)
(e) Number of stages (proposed) One or Multistage
(Furnish during detail engineering as per design)
(f)  Head – H (at 50 Hz)  110 meter (Towards Piplod)
 80 meter (Towards Pishwar)
(g) Discharge – Q (at 50 Hz)
9786 m3/hr (Towards Piplod)
9118 m3/hr (Towards Pishwar)
(h) Pump Speed – RPM - Furnish during detail engineering as per design
At 50 Hz (considered)
(j) Pump Location In Intake Well
(l) Min. Guaranteed BOWL 87 % or more (Without negative tolerance)
Efficiency, at 50 Hz at duty
point
(n) Quantity 5 no. (4 w + 1 SB) (for pumping towards Shale
and Piplod)
5 no. (4 w + 1 SB) (for pumping towards Umja
and Pishwar)
(c) Type of sealing Stuffing Box
(d) Type of coupling Direct, with reverse rotation
preventing arrangement
(e) Number of stage Furnish during detail engineering as per design,
i.e. Single or Multiple
length, thickness.
(g) Discharge level with respect Above floor
to floor
3.0 Design Data

Sr.
No.
(b) Min, submergence required.
Measured from bottom of
bowl for cavitations free
operation of pumps in
(1) Solo
(2) Parallel operation. Furnish during detail engineering
(c) Delivery Pipe Diameter (mm) Furnish during detail engineering
(f) Life of Thrust bearing (Hours) Minimum 75,000 Hrs. of operation
4.0 Liquid Data
(VT Pump)
(a) Column pipe ERW, M.S. IS 2062, Gr. Fe 410 of required wall
thickness with inside and outside epoxy painted
in maximum 2.5 Mtr. Sections
(b) Suction bell Cast Steel ASTM A 216 Gr. WCB with inside anti-
corrosive coating
(c) Pump casing / Bowl Cast Steel ASTM A 216 Gr. WCB with inside anti-
corrosive coating
(j) Pump-Motor Couplings Pl. furnish details
(k) Suction strainer S.S AISI – 304
water
(n) Companion flanges M.S.

Sr.
No.
(u) Discharge Elbow MS IS: 2062, minimum 14 mm wall thickness
with inside and outside epoxy paint
Required
(e) Spares parts recommended YES
(Furnish during detail engineering separate list)
(g) Start-up / essential spares YES
7.0 Testing
7.3 A Static balancing test Required
7.6 Parallel Operation test at site Required
8.0 Other
8.2 Hydraulic Test Pressure 1.5 times on shut off or 2 times of duty point
whichever is higher
8.3 Safe operating time at shut- Furnish during detail engineering
off (in min.)

components like, Discharge
Head Assy., Column Pipes /
Shaft, Pump Assy. Etc., but

Sr.
No.
excluding motor)
discharge head (including the
base plate) – L X B X H (mm)
8.5 DEVIATION Deviations (if any), from the above specifications,

DATA SHEETS FOR GUARANTEED PARTICULARS ( NIZAR)

[1] VERTICAL TURBINE (VT) PUMPS
Sr. Offered
Required Specs. Unit Required Specs.
No. Specs.
Rated Discharge (Q)(at rated speed and at
A rated frequency, i.e.50Hz)
M3/hr 9741 (Nizar Left Side)
9137 (Nizar Right Side)
Rated Head Effective (H)(at rated speed

B and at rated frequency, i.e.50Hz)
Meters 110 m (Nizar Left side)
80 m (Nizar Right side)
Water Horse Power (WHP), at 50 Hz WHP
C 3911 (Nizar left side)
2668 (Nizar right side)
Pump input KW at rated condition, at 50 KW
D Hz
3354 (Nizar left side)
Pump Efficiency at rated parameters, at
E duty point - At 50 HZ
% 87.0
Motor efficiency at rated condition and
F steady state temperature
% 94.0
Input to motor at rated condition, i.e.50 KW
3568 (Nizar left side)
G Hz
Overall Efficiency of Pump Motor set at
% 81.78
H rate condition
Maximum NPSH required under operation
I at:Normal Water Level Meter
As per vendor design
Lowest Water Level Meters
Minimum Submergence required for
J safeoperation
Meter As per vendor design
Notes:
components.
(b) Bidder to furnish GA drawing indicating overall dimensions, weight, and height
details along with offer.
(c) Bidder to furnish Performance curves for Head V/s Capacity, Efficiency V/s
Capacity and Power (BKW) V/s Capacity.
(e) Bidders have to submit performance test reports and, family curves (Head (H) v/s
Discharge
(Q), Efficiency v/s Discharge and Power (P) v/s Discharge (Q) for similar model of
pump.
(f) There shall be a difference of 50 BHN hardness between casing ring and impller
ring.
(g) If the guaranteed, efficiency of pump quoted by the bidders is less than minimum
specified in the tender than the offer of bidder is liable to be rejected.
(h) Bidder to furnish deviations (if any), from the above specifications, clearly. If the
deviation is for betterment in design / performance, then it will be clearly mentioned
(j) Bidder to furnish guaranteed technical particulars duly filled.

ELECTRICALLY OPERATED OVERHEAD TRAVELLING (EOT)CRANES
Sr.
No.
5.3 Capacity (Tones) EOT crane lifting capacity shall be minimum 10

tons. However the final selection of crane
capacity shall be appropriately provided for
lifting of the component having height-weight

engineering details
5.6 Quantity 1 no.
5.10 Length of the runway (m) 50 meters is envisaged. However, it will be as

per final approved drawing
5.12 Method of operation / VFD Floor Operated, Through P. B. Station with VFD
5.13 Drum M. S. Seamless Pipe, as per ASTM 106, Gr. B.
(a) Hoisting (Main & Aux.) m / (Around 2 MPM)

min. Furnish during detail engineering
bearing)
5.16 Hoisting Rope


Sr.
No.
5.18.1 Motor for hoisting
5.18.2 Motor for Cross Travel
5.18.3 Motor for Long Travel

motion
brake
thruster brake

height and necessary details

betterment in design / performance, then it will
be supported with technical justification.

Sr.
No.
6.6 Quantity 1 no.
6.12 Method of operation Floor Operated, Through Down Pendant P. B.

Station
6.13 Drum M. S. Seamless Pipe, as per ASTM 106, Gr. B.

bearing)
6.17 Hoisting Rope


Sr.
No.

motion
brake
thruster brake

height and necessary details

clearly. If the deviation is for betterment in
design / performance, then it will be supported

Sr.
No.
7.3 Size (mm) 450
7.6 Rating 5
7.7 Motor
(c ) Total Nos. provided Furnish during detail engineering (It will

be as per approved drawing and sufficient
quantity as per pump house requirement)
(i) Total Weight (kg) of the Complete Furnish during detail engineering
Assembly

complete assembly
(3) L X B X H (mm)

for betterment in design / performance,
then it will be supported with technical
justification.

Sr.
No.
1 General

(d) Rating PN 2.0

Sr.
No.
(f) Application / Location To be fitted on water pipe-line for release of air
Valve etc.
(SG Iron, IS-1865, Gr. 500/7)
(SG Iron, IS-1865, Gr. 500/7)
3 Accessories Required with isolating Sluice Valve. Bidder to
confirm.
4 Mfg. Quality Assurance Plan To get approved, prior to manufacturing
(QAP)
5 TESTING
test) – Kg/cm2
6 Construction
built in or separate (Separate Sluice Valve with same rating & size
of Air Valve is preferred)
Spindle
(Large orifice)
(Small orifice)
(e) Isolation valve stem details (if Furnish during detail engineering
built-in)
Complete Assembly
complete assembly – L X B X
H (mm)

M.S. PIPE LINE

IS: 3589-2000 & IS 5504
- of approved make
2 Welding & Electrodes ASME – SECT – IX, IS – 7310, IS – 7307, IS: 814,
IS: 3613, IS: 6419, IS: 7280, IS – 9595
Inside of pipeline micron Dry Film Thickness (DFT), solvent free,
high build, food-grade epoxy lining, confirming to
AWWA C-210-07/ BS 6920 - suitable for potable
water application as per specification
4 Epoxy Paint Coating for out- Shot blasting, followed by supply and application
side of pipeline For Pump of primer & suitable epoxy paint, making total
DFT as 200 microns as per specifications
House
5 3LPE for outside of Main Pipe External anti-corrosion coating of pipes by using
line 3 Layer Side Extruded Polyethylene coating
conforming to DIN-30670, 1991, `Polyethylene
Coating for Steel Pipes ‘ and the requirements of
> DN 100 ≤ DN 2.7 specification (3.7 mm thickness)
250 mm
> DN 250 < DN 2.9
500 mm
≥ DN 500 < DN 3.2
800 mm
≥ DN 800 3.7
mm
6 Fabrication & Manufacturing IS: 3589 /IS: 5504
of Pipe
7 Deviation Deviations (if any), from the above specifications,
clearly. If the deviation is for a betterment in
design / performance, then the it will be with
8 Quality Assurance Plan - QAP To get an approval from Client/ Client’s
representative before supply of pipes

MOTORS – HT & LT
Sr. Required Specs.

Description
No.
1 Make As per approved vendor list (8 Working+
2Standby)
5 No. of Motor 5 no.
9 Indicative Rated KW 895 & 610 kW
11 Frequency 50 Hz.
± 10% combined voltage and frequency variation
21 Starting current with soft Less than or equal to 3 times of FLC of motor
starter
25 Starting torque in Kg-m at rated Furnish during detail engineering
voltage
26 Minimum accelerating torque at Furnish during detail engineering
min permissible voltage
27 Starting torque Sufficient starting torque to start the pump with
% of full load torque delivery valve open and when other pumps are
running.
28 Pull out torque Sufficient to bring the motor to normal speed in
% of full load torque minimum time
29 Class of insulation & temp. rise Class “F” but Temperature rise restricted to that
by thermometer of class “B”
30 Maximum Ambient temperature 50°C.
31 Location Indoor
Sr. Required Specs.

Description
No.
STC rating of Terminal Box 50 KA for 0.25 Sec
protection class IP 55.
38 External cable details. Al conductor, XLPE insulated, armoured 6.6 kV
(UE) grade Cable
a) No. of cores. As per design
b) Size As per design .
41 Make of bearings (A) As per approved vendor list
A) Make (B) Furnish during detail engineering
B)Recommended lubrication (C) Furnish during detail engineering
C) Recommended Life Span in
Hr
42 Type of bearings Ball bearing at non drive end / Roller thrust at
drive end
43 Colour shade of paint if special Grey shade 631 as per IS 5
44 Space heater for motors 240 V, 1 Ph., 50Hz., A.C. for winding heating
required
45 Thermistors / RTD’s / required For indicating, alarming and trip. ( 6 nos min)
48 Standard to be followed IS 325, 8225, 4889, 4772, 4029, 4691 and
other relevant Indian Standard or equivalent
BSS.
a)Duty point (d) Specify during detail engineering

b) Full Load
c) 0.75 Load
d) 0.50 Load
50 Power Factor at
d) 0.50 Load

[B] LT MOTORS
Sr. Required Specs.

Description
No.


16 Applicable Standard IS 325
17 Motor Energy efficiency class EFF2 as per IS- 12615
At full Load
At 75% Load
At 50 % Load
23 Efficiency
At full Load
At 75% Load
At 50 % Load
24 Maximum Ambient Temperature 50 deg C
for Continuous Operation oC
25 Maximum Temperature Rise at 70 deg C
Full Load oC
29 Starting current at rated Voltage
DOL Starting Current Amps
Star Delta 6 Times
Soft Starting Current Amp 3.5 times
Not be more than 3 times
30 Starting torque at rated Voltage 80%V 100%V 110%V
Starting torque
Pull out torque
Locked rotor torque
With load

Sr. Required Specs.

Description
No.
equipment coupled
32 Heating time constant Bidder to specify
33 Successive start- Hot & Cold Bidder to specify
Make
Type
Type Stud Type
Fault current with stand capacity 50 KA for 0.25 Sec
Size
Cable lugs To confirm suitable for cable size
Nos, watt, Voltage
Type
Type
On motor body 2 Nos
Pump
Motor
Total
Stator
Rotor
Total
47 Noise level Bidder to Specify
48 Vibration Level Bidder to Specify

BUTTERFLY VALVES
Sr.
No.
(c) Rating PN 2.0

(c) Disc Ductile Iron as per IS 1865 Gr. 500/7 (Dual
Ended, Flat faced flanged)

(QAP)
11.5 Testing
test) – Kg/cm2
test) – Kg/cm2
(c ) Disc Strength Test – Kg/cm2 As per IS 13095
betterment in design / performance, then it will
be supported with technical justification.
Complete Assembly
L X B X H (mm)
11.8 By-pass Valve to Main Valve Required
Bidder to confirm provision.

[2] General Note:
a) Bidder shall furnish material test certificates of all the major components during
inspection of the equipment.
b) The datasheet given in this chapter of all the components shall be read in conjunction with
the respective Technical Speciation of Civil, Mechanical, Electrical and Instrumentation works
(Vol-III-A, B, and C and D) and drawings.
c) Bidder should not mention or fill e.g "during detail engineering" or "submitted later on".
d) Mentioned all performance and technical values are equal as per data sheet or better than
it.

DATA SHEETS FOR MECHANICAL WORKS – PIPE

LINE
Sr.
ITEM DESCRIPTION
No.
2 AIR VALVE
4 M. S. PIPE LINES
5 UPVC PIPE
6 DI PIPE
6 SURGE CONTROL DEVICES – ZERO VELOCITY & AIR CUSHION VALVES

Sr. No. Description Required Specs.

(b) Type Sluice Valve (SV) – Non-rising Spindle Type or
Gate Valve – Rising Spindle Type
(d) Rating PN 1.0
manufactured (2) API – 600 / 603/6D BS – 1414 (for Gate
Valves)
(3) IS 1538 / 1976, Part IV & VI or standard,
suitable to size
(for Flange)
1.2 Mode of Operation: Motorized, Hand Operated
(mm)
(e) Gland Packing Jute & Hemp (IS 5414) / PTFE impregnated
Plan QAP)
1.5 Testing
test) – Kg/cm2
test) – Kg/cm2
1.6 Construction
arrangement

Sr. No. Description Required Specs.

arrangement

Epoxy for Internal.
Complete Assembly

X H (mm)


Sr.
No.
1 General

(d) Rating PN 1.0
(f) Application / Location To be fitted on water pipe-line for release of air
(a) Body, Cover, Cowl / Auto Valve
etc.
(SG Iron, IS-1865, Gr. 500/7)
(SG Iron, IS-1865, Gr. 500/7)
3 Accessories Required with isolating Sluice Valve. Bidder to
confirm
4 Mfg. Quality Assurance Plan To get approved, prior to manufacturing
(QAP)
5 TESTING
(b) Body Test Pressure (Hydro-test) As per standard
– Kg/cm2
6 Construction
built in or separate (Separate Sluice Valve with same rating & size of
Air Valve is preferred)
Spindle
(Large orifice)
(Small orifice)

Sr.
No.
(e) Isolation valve stem details (if Furnish during detail engineering
built-in)
7 DEVIATION Deviations (if any), from the above specifications,
clearly. If the deviation is for a betterment in
design / performance, then the it will be with
Complete Assembly
complete assembly – L X B X
H (mm)

BUTTERFLY VALVES
Sr.
No.
(c) Rating PN 1.6
3.2 Mode of Operation: – Motorised
– Manual Valve should be compatible with Actuator
for future connection with SCADA.
(c) Disc Ductile Iron as per IS 1865 Gr. 500/7 (Dual Ended,
Flat faced flanged)
Plan (QAP)
3.5 Testing
test) – Kg/cm2
test) – Kg/cm2
Kg/cm2
Epoxy for Internal.
clearly. If the deviation is for betterment in design /
performance, then it will be supported with
Complete Assembly

Sr.
No.
L X B X H (mm)
Valve Bidder to confirm provision
M. S. PIPELINE
Sr.
No.
IS: 3589
- of approved make

814, IS: 3613, IS: 6419, IS: 7280, IS – 9595
specification


`Polyethylene Coating for Steel Pipes ‘ and the
> DN 100 ≤ DN 2.7 requirements of specification
250 mm
> DN 250 < DN 2.9
500 mm
≥ DN 500 < DN 3.2
800 mm
≥ DN 800 3.7
mm

8 Quality Assurance Plan – To get an approval from Client/ Client’s

UPVC Pipes
Sr.
No.
1 Pipe material Un-plasticized Poly Vinyl
Chloride - uPVC

- Bidder to Confirm
Specials
(a) Pipe Manufacturing IS: 4985-1988
(b) Pipe Installation IS: 7634 (Part – 3) - 2003
(c ) Pipe Testing IS: 12235 (Part 1 to 11) -

1986
(d) Elastomer Rings IS: 5382 - 1985

following Working
Pressures in Kg / Cm2
(I)2.5
(IV) 4.0
(V) 6.0
(IV)10.0
- Bidder to mention the
offered PN Rating of Pipe
as per BOQ
Temperature Range
7 Recommended Safe 100 Kg / Cm2 at 20° C

Working Stress

BOQ
9 Pipe Wall Thickness - Bidder to mention the

offered wall thickness of
Pipe as per BOQ


per BOQ
DI Pipe
Sr.
No.
1 Pipe material Ductile Iron

- Bidder to Confirm
Specials
(a) Pipe Manufacturing IS: 8329:2000
(b) Pipe Installation IS: 12288:1987
(c ) Pipe Testing IS: 8329:2000

following
(VI) K7
(VII) K8
(VIII) K9
(IX) K10
- Bidder to mention
Temperature Range

BOQ

per BOQ

Sr.
No.
9 ISI Marking / Required
BIS Certification - Bidder to Confirm
10 Routine Tests Required as per relevant

standard
- Bidder to Confirm
11 Type Test Required as per relevant

standard
- Bidder to Confirm
12 Marking Required as per relevant

standard and Tender
Specifications
- Bidder to Confirm
13 Make of Pipes and Specials Bidder to furnish as per

the approved vendor list
14 Pipe Ends Bidder to mention

from below types
(a) - Plain
(b) - Socketed
(c ) - Threaded
(d) - Flanged
15 Pipe Jointing Bidder to mention

from below types
(a) - Socket & Spigot Flexible

push on joints
(b) -Restrained joint
(c ) -Mechanical
(d) - Flanged
16 DI Pipe Jointing with Shall be by a Flange Joint

other materials‟ pipes / - Bidder to Confirm
fittings / valves etc. (like
metallic)
17 Standard Length of Pipes 4 / 5 /5.5/ 6 meters

- Bidder to mention
18 Pipe Installation Under Ground /
Over Ground
- Bidder to Mention

Sr.
No.
19 Anchoring and Supports Shall be provided as per
to Pipes / Fittings and specifications /
standards
Valves
- Bidder to Confirm
20 Hydraulic Testing of Shall be carried out as per
the Pipes and Fittings specifications and
relevant standards
(a) At Works - Bidder to Confirm
(b) At Site - Bidder to Confirm
21 Surge Conditions Piping work shall be

capable for safe working
with surge condition,
which may occur
- Bidder to Confirm
22 Deviation Bidder to furnish

deviations (if any), from the
above specifications,
clearly. If the deviation is
for betterment in design /
performance, then it will be
supported with a technical
justification
23 Quality Assurance Plan To get an approval from
- QAP Client/ Client’s
representative before
manufacture, testing
and supply of the pipes
and fittings



Sr.
No.
1 Zero Velocity Valve Of required size as per pipe
diameter and rating as per the
design
2 Vacuum Breaker cum Air Cushion Valve - 1 Of required size as per pipe
diameter and rating as per the
design
OR
Sr.
No.
1 Surge Anticipation Valve –1 Pressure activated Of required size as per
hydraulic control valve with combination air hydraulic design and pipe
valve if required diameter and rating as per the
design
N o te : T he su cc e ssf ul c o nt ra c t or h as t o su bm i t d et ai l ed de si g n &
ca l cu la ti o n s . L o ca ti o n of Ai r Ve s se l s & Sur g e C o n t r ol D ev i ce ar e
t o be de ci d ed b y t h e su c ce s sf u l c o n tr a ct o r o n t h e ba s e of de t ai le d
de si g n s ub mi tt e d & g o t a p pr o ve d f r o m t he de p ar t me n t c o mp e te n t
au t h or it y b ef o re ex ec ut i o n. T he Ma x i m um s ur g e p re s su re t o b e
re s tr ic t ed s ha l l be l es s t h a n or e qu al t o 10 k g/ c m 2 .
General Note:
a) Work allotted EPC agency shall furnish material test certificates of all the major
components during inspection of the equipment.
conjunction with the respective Technical Specification of Civil, Mechanical, Electrical &
Instrumentation works (Vol-III-A, B, and C & D) & drawings.
c) Bidder have to confirm guaranteed particular and technical values shall be equal or
better then indicated in the datasheet. However all complete technical datasheet (to
meet tender requirement) shall be filled during detail engineering by work allotted
EPC agency.

Sr.
No.
1 General

manufactured
pressure
Plan (QAP)
Complete Assembly
X H (mm)

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Uchchhal,Songadh and Nizar Lift Irrigation Scheme

FOR OFFICE USE ONLY CONTRACT No.

TENDER PAPERS FOR

Cost Put to Tender: Rs. 849,59,28,124.23

NAME OF WORK: Ukai Reservior based Uchchhal,

VOLUME – III(B) (TECHNICAL SPECIFICATION FOR MECHNICAL

Date of Downloading Up to Dt.25-01-2019 to 25-02-2019,

OFFICE OF THE SUPERINTENDING ENGINEER

Geo- Designs & Research (P.) Ltd.

Tender Cost Time limit for the

VOLUME III (B): TECHNICAL SPECIFICATION FOR MECHANICAL WORK

Geo- Designs & Research (P.) Ltd.

VOLUME – I PRE – QUALIFICATION BID AND TECHNICAL DATA-SHEETS

VOLUME – II CONDITIONS OF CONTRACT

VOLUME – III(A) TECHNICAL SPECIFICATIONS FOR CIVIL WORKS

VOLUME – III(B) TECHNICAL SPECIFICATIONS FOR MECHANICAL WORKS

VOLUME – III(C) TECHNICAL SPECIFICATIONS FOR ELECTRICAL WORKS

VOLUME – III(D) TECHNICAL SPECIFICATIONS FOR INSTRUMENTATION

VOLUME – III(E) DRAWINGS

VOLUME – III(F) TECHNICAL BID

VOLUME – III(G) OPERATION & MAINTENANCE – SCOPE & SPECIFICATIONS

VOLUME – IV PRICE BID

Geo- Designs & Research (P.) Ltd.

Geo- Designs & Research (P.) Ltd.

Geo- Designs & Research (P.) Ltd.

13.7 CHEMICAL COMPOSITION ............................................................................................................ 79

Geo- Designs & Research (P.) Ltd.

These General Mechanical and Electrical Technical Specifications are meant to

The contractor shall be fully responsible for the maintenance of electrical,

1.1 ACCOMPANIMENT TO BID

It is the intention of the specification and drawings to design, supply, and

1.3 INTERPRETATION OF PROJECT DOCUMENTS

The specifications and price schedule shall be considered as part of this

in the specification or vice versa shall be executed as if specifically called in for

1.4 SCOPE OF Specification

These specifications cover design, manufacture, factory testing, supply,

Any item of work, either supply and/or erection of material/machinery which

The following mechanical and electrical equipments are to be covered under

d) E.O.T. Crane of required capacity

1.5 AMBIENT CONDITION

The equipments are to be operated in tropical climate with high ambient

1.7 REGULATIONS AND STANDARDS

The installation shall conform in all respects to Indian Standard Code of

also be in conformity with the current Indian Electricity rules, Indian

1.8 LIST OF APPLICABLE INDIAN STANDARD AND CODE OF PRACTICE

SR. STANDARD NO. TITLE

13. IS – 900 Code of practice for installation and maintenance of

rotating electrical machinery.

80. IS – 8061 Code of practice for design, installation and

103. IS – 14845 Air Relief Valves

1.9 MATERIAL AND EQUIPMENT

Where manufacturer's names and/or catalogue numbers are given this is an

1.11INSPECTION AND TESTING

The Engineer-In-Charge reserves the right to inspect and test at

approved by the Engineer-In-Charge. The detailed quality plans for

1.12RECTIFICATION AND TAKING OVER

At anytime and at the request of the Engineer-In-Charge, the contractor shall

The contractor shall prepare instruction manuals in English, on operation,