Utilities - Irrigation PDF

Table of Contents
SECTION 1.01 IRRIGATION SYSTEM .................................................................. 4

1.01.1 SCOPE OF WORKS .......................................................................................... 4
1.01.2 SUBMITTALS .................................................................................................... 4
1.01.3 AS-BUILT DRAWINGS AND OPERATION & MAINTENANCE
MANUAL ...................................................................................................... 6
1.01.4 CIVIL WORKS ................................................................................................ 8
SECTION 1.02 IRRIGATION NETWORK ............................................................ 10
1.02.1 GENERAL ...................................................................................................... 10
1.02.2 SCOPE AND BASIS OF PAYMENT ........................................................... 10
SECTION 1.03 PIPES AND FITTINGS ................................................................... 11
1.03.1
1.03.2
1.03.3
1.03.4
1.03.5
1.03.6
1.03.7
1.03.8
1.03.9
1.03.10
HDPE PIPES AND JOINTS ......................................................................13

GRP PIPES AND JOINTS ..........................................................................13
UPVC PRESSURE PIPES AND FITTINGS .............................................16
STEEL PIPE AND FITTINGS ..................................................................17
DUCTILE IRON PIPE AND FITTINGS .................................................18
DISMANTLING JOINT AND FLANGE ADAPTOR ............................19
DIELECTRIC COUPLINGS ......................................................................19
BOLTS, PIPE HANGERS AND SUPPORTS ...........................................19
UNDERGROUND SERVICES WARNING TAPES ................................20
PVC DUCTS ................................................................................................20
SECTION 1.04 VALVES .......................................................................................... 21

1.04.1
1.04.2
1.04.3
1.04.4
1.04.5
1.04.6
1.04.7
1.04.8
1.04.9
1.04.10
GATE VALVES ..........................................................................................21

BUTTERFLY VALVES .............................................................................21
NON-RETURN VALVES ..........................................................................22
SURGE ANTICIPATOR RELIEF VALVES ..........................................23
PRESSURE REDUCING AND SUSTAINING CHECK VALVES ......24
PRESSURE RELIEF VALVE ...................................................................24
VALVE ACTUATORS ................................................................................24
AIR VALVES ..............................................................................................25
MANHOLE COVERS ................................................................................26
CHAMBER IDENTIFICATION PLATE ................................................26
SECTION 1.05 PUMPS ............................................................................................26

PART 1 GENERAL ..............................................................................................26
1.05.1 SCOPE ............................................................................................................26
1.05.2 SUBMITTALS ................................................................................................27
1.05.3 QUALITY ASSURANCE ...........................................................................................28
1.05.4 WARRANTY ................................................................................................28

1.05.5 DELIVERY, STORAGE, AND HANDLING ..........................................28
PART 2 PRODUCTS ...............................................................................................28
1.05.6 MANUFACTURERS ...................................................................................28
1.05.7 PERFORMANCE AND DESIGN REQUIREMENTS ...........................28
1.05.8 OPERATING PARAMETERS ...................................................................29
PART 3 - MECHANICAL ........................................................................................29
1.05.9 DISCHARGE PIPING WITHIN PUMP STATION ...............................29
1.05.10 BOLTS .............................................................................................................30
PART 4 - PUMPS ........................................................................................................30
1.05.11 VERTICAL TURBINE PUMPS .................................................................30
1.05.12 DISCHARGE HEAD ..................................................................................30
1.05.13 SOLEPLATE ................................................................................................30
1.05.14 COLUMN PIPE ..........................................................................................31
1.05.15 PUMP WET END .......................................................................................31
1.05.16 FACTORY TESTING ................................................................................32
PART 5 MOTORS ..................................................................................................32
1.05.17 VERTICAL HOLLOW SHAFT MOTORS ..............................................33
1.05.18 HIGH EFFICIENCY VERTICAL HOLLOW SHAFT MOTORS
33
1.05.19 MOTOR SPACE HEATER
33
1.05.20 PUMP SPARE PARTS
34
1.05.21 FILTERS .......................................................................................................34
1.05.22 EXHAUST FAN ..........................................................................................34
1.05.23 FERTILIZER INJECTION UNIT .............................................................35
PART 6 - ELECTRICAL ..........................................................................................35
1.05.24 SCOPE .............................................................................................................35
1.05.25 ELECTRICAL EQUIPMENT ......................................................................35
1.05.26 SYSTEM CONTROLLING EQUIPMENT ...............................................35
1.05.27 OPERATION ..................................................................................................45
1.05.28 START UP .....................................................................................................45
SECTION 1.06 ELECTRICAL TESTS .................................................................46
1.06.1 ELECTRICAL EQUIPMENT AND INSTALLATIONS .........................46
Utilities - Irrigation
SECTION 1.01
IRRIGATION SYSTEM
1.01.1 SCOPE OF WORKS

The scope of works under this section covers the supply of material,
construction, completion, testing and commissioning of the Irrigation System. The
contract shall include for the complete installation, testing, commissioning of the
Irrigation System as summarized below and detailed on the contract drawings and
in these specifications.
The works shall comply with the Kingdom of Saudi Arabias (KSA) and
applicable international standards both for the materials and quality of the
workmanship.
Note:
1. Pump station works including all MEP works shall be done by
Specialized MEP contractor qualified/approved for Electro-Mechanical
works. MEP contractor shall have minimum 10 years Experience in
such Installations,
2. High level of coordination will be required with other infrastructure
Works. The Scope of the Works includes:
1. Construction of Irrigation reservoir, Irrigation pumping station and
laying of main lines.
2. Supply and installation of electric control panel, PLC and
instrumentation including power supply and all related connections.
3. Supply and installation of all MEP equipments including all
connections, and supports.
4. Construction of RCC valve chambers, installation of isolation valves
and air valves complete with all fittings.
5. Tie in connection to the existing irrigation supply /STP and the reservoir.
6. Testing and commissioning of the complete system including pumping
station and all MEP works.
7. Contractor to consider any other item required for the successful
testing, commissioning and smooth operation of the pump station.
8. Submittal of shop drawings.
9. Submittal of As built drawings and O&M
1.01.2 SUBMITTALS
The Contractor shall submit to the Engineer the following documentation
for review and approval, before commencing work:
A.
Material and Equipment Schedule
Page 4 of 47
All catalogue cuts, diagrams, samples, drawings and such other data may
be required to demonstrate compliance with the specification.
B.
Existing Services and No Objection Certificates
Prior to start of any work at site, the Contractor has to obtain NOC/work
permits from the Service Authorities in KSA for the work included in this contract
and record drawings for any existing services. Copy of these drawings and no
objection certificates should be submitted to the Engineer before starting the actual
work at site.
C.
Manufacturers Certifications
Certification by a recognized certification mark scheme by an independent

third party testing organization approved by the Engineer, that production has been
carried out under a system for supervision, control and testing, applied during
manufacture as per standards
-
Valves and Special Steel Fittings
Manufacturer's certificate for pressure testing, and coating, including

holiday and DFT test reports for each valve, fitting, spool if applicable.
D.
Recommendation of the Manufacturers
The Contractor shall submit manufacturers' recommendations for

installation and commissioning of each material or piece of equipment for approval
prior to commencing work. Recommendations shall include testing methods,
storage requirements (if applicable), maintenance and operational data. The
Contractor shall have a copy of the manufacturers' instructions available on site at
all times while works are in progress and shall follow these instructions unless
otherwise authorized to deviate by the Engineer.
E.
Spare Parts
The Contractor shall submit manufacturer's list of recommended spare parts

for approval prior to commissioning any piece of equipment. Recommendations
shall include stocking recommendations, exploded assembly diagrams illustrating
location and spare parts to be utilized and all relevant operational data.
F.
Installations and Testing
The Contractor shall submit his proposed work method statement for
approval prior to commencing work. The statement shall detail proposed sequence
of work, hold points, testing frequency and document control.
G.
Circuit Diagram
Page 5 of 47
Contractor must submit all circuit diagrams of electrical installation along

with samples and specifications of materials proposed in order to obtain approval
prior to fabrication or installation of the control panels.
1.01.3 AS-BUILT DRAWINGS AND OPERATION & MAINTENANCE
MANUAL A. As-Built Drawings
The Contractor shall maintain one set of contract drawings for the sole
purpose of recording accurate changes made as the work progresses ("As-Built"
conditions) of the irrigation system. All changes previously approved and all
completed work shall be recorded on these drawings.
The Contractor shall prepare as-built drawings clearly showing all
locations, depths, slopes, heights, shapes and dimensions of all the works as
executed.
Sizes of all the as-built drawings shall be 120cm X 60cm) size.
All as-built drawings shall be prepared using AUTOCAD or micro station
(using the latest Windows software). Mainline layouts to be on survey sheets
(scale 1:1000) as per contract requirements and approval.
Contractor shall prepare and submit as-built drawings for the pipeline
profiles of the Mainlines which are of size 200mm and above. Pipeline profile
drawings should be in Horizontal scale of 1:1000 and Vertical scale of 1:100.
Pipeline profiles to be submitted on separate drawings with clear references to
mainline layout drawings marked on the same.
Chambers Schedule is to be prepared indicating all relevant construction
items and giving coordinates for each manhole in compliance with contract
requirements.
The Contractor must submit as-built drawings for all the electro-mechanical
installations. All the details of the installed equipments regarding manufacturer and
model number, type, size, etc., shall be provided in the legend of the drawings.
The Contractor shall follow the standards (regarding legend, lifestyles,
colors, levels, size of drawings, title block, etc.) as per the contract drawings and
requirements.
After final approval of the as-built drawings, Contractor to submit the
following before the taking-over of the project.
Three complete sets of "As-Built Drawings" folded properly and provided
in plastic folders as a part of Operation & Maintenance Manual;
- A copy of computer discs/CDs (with proper titles and plastic enclosure box
-
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Provisional acceptance will not be considered unless Contractor
submits all the above as-built drawings.
B.
Operation & Maintenance Manuals

1) Assemble three (3) copies of manuals containing Operating &
Maintenance Instructions for each piece of equipment and system
requiring service and prints of as-built drawings as described
above. O & M manuals shall be bound in a hard cover 3-ring binder
of suitable size and properly indexed.
2) O & M manuals shall include the following information:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
Description of equipment.
Operation of equipment.
Maintenance of equipment & lubrication schedule.
Servicing of equipment.
Control diagrams.
Irrigation Valve Operation Schedule c/w Controller Station
No., Valve no., size, flows, operating time, etc.
Diagrams of the system.
Logic of Operation of the systems.
Valve charts.
Performance Characteristics: Curves and charts for equipment
(Data shall refer to, and identify specific model in service and
shall not be general advertising data).
Spare parts list.
Names, contact numbers and addresses of spare part suppliers.
Test reports.
Certificates.
Bill of Quantities of material used in the contract.
Letter of satisfaction.
Guarantees.
A digital copy (CD) of Operation & Maintenance manual shall be

submitted to along with As-built drawings.
3) Submit one copy of the manual to the Engineer for review and
three (3) final copies to the Client after the final approval of the
Engineer. Provisional acceptance will not be considered unless
Contractor submits complete O & M manuals and as-built
drawings.
C.
Warranty
As per contract documents.
D.
Product Storage and Handling
Page 7 of 47
All products shall be delivered in the manufacturers' original protective

packaging and shall be inspected at time of delivery. Any product that will be
damaged and not in accordance with specifications, or date stamp expired, shall be
immediately removed from the site and replaced.
All products shall be handled and stored in accordance with printed
recommendations of the manufacturer.
All site storage areas shall be shaded at all time. Pipe stacks shall be
designed to ensure that pipes, and especially pipe sockets, are not deformed during
storage and/or affected by sunlight.
Precautions shall also be taken to protect items sensitive to sunlight or heat
prior to backfilling operation. Any pipe, whether installed or not, which is observed
to be sunburned or oval, shall immediately be removed from the site and replaced.
1.01.4 CIVIL WORKS
The civil works for the irrigation network system and reservoir shall be
as per the main contract, but not be limited to the following:
a) Carrying out and reporting of all topographic survey verifications, soil
investigation verification as well as carrying out any additional surveys
and investigations necessary for the execution of the Works. This shall
include trial holes and soil resistivity surveys as required. Contractor to
review soil investigation reports prior to start of the works.
b) Carrying out site earthworks including cut and fill, site grading and
leveling, and formation of slopes back to existing ground levels at the
limits of earthworks within the site with all the necessary engineering
studies and designs for achieving slope stability. Scope shall include for
the import of approved fill material for the works from offsite as well as
the disposal and transport of any excess cut material or unused fill
material to a destination defined and approved by Engineer.
c) The scope also includes liaison with relevant Parties for the required
connections to the designated discharge points, as per the standard
connection procedures and methods.
d) All paving works for site access road, internal circulation roads, loading and
unloading yards, and parking spaces within the site. Scope shall include ground
preparation, improvement, laying sub-base, base and asphalt courses (or
interlocking tiles pavement where required) with the construction of kerb stones
and carriage way drainage system. The scope also includes liaison with relevant
parties for approved tie-in points.
Page 8 of 47
e) All civil works within site boundary, including gravel surfaces

(unpaved surfaces), lighting poles foundations, boundary walls,
security fences and access gates to the site.
f) RCC U/G water Storage Tank complete reinforced concrete
structure complete with lining material, paint, manholes, access
ladders, inter connected pipes and all associated works complete for
the irrigation water reservoir as per authority standards.
g) All pipe work inclusive of trenching, laying, backfilling,
construction of required thrust blocks, disinfection, flushing and
testing and the same in valve chambers, with the associated fittings,
couplings, dismantling joints, and flange adaptors, tees, elbows,
reducers, puddle flanges, coatings and corrosion protection etc for
the following and as shown on the drawings:
h) All reinforced concrete valve chambers, supports, platforms,
trenches cable and instrument cable ducts and channels, covered cable
trenches and any other civil structure required for the site wide
installed equipment. All chambers to be complete with all
accessories, access covers, access ladders, ventilation pipes,
supporting steelwork, pipe supports, sumps, cable ducts, brackets,
chamber posts, identification and marker plates, including sealants,
tanking, coatings and corrosion protection, etc as required.
i) Complete architectural and engineering, design and construction of a
complete pump station building including all structural work, roof
slab wall cladding, rain water pipe work, reinforced concrete work
including substructure and foundations, platforms, stairs, equipment
bases, pipe supports, electrical and instrument cable trenches, doors,
windows etc. with all specified internal and external finishes. Scope
shall include the Steel structure complete with crane beams for the
electrically operated overhead travelling crane in the pump station
building.
j) Complete architectural and engineering, design and construction of a
complete guard house at the site main access gate including all
reinforced concrete and block works, rain water pipe work, doors,
windows, and drainage system, etc. with all specified internal and
external finishes.
k) Potable water supply distribution system and all plumbing and
drainage systems from all the toilets, sinks and washing basins,
gullies, and air conditioning condensate water, drain pipes, septic
tanks, soakaway pits for all the buildings identified above.
Connections shall be provided to external sewerage/drainage
networks as per the standard connection procedures and methods.
l) Temporary and permanent signage requirements throughout the
works for construction, operation and maintenance, safety and
information purposes.
Page 9 of 47
SECTION 1.02
IRRIGATION
NETWORK 1.02.1 GENERAL

These works comprise for the complete material, workmanship, installation,
testing and commissioning of the irrigation network, TSE water storage tank and
pumping station including all civil, electrical, mechanical works and tie-in
connections to the supply source for the irrigation water and electrical supply for the
pump station.
The Contractor shall have minimum 10-years experience in large scale main
irrigation network projects, and shall be previously approved by local authority for
similar large irrigation and sewerage projects, including temporary diversion works.
All materials should be as per local and international standards to the
approval of Consultants and the Client and shall also be approved by the local
authority as required.
Note: Following are general specifications for the irrigation materials, the items which
are not required in this project shall not be considered in the scope of the
works.
1.02.2 SCOPE AND BASIS OF
PAYMENT A. Scope of Payment
The Contractor shall consider that all items shown in contract and
corresponding to BOQ shall include full payment for all labour, material, tools,
equipment, organizational costs, insurance, shipping, duties and other charges,
overheads, profit, royalties, transport, handling, setting up, payments to others for land
or use of land or damage to property of others, all temporary works, incidental works
necessary for proper completion of the Works and which shall not be paid for directly
but shall be considered as subsidiary works the costs of which shall be deemed to be
included in the Contract Rates and Amounts for related Pay Items.
Page 10 of 47
B.
Basis of Payment
For the basis of payment, quantities determined in accordance with the

Standard Method of Measurement for water works issued by the Ministry of
Water and Electricity (MOWE) and included in the Potable water specification
volume, shall be followed and paid for at the respective Contract Rates and Amounts
and Contract rates per unit of measurement, for each of the particular Pay Items
shown in the Bills of Quantities, which rates and amounts shall be full compensation
for furnishing everything necessary for the proper execution, completion of the
Works.
Unless shown as Pay Items in the Bill of Quantities, all other works
prescribed in the various Sections of the Specification, shall not be measured for
direct payment, but shall be considered as subsidiary works the costs of which shall
be deemed to be included in the Contract Rates and Amounts for related Pay Items.
SECTION 1.03
PIPES AND FITTINGS
A.
Scope
Piping and Appurtenances cover all pipes, fittings, valves, irrigation
equipment and accessories relevant to the irrigation network.
B.
Special Requirements
Notwithstanding the specific standards relevant to every pipe material, the
following general requirements shall apply to all pipe materials:
1) Manufacturers Certificate
Every shipment shall be accompanied by an original statement from the
manufacturer certifying that the products have been subject to the tests
specified in the relevant standards, have been found to meet the
requirements there of and are manufactured in complete accordance with the
specified standards.
Records of all tests carried out at the factory shall be kept and made
available to the Engineer.
2) Marking
Products shall have the following marks legibly cast, stamped or indelibly
painted on, as appropriate:
Trade name or manufacturers name, monogram or identification mark.

Relevant standard(s)
Nominal diameter inside/out sideand pressure class designation
Length of pipe if shorter than standard length
Angle of bends in degrees
Date of manufacture
Page 11 of 47
lot reference
Material used
3) Retest
For the purpose of this specification, the term batch shall be deemed
to include products of the same material, size and pressure class only.
The Engineer reserves the right to require additional tests or retests on
selected products and the Contractor shall defray all costs.
These tests when required shall be carried out at an independent testing
organization approved by the Engineer through the offices of the
Contractor, in accordance with the latest applicable standards. The
samples to be tested shall be selected by the Engineer with at least one
from every batch, and shall be subjected to any or all of the tests
specified in the applicable standards.
If a sample shall fail to pass a given test, two additional samples of the
same batch shall be subjected to the same test. The failure of one of
these additional samples to pass this test shall be cause for rejection of
that size, pressure class and type of manufacture during the same shift
as the test samples.
4) Handling
All products shall be delivered to and distributed at the site by the
Contractor. The Contractor shall follow the manufacturers
recommendations for handling, repairing, laying, jointing, anchoring,
testing and other works with due respect to the following:
a.
Loading and unloading shall be carried out by lifting with hoists,

using ropes or slings in order to avoid shock or damage. Fittings
shall be loaded and unloaded individually. Under no
circumstances shall such materials be dropped. Pipes handled on
skid ways shall not be skidded or rolled against pipes or other
materials already on the ground. No dragging on the ground will
be allowed.
b.
Pipes shall be stacked by placing the first layer on level timber.

Pipes shall not rest on sockets or joint faces. Pipes of the same
diameter shall be stacked together with suitable labels, on which
shall be entered date of delivery at the site and the number of
pipes. Height of stack shall be to the manufacturers instructions.
Rubber rings plastic materials and any other materials as
recommended by the manufacturers, shall be stored in shaded
locations in their original packing.
Each pipe shall be unloaded on site opposite or near the place where it
will be installed.
5) Pipes, Fittings and Accessories
Page 12 of 47
The pressure class of the pipes, fittings and accessories shall be as indicated in
the specifications that follow unless otherwise specifically indicated on the
drawings.
1.03.1 HDPE Pipes and Joints
HDPE High Density Poly Ethylene pipes shall be PE-100 manufactured to
ISO 4427 latest editions or its equivalent and suitable for underground installations
for pressure rating of 16 bar. Life expectancy of the PE pipes shall not be less than
50 years. The PE pipe shall be tough, resilient material capable of withstanding the
normal rigorous of pipe laying and weather conditions. PE pipes shall be suitable
for the use with TSE water. PE pipes shall have good weather ability properties and
shall withstand temperature variations. PE pipes shall be protected from the UV
light at all times. Contractor to submit all test certificates and manufacturer
warranties in support of the product. PE pipes shall be joined together with Butt
Fusion Joining system as per the manufactures recommendations. Mechanical
fittings Tees Elbows shall be as produced by company specialized in manufacturing
PE fittings for pressure rating of not less than 16 bars. All nuts and bolts with the
mechanical joints shall be SS3 1 6/A4. All mechanical joints shall be capable to
withstand end thrust induced by internal hydraulic pressure. Contractor to submit
manufactures product data sheets and samples for approvals.
1.03.2 GRP Pipes and Joints
The GRP pipes and fittings shall be manufactured from thermosetting resins
reinforced by glass fibers. All pipes and fittings shall have a resin rich inner layer,
having minimum thickness of 1.0 mm and a resin rich outer layer having a
minimum thickness of 0.25 mm incorporating one layer of C glass. The remainder
of the liner shall consist of at least one layer of 450 g/m powder bound acid
resistant chipped glass strand mat having a glass content between 25 and 30% by
weight.
(i)
The resin to be used for the internal face shall be of Vinylester or

Bisphenol type. For the remainder of the pipe isopthalic polyester type
of resin shall be used. No coloured pigments shall be used in the pipe
or fittings. Fine silica sand containing no impurities and complying
with requirements of BS 5480 Part-1 can be added to the outer layer to
achieve the thickness for required stiffness. The pipe and fittings shall
effectively resist the corrosive effects final effluent of temperatures
upto 50 degree C.
(ii) All glasses reinforcement shall be of the ECR type.

(iii) All pipes and fittings shall have an initial stiffness of not less than 10,000 N/M
and satisfy the requirements of ASTM D-3262-87. Pipes of upto 700 mm
diameter shall withstand longitudinal tensile force of 100 N/mm of
circumference. Pipes for use in microtunnelling or similar jacking operations,
the stiffness shall be minimum 50,000 N/M unless enclosed in concrete.
Page 13 of 47
(iv) No crazing or cracking shall be evident under parallel plate load test
upto deflection of 15% and no structural failure shall occur upto
deflection of 25%.
(v)
Representative samples shall pass the strain corrosion test according

to ASTM D-3681 and D-3262-87 for the 100 and 1000 hair test.
(vi) GRP pipes shall be joined by Reka type (double socket coupling).
The rubber rings shall be resistant to chemical effects of
TSE/Sewerage water.
(vii) The resin shall be cured to achieve minimum 90% of the hardness
recommended by the resin manufacturer and tested in accordance with
BS 4549, Part 1 Appendix- A. Internal face of the laminate shall also
withstand the commercial acetone test.
(viii) For cutting and sealing of the GRP laminate with a suitable resin the
manufacturers representative shall demonstrate and train the
Contractors staff in presence of the Supervision Consultants
representative.
(ix) Allowable tolerance for pipes resting freely on the ground at site shall
be as follows:
Internal diameter
Wall thickness average
(x)
+/- 0.5%
+ 15% - NIL
Deviation in straightness of bore 0.3% of effective length or 15 mm

whichever is less.
(xi) All pipes shall be visually inspected at site before installation for
defects such as delamination, exposed or protruding fibre, cracks,
scratches, air voids, pitting and wrinkles, etc. any repair at site if
approved by the Supervision Consultant shall be carried out by
qualified and skilled staff of the manufacturer.
(xii) The pipes shall be designed for a life of not less than 60 years,
calculations shall be submitted for initial and long term deflection
under live load, buckling and strain etc. in accordance with AWWA
C-950-81. In addition the design shall take into account additional
superimposed load from future road laying and filling of low areas
over the route.
(xiii) The Contractor shall be responsible for the choice of wide or narrow trench
formation, pipe bedding material, the method of bedding pipe laying and
backfilling based on the native soil condition and strength of the proposed pipe.
The choice of design parameter shall be as per manufactures recommendations
subject to the approval of the Supervision Consultant.
Page 14 of 47
(xiv) The design of pipe bedding and backfilling method shall be such that
the initial and long term deflection does not exceed the following
values:
Initial after backfilling
6 months after installation
: 2% of internal diameter
: 4% of internal diameter.
(xv) Method of handling, installation, backfilling, etc. shall be as per

manufacturers recommendations. If the Supervision Consultant
consider that the soil condition, bedding material or workmanship is
not satisfactory he shall have the right to order wide trench formation
(up to 5 times the pipe dia.), change in bedding material bedding
foundations or improved class of bedding all at no extra cost to the
Employer.
(xvi) Manufacturers Certificate of quality control test as required by
ASTM and BS Standards shall be required for approval of the
supplier of the pipes or fittings.
(xvii)Glass Reinforced Plastic (GRP) pipes and fittings shall conform to BS
5480 and AWWA C 950-8 1 to be approved by the Supervision
Consultant. Pipe shall have a 50 year strain corrosion value of 1.0%
per ASTM D3262-87. Complete design calculations per AWWA
C950 Appendix A shall be submitted for Supervision Consultants
approval.
(xviii) Couplings shall be Reka double socket type, allowing 2 degrees
deflection. Stainless steel coupling shall be used at change of pipe
material.
After installation and before backfilling the stainless steel coupling
shall be wrapped with Denso tape. Bonded joints shall be made in
accordance with manufacturers instructions.
(xix)
Following tests shall be carried out on the manufactured pipes.

Witnessing of all factory tests by Supervision Consultants
Representative may be required prior to delivery.
Chemical Control Tests: In accordance with the requirements of
ASTM D - 3262-87 with Test Method as described in D-3681 on
samples of manufactured pipe.
Hydraulic Tests: The manufacturer shall carry out internal hydraulic
pressure test on all pipes. The pipes shall be subjected to a pressure as
follows:
Pressure pipes
Gravity pipes
16 bars
2 bars
Page 15 of 47
There shall be no leakage after application of the test pressure of a

minimum period of 5 minutes.
Stiffness: Pipe stiffness at 5% deflection shall be determined as per
procedure of ASTM Test Method D-2412 and the requirements of
ASTM D - 3262.
Wall Thickness: Wall thickness to be measured for each pipe shall
be in no case be less than the nominal design thickness nor 15%
more than the design thickness.
Internal Diameter: Every pipe shall be checked for accuracy of
internal diameter. Tolerances shall be +/- 0.5% whichever is
greater.
Hardness: Every pipe shall be subjected to a Barcol hardness test in
accordance with BS 4549, Part 1 Appendix A to ensure that the
resin has been cured to achieve the required hardness.
Loss of Ignition: Minimum one pipe of every 30 pipes
manufactured to be tested as per ASTM D2484 Standard Method
of Test for Ignition loss of cured Reinforced Resin.
Hoop Tensile Strength: Minimum pressure pipe for every 30 pipes
manufactured to be tested for Hoop Tensile Strength in accordance
with the requirement of ASTM D-3 517 for the pressure class.
Longitudinal Tensile Strength: Minimum one pipe for every 30
pipes manufactured shall be tested in accordance with ASTM
D-3262 for gravity pipe and ASTM 3517 for pressure pipe.
Copies of the pipe manufacture test reports shall be submitted to
the Supervision Consultant for each consignment of pipes
delivered to the site.
1.03.3 UPVC Pressure Pipes and Fittings
uPVC piping shall be fabricated from unplasticized polyvinyl chloride
according to BS-EN 1452-2 or equivalent KSA standards. Rating and size shall
be as shown on the drawings but not less than Class D. Pipe shall be supplied in
lengths no smaller than six (6) meters. Each length of pipe shall bear markings to
identify type and grade. All piping shall show no evidence of blisters, grooves or
other extrusion marks. The Contractor shall provide three (3) samples of each
size, one meter in length for approval prior to supply and installation. All pipes
three inches (3") and above to be with Lock Ring Socket. The socket to be
integral part of the pipe and in accordance to BS 4346 Part 2: 1970 or its
equivalent KSA standards, and it should incorporate a triple compression rubber
seal complying with BS 2494: Part 2, and when jointed offers three-fold
hydraulic security under both positive and negative pressure heads. The socket
should have the same wall
Page 16 of 47
thickness as the pipe with an extra sleeve to maintain the correct pressure rating at
the joint.
All joints in pipes below 3 inches in diameter shall be made by solvent
welding using adhesive solvent and primer as recommended in writing by the
manufacturer and approved by the Engineer. All cans of solvent and primer shall
have labels intact and shall be stamped with date of manufacture. No cans dated
over two years old will be permitted. No thinning of solvent or primer will be
permitted. Lubricant and solvent cement used to make joints shall be approved in
writing by the pipes manufacturer or his designated representative and the
Engineer. Only male joints may be used up to 2".
Joints larger than 2" shall not be threaded. All threaded joints shall be made
up using PTFE tape or an approved equal thread sealant.
Pipes sized 1-1/4 and larger shall be of Class D (12 bars working pressure)
and smaller pipes shall be Class E (15 bars working pressure). Fittings shall be
fabricated from UPVC according to BS 4346.
All uPVC pipes and fittings should be covered by licensed Kite mark or its
equivalent KSA standards. All uPVC fittings shall have pressure ratings not less
than 15 bar.
On no account shall saddle and cross type connections be made to uPVC
pipe. All pipes passing through ducts shall be solvent weld joints.
Flange couplers shall be PN 16 and in accordance with BS 4504. Bolts and
nuts (whether part of the coupler or for fixing) shall be A4-70 stainless steel.
Fittings for the 200mm diameter and above uPVC pipes shall be GRP
fittings as per BS 5480 suitable for the pressure rating of minimum 16 bars.
1.03.4 Steel Pipe and Fittings
Steel pipe shall conform to API standard schedule 80 or other equal and
approved. Welded fittings shall be schedule 80 and weld neck. Flanges shall be in
accordance with BS4504 PN16. All bolts, nuts and washers used for flange
assembly or integral with bolted couplers shall be stainless steel 316 (A4-70).
All pipes and fittings to be coated inside and outside by electrostatic fusion
bonded epoxy to average DFT 150 microns, or by fusion bonded plastic powder
coating to average DFT 500 microns.
THREADED STEEL PIPES & FITTINGS (FOR 3 AND BELOW)
Threaded steel pipes and fittings used for risers shall be hot dip galvanized mild steel Class C in accordance
with BS 1387.
Page 17 of 47
All G.I. & steel pipes and fittings to be coated, inside and outside with
electrostatic fusion bonded epoxy to average DFT 150 microns or by fusion bonded
plastic powder coating to average DFT 500 microns.
Any galvanized pipe installed in contact with the soil shall be wrapped with
at least two layers of an approved petrolatum impregnated tape of minimum
thickness of 1.15mm and applied with 50% overlap. The wrapping tape shall extend
a minimum of 100 mm above the soil. Steel piping and fittings shall only be
installed above ground or otherwise specified.
Joints shall be threaded and sealed with PTFE tape or some other approved
method. Connections to the flanged equipment shall be via threaded flanged
adopters. All bolts, nuts and washers used for flange assembly or integral with
bolted couplers shall be stainless steel A4-70.
1.03.5 Ductile Iron Pipe and Fittings
Ductile iron pipe and fittings shall be in accordance with BS 4772 or ISO
2531 also according to ISO 1083 a grade 500 having min. tensile strength of 500
N/sq.mm. Fittings to have surface prepared by sand blasting and have fusion
bonded epoxy coating of minimum 300 microns dry film thickness inside and
outside. They shall be supplied by an internationally known and approved
manufacturer. Ductile iron pipes and fittings shall be supplied, stored, laid,
backfilled and tested in accordance with CP 2010. The pipes shall not exceed 5.5
meters in length and push-in or flexible mechanical joints shall be used unless
otherwise stated.
Where flanged joints are used, the flanges shall be faced and drilled to PN16
as defined in BS 4504, unless directed otherwise. Flanged joints shall be made with
inside bolt circle gaskets as described in BS 4865 Part 1, and gaskets from plain
rubber to BS 1737. Bolts shall be stainless steel 316 Grade A4-70, complete with
nuts and washers. The threaded portion of bolts shall be of such length that at least
two threads shall protrude beyond the nut when tightened.
Pipe barrels shall be Class K9, tapers, bend and pipes with cast on flanges
shall be Class K12, and tees shall be Class K14.
The internal and external surfaces of all ductile iron pipes and fittings shall
be coated according to one of the following methods:
i.
Fusion Bonded Plastic Powder Coating (average 500 microns)
ii.
Fusion Bonded Epoxy Coating (minimum 300 microns)
Page 18 of 47
1.03.6 Dismantling Joint and Flange Adaptor

1. Dismantling Joint
This shall be used on the pipe as shown on the drawings. Dismantle joint
shall provide flexibility at installation stage of flanged pipe work.
The dismantling joint to comprise of a flange adaptor, flange spigot
piece and tie bars, in a complete package and to allow a greater
adjustment length allowance at the installation stage. Adjustability to be
provided by the combination of a flange adaptor and flanged spigot. Up
to 50 mm of longitudinal adjustment (dependent upon diameter) to be
available due to telescopic action of the spigot within the flange
adaptor. Once the final installation position is achieved bolt up
procedures for the flange adaptor and tie bars to be applied.
The dismantling joint shall be fitted in accordance with the
manufacturers recommendation. Flanges shall be PN 16 rating.
Steel for spigot and flange adaptor body in accordance with BS EN
10025:1990 Grade Fe 430 A. Rubber gasket to BS 2494:1990 or to suit
service. All studs nuts bolts and washers shall be SS 316 grade.
2. Flange Adaptor
Ductile iron Flange adapters shall be used on pipe work as required
enabling plain-ended pipe to be connected either to flanged pipe or
flanged valves or other fittings. Flange adaptor to be provided with flat
mating faces, suitable for bolting to raised faces. Flange adaptors to suit
pressure rating of the flange PN1 6. Nuts and bolts shall be SS 31 6/A4.
1.03.7 Dielectric Couplings
Where pipes of dissimilar metals are joined, provide dielectric (insulating)
couplings, fittings, unions or flanges.
1.03.8 Bolts, Pipe Hangers and Supports
1. All bolts for couplings, covers, flanged joints, etc. to be of SS 316
stainless steel.
2. Piping hangers, supports and anchor points shall be fabricated to British or
approved equal standards. The hangers, rods, supports and other supporting
devices and accessories shall be capable of supporting at least twice the line load
of the products being supported. Pipe hangers and supports and all bolts, nuts,
washers, etc. shall be of good quality stainless steel.
Page 19 of 47
3. Fixing to concrete to be done using chemical anchor of approved by

the Supervision Consultant manufacturer.
1.03.9 Underground Services Warning Tapes
All pipes within trench shall be provided with warning tapes on top of
the pipe. Tapes shall be durable and detectable by electro-magnetic means using
low output generator equipment. They shall remain legible and color-fast in all
soil conditions at pH values of 2.5 to 11.0 inclusive.
The tapes shall be flexible and shall be subject to the Consultants approval.
Text in Arabic and English indicating the Irrigations pipe line below, tape
shall be permanent ink bonded to resist prolonged chemical attack by corrosive
acids and alkalis with the message repeated at a maximum interval of two
meters. Tapes shall be colour coded as follows with black text as indicated.
Irrigation Pressure Mains
CAUTION
: Orange
: Irrigation Pressure Main below
Services protection tapes, of 150 mm width, shall be installed above all

main irrigation pressure lines installed under this contract.
Tape shall be placed over the centerline of the pipeline at 600 mm below
finished surface level during backfilling and compaction operations. For
pipelines with less than 900 mm cover to the top of the pipe barrel, the tape
shall be placed over the centerline of the pipe at 300 mm above the top of the
pipe barrel during backfilling, compaction and reinstatement operation.
The tape shall be continuous over pipelines and at joints between tapes
from separate rolls the joint shall be lapped a minimum of one meter.
1.03.10 PVC Ducts
Ducts are to be high impact resistant uPVC pipes. The size of ducts shall
be as indicated on the Drawings or minimum 50mm higher than the pipe
passing through the duct. Ducts shall be BS-EN 1452-2 class C or its
equivalent in KSA standards.
Ducts running under streets or paved areas are to be encased in concrete
with minimum thickness as shown on the Drawings.
A pull wire is to be placed in all ducts stretching the complete length and
fixed to wooden block.
A.
Duct Markers
Aluminum duct markers shall be placed on both sides of the duct. Duct markers shall show size and number
of ducts crossing the road in English and Arabic on the duct
Page 20 of 47
marker. Samples of the duct Markers shall be approved by the consultants prior to
ordering of the material by the Contractor. All duct markers shall be of heavy duty
suitable for the local conditions and for installations within the road right of way.
SECTION 1.04
VALVES
All valves and flanges shall have minimum pressure rating of 16 bars
manufactured to British Standards or its equivalent and approved. The flange to
flange length of the valve shall conform to ISO 5752 Series 3, 14 or 15 as specified
below with various valve types. All construction Nuts & bolts shall be SS Grade
31 6/A4. Valves shall be non-rising stem types and the stem shall be SS Grade 316
TI/1.4571 or cast aluminum bronze with gun metal or Bronze stem nut. Valves
shall be suitable for TSE water. Contractor to take approvals of all equipments
prior to ordering and installation.
1.04.1 Gate Valves
Gate Valves body shall be ductile iron SG GGG40/50 and comply with BS
5163 or its equivalent. Gate Valves which are hand-wheel operated shall have
anti-clockwise opening. Maximum force required at the circumference of the
hand-wheel to open the valve against unbalance pressure should not exceed 500N.
All valves shall include a double O Ring releasing system which complies with
Clause 9 of BS 5 163:1986. Hand-wheel shall have marked words open and
close in English with rotation direction arrows. Hand-wheel shall be protected
with epoxy coating.
Stem of the valve to be of stainless steel. Seats on body and wedge to be
made from stainless steel for sizes above DN 400. Upto size DN 400 Resilient
seated gate valves are preferred with ductile iron wedge fully covered with rubber
on all sides and with replaceable stem nut.
Valve body to have epoxy resin coating of 300 microns (dft) inside and
outside. Valve stem seals shall be of the stuffing box and gland form for valves
above DN 400 and of the double O ring system enclosed in stainless steel PN 16
material for size up to DN 400.
Flanges shall be of faced and drilled to PN 16 unless to suit already existing
pipe work and approved by the Supervision Consultant.
1.04.2 Butterfly Valves
Butterfly valves shall be ductile iron SG-GGG40/50 and shall comply in all respects
with BS 5155 : 1984 or its equivalent . Body with all flanges faced and drilled for PN 16 and
the disk shall be made of Ductile cast iron corresponding to BS 2789-73 Grade 500/7. Disk
shall be mounted on stainless steel shafts located in PTFE lined self lubricating bearings with
synthetic nitrile rubber shaft seal.
Page 21 of 47
The valve disc shall be the double offset eccentric type single offset for
DN 1000 and larger fitted with a non-ageing sealing element of NBR (nitrile
Rubber Profile Seal) or similar approved material held in place by an adjustable
one-piece clamping ring secured with Stainless Steel adjusting set screws
mechanically locked in place (not resin bonded). The profile seal shall provide a
bi-directional tight shut off, against a solid rolled in body seat ring of Stainless
Steel.
The valve disk shall be as streamlined as possible to ensure low head losses
and secure movement without disk flutter.
The disk stub shafts shall be manufactured from Stainless Steel, and
positively keyed to the valve disk and incorporate a key securing device (valve
disks pinned to stub shafts are not acceptable).
The stub shaft bearings shall be of maintenance-free self-lubricating PTFE
lined bushes, and shaft seals of NBR or equivalent.
The epoxy coated valve gearbox shall be fitted with a sealed for life
maintenance-free travelling fork and nut gearbox, suitable for buried service duty
and capable of easy operation at full pressure differential equal to nominal
pressure, enclosed in cast iron casing, grease packed, with ball thrust bearings
coupled with hand wheel and position indicator.
Travelling fork and nut gearboxes shall be used for small and medium
sizes, slider-rank gearbox for bigger ones, according to the pressure rating.
1.04.3 Non-return Valves
Non-return valves body shall be ductile iron SG GGG40/50 single door
swing check type including hydraulic damper lever arm and balancing weights.
The disk shall be resilient seated. Valves shall be provided with removable covers
on top of the body to enable hinges and disk to be inspected and removed. Spindle
should be made of stainless steel.
Valves shall be provided with air release lock on the removable cover. Face
to face length of non-return valves shall be either two times nominal dia plus 100
mm or to ISO 5752 series 10. All construction bolts and valve spindle shall be
stainless steel grade ASTM 316 L. If application allows short body type check
valves to ISO 5752 series 14 with hydraulic damping device will also be
acceptable.
This short body tilting disk check valves must meet following requirements.
The check valves shall be the double flanged type of short body (face-to-face
dimension to ISO 5752 Series 14) drilled to BS 4504 PN 16. The body shall be of ductile cast
iron to BS 2789-73, grade 500/7 or better.
Page 22 of 47
The valve disk shall be of the same material as the body and be as
streamlined as possible to ensure low head losses.
Shafts will be of high-tensile ferric chrome-nickel steel and disk seat ring
of stainless chrome-nickel steel.
Precise seal of the valve disk inserted in ring of stainless steel. This seal
provides tight sealing of the valve at pressure below 2 bars.
Bearing bushes shall be self-lubricating/PTFE lined and maintenance free.
The check valves shall be equipped with lever and counter weight and if
necessary according to application with Hydraulic damping device for setting the
closing time.
The hydraulic damping device shall be used to damp closing and opening
shocks of the valve and shall act in both limit positioning (damped opening range 10
degrees and damped closing range 15 degrees).
1.04.4 Surge Anticipator Relief Valves
Surge anticipator relief valves shall be fluid actuated and have a single
moving assembly. A flexible, non-wicking, FDA approved, nylon fabric reinforced
synthetic elastomer diaphragm shall be integral with this assembly to form a sealed
chamber, operating free of drag or wear. The diaphragm shall not be used as a
seating surface. This assembly shall have a stem which is fully guided by separate
upper and lower bearings to preclude binding or deflection. When the valve is in
the closed position sealing at the seat shall be accomplished by the contact and a
smooth seat surface. The seat design shall be removable and not have edges that will
induce seal cutting, or wear at low flows. Progressive throttling of flow shall be
accomplished by a characterized profile quad ring retainer washer. The valve body
and cover shall be of cast iron. An FDA approved fused epoxy coating shall be
applied to the internal and external exposed surfaces of these components after
cleaning and degassing. This coating shall be standard on all basic valves 2-16. All
internal valve components shall be removable and repairable while the valve body
remains in the line. Packing glands and/or stuffing boxes are not permitted and
there shall be no pistons operating the valve or controls. Valve sizes 2-3 shall be
standard equipped with a flow-clean strainer mounted in the inlet supply port of the
main valve. Valve sizes 4 and larger shall be standard with an externally mounted y
- strainer for protection of the control circuit and WATTS ball valves to isolate the
pilot system from the main valve.
The valves shall open on a low or high pressure wave. The high pressure relief pilot
shall be set to open at any pressure above the normal operating pressure of the system. The
high pressure control shall be adjustable, spring loaded, normally closed, direct acting,
diaphragm valve designed to permit flow when controlled pressure exceeds the spring
setting. The low pressure pilot shall be set to open the main valve at a pressure below normal
system operating pressure.
Page 23 of 47
1.04.5 Pressure Reducing and sustaining check Valves

Pressure reducing valves shall be capable of maintaining a constant
downstream pressure from higher constant or variable upstream pressure and shall
be drop tight under no flow conditions.
The valve operation shall be achieved by the interaction of the inlet
pressure, outlet pressure and an intermediate pressure produced by a pilot valve or
relay system acting on the upstream side of the main valve. The pilot or relay
system shall be operated by a diaphragm connected to the outlet pressure.
The valve body shall be of ductile iron GGG 40/50. The valves shall be
arranged for automatic operation and shall be manually adjustable.
The valves shall be capable of operating on the required pressure and shall
be designed to provide the necessary loss of head and operate without hunting. They
shall be of the globe valve type with the main body of ductile iron GGG40/50 and
with bronze and gunmetal trims. The valve mechanism shall be diaphragm operated,
controlled from a servo diaphragm actuated by an adjustable spring balance relay
comparing pressure generated across an integral orifice plate.
Each valve shall be fitted with a pressure gauge to facilitate checking of
operation, each shall have the body rated to PN 16. Each valve shall be installed
complete with all accessories to form a complete system.
All valves shall have a drain plug at the bottom of
the body. 1.04.6 Pressure Relief Valve
These valves shall be installed in the pump room as shown in drawings to
release excess pressure away from the system.
The valve shall be flanged, diaphragm type, hydraulically operated, pilot
controlled and modulating type. The pilot shall be brass and tubing of
copper/brass. The valve shall be fast opening and slow closing. The valve shall be
flanged and of ductile iron body. All internal and external exposed surfaces shall
be FDA approved epoxy coated to minimum DFT 300 microns. All nut bolts to be
of stainless steel grade 31 6/A4-70.
1.04.7 Valve Actuators
The manufacturer shall be approved by local authorities/
Municipality/Local Government Agency and must demonstrate the experience and
capability to produce electrical actuator as specified.
The Contractor shall procure and supply all materials as identified in the scope of work, specifications and
drawings to complete the installation.
Page 24 of 47
The Contractor shall be responsible for providing all other materials which
are not identified in this document in order to complete the job e.g. cable glands,
cable lugs, wires connectors, etc.
It is the Contractors obligation to evaluate the materials requirements and
supply of sufficient quantities in order to achieve final completion of the described
works.
All materials and equipment shall be new, of first class quality and supplied
by reputable manufacturers.
Each actuator is to be tested in the factory before shipping. Standard
manufacturer testing procedures are acceptable. Original Test Certificates are to be
supplied with the actuators.
The Contractor shall provide all the necessary labour, tools, test,
instruments, temporary materials for carrying out the necessary test.
Inspection and testing are to be carried out in accordance with the approved
inspection sheets. It is the Contractors responsibility to prepare the test sheets and
submit them to the Client.
The Contractor shall arrange with the Client before any Site Testing are to
be conducted. The test will be carried out by the Contractor. All measuring
instruments and special apparatus required for carrying out the site test shall be
provided by the Contractor.
All test and checks shall be recorded on previously approved check,
functional test and energized system test sheets. The Contractor is to provide a
complete set of these sheets duly signed with the final dossier and as-built
drawings.
All actuators shall be tested. Test shall be, but not necessarily be limited to
the following:
-
manual drive engagement

Valve Closing
Valve Opening
Automatic disengagement of hand wheel.
In the event that the electrical actuators are assembled not by the original
manufacturer, the Contractor and or supplier shall provide a Certificate of
Acceptance from International Testing Authorities for the Supervision Consultant
approval. Cable glands shall be water tight.
Page 25 of 47
Provide automatic double orifice air valves at all high points on the
pressure mains. Air valves and other similar items shall conform to BS 2591 or its
equivalent and approved. Automatic air valves shall have non-corrosive floats in
chamber with clear space ensuring blockage free operation. All components for the
air valve actuating mechanism including the actuating lever shall be stainless steel
and suitable for TSE water.
The float should activate the valve, which shall not be in contact with
sewage. Nozzles with seals and actuating mechanism to be located in the removable
upper plate connected to the valve body using stainless steel bolts. The valve body
shall be ductile iron and shall have flanged inlet connection. Incorporated with each
automatic air valve an isolating valve shall be fitted to the inlet connection.
Pressure rating shall be 16 bars. Material for bolts and nuts shall be SS Grade 316.
Body of the air valves shall be ductile iron SG-GGG40/50.
1.04.9 Manhole Covers
All manhole covers and frames shall be Ductile Iron heavy duty suitable for
the vehicular traffic type D400-H, circular in shape in green color with the wording
Irrigation Main in English and Arabic.
1.04.10
Chamber Identification Plate
Chamber identification plate shall be stainless steel 316 150 mm long 20mm
wide by 5 mm thick. The plate is to have engraving 2 mm deep as shown on the
drawings for each relevant chamber. Since valve chambers are to be constructed
within the asphalt road therefore fixing of the plate shall be in such a way which is
strong enough to with stand continuous flow of traffic. Fixing screws shall be SS
316 and long enough to penetrate deep inside the concrete chamber.
SECTION 1.05
PUMPS PART 1
GENERAL
To provide a single source responsibility for the manufacture, warranty,
fully automatic variable speed pumping system for irrigation. The pumping system
shall automatically maintain a constant discharge pressure regardless of varying
flow demands within the station rating. Pumping system shall conform to the
following specifications in all respects. This specification covers the minimum
requirements; however, it should not be construed as all inclusive. It is the
successful Contractors responsibility to include all necessary appurtenances to
provide for a complete, automatic, smooth operating, and reliable pumping system.
Page 26 of 47
The pumping system shall be as approved by the engineer and as shown on

the drawings and in these specifications. This section covers the furnishing of
vertical turbine pumping unit(s) as required and to the expectations of the
ENGINEER with regard to the manufacture of the equipment.
All equipment must be supplied by the same pump Manufacturer including
bowls, impellers, column, shafting, heads, coupling, sleeves, seals, and motors.
Well drillers, distributors, or other fabrication shops will not be allowed to furnish
equipment built in their local fabrication shop. Equipment furnished under this
section shall be fabricated and assembled in full conformity with drawings,
specifications, engineering data, instructions, and recommendations of the
equipment manufacturer, unless exceptions are noted by ENGINEER.
1.05.2 Submittals
Complete fabrication and assembly drawings together with
detailed specifications and data covering materials, parts, devices and
accessories forming a part of the equipment furnished, shall be
submitted in accordance with the submittals section. The data and
specifications for each pumping unit shall not be limited to the
following:
Name of manufacturer.
Type and model.
Design rotative speed.
Number of stages.
Type of bowl bearings.
Number of stages.
Type of bowl bearings.
Type of lineshaft bearings.
Size of shafting.
Size of pump column.
Size of discharge outlet.
OD of pump bowls.
Weight.
Data on shop painting.
Max overall dimensions.
Total Weight.
Complete performance curves showing capacity versus head, NPSH required,
efficiency, and bhp plotted scales consistent with performance requirements.
Adequate operation and maintenance information shall be supplied. Operation and

maintenance manuals shall be submitted in accordance with the submittals sections. The
operation and maintenance manuals shall be in addition to any instruction or parts lists
packed with or attached to the equipment when delivered. Operation and maintenance
manuals shall including the following:
Page 27 of 47
Equipment function, normal operating characteristics, and limiting

conditions.
Assembly, installation, alignment, adjustment, and checking instructions.
Operating instructions for startup, routine, and normal operation,
regulation and control, shutdown, and emergency conditions.
Lubrication and maintenance instructions.
Guide to troubleshooting.
Parts lists and predicted life of parts subject to wear.
Outline, cross-section, and assembly drawings; engineering data; and
writing diagrams.
Test data and performance curves, where applicable.
1.05.3 Quality Assurance

Supplier shall be certified to the ISO 9001 standard for design and
manufacture of vertical turbine pumps.
Vertical turbine pump manufacturer shall have a minimum of 25-50 years
of design, manufacturing and testing experience.
1.05.4 Warranty
As per contract
requirements. 1.05.5 Delivery,
Storage, and Handling
The pumps shall be adequately supported during transit to ensure the
pumping unit is not subjected to undue stresses.
Spare parts shall be furnished as specified. Spare parts shall be suitably
packaged with labels indicating the contents of each package. Spare parts shall be
delivered to CLIENT as directed.
Final documentation shall be delivered on compact disk, readable using
Acrobat, MS Office, and if required in Solid works.
PART 2 PRODUCTS
1.05.6 Manufacturers
Pre -Approved by Client and his appointed Engineer
1.05.7 Performance and Design Requirements
Pumping units shall be designed for performance and design requirements as required,
required, at maximum speed unless otherwise noted.
Page 28 of 47
If the pumps are to be run utilizing a variable frequency drive, the pump
curve shall be continuously rising and shall be free from dips & valleys from the
design point to the shutoff head. The shutoff head shall be at least 115% of the
head that occurs at the design point.
For design and rating purposes, the water to be pumped shall be assumed to
have a temperature of 45C.
Pump performance shall be stable and free from damaging cavitation,
vibration, and noise within the operating head range. The performance of each
pump with an enclosed impeller shall be based on a radial running clearance
between the bowl wearing ring and the impeller of not less than 6 mils, or 0.5 mil
per inch of wearing ring diameter, whichever is greater. The performance of each
pump with an open impeller shall be based on a radial running clearance between
the bowl and the impeller of not less than 15 mils.
The pumping application required for this project demands equipment that
will operate reliably for many years. Un-scheduled downtime is unacceptable to
the Client, and it is the objective of this specification to deliver the highest quality
equipment that meets operating parameters stated.
At any operating speed, the ratio of rotative speed to the critical speed of a
unit or its components shall be less than 0.8 or more than 1.2.
1.05.8 Operating Parameters
The operating parameters shall be as shown on the drawings. For
consideration, the Contractor shall also furnish the following data:
Complete submittal data for all major equipment (pumps, motors,

filter, variable frequency drives (VFD), programmable logic
controllers (PLC), valves, and motor starters).
An electrical schematic showing power wiring.
Installation references of Minimum 5 variable frequency drive
pumping systems of comparable size and performance that have
been in operation in the KSA for a minimum of 3 years. Location of
closest factory trained service centers.
PART 3 - MECHANICAL
1.05.9 Discharge Piping within Pump Station
All piping shall be constructed from schedule 80 pipe. Piping shall be grit-blasted
with #50 steel grit per SSPC-10 to a near white metal condition. The cleaned steel surface
shall be immediately primed with an industrial grade primer to thickness of 2 1/2 to 3 mils
epoxy primer. The finish coat shall be acrylic enamel to a thickness of no less than 3 mm and
applied through an electrostatic method to insure proper adhesion. The color of the pipe work
inside pump room for irrigation system shall be blue, pipe work to show flow directions.
Page 29 of 47
All pipe work, valves and other equipments as required shall be provided
with suitable RCC supports.
1.05.10
Bolts
All nuts, bolts used in the assembly of the pumping system shall be SS 316
/A4 with SS 316 grade washers to be used on each side of fastener.
PART 4 - PUMPS
1.05.11 Vertical Turbine Pumps
The main irrigation pump(s) shall be of the vertical turbine type with flow
and head defined on the drawings. The vertical turbine pumps shall be
manufactured according to the standards of the Hydraulic Institute and to ANSI
specification no. B58.1. The pumping systems manufacturer shall have a network
of service centers which shall have available spare parts and trained pump
technicians to handle service, repair and warranty procedures. There shall be a
minimum of one foot spacing between the pump motors to allow maintenance
access.
Capacity and head of these pumps should be as shown on the drawings.
1.05.12 Discharge Head
The discharge head shall be of the fabricated steel type with a minimum
60,000 PSI tensile strength. The discharge shall have a working pressure of not less
than 275 PSI and incorporate a 150 ANSI discharge flange. Complete discharge
head shall be hydrostatically tested to a minimum of 413 PSI. A product lubricated
high pressure stuffing box containing at least six rings of packing and two lantern
rings shall be provided. Packing shall be compressed around shaft by an adjustable
two-piece gland. Dual bypass tubing shall be included for proper packing
lubrication and cooling. The discharge head stuffing box area shall also include a
drain which will be piped back to the wet well. Discharge head to be designed to
include leak less configuration. Discharge head shall incorporate an integral air
separation chamber, allowing air to be discharged through an air release line
mounted on top of head. Stuffing box bushing shall be SAE 660 Bronze.
The head shaft shall be of the two piece type, 416 stainless steel and shall be
turned and ground. The pump manufacturer shall include a method for adjusting the
impeller running clearance at the top of the head shaft. Adequate space shall exist to
couple the head shaft and the line shaft above the stuffing box. Coupling shall be
extra heavy duty AISI 416 SS with a minimum service factor of 2 to 1.
1.05.13
Soleplate
Pump supplier shall incorporate fabricated steel soleplate as part of supply
scope. Suitable size straight sleeve type anchor bolts in 4140 material to be
provided to mount the sole plate to existing concrete base. (Refer pump layout
drawing for details).
Page 30 of 47
1.05.14 Column Pipe
Column pipes shall be flanged 316 stainless steel schedule 80 material, in
inter-changeable sections not more than 10 feet in length. Pump line shaft shall be
AISI 416 SS grade. The size of the shaft shall be no less than determined by ANSI
specification B58.1. Bearing retainers shall be bronze with rubber bearings. All parts
shall be suitable for TSE water use.
1.05.15 Pump Wet End
The pump bowls shall be ASTM A48 Class 30 cast iron free of detrimental
defects. All bowls larger than 8" should be of the flanged type construction. All
pump bowls shall have porcelain enamel lined (or) epoxy lined water passageways
for high efficiencies.
The impellers shall be C83 800 hydraulic bronze and of the enclosed type
design. The impeller collets and all bolting shall be AISI 316 SS. Pump shaft
shall be AISI 416 SS turned and ground. The shaft shall be supported by bronze
bearings above and below each impeller. The suction bell bearing shall be extra
long and permanently greased packed and sealed with a bronze C844 sand collar.
Each bowl and impeller quoted shall have individual wear rings in AlBronze/Al-Bronze (Alloy 954) with min. 50 BHN differences
A stainless steel clip on type inlet strainer shall be mounted on the bottom of
each pump. Inlet area shall not be less than 4 times the suction bell inlet area.
Pumps shall be suitable for installations on treated sewage effluent supply.
Page 31 of 47
1.05.16
Factory Testing
A. Installations and Testing
The Contractor shall submit his proposed work method statement for
approval prior to commencing work. The statement shall detail proposed sequence
of work, hold points, testing frequency and document control.
The bowl assembly, column, discharge head shall be non-witness
factory pressure tested in accordance with the Hydraulic Institute Standards to
150% of maximum shut off pressure or to 200 psi or whichever is greater. Test
pressure shall be maintained for a minimum five-minute duration.
B. Factory Coating
The bowl assembly OD, column ID & OD, discharge head ID & OD
shall be factory painted with a NSF 61 approved two part epoxy coating. The
coating shall be applied in two coats of 4-6 mils DFT, with a final dry film
thickness no less than 10-12 mils. Prior to coating, all surfaces are to receive a
commercial blast meeting SSPC-SP 10 and shall be primed.
C. Engineered Analysis
The pumping unit shall be deigned to safely operate free of resonant
frequency. A natural frequency analysis of the head, motor stand (if applicable),
and electric motor shall be performed by a licensed Professional Engineer using
FEA software. A report shall be provided with the submittal showing that the
natural frequencies and mode shapes of the pump and motor have been considered
in the design of the discharge head, and certify that the critical frequency is at least
20% above or below the operating range.
D. Sump Pump
The pump shall be of robust construction and suitable for pumping
corrosive, treated effluent with high sand content. It should operate at minimum
100mm depth of water.
Pump body, impellor as well as vital pump components to be of Stainless steel
Capacity shown on drawings. Delivery line of pump to be connected to
the nearest storm water drainage manhole. This connection shall strictly be as per
the specifications & the requirements of local authority.
Float switch to be provided to operate the pump automatically. All
switches and control devices related to these pumps to be fixed in the electric
control panel.
Page 32 of 47
1.05.17 Vertical Hollow Shaft Motors

Motor(s) for irrigation pump shall be of the vertical hollow shaft high
thrust design. Motor shall have a TEFC enclosure, 1.15 service factor, and class F
insulation. Motors shall be wound for the starting configuration as called out in the
technical data sheet. Design pump brake horsepower shall not exceed 90% of motor
horsepower exclusive of service factor. Maximum pump run out horsepower
shall not be greater than motor rating exclusive of service factor. Motor shall be
rated for continuous duty and be designed to carry the maximum thrust load of the
pump and will have B 10 bearing life of no less than 5 years. Motors shall have
non-reverse ratchets. Motors shall be rated and tagged for VFD service, 50 C
ambient temperature and proper altitude per motor manufacturers
recommendations.
HP
Shaft Type
100
Hollow Shaft
RPM
1770
Voltage
230/460
Enclosure
TEFC
Efficiency Rating
Energy Efficiency
Yes
Non-Reverse
Ratchet
Motor Operation
Variable Speed
Service Factor
1.15
1.05.18 High Efficiency Vertical Hollow Shaft Motors

The pump manufacturer shall provide high efficient type, vertical hollow
shaft motors to meet the minimum design efficiency ratings as called out in the
technical data sheets.
1.05.19 Motor Space Heater
The pump manufacturer shall provide on each pump motor a 230 volt,
single phase space heater of ample size to prevent condensation from occurring
within the motor during non operating periods. The space heater shall be
de-energized when the motor is running.
Special Tools and Accessories
Equipment requiring periodic repair and adjustment shall be furnished
completed with all special tools, instruments and accessories, required for proper
maintenance. Equipment requiring special devices for lifting or handling shall
be furnished complete with those devices.
Page 33 of 47
1.05.20 Pump Spare Parts
The Contractor shall submit manufacturer's list of recommended
spare parts for approval prior to commissioning any piece of equipment.
Recommendations shall include stocking recommendations, exploded assembly
diagrams illustrating location and spare parts to be utilized and all relevant
operational data.
1.05.21
Filters
Automatic self-cleaning filters specifically designed for use with

organic contaminants. Cleaning shall be effected by a hydraulically powered
suction scanner, automatically activated when the differential pressure across
the filter reaches an adjustable level, nominally 5 psi.
The screen shall be stainless steel grade 316 with 200 mesh size.
Flushing line to be connected to the soak pits or nearest storm water drainage
manhole.
The control system shall feature a fail safe timer to prevent
continuous flushing due to malfunction.
The control system for the filters should be such that it will not flush
the filters if the pumps and/or irrigation system is not operating. Filters should
flush only during the operating hours of the Irrigation System.
Filters to be installed in the pump room r shall have capacity as
shown on the drawings.
All the filters shall have isolation valves in the suction as well as
delivery side for easy maintenance. The controller for the filters shall be
equipped with timer and pressure differential control unit. Controller will be
fixed in the Electric control panel.
All nuts and bolts shall be of stainless steel grade 316 or A4-70.
The filter body and internal parts including flanged connection shall
be stainless steel. Pressure gauges to be connected t suction and delivery side of
each filter, pressure gauges to be mounted in the electric control panel in
isolated compartment.
The filter shall be suitable for the treated water use and mesh size
shall be strictly as per the requirements of drip irrigation system.
1.05.22 Exhaust Fan
1 no. extra heavy duty industrial type aluminum body exhaust fan required to provide
10 air changes per hour to be fixed in the pump station roof.
Page 34 of 47
1.05.23 Fertilizer Injection Unit

The fertilizer/chemical injection unit shall comprise of 500 liter
rigid polypropylene make up tank with reinforced ribs mounted on a pedestal
and dosing pump with a range of 2 to 120 l/h, calibrated in 2 l/h or less
increments, complete with valves and fittings, filters and connecting pipes.
The elevated make up tank shall have level marks molded into the
side of the tank. A second outlet complete with stop-cock shall be provided
in bottom of tank for draining and washing out. An agitator shall be
provided to ensure that there is no separation of liquids. The agitator unit
shall be removable to allow access for cleaning the tank.
The dosing pump shall be constructed of corrosion resistant
material, close coupled to a suitable splash proof electric motor. The unit
shall have an operating head of 100m over the full flow range. The injection
rate shall be set manually to required flow.
Fertilizer injection pump shall be complete with dry running
protection system, all the piping and parts in contact with the liquid shall be
acid resistant. All controls /power supply locally arranged.
PART 6 - ELECTRICAL
1.05.24 Scope
To provide complete SEC approved instrumentation and controls
to automatically start, stop and modulate pump speed(s) to smoothly,
efficiently and reliably pump variable flow rates at a constant discharge
pressure. Full alarms and safety features needed to protect the equipment
and irrigation piping system. Control panel shall be suitable for connecting
to generator. Electrical control panel shall comprise of all controls for smooth
operation of the irrigation pump station, including power supply.
1.05.25 Electrical Equipment
All electrical equipments shall be in accordance with SEC
regulations and electrical specification. Enclosures shall be protected in
accordance with IP55 for equipment installed above grade and IP58 for
equipment installed below grade. Wiring to and from control panels shall be
routed in PVC conduit below the ground. Above grade conduit to be liquid
tight flex, or galvanized steel, provision to be made for inspection tee's and
ells to facilitate removal in the future.
1.05.26 System Controlling Equipment
Page 35 of 47
A.
Electrical Control Panel

All equipment and wiring shall be mounted within the enclosure and labeled
for proper identification. All adjustments and maintenance shall be able to be done
from the front of the control enclosure. A complete wiring circuit and legend with
all terminals, components, and wiring identification shall be provided. Main MCCB
disconnect shall be interlocked with door.
Control Panels shall be constructed of mild steel sheet enclosures with

stainless steel 316 lock and hinges front opening door having a protection range
not lower than IP 65 according to IEC and to be class 3(form-4). The panel shall
have provision for connecting to generator.
Control panels to be fixed on concrete base (300 mm above ground level).
Contractor to submit shop drawings prior to construction of concrete base for
engineers approval.
Panel shall have main circuit breaker for the power main and earth leakage
protection. Each power circuit should have circuit breaker, earth leakage protection
and power indication lamp. Each switch and light on the exterior of the panel shall
be marked with an engraved plastic name identifying each item. The panels shall
have serially numbered terminals for terminating all incoming and outgoing cables.
Anti-condensation heaters shall be provided inside the panel. Control panels shall
strictly be as per SEC standard Specifications in all aspects and subject to the
Engineers approval.
B.
Lightning and Surge Arrester

All electrical equipment shall be protected by a U.L. Listed approved
Category C and Category B surge arrester to suppress voltage surges on incoming
power. The devise under IEEE C62.41 Category C will withstand a impulse of
10Kv/10Ka and Category B to withstand a ring wave of 6Kv/500a and a impulse
of 6Kv/3Ka. Pass voltage for a 480v devise to the end equipment shall not exceed
1500V-1800V when subjected to a 8ms * 20ms wave shape resulting in the
following performance statistics: 3720 joules minimum with a power dissipation of
82,500,000VA at 1 800V maximum pass voltage to the protected equipment.
Response time shall be less than 5 nanoseconds.
C.
Main Disconnect
A circuit breaker (MCCB), shall be provided to completely isolate all
controls and motor starting equipment from incoming power.
D.
Control Power
Power for the controls shall be provided by a control power transformer which will
provide low voltage, single phase power for the pumping system control operation. Control
power transformer shall not be used for any other external load. The control power
transformer shall be protected on the primary side by circuit breakers of adequate size and
voltage rating. All control components will be protected by time delay circuit breakers of
adequate size.
Page 36 of 47
E.
Skid Conduit
All on skid conduit shall be flexible conduit with water tight
connections at enclosure and termination device. All conduits shall be
fastened to the skid every 24.
F.
Junction Boxes
All off skid devices requiring control interface shall be terminated in
a junction box. This junction box shall be located at the skid edge nearest
the installation point of the off skid device.
G.
Motor Starting Equipment

All motor starters for the pumping station shall be mounted on a single
back panel in a single Form IV, IP54 rated enclosure as specified Motor
starters shall meet I.E.C. standards and shall be rated for a minimum of
1,250,000 operations. Each main irrigation motor shall have dual
contactors, which are both electrically and mechanically interlocked to
allow the VFD to operate on any of the motors as called out in the technical
data sheet. Motor overload relays shall be I.E.C. rated class 10 ambient
compensated. Fuses shall supply short circuit protection to each motor and
shall be rated for a minimum 200,000 amp interrupting capacity. Motor
over-loads shall be manual reset only. Auto-reset of motor overloads shall
not be permitted. The motor starters shall be furnished one size above
design. (i.e. if 75 HP is needed, 100 HP shall be furnished)
H.
Variable Frequency Drive

The variable speed drive shall be a digital, pulse width modulation (PWM)
variable frequency drive (VFD) with IGBT transistors. The VFD shall include a 3%
input line reactor to protect against voltage transients. The VFD shall have a
minimum wire to wire efficiency of 98.5%, and shall be rated up to 550 volt
operation in order to eliminate nuisance tripping at marginally high voltage
conditions. Incoming power end shall be protected by fast acting semiconductor
fuses. Any VFD error messages shall be displayed on a 80 character LCD readout in
English or any one of 11 other languages. The following fault protection circuits shall
be included: Over current (240%), Overvoltage (130%), Under voltage (65%), Over
temperature (70 Deg. C), Ground fault, and motor overload. The VFD shall be
capable of starting into a rotating load and accelerate or decelerate to set point
without safety tripping. The VFD shall have an automatic extended power loss ride
through circuit which will utilize the inertia of the pump to keep the drive powered.
Minimum power loss ride-through shall be one cycle based on full load and no
inertia. The VFD shall be optimized for a 3 kHz carrier frequency to reduce motor
noise. The VFD shall employ three current limit circuits to provide "tripless"
operation. The following operating information shall be displayed on the VFD LCD:
KWH, elapsed time, output frequency (Hz), motor speed (RPM), motor current
(amps), and voltage. Line reactor will be installed on input of VFD to protect against
voltage transients. The VFD LCD display shall continuously scroll through all
operating information and shutdown faults while the drive is running and while
stopped. The information shall be viewable through a water tight plexiglass window on
the control panel door as specified in Section 3.10. VFD shall be as manufactured by
SEC approved manufacturer. The VFD shall be furnished one size above design.
(i.e. if 75 HP is needed, 100 HP shall be furnished)
Page 37 of 47
I.
Control Enclosure
Controls shall be housed in a Form IV enclosure with integral latches. The
control enclosure should be constructed of 12 gauge steel and the back plate
assembly shall be constructed of 12 gauge steel.60 wide and larger to be 10 gauge
or thicker. The enclosure shall be Powder coat painted. All enclosure cut-outs to be
done by laser for proper fit, sealing and coating retention. All indicating lights,
reset buttons, speed potentiometer, selector switches and the operator interface
device shall be mounted on enclosure door and also be IP 65. All internal
components shall be mounted and secured to the removable back plate assembly.
An air conditioned system shall be included to cool the insulated enclosure and
reject heat from the VFD. Open type cooling systems allowing outside ambient air
to enter the panel are not acceptable. No water line connections shall be permitted
inside of the control enclosure. VFD status and internal parameters must be
viewable without the opening of the enclosure door.
J.
Ultra sonic transmitter

For level measurements within the tanks ultrasonic level transmitter shall be
installed. Ultrasonic transmitter shall be capable of external installations. The level
measurement shall be made utilizing a ultrasonic pulsed echo from the liquid
interface and the sensitivity of the system shall be able to detect liquid levels as
low as 1 cm to a full pipe condition. Ultrasonic level transmitter shall be
installations inside the water tank or outside. All connections shall be water tight
and as per local authority regulations. Cabling work shall be through suitable GI
conduit pipe outside of the pump room. All nuts bolts, fixtures shall be stainless
steel 316 grade.
The sensors shall be designed to operate continuously over a temperature
range of 0 to 82.2 deg. C.
K.
Pressure Transducer
Pressure transducer shall be utilized for providing all pressure signals for the
control logic. Pressure transducer shall be a solid-state bonded strain gage type
with an accuracy of plus/minus 0.20% and constructed of 316L stainless steel.
Transducer shall be rated for station discharge pressure as shown on technical data
sheet, and shall provide gauge pressure output, rather than an absolute. Pressure
transducer constructed of plastic is not acceptable. Threshold transducers are
not acceptable.
L.
Pressure Gauge
A pressure gauge shall be mounted on the discharge header with a
isolation ball valve. All gauges shall be glycerin silicon filled to reduce wear due
to vibration. Accuracy shall be within 2%. Gauge diameter shall be 4 - 3 1/2"
minimum. Range shall be at least 50% higher than the highest pressure attainable
from the pumps at shutoff head conditions. Stainless steel back & bronze internal.
Pressure gauges shall be stainless steel, bourdon tube (Industrial series) rated
pressure 1 6bars, operating temperature 30 degrees accuracy +/- FS. Case material
shall be stainless steel 316.
M.
Electromagnetic Flowmeter
The pump station shall have a flow sensor installed, which shall be utilized for control
and to display total flow locally and through the pump station controller operato
Page 38 of 47
interface device (OID). Flow meter shall be electromagnetic flow meter comprised
of two major components, a primary head and a signal converter. Flow meter
signal converter shall produce two separate signals, pulse and 4-20mA, in linear
proportion to flow rate. Flow meter shall read flows from 0-40 fps, with a worst
case inaccuracy of 0.5% of indicated value (not a percentage of full scale) at 1.3
fps or greater. Flows under 1.3 fps shall have a lower accuracy with accuracy
applying to indicated value (not full scale). Flow meter shall be sized so that
maximum system flow lies between 16 and 24 fps through the meter. Meter shall be
installed according to manufacturers recommendations. Flow meter shall be as
manufactured by Krohne or an approved manufacturer.
N.
Primary Head
The flow tube shall be a ANSI B 16.5 class 150 flanged for sizes less than
24" and AWWA class D flanged for sizes above 24" with a 304SS spool. Wetted
liner shall be hard rubber. Liner shall extend beyond the ends of the flow tube and
over the flange faces. Liner shall remain stable and in place under a 500 mBar
absolute vacuum or pressure situation. Liner shall be rated for the medium
pumped. magnetic coils shall be wound by the flow meter manufacturer and held
in place in such a way as to prevent any fluctuation in the magnetic field generated.
Magnetic coils in flow tubes 6" and smaller shall be epoxied together through a
fusion bonding process, which renders the magnetic coil a single solid piece with
no loose windings. Electrodes shall be from Hastelloy C4. They shall be inserted
from the inside of the flow tube, and shall be sealed along their length. Electrodes
sealed at one or more discrete points shall not be accepted. The wires connecting
the electrodes to the primary head shall be fastened in place along their entire
length to prevent the transmission of erroneous data or signal noise acquired
through signal wire movement. All wiring shall be brought into the primary head
connection box and terminated. The shroud protecting the coils and electrodes
shall be welded in place, and internally pressure tested to 1.5 atmospheres with air
pressure. On completion, the flow tube shall be finish painted on all outside
metallic surfaces. Primary head shall be NEMA 6 rated.
O.
Signal Converter
The signal converter shall be NEMA 4X rated, and shall house the
microprocessor-based electronics required for magnet excitation and flow
measurement. Functions and data requirements shall be set by either a PC or by a
hand held programmer. Unit shall process flow using a bipolar pulsed DC signal.
Power supply shall be 230VAC 50 Hz. Outputs shall be 4-20 mA and pulsed output
scalable at 0-100Hz or 0-1000 Hz for full scale range. Signal converter shall also
include a binary output to indicate direction of flow.
P.
Grounding Rings
Where magnetic flow meters are placed in a pipeline that insulates the water from
ground (e.g. epoxy lined steel pipe or plastic) grounding rings are required at both ends of the
flow meter to eliminate eddy currents that may exist within the medium being pumped.
Grounding rings and flow meter body must be grounded properly in accordance with
manufacturers recommendations.
Page 39 of 47
Q.
Calibration and Testing

Meter shall be hydraulically calibrated on a testing device that is at least 10
times more accurate than the meter, and shall not be calibrated against a master
meter. Each and every flow meter produced by the flow meter manufacturer shall
be flow tested and hydraulically calibrated according to this procedure.
Manufacturer's test and calibration equipment shall be internationally certified, and
shall be re-certified every three years. Calibration shall be accomplished through
direct volumetric comparison, on rigs certified as having a measurement error of
equal to or less than 0.03% A calibration certificate shall be issued for each and
every flow meter produced by the flow meter manufacturer. Calibration certificate
shall be traceable to the US National Bureau of Standards. Meters shall be
calibrated under standard conditions to a measurement error of less than 0.50% of
rate.
R.
Controls
All control logic shall be handled by an industrial grade programmable logic
controller (PLC) with a 160 character LED industrial operator interface providing
data entry and read-out capabilities. PLC shall provide demand controlled
sequential pump start-up, shutdown and safety features through its pressure
sensing, flow sensing and voltage sensing devices. PLC shall have LED indicators
for input, output, and six diagnostic read-outs showing PC Run, CPU Fault, and
two communications, (battery and force). An LED visual status light is provided
for each I/O to indicate on/off status. PLC shall be provided with a built in
EEPROM, capacitor, and battery for memory backup. All logic for system control,
timing, and control of VFD speed shall be handled by the PLC. A separate set
point controller is not acceptable. PLC shall have a built in clock calendar. .
Control software shall be parameter driven, fully documented, and allow
user to easily change ALL operational parameters. Standard control features and
equipment which need to be included as a minimum are as follows:
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Alarms and shutdowns:

Low discharge pressure
High discharge pressure (Attempt
restart)* Low water level (attempt
restart)
Phase loss (Attempts restart)*
Low voltage (Attempts restart)*
Phase unbalance (Attempts
restart)* Phase reversal
Individual motor overload/phase loss (indicates which individual motor was
shut down) Manual reset only. Automatic reset is not acceptable.
VFD fault (shutdown VFD pump only and attempts restart)*
* Three unsuccessful restarts in 60 minute period will give hard shutdown.
All alarms will be indicated by a red general alarm light. Specific alarm
conditions along with procedures for correction will be displayed in English on the
operator interface display (OID).
Panel Face Switches and Lights Controls shall be designed so operator can
discretely start and stop all pumps in all modes of operation including manual mode,
operator interface failure, VFD bypass and PLC bypass modes with enclosure doors
closed and disconnect switch fully engaged. Enclosure shall include the following
switches/ or indicator lights:
A.
Individual pump run lights

Individual pump on/off switches
System Hand / Off / Automatic switch
Mode select switch allows automatic bypass mode of operation
which can be used in the even of VFD failure
VFD selector switch in manual mode, allows user to select which
pump will be run of the VFD
Reset Acknowledges pump station alarms
Speed potentiometer in manual mode allows user to adjust VFD
pump speed
Low discharge pressure over-ride switch disables low discharge
pressure alarm Individual pump run lights
Individual pump on/off switches
System Hand / Off / Automatic switch
Mode select switch allows automatic bypass mode of operation
which can be used in the even of VFD failure
VFD selector switch in manual mode, allows user to select which pump
will be run of the VFD
Reset Acknowledges pump station alarms
Speed potentiometer in manual mode allows user to adjust VFD pump speed
Low discharge pressure over-ride switch disables low discharge pressure
alarm
Page 41 of 47
B.
PLC bypass switch allows user to manually operate pumps should PLC fail.
The bypass switch shall be din-rail mounted inside the enclosure. When in bypass
the station shall be capable of running all pumps in the manual mode with door
operator switches. Any excess flow and pressure shall be bypassed through the
pump station relief valve
C.
Six distinct set point pressures (normal, lockouts 1 & 2, and 3 high
elevation). The lockout feature gives the user the flexibility to lower the set point
pressure automatically at days and times, and "locking out" the operation of one or
more of main pumps if local power authority imposes penalties for operating these
pumps during such times. It also allows user to set a maximum RPM for the VFD
pump during these lockout times so that user can limit amperage draw during
penalty periods. The high elevation set point can be tied into a computerized
irrigation system, or directly linked to high elevation satellites. When high
elevation satellites are operating, control software will automatically and gradually
elevate the pressure to the new desired set point. When finished, the high set point
will be lowered back to normal. The high elevation set point will only be used if
called out on the technical data sheet.
D.
Software will be included to automatically and gradually ramp up irrigation
system pressure to the desired operating pressure (i.e., 1 PSI every 4 seconds)
without overshooting design pressure. This feature operates whenever pressure
drops below set point pressure. This ramp up time is fully adjustable by the
operator. This control feature is based on an increase in pressure over a pre-defined
time period. The acceleration control on the VFD is NOT an acceptable means of
adjusting pressure ramp up speed.
E.
Software will be included for optionally maintaining a lower irrigation
system pressure when not irrigating. Reduced pressure values will be shown in the
technical data sheet. Controls will cycle the PM pump at these reduced pressures
during non irrigation times and pressure will gradually increase to design pressure
when the irrigation periods begin.
F.
Neither flow meter nor VFD output frequency shall be used for shutting
down last VFD driven pump. Controls and software shall incorporate a method to
eliminate excessive cycling of VFD pump at very low flow conditions, yet not run
the pump excessively at no flow conditions.
G.
Automatic alternation of VFD driven pumps. This shall be accomplished by
incorporating dual mechanically and electrically interlocked contactors allowing alternation
of the VFD between pumps. The controls shall alternate pumps based on individual run time
allowing each pump to acquire equal operation.
H.
Real time clock calendar allows PLC to internally provide all date, time and day of
week functions used above.
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I.
Two separately adjustable PID control loops for both low flow and high
flow pressure stability.
J.
User shall be able to field select either of two modes of VFD operation.
Auto switch VFD option allows VFD to sequentially start each pump. The standard
mode of operation starts the first main pump on the VFD and the remaining pumps
start across the line as required.
K.
Shutoff algorithm for fixed speed pumps to minimize pump cycling while
also remaining responsive to sudden flow reductions. Minimum run timers alone
for minimizing fixed speed pump cycling is not acceptable. Discharging through
relief valve during pump transitions is not acceptable.
L.
Full manual operation capability with panel face mounted speed
potentiometer for manually adjusting VFD speed.
M.
Light test sequence: Pressing the reset button for 5 seconds illuminates all lights.
N.
All pump station shutdowns shall be of the controlled type that sequentially
retires pumps at user selectable intervals to reduce water hammer within the
irrigation system. Phase fault shut-down shall have accelerated rate to minimize
motor damage. All pump system shut downs shall be of a controlled type that
sequentially retire pumps at intervals appropriate to the specific individual alarms.
O.
The pump station software program shall be user friendly enough to enable
the set point pressure from being raised or lowered by the end user at the pump
station or through the remote monitoring software package if provided. The pump
station software ladder logic shall be written in such a way that no other value
would require changing if the set point pressure had to be adjusted. Pressure
maintenance pump and main irrigation pump start pressures, the pressure
maintenance pump stop pressure, low discharge shutdown and high discharge
shutdown shall not be at a specific value but a differential pressure off of set point
(i.e. pressure maintenance pump (PMP) to start 5 psi below set point and stop 5 psi
above setpoint).
S.
Individual motor phase failure and low voltage safety circuitry

Individual motor phase failure and low voltage safety circuitry shall retire any pump
that experiences low voltage, phase failure or phase unbalance as monitored at the load-side
of each pump motor contactor. Each pump motor shall have its individual protective device
and time delay to allow for transient low voltage during motor starting to allow maximum
motor protection. Separate main phase failure and low voltage safety circuit shall also be
provided to retire the pumping system if it experiences low voltage, phase failure or phase
reversal as monitored at line-side of control enclosure. Phase monitor shall have a time delay
to allow for transient low voltage during motor starting and to allow maximum motor
protection. Operator interface device (OID), mounted in enclosure door, shall signal phase
failure for any affected pump. The individual pumps or pumping system shall not operate
until the voltage problem has bee
Page 43 of 47
corrected and safety has been manually reset. Single incoming phase monitor
safety circuit is not acceptable.
T.
Color Touch screen Operator Interface Device (OID)

The pump station shall include a NEMA 4, 320 x 240 resolutions, 8 color
touch screen display mounted on the control panel door. This device will allow the
operator to view and selectively modify all registers in the PLC. The unit shall store
its messages in non-volatile memory. The operator interface device shall incorporate
password protection for protecting data integrity. The device will allow for display
and modification of all timers, set points, lockout times, etc. The device shall
communicate with the PLC through the programming port, and shall include an
RS232 communications port allowing a printer to be attached for real time station
status logging
In addition to the data entry keys, the following shall be included on the
systems main menu.
1.
Pressure, Flow and System Status:

The current pressure, flow, VFD RPM and a system status overview
shall be displayed. Codes or Faults ID numbers shall not be adequate.
2.
Current Condition of all Alarms: The input state and alarm

state, for all active alarms shall be shown.
3.
Pump Runtime and Starts:

Runtime and number of starts for each pump shall be readily. The starts
and runtime must be verified by electrical pump feedback. The OID will
include a grand total and since reset value for each pump.
4.
Alarm History:
The last nine alarms shall be stored in PLC Memory with detailed
information about time, pressure and flow at the time of occurrence. The log
will also include diagnostic and recommendations for correction of
condition.
5.
Total Flow Output: This total shall include a grand total since
commission and a total since reset.
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6. Stations Events:
The last 255 events shall be stored in PLC memory. This will include all
alarms, individual pump starts and stops, and change in system status.
7.
Diagnostic Information
The display shall provide detailed diagnostic information to the
operator about the logical state which starts and stops irrigation pumps.
This diagnostic information will provide direct insight to controller internal
logic.
8.
Pump Station Software Program

The pump station software program shall be user friendly enough to
enable the set point pressure from being raised or lowered by the end user at
the pump station or through the remote monitoring software package if
provided. The pump station software ladder logic shall be written in such a
way that no other value would require changing if the set point pressure had
to be adjusted. Pressure maintenance pump and main irrigation pump start
pressures, the pressure maintenance pump stop pressure, low discharge
shutdown and high discharge shutdown shall not be at a specific value but a
differential pressure off of set point (i.e. pressure maintenance pump (PMP)
to start 5 psi below set point and stop 5 psi above set point).
1.05.27 Operation
During non irrigation times, the pressure maintenance pump (PM) will
cycle on and off as required to maintain irrigation system pressure. The start and
stop pressures shall be a differential off of set point. The cycling pressures can be
user selected and can be set substantially below normal set point pressure, if
desired. If the PM pump cannot maintain the desired pressure, then the VFD will
start the first pump and will gradually ramp the pressure up to desired irrigation
pressure. The start pressure of the VFD pump shall be a differential below the set
point. The pump speed will be modulated to hold a constant discharge pressure
regardless of flow. As the flow rate increases and the VFD pump can no longer
maintain pressure while at maximum speed, the next sequential pump will be started
and the VFD driven pump will accordingly reduce its speed and modulate. An
algorithm shall be included for accurately reducing the VFD pump speed as the
next sequential pump is started so that no pressure surges are generated during the
transition (even with across the line starting). If the user prefers to switch the VFD
from pump to pump for sequential starting, he can select this option with the OID.
As the flow continues to increase, pumps will sequentially be started until all
pumps are running. As the flow begins to decrease, pumps will be sequentially
turned off until only a single VFD driven pump is operating. When a no flow
condition occurs, PLC must check and verify pump curve position prior to station
shutdown.
1.05.28
Start Up
When discharge piping, electrical connections, and electrical inspection have been
completed, the pump station manufacturer shall be contacted for start up. A minimum one
week notice shall be given to manufacturer prior to scheduled start up date. During start up,
the complete pumping system shall be given a running test of normal start and stop, and fully
loaded operating conditions. During this test, each pump shall
Page 45 of 47
demonstrate its ability to operate without undue vibration, or overheating and shall
demonstrate its general fitness for service. All defects shall be corrected and
adjustments made at the expense of the pump station manufacturer. Test shall be
repeated until satisfactory results are obtained. Start up assistance will be provided
but will be limited to one 8 hour day unless otherwise specified.
After the station startup has been completed, but before leaving the job site,
a training session will be given. The training session will be given to the Client or
the Client's representative to familiarize them with the pumping system operation,
maintenance and adjustments.
SECTION 1.06
ELECTRICAL TESTS
Each electrical equipment, cable and complete system shall be thoroughly

inspected and tested before finally placing in service under the full responsibility
of the Contractor. All tests shall be made in compliance with respective
regulations, recommendations and standards. Any modifications or repairs deemed
necessary upon completion of the tests shall be executed at the Contractor's
expenses. Further tests shall be carried out on any modified or repaired equipment
until it is certified trouble free and acceptable for its intended service. All testing
shall be demonstrated to the Engineer in a manner to be agreed.
1.06.1 Electrical Equipment and Installations
All electrical equipment under these contract documents shall have passed
adequate routine factory tests. Field tests should be made by a qualified personnel,
approved by the Engineer. The Contractor shall furnish all apparatus, material,
labor and facilities for performing the required tests. Unless otherwise specified the
individual electrical equipment shall undergo the following tests in accordance
with the IEC recommendations or other approved standards.
For Workshop:
High voltage test
Check on mechanical function
Pre-test of functional sequences
At Site:
Visual inspection
Insulation test (megger test)
Check of functional sequences
The Contractor shall submit to the Engineer acceptance test certificates of all tests
carried out in his workshop including all measuring data and subsequent evaluation.
Page 46 of 47
The following tests are to be carried out for all cables as a minimum:
Resistance measurements
Insulation test with specified AC power frequency test voltage
Insulation resistance measurement of every individual cable length at site
Electrical continuity test for all controls.
The following test shall be carried out upon completion of the earthing system:
Measurement of the conductance of the earthing wires

Measurement of the intermediate resistance of the earthing electrodes
The Contractor shall provide at his expense the necessary qualified

personnel and measuring instruments of the above measurements.
END OF SECTION
Page 47 of 47

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Table of Contents

SECTION 1.01 IRRIGATION SYSTEM .................................................................. 4

HDPE PIPES AND JOINTS ......................................................................13

SECTION 1.04 VALVES .......................................................................................... 21

GATE VALVES ..........................................................................................21

SECTION 1.05 PUMPS ............................................................................................26

1.05.4 WARRANTY ................................................................................................28

1.01.1 SCOPE OF WORKS

Material and Equipment Schedule

Existing Services and No Objection Certificates

Certification by a recognized certification mark scheme by an independent

Valves and Special Steel Fittings

Manufacturer's certificate for pressure testing, and coating, including

Recommendation of the Manufacturers

The Contractor shall submit manufacturers' recommendations for

The Contractor shall submit manufacturer's list of recommended spare parts

Installations and Testing

Contractor must submit all circuit diagrams of electrical installation along

Operation & Maintenance Manuals

A digital copy (CD) of Operation & Maintenance manual shall be

Product Storage and Handling

All products shall be delivered in the manufacturers' original protective

e) All civil works within site boundary, including gravel surfaces

NETWORK 1.02.1 GENERAL

For the basis of payment, quantities determined in accordance with the

PIPES AND FITTINGS

Trade name or manufacturers name, monogram or identification mark.

Loading and unloading shall be carried out by lifting with hoists,

Pipes shall be stacked by placing the first layer on level timber.

The resin to be used for the internal face shall be of Vinylester or

(ii) All glasses reinforcement shall be of the ECR type.

Representative samples shall pass the strain corrosion test according

Deviation in straightness of bore 0.3% of effective length or 15 mm

(xv) Method of handling, installation, backfilling, etc. shall be as per

Following tests shall be carried out on the manufactured pipes.

There shall be no leakage after application of the test pressure of a

Fusion Bonded Plastic Powder Coating (average 500 microns)

Fusion Bonded Epoxy Coating (minimum 300 microns)

1.03.6 Dismantling Joint and Flange Adaptor

3. Fixing to concrete to be done using chemical anchor of approved by

Services protection tapes, of 150 mm width, shall be installed above all

1.04.5 Pressure Reducing and sustaining check Valves

manual drive engagement

Chamber Identification Plate

The pumping system shall be as approved by the engineer and as shown on

Adequate operation and maintenance information shall be supplied. Operation and

Equipment function, normal operating characteristics, and limiting

1.05.3 Quality Assurance

Complete submittal data for all major equipment (pumps, motors,

1.05.17 Vertical Hollow Shaft Motors

1.05.18 High Efficiency Vertical Hollow Shaft Motors

Automatic self-cleaning filters specifically designed for use with

1.05.23 Fertilizer Injection Unit

Electrical Control Panel

Control Panels shall be constructed of mild steel sheet enclosures with

Lightning and Surge Arrester

Motor Starting Equipment

Variable Frequency Drive

Ultra sonic transmitter

Calibration and Testing

Alarms and shutdowns:

Individual pump run lights