Tender Specifications - Bansujara Madhya Pradesh

Ban Sujara Major Project
TECHNICAL SPECIFICATION
Government of Madhya Pradesh

Water Resources Department
BANSUJARA MAJOR PROJECT

BANSUJARA PRESSURIZED CANAL SYSTEM
DISTRICT -TIKAMGARH (M.P.)
VOLUME-III
TECHNICAL SPECIFICATIONS
Supplying of water by constructing Balancing reservoir/Distribution chamber at RD

30900 m of Bansujara Project left bank main canal and delivering at farmers field
through pressurized pipeline system for micro irrigation in the Culturable command
area of 75000 hectare out of Gross command area of 93402 hectare (the entire
arable area from the initial reaches to tail end of all mains should be fully covered and
any arable area found in excess should be dropped at the tail end of mains )
indicated in the index map. It includes all activities starting from survey, investigation,
designing, procurement, construction, laying, installing, energizing, etc of pumping
system ,rising main , main line, branch lines, distribution network ,controlling and
regulation system etc for supply of water for irrigation under pressure. .
GOVERNMENT OF MADHYA PRADESH
WATER RESOURCES DEPARTMENT
Page 0
VOLUME III
INDEX
S.No.
1
2
3
4
5
6
7
Description
Section I General
Section II Survey
Section III Land Acquisition
Section IV Excavation and Earth work
Section V Cement Concrete
Section VI Pumps & Motors
Section VII (A) Pipe line
(B) Appurtenance works
(C) Instrumentation, Automation &
Page No.
2
4
6
8
10
12
49
85
99
8
9
10
11
12
13
Local SCADA System

Section VIII Steel & Iron works
Section IX Road Works
Section X- Transmission Lines & Switchyard
Section XI Specifications for building works
Section XII Quality Control Guidelines
Section XIII Design and Drawings Parameter
103
105
107
108
110
112
14
15
Section XI V Reference Information

Annexure-1 Specifications for 3 LPE coating
116
126
Page 1
SECTION - I
GENERAL
Volume - III
Page 2
Section I
GENERAL
The specifications contained under different sections in this document are for
general guidance. In case of disagreement between the specification of the
department and standard practices being followed and specifications not provided
specifically, then relevant specifications under Indian standards, Indian road
congress, manual on water supply and treatment published by Central Public
Health and Environmental Engineering Organization (CPHEEO), ministry of urban
development, government of India and approved manufacturer specifications shall
prevail. The exact specification shall be got approved by Chief Engineer as per
WRD Manual or as per IS standards to meet the requirement under this tender. In
absence of provisions in the MPWRD manual/IS code, these will be approved
based on standard engineering design practices/calculations
based on next
nearest technical parameters as may be used in IS code for similar items.
Page 3
Section II
SURVEY
Page 4
Volume III
Section - II
Survey and Preparatory Work
The relevant specification for irrigation projects (November 1991) volume-I, section-I,
chapter-2 of E in-C Water Resources Department M.P. Bhopal shall be strictly followed
for carrying out the survey for fixing the alignment of rising main/gravity main/main piped
canal along with distribution network complete) including survey for construction of intake
well / pump houses, various structures, buildings, roads and transmission line etc.
In addition to above the relevant Indian standard codes (updated) / IRC specifications
(updated) / MPPKVVCL/CPHEEO specifications will also be followed for the above work
and as directed by Engineer In-charge.
In addition to above the agency can also submit survey for alignment marked on Google
earth map to department for approval purpose.
Page 5
Section III
LAND ACQUISITION
Volume III
SECTION - III
Page 6
Land Acquisition
(A) After the alignment and locations of the various work components of the
project are finalized by the competent authority, the turnkey agency will
start the process of temporary land acquisition for underground pipe lines,
rising mains, gravity mains, piped canals & disnet system up to 0.6 to 1.2
ha. chak and permanent land acquisition for intake well / pump houses,
B.P. tanks & residential & non residential buildings required. The work
components requiring permanent land acquisition should preferably be
constructed on govt. land available & permanent acquisition of the private
land should be minimized. Private lands shall be purchased at the first
instant by the contractor for which he shall be reimbursed the cost as per
actual, subject to the ceilings imposed by land acquisition act/purchase
policy of the State Govt. in force at that time if any. Such land shall be
handed over to the State Govt .under provisions of the MPLRC after
completion of the work along with other assets. In case contractor fails to
procure land on his own, on his request the State Govt would procure land
as per the prevailing provisions of the land acquisition act/purchase policy
of the State Govt. but the delay in this process if any shall not be
attributable to the State/WRD. The cost for preparation of L A cases
(permanent and temporary), the cost of temporary land acquisition and
payment for crop compensation, if any, etc. is to be borne by the turn key
agency.
(B) The turn key agency has to prepare the proposals for private /govt./forest
land and will be responsible to get the clearance in scheduled time from
the GoI or GoMP as the case may be. The department will only help the
turnkey agency in getting the clearance from the competent authority. The
delay in clearance of the forest land or other land will be attributable to the
turnkey agency. Cost for compensatory afforestation will be borne by State
Government but cost of preparing case and getting clearance will be borne
by the turn key agency.
Page 7
Section IV
EXCAVATION AND EARTH WORK
Page 8
Volume III
Section - IV
Excavation and Earthwork
The relevant specification for irrigation projects (November 1991) volume-I, section-II,
chapter-4 & 21 of Ein-C Water Resources Department M.P. Bhopal shall be strictly
followed for carrying out Excavation for rising main/gravity main/main pipe canal along
with distribution network complete, including
excavation for construction of pump
houses, various structures, buildings, roads and transmission line etc.

In addition to above the relevant Indian standard code (updated) / IRC specifications
(updated) / MPPKVVCL specifications and "manual on water supply in treatment" publish
by Central Public Health and Environmental Engineering Organization (CPHEEO) shall
also be followed for the above work and as directed by Engineer In-charge.
Page 9
SECTION - V
Cement Concrete
Page 10
Volume III
Section V
Concrete Works
The relevant specification for irrigation projects (November 1991) volume-I, II & III of
Ein-C Water Resources Department M.P. Bhopal shall be strictly followed for carrying
out Concrete works for rising main/gravity main/main pipe canal along with distribution
network complete, including Concrete works for construction of pump houses, various
structures, buildings, roads and transmission line etc.
(updated) / MPPKVVCL specifications and "manual on water supply in treatment" publish
by Central Public Health and Environmental Engineering Organization (CPHEEO) shall
also be followed for the above work and as directed by Engineer In-charge.
Page 11
SECTION - VI
PUMPS AND MOTORS
Page 12
VOLUME III
Section-VI PUMPS AND MOTORS
1 : V.T.PUMPS
Each V.T. pump (Self Water lubricated) shall be of approved make Jyoti / Kirloskar /
Xylam/ WILO or other standard make as may be approved by Chief engineer and
suitable to the approved duty conditions and operating conditions.
Characteristic Curves:
1.1.
System head curves shall be furnished by the tenderer. The tenderer shall furnish
characteristic curves of bowl assembly and also pump after deducting column losses etc.
The tenderer shall furnish along with his tender the characteristic curves superimposed
on system head curves for single and multi pump operation. The pumps shall have
stable characteristics over the entire range of working head. The pump shall be suitable
for starting against closed sluice valve i.e. shut off condition. The efficiency curve shall
be reasonably flatter between designed head range.
Codes and Standards:
1.2.
The design, manufacture and performance of the V.T. pumps shall comply with all
currently applicable statues, regulations and safety codes applicable in the locality here
the equipment will be installed. The equipment shall also confirm to the latest applicable
Indian Standards. In particular the equipment shall confirm to the latest revisions of the
following:
IS 1710 - Vertical turbine pump for clear cold, fresh water
IS 5120 - Technical requirements for roto-dynamic special purpose pumps
Where the above standards are in conflict with the stipulation of this specification, these
specifications will supersede
1.3 Design Requirement:

The equipment shall be capable of developing the required total head at rated capacity
for continuous operation. The total head discharge curve shall be continuously rising
towards the shut off with highest at shut off point. Pumps shall be identical and shall be
Page 13

suitable for parallel operation with equal load division. Impellers shall preferably be of
non over- loading type. Pumps shall run smooth without undue noise and vibrations.
The magnitude of peak to peak vibration at slip will be limited to 100 microns at the
bearing housing. Pumps shall be SINGLE STAGE/Multistage vertical turbine type and
suitable for the service condition stipulated.
1.4 Bowl Assembly:
A pump bowl shall be flanged with machined matching of faces. The suction bell mouth
to bowl assembly, to column and to discharge head, i.e., all joints shall be flange joints.
The bowl shall be capable of withstanding a hydrostatic pressure equal to twice the duty
head or 1.5 times shut off head whichever is greater.
1.5 Suction Bell mouth & Strainer:
A cast iron / M.S. bell mouth shall be fitted to the suction nozzle to limit the velocity. The
suction strainer shall be of S.S, net opening area in strainer shall not be less than 3
times of entrance area of bell mouth. The shape and curvature of the bell mouth shall be
designed to streamline the flow of bowl suction. The thickness of bell mouth shall not be
less than 10mm.
1.6 Impeller:
The impellers shall be dynamically balanced so as not to cause any vibrations during
operation. The impellers shall be closed type and shall be made in one piece and
securely fixed to the stainless steel shaft, to assure accurate adjustment of each
impeller. The water passage will be finished smooth by hand. Balancing holes/ device for
reducing hydraulic thrust shall not be provided.
1.7 Wearing Rings:
Wearing rings shall be renewable type. These shall be held in place by screwing against
rotation, press fit or locked with pins, flanged and screwed. Wearing rings shall be
provided on both casing and impeller.
Hardness of wearing rings shall be less by at least 50 BHN than the impeller.
Page 14
1.8 Shaft:
The design of the shaft shall also take into consideration the critical speed of the shaft,
which shall be at least 20% above / below the operating speed.
The shaft shall be properly balanced so as not to cause any vibrations during operation.
The pump shaft bearings i.e. bush bearings would be stainless steel, water lubricated.
Extra long bearing shall be provided for suction and discharge bowls. The hardness of
bush bearing shall be less by at least 50 BHN than that of shaft.
1.9 Column Pipe Assembly:
Column pipes shall be of M.S. Fabricated heavy weight, flanged type each in 2 m length
or less so that after complete erection of the pump/s the bottom of strainer shall be at 1.5
m and length of strainer shall be adjusted accordingly.
The total length of column
assembly, bowl assembly, bell mouth and strainer shall be decided by the bidder based
on the data given in the tender.
The column assembly length (including column pipes, bowl, assembly, bell mouth and
strainer) shall be adjusted considering the pump floor levels. A matching piece shall be
provided if required. The stiffeners shall be provided to all pipe flanges. The discharge
head/ tee and column pipe dia shall be same. The discharge head tee incorporate full
diameter elbow.
1.10 Line Shaft:
The shafts shall be of solid circular section, prepared from stainless steel machined and
ground thoroughly and coupled with muff couplings. The shaft sections shall be provided
with non-corrosive and abrasion resisting wearing surfaces particularly at the location of
each guide bearing. Length of line shaft shall not be more than 2 m each.
1.11 Line Shaft Bearing:
These shall be designed to be water lubricated by the pump set water and shall be
placed in bearing holders located in position at the joint of columns. Line shaft bearing
shall be of cut less hard rubber designed for efficient water lubrication. Composite design
of line shaft materials and diameter and bearing centers shall ensure that the entire
Page 15

rotating assembly is brought from stand-still to full speed without any vibrations and shaft
deflection and to ensure that first critical speed is not within 80% to 120% of full speed.
1.12 Discharge Head & Motor Stool:

The discharge head shall be fabricated from M.S. and shall incorporate mounting flange
for motor stool for solid shaft motor, stuffing box with renewable gland packing and
tapping for pressure gauge mounting etc. The discharge head shall be of robust
construction and shall be designed to support entire load of pump assembly, water
column and motor etc.. and shall withstand all static and dynamic, torsional loads,
hydraulic thrust imposed during operation from shut off to stipulated operating conditions
and thrust due to change in direction of flow, without any vibrations. Discharge head with
sole pads will not be accepted. The discharge head shall be installed on sole plate with
ISMB frame and entire load of motor and pump shall be on the lower floor.
Drain arrangement for gland leakage water shall be provided at bottom of discharge
head with G.I. pipe. The base of the discharge head shall be sufficient to properly
support the pump.
The power shall be transmitted from motor to vertical shafting
through a flexible coupling. Both halves of the coupling shall be machined all over,
securely keyed to their respective shafts. The pins shall be of stainless steels. The
arrangement of two halves shall be suitable to check alignment and parallelism.
A self alignment thrust bearing shall be housed in the head gear adequately designed to
accommodate entire weight of rotating parts and hydraulic through and shall be suitable
for reserved rotation up to at least 150% normal forward speed.
Bearing shall be
designed for 30,000 hours life. The bearing shall be of oil lubricated type and shall be
provided with oil level gauges and suitably positioned temperature probes. Two sets of
adjustable contacts shall be provided one for an alarm and other for tripping the pump
motor. This shall be connected to scanner panel so that digital temperature can be read
out with alarm and tripping.
Motor stool shall be provided for mounting the electric motor. The motor stool shall
accommodate the pump thrust bearing and pump motor coupling. The motor stool shall
be robust construction and of fabricated mild steel and adequately sized with opening to
work on the flexible coupling. Height of pump supporting girder/ channel, discharge head
and motor stool shall be adjusted to have motor base at or marginally above panel floor
level.
Page 16
The pump shall be provided with non reversible ratchet to prevent them from rotation in
reverse direction. Pressure gauge to each pump and manifold pipe shall be provided.
Pressure gauge shall be 150 mm dial size and least count shall be 0.05, each pressure
gauge shall be fitted with restrictor nozzle of brass and G.I. Pipe and U tube. Pressure
gauge on manifold shall also be provided. All pressure gauges shall be installed in pump
house on wall with necessary G.I. pipe connections from manifold to pump house. The
pressure gauges shall be installed at suitable height so that the reading can be taken
accurately.
1.13 Sole Plate:
The M.S. sole plate arrangement shall be provided under the discharge head for precise
horizontal and vertical alignment. Thickness of sole plate shall not be less than 70 mm.
It shall be independent of base plate integral with the discharge head. The contact
surfaces of the sole plate arrangement as under shall be machined for precise leveling
and shall ensure vibration free operation of the pump.
Corner plates and sole frame
Sole frame and sole plate
Sole plate and discharge head
All joints between machined contact surfaces shall be with nut bolts/ tapped studs/ bolts.
The opening in the sole-plate/frame shall be of adequate size to pass the bowl assembly
etc. very easily. M.S. base frame shall be anchored in the floor ensuring complete
rigidity. Entire structural fabrication and foundation arrangement shall be designed and
submitted for approval . M.S. plates shall be grouted on pump supporting R.C.C. beams
provided in civil structure. The fixing of M.S. plates on the R.C.C. beams and subsequent
anchoring of M.S. sole frame in proper level shall be the responsibility of pumping
machinery contractor with all related works.
1.14 Air Release Arrangement:
An air cock of dia 50 mm with same size G.I.pipes, bend shall be fixed to the discharge
head. The G.I. pipes shall be suspended vertically in the well with adequate length to
release air.
Page 17
1.15 Water Lubrication Tank and Other Accessories:

In order to lubricate line shaft bearing of the pump, lubrication arrangement comprising
the following shall be provided.
Lubrication tanks 2 Nos. interconnected with each other common for all pumps.
Each lubrication tank shall be equipped with the following:
W L sight gauge
Overflow lead to sump
Drain valve lead o sump
G.I. pipe connection with isolating valve and non- return valve to each pump column
assembly for lubrication. The valve shall be located near the tank. The size of individual
pipe and valve to pump shall be 40 mm diameter Inlet connection with solenoid operated
valve and suitable removable strainer by suitable tapping from common header.
Float valve in the tank for control of overflow.

Any other item necessarily required for proper functioning.
All accessories required for proper and safe operation, dismantling and erection and
pump shall be supplied with heavy duty clamps for column and line shafts, one pair for
each pump.
1.16 Material of Construction:
a) Discharge and suction case, Bowls
: C.I. I.S. 210 Gr. FG 200
b) Discharge head, Bell mouth
: M.S. Fabricated
and motor stool

c) Impeller
: CF8M / Ca6NM
d) Impeller shaft
: High grade carbon steel/ stainless

steel AISI 410/416
e) Column pipes
: heavy duty fabricated
f) Shaft Sleeve
: Stainless steel AISI 410/416
g) Line shaft
: Stainless steel AISI 410/416
h) Nut bolt and washer
: Stainless Steel AISI 410
i) Wearing ring
: Stainless Steel
j) Line shaft bearing
: Cutlass hard rubber / Neoprene
Page 18
1.17 Testing :
All the pumps shall be subject to factory test in presence of Engineer-in-Charge or his
representative and third party appointed for the purpose.
The contractor shall arrange all required test equipment duly calibrated, Field
performance test shall be witnessed by authorities.
A) FACTORY TEST:
Review of raw materials test certificates and quality control procedure.
1) Hydrostatic Test:
Following items shall be tested at hydrostatic pressure equal to twice duty
head or 1.5 times shut off head of bowl assembly whichever is higher as per
IS: 5120.
(a)
Bowl assembly
(b)
Discharge head / tee
(c)
20% quantity of column pipes.
2) Performance Test:
The test shall generally be carried out as per IS 9137. Class pumps of
acceptable test for pumps class-C. The test shall be carried out at full speed,
full load at manufacturers work. The test shall cover minimum 6 points, i.e.,
(a) Duty point
(b) 2 points above duty point
(c) 2 points below duty point
(d) Shut off head
(e) Power consumption at all above points
(f) Zero reading confirmation for V. notch.
The test shall be carried out only by the job motor which will be supplied
under this contract. The test at reduced speed and reduced load will not be
acceptable.
Page 19
3) Strip Inspection:
All the pumps after completion of its performance test and as selected by the
Engineer or Inspector at random will be offered for strip inspection and
dimensional checking. The manufacturer/ contactor shall submit all required
dimensional drawings of strip inspection. Minimum points as under shall be
checked.
Condition of all components particularly bushes, bearings and wearing rings
to examine undue rubbing, wear etc.
Hardness of cut less rubber bearing
Dynamic balancing of
(a) Impellers
(b) Flexible coupling
Clearance and tolerances between
B)
(a)
Wearing rings
(b)
Impeller shaft and bearings
(c)
Impeller shaft and key
(d)
Shaft and flexible coupling
(e)
Key and keyway on shaft at (d)
MATERIAL TEST CERTIFICATE:

Material Test Certificate of the various pump components shall be furnished by
contractor.
C) FIELD PERFORMANCE TEST:

The test shall be carried out as per IS: 9137 code of acceptance test of pump ClassC, in general and as started below in particular.
The purpose of the field test is not to ensure whether pump performance as regards
parameter i.e. head, discharge and power etc. within acceptance limit as per IS:
9137. The purpose is to ensure that the pump performance is generally acceptable or
otherwise. Final acceptance shall be as per following criteria.
i)
As regards H-Q characteristic for acceptance it shall be checked whether

motor is not getting overloaded within the specified head range.
Page 20

ii) Ultrasonic measurement shall be taken for flow. The flow meter to be provided by
contractor.
iii) The head shall be measure with calibrated pressure gauge of accuracy 1% or
better .At least 3 pressure gauges shall be got calibrated from two different
institutions with prior approval of the Engineer- in-charge. The calibration shall
be point to point and not mere for percentage error. The gauge shall be fitted at
suitable place from the discharge nozzle.
It may be noted that pressure gauge shall be installed at least 2 times
diameter away from discharge nozzle and delivery valve be placed at least four
times diameter away from discharge nozzle. Such conditions shall be simulated at
site condition and no allowance for this deficiency shall be considered. The
decision of Engineer-in- Charge shall be final.
iv) The input power to motor shall be measured by 2 wattmeter method. The watt
meters shall be of Laboratory grade having accuracy of min. 0.5% and these
should be digital type.
v) The speed shall be measure by non contact tachometer with digital display
calibrated. The field test shall be taken with entire head range in such a manner
that it would cover at least 6 points (i.e. duty point, 2 above duty points, 2 below
duty point and shut off). The guarantee for head and discharge shall deem to be
fulfilled as per clause.
The field performance test at site is absolutely essential as above (i) to (v)
and the manufacturer shall also be asked to attend the same.
1.18 Inspection :
The inspection of the pump at factory site will be carried by the the employer and or
inspection agency appointed by the employer, in the manufacture's workshop. All
the tests as required as per IS shall be carried out in presence of inspecting
agency. The pump shall be dispatched only after issue of test certificate by the
inspecting agency for satisfactory performance of test pump. The inspection
charges for such tests shall be born by the turn key agency.
Page 21
Induction Motor
2.
2.1. Design Requirements

2.1.1.
The motors shall generally conform to IS: 325 or relevant equivalent internationally
approved standards. Additionally the specific requirements mentioned in the
following clauses shall also be met.
2.2.
2.2.1.
Performance and Characteristics

Motors shall be capable of giving rated output without reduction in the expected life
span when operated continuously under the following supply conditions:
2.2.2.
2.3.
2.3.1.
a)Variation in supply voltage
+ 10%
b)Variation in supply frequency
+ 5%
c) Combined voltage and frequency variation
10%
LV motors shall be suitable for star- delta starting.

Insulation
Any joints in the motor insulation such as at coil connections or between slot
and winding sections, shall have strength equivalent to that of slot sections of
the coil. The insulation shall be given tropical and fungicidal treatment for
successful operation of the motor in hot, humid and tropical climate. The motors
shall be provided with class F insulation with temperature rise limited to that of
class B insulation.
2.3.2.
Motors shall be given power house treatment. This comprises an additional

treatment to the winding over and above the normal specified treatment. After
the coils are placed in slots and all connections have been made, the entire
motor assembly shall be impregnated by completely submerging in suitable
insulating compound or varnish followed by proper baking. At least three such
submersions and baking shall be applied to the assembly.
2.4.
2.4.1.
Constructional Features
The motor construction shall be suitable for easy disassembly and reassembly.
The enclosure shall be sturdy and shall permit easy removal of any part of the
motor for inspection and repair.
2.4.2.
Motors weighing more than 25 kg shall be provided with eyebolts, lugs or other
means to facilitate safe lifting.
Page 22

The rotor bars shall not be insulated in the slot portion between the iron core
2.4.3.
laminations for squirrel cage motors.

2.5.
2.5.1.
Terminal Box
Terminal boxes shall be of weather proof construction designed for outdoor
service. To eliminate entry to dust and water, gaskets of neoprene or approved
equivalent shall be provided at cover joints and between box and motor frame. It
shall be suitable for bottom entry of cables. It shall be capable of being turned
through 360 degrees in steps of 90 degrees.
2.5.2.
The terminals shall be of the stud type with necessary plain washers, spring
washers and check-nuts.
They shall be designed for the current carrying
capacity and shall ensure ample phase to phase and phase to ground
clearances. Suitable cable glands and cable lugs shall be supplied to match
specified cables.
2.6.
Accessories
Two independent earthling points shall be provided on opposite sides of the
motor, for bolted connections. These earthling points shall be in addition to
earthling stud provided in the terminal box.
Page 23
TECHNICAL DATA SHEET FOR INDUCTION MOTOR AT RAW WATER INTAKE PUMPING
STATION
Sr. No.
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
Description
Application
Type of motor
Make
No. of units.
Supply system fault level.
Supply neutral
No. of Phases & frequency
Supply condition
9.0
Duty condition as per IS 325 or

equivalent
Method of starting
Efficiency
a) Duty point
b) Full Load
c) 0.75 Load
d) 0.50 Load
Power Factor
a) Full Load
b) 0.75 Load
c) 0.50 Load
Starting torque
% of full load torque
10.0
11.0
12.0
13.0
14.0
15.0
18.0
19.0
20.0
21.0
22.0
23.0
24.0
25.0
26.0
Pull out torque

% of full load torque
Class of insulation & temp. rise
by thermometer
Ambient temperature
Location
Hazardous area division
Atmosphere
a) Type of Cooling
c) Degree of protection
Terminal box
Particulars
Vertical turbine Pump & Others
Squirrel cage induction
As per approved make
250 MVA
Resistance earthed
3 Phase & 50 Hz.
10% voltage variation
5% frequency variation
10% combined voltage and frequency
variation
S1 suitable for continuous operation
DOL
95 % (minimum)
95 %
94.5%
93.4%
0.86 %
0.82 %
0.72 %
Sufficient starting torque to start the pump with
delivery valve closed and when other pumps are
running.
Sufficient to bring the motor to normal speed in
minimum time
Class F but Temperature rise restricted to that
of class B i.e. 65 c. / 75 c.
46 c.
Indoor
N.A.
Humid, Dusty at a time
CACA
IP 55
Phase segregated terminal box for line and
neutral side. And shall be suitable for termination
of heat shrinkable termination kit or push on type
termination kit.
External cable details.

a) No. of cores.
b) Size
3
As per single line diagram
Shaft orientation.
Horizontal / Vertical / Hollow shaft
Type of Couplings
Vertical solid shaft

Flexible
Page 24
Sr. No.
27.0
28.0
Description
Type of bearings
Colour shade of paint if special
Particulars
Antifriction Ball /Roller Bearing
Grey shade 632 as per IS 5
29.0
30.0
Space heater for motors required

Thermisters / RTDs / required for
winding and bearings
Bearing temp. Detectors
Winding connections
Standard to be followed
240 V, 1 Ph., 50Hz., A.C. for winding heating

For trip, alarming and indicating
31.0
32.0
33.0
2.7
Required for alarm / trip.

6 Terminals
IS 325, 8225, 4889, 4772, 4029, 4691 and other
relevant Indian Standard or equivalent BSS or
JEC 37
Inspection :
The inspection of the motor at factory site will be carried at by the the employer
and or inspection agency appointed by the employer, in the manufacture's work
shop. All the tests as required as per IS shall be carried out in presence of
inspecting agency. The motor shall be dispatched only after issue of test
certificate by the inspecting agency for satisfactory performance of test motor. The
inspection charges for such tests shall be born by the turn key agency.
2.1
MATERIAL TESTING OF EQUIPMENT

The Contractor shall furnish the material composition certificates for all the
important components of pump and motors. Random test certificates for raw stock
materials and typical test certificates for special stock items like bearing metal
etc., used for the manufacture of the several components shall also be furnished.
2.2
QUALITY ASSURANCE PLAN

The quality assurance plan for all the components of the pump,
controller/governor and associated equipments shall be furnished for the approval
of Owner indicating the tests at factory with customer witness points. The same
shall be generally according to the Quality assurance Plan .
2.3
MODEL TESTS
GENERAL
Before commencement of manufacture of prototype pumps the Contractor shall
perform model tests to demonstrate that the efficiency and other guarantees as
well as requirements of the specifications for the performance of the pumps will be
met.
The test shall comply with the international code for model acceptance of
hydraulic pump IEC publication no. 193
The place where model tests would be conducted shall be indicated by the Bidder
in his Bid. A team of Owners Engineers shall be deputed to the manufacturers
works where the model test is proposed to be conducted for witnessing the model
tests. The Contractor shall extend all facilities to witness the tests.
Page 25
2.4
MODEL PUMP
After the award of contract, the Contractor shall build a model of the pump. The
water passages of the model shall be fully homologous with those of the prototype
from the upstream draft tube termination point of the pump to the delivery valve.
The draft tube shall be transparent to permit observation and for taking
photographs of the vertex flow pattern and cavitation phenomenon. The
Contractor shall submit to the Owner, drawings, description covering details of the
proposed model, testing equipment, instrumentation, and test procedures for
individual tests, method of interpretation and computation of test results for
approval of Owner.
2.5
TESTS ON PUMP MODEL

The final model test series shall include the following tests :Pump performance
(efficiency) tests under various conditions. Cavitation tests .Runaway speed test.
Pressure fluctuation tests. Hydraulic thrust test. Wicket gate/ torque test.
The model test shall simulate all possible normal operating conditions of the
prototype for the entire range of reservoir and delivery levels, wicket gate
openings etc.
2.6
STEP-UP FORMULA
In deriving proto type pump from model tests data, step-up formulae if any as per
relevant IEC or any other equivalent standards may be used. The bidder shall
indicate the step-up formulae proposed to be used with justification and reference
to standards.
2.7
THE MODEL TEST REPORT

After completion of the model test studies, the Contractor shall furnish the model
test reports to the Owner within one month from date of completion of model test
for owners review and approval. The test report shall include but not necessarily
be limited to the following:
Model hill curve
Model efficiency curves extended to the runaway speed.
Prototype performance diagrams in compliance with all applicable

requirements.
Curves showing sigma versus efficiency and sigma versus unit power and unit
discharge for specified head with envelope curves drawn.
Photographs and sketches of the cavitation phenomenon.
A sample calculation for each computation in a complete manner.
Curves showing relationship between guide vane angle and servomotor

stroke related to maximum opening of guide vane and clear opening between
two adjacent guide vanes.
Curves showing the relationship between the head and power for the full
range of operation.
Record of calibration of all test instruments and equipments.
Description of test equipment and test procedures.
Page 26
2.8
CHARGES FOR MODEL TEST

The charges for the Model test shall be deemed to be included in the EPC
contract price.
2.9
MODEL ACCEPTANCE
The Contractor shall notify to the Owner, at least one month in advance, the
readiness of the model for witnessing the test and to carry out the dimensional
checks of the model.
Should the model fail to meet the guarantees and requirements, it shall be
optional for the Owner to conditionally accept the model and direct the Contractor
to modify the model unit to comply with the requirements. All expenses involved
for the modifications and subsequent model tests shall be borne by the
Contractor.
The Owner reserves the right to get the model tested in an independent laboratory
or suggest the laboratory where the model testing is to be conducted from among
the pre-approved labs indicated by the supplier.
The Contractor shall also furnish detailed calculations for impeller setting, the
basis for selected plant sigma and critical sigma as per model test. The Contractor
shall guarantee the operation of the pumps without undue cavitation under the
above conditions.
2.10
PERFORMANCE GUARANTEES AND PENALTY FOR SHORTFALL IN

EFFICIENCY AND OUTPUT
The pump should be designed to have maximum efficiencies at the outputs
corresponding to the rated head with as flat a curve of efficiency as possible
between half and full loads.
2.11
PENALTY FOR SHORTFALL IN PERFORMANCE:

For each kW differential in the actual motor input over the guaranteed motor input
at duty point indicated in the schedule of Technical Particulars (without any further
tolerance), penalty will be levied at Rs.52,000/- per kW per pump set.
For this purpose the power input measured during performance test on the full
size pump at the purchaser's site will be considered.
Should the performance test results deviate from the guaranteed values subject to
the tolerances specified in IEC, the Contractor shall correct his equipment at no
extra cost to the Owner and repeat the performance tests within a reasonable
period as agreed to by the Owner. As regards the power consumption, if the
Contractor fails to meet the guaranteed values, the Owner will levy a penalty as
indicated above. However, if the deviation in power consumption exceeds 5% of
the guaranteed value or the Contractor is unable to meet the guarantee for items
under correction, the Owner retains the option to reject the equipment in which
case contractor shall replace the entire equipment with the one that meets the
guaranteed values.
2.12
PERFORMANCE WITHIN GUARANTEE PERIOD:
Page 27

The Owner/Purchaser reserves the right to carry out further test to check the
performance and efficiency of the plant at the end of one year. Adjustments to the
plant as may be considered part of normal operating routine shall be carried out
prior to these tests.
Should the results of such repeat tests carried out by the Owner/Purchaser
indicate that performance values deviate from Guaranteed value or the Power
consumption exceeds 1.0% of the guaranteed value, then the contractor shall be
given an opportunity to take corrective measures and carry out further test, all at
his own expense. Should the test indicate performance and Power consumption
values below the guaranteed value then a reduction in the contract price may be
issued by the Owner.
2.13
CRITICAL PLANT SIGMA AND PUMP HILL CHART

Value of Thoma's Co-efficient as computed by IEC code on the basis of model
tests shall be given in the form of curves, efficiency vs. sigma for different heads
of operation. Curves of critical sigma for different operating conditions, as
determined by the IEC code on the basis of model tests for different heads of
operation shall be furnished and the plant sigma values shall also be plotted on it
to clearly show the safety margin. The Contractor shall also submit model test
report on cavitation.
2.14
RECTIFICATION TO MEET GUARANTEE

The Contractor shall make good and meet the guarantees again within a period of
four (4) months from the date of witnessing the original field test, should the
original tests be unsuccessful to meet the guarantees. The penalty or rejection
shall apply if the second attempt is also unsuccessful in meeting the guarantee.
2.15
CAVITATION GUARANTEE
The Bidder shall guarantee the impeller, stay ring, guide vanes and other
hydraulic passages against excessive pitting caused by cavitations for 24 months
from date of commissioning or 8,000 hrs. of actual operation, whichever is earlier.
Excessive pitting shall be defined as the removal of metal from impeller and other
passages exceeding a weight of W = 0.1D per 1,000 hrs of operation during the
guarantee periods defined above, where W is weight in kg. and D is the throat
diameter of impeller in meters. The bidder shall indicate the method which he
proposes to use for measuring the amount if the metal removed on account of
cavitations, which shall be subject to the approval of Owner.
If the 24 months guarantee period expires prior to the completion of 8000 hrs. of
actual operation, the bidder shall guarantee that the weight loss shall not exceed
the value proportional to the number of hours actually operated.
In case of excessive cavitation being present, the Bidder at his cost shall correct
the condition and rectify and/or replace the part thus affected. The pump after
such modifications and repairs and/or replacements of part or parts shall be
subject to the same cavitation guarantee as for the original equipment.
In determining whether or not excessive pitting has occurred, metal removed by
erosion, corrosion by the presence of injurious foreign element in water or by
chipping and grinding preparatory to repairing the pitted area, shall be excluded.
The manufacturer shall adopt necessary improvements modifications in the
designs, manufacturing to minimize the cavitation pitting within the permissible
limit. Within the guarantee period ,within 6 months after commissioning, the
Page 28

contractor shall be entitled for joint inspection to make sure that cavitation
damage is not caused or aggravated by local defects of pump shape as well as to
repair damages that might have been caused and take steps to prevent future
cavitation. If the inspection reveals that cavitation guarantee is not sustained, the
Contractor shall supply a full set of new impeller and throat ring free of charge
delivered and installed at site.
2.16
TEST AT WORKS
The test to be conducted at works shall include the following:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
All the static parts of the pump shall be completely assembled in the
manufacturer's shop and properly match marked and doweled to ensure correct
assembly and alignment at site. Dowels required for insertion after erection at
site shall also be supplied.
Assembly of Guide apparatus, measurement of Guide vane clearances and
recordings.
Guide vane servomotor: Pressure test, functional test, measurement of stroke,
check function of the lock in open and closed position.
Shaft Seal: Assembly of ring with static seal. Check function of the static seal.
Static balancing of impeller.
All pipes, fittings, pressure tanks and other components of the
controlling/governing system shall be tested under a pressure equal to 150% of
the maximum operating pressure maintained for not less than half an hour and
the equipment shall withstand this pressure without any signs of leakage,
distortion, and failure.
Assembly of guide bearing housing with top cover and dummy shaft and
dimensional checks etc.,
Functional tests of all equipments wherever applicable.
In addition to the above, each mechanical and electrical subassembly shall be
tested for proper functioning and continuity of electrical circuits.
Mechanical Over speed Device: Calibration of over speed device.
Testing of auxiliaries including cooling water system, air compressor system,
dewatering and drainage system, oil pressure system, etc.
Testing of controllers/governors, both hydro mechanical and electrical cubicle
jointly for functional checks.
Inspection of flow metering equipment at works for calibration, performance and
discharge measurement. The Owner reserves the right to be present during the
above tests and also for the inspection of the equipment at the
Contractor/manufacturers works/sub-supplier's works unless waived in writing.
The Contractor shall furnish detailed testing procedures for all the above tests
and routine tests on all the equipments to be conducted as per international
standards for the review and approval of the Owner well before witnessing the
tests.
Material testing of important casting/ forging fabricated steel works shall be
according to the enclosed Quality Assurance Plan.
Page 29

The Contractor shall furnish inspection reports in respect of assembly of main
pump and other associated equipments duly mentioning the key points, such as
limits of tolerance etc., or such information for use/ guidance during erection/
maintenance at site.
Any other tests and inspection that the Owner considers necessary to satisfy
itself that the pump conforms to these specifications in performance,
workmanship, design and quality of materials.
2.17
FIELD ACCEPTANCE TESTS

Field acceptance tests of pump (Efficiency and output tests)
The Contractor shall furnish in detail the method proposed by him to do the field
efficiency test on the pumping unit.
Finalization of measurement section and location of installing various instruments
shall be done after obtaining the permission of the Owner.
The layout ,scheme and details of the tappings etc. ,Stainless steel tubing along
with the valves and fittings for various tappings, which are to be embedded shall
be included in the scope of supply.
The calibration of instruments, arrangement of all required instruments,
arrangement of personnel for testing, supervision of field tests at site etc. shall be
the responsibility of the Contractor
After complete installation of the pumping units at site the units shall be tested in
accordance with IEC standard.
2.18
DRAWINGS
The contractor shall furnish 6 sets of assembly drawings, wiring diagrams, etc., for
approval. The drawings shall include but not be limited to:
(a) Layout drawings indicating the location of various equipments.
(b) Detailed foundation drawings to withstand hydraulic thrust, magnitude of
forces due to unbalanced rotating parts, mass of rotating parts, etc., in a
complete manner.
(c) Loads on foundation for civil structure designs.
(d) Drawings showing ducts, openings, pipe routings, etc.
(e) Drawings showing embedment of pipes and foundation parts.
(f) Assembly and sub-assembly drawings of all assemblies/ components showing
elevations, plans & sections for the pump, controller/governor parts, control
panels, etc.
(g) Control gear diagrams for pump, controller/governor oil system, CW system,
DD system, compressed air system, etc.
h) Detailed drawings showing draft tube profiles, controller/governor, guide
bearing, shaft gland, etc.
i)
Wiring and schematic diagram for control, protection and indication, etc.
j)
Drawing showing parts to be welded at site, method of welding with details of

type and quantity of electrodes and capacity of welding sets.
k) Schematic and detailed drawing for all piping, lubrication and cooling
arrangement.
Page 30

Drawings indicating lifting arrangement of important components/ assemblies
with crane clearances.
l)
m) Part list of all the components with details viz. part numbers, quantity,
reference drawing numbers, packing list, weight and dimensions etc.
n) The assembly/sub assembly drawings of Pump guide bearing, shaft gland,
Impeller, volute casing, draft tube, air valve, test equipments for Impeller,
metallic volute etc.,
o) Drawing of the main cross-section of the pump showing the various
components/parts/assemblies for the pump to the extent possible.
p) Drawing showing combined cross section of pump and motor.
q) Schematic drawings of piping system.
r) Efficiency curves and hill chart
s) Curve showing areas and velocities at different sections of the draft tube.
2.19
HYDRAULICALLY OPERATED PUMP DISCHARGE (HOPD) VALVE
2.19.1 TYPE AND DESCRIPTION:

Each pump shall be provided with HOPD - oil pressure operated butterfly valve,
and electrically operated bypass valve with guard valve for equalizing the
pressure on the valve door before opening. The valve shall have maximum
capacity to allow maximum flow of pump discharge. The valve shall be designed
to withstand the maximum transient pressure and shall be free from vibration and
abnormality under the whole operating range of pump including any transient
conditions of operations. The inside diameter of the valve shall be decided by the
bidder considering the maximum permissible discharge of the pump & velocity
limits permissible. The valve shall be so designed as to be capable of closing
from fully open position under the condition of maximum flow at every head with
minimum oil pressure supplied to servomotor. Alternatively the bidder may
choose closing by counter weight.
The opening and closing time of the valve shall be selected depending on the
pump characteristics including the operating time of bypass valve with normal
operating pressure.
2.19.2 DISCHARGE VALVE OIL PIPING AND VALVES:
All valve oil piping and valves complete with flanges, bolting materials, gaskets,
packing etc., required for inter-connections between the various equipment shall
be included in the offer. All piping shall be steel, suitable for maximum oil working
pressure. All valves shall be ductile iron or fabricated steel valves having flanged
ends.
FOUNDATION MATERIALS
The contractor shall furnish all foundation materials required for installation of the
valve including foundation bolts and nuts, base plates or sole plates.
DESCRIPTION OF VALVE
a) Body
It shall be of cast ductile iron or fabricated welded steel construction
accurately bored, reinforced with heavy ribs and flanges on both ends with
rubber seals for connection to the upstream make up piece and downstream
dismantling joint and hubs for trunnions. The body shall be provided with self
Page 31

lubricating bearings without any external greasing at both ends where the
shaft is horizontally in contact. The bearings shall be provided with necessary
packing cup seals inside to prevent inflow of sand or other foreign matter
contained in the water and also at the outside end to prevent water leaking.
The trunnion bearings shall be designed to take full load exerted because of
maximum hydraulic pressure including the full weight of the valve disc and
trunnion and smooth opening/closing operations. The bearings shall be selflubricated without external greasing.
The body shall be provided with weld deposited or separately fixed and
accurately bored/ machined stainless steel seating/contacting ring while the
disc shall be fitted with rubber ring to have drop tight sealing under all working
conditions.
The valve body shall incorporate the bracket feet supports suitable for
anchoring against maximum servomotor and hydraulic forces. All necessary
foundation plates and anchor bolts shall be provided.
b) DOOR/DISC WITH SEALING DEVICE:
Lattice/Bi-plane/flow through type, cast ductile iron or fabricated steel
construction with integral trunnions designed with sufficient strength not
causing any distortion/deformation or any abnormal vibration when the disc is
in open position or during operation shall be provided. The valve disc shall be
in one piece with integral high strength spindles and streamlined/shaped to
minimise flow disturbance and head loss. A peripheral rubber seal shall be
provided on the disc to seal the leakages, seating against stainless steel seal
ring welded on the inner surface of the valve body. The rubber seal ring shall
be firmly fixed in position to the disc by removable rust resistant steel rings
fixed by stainless steel screws and stainless steel nuts.
The sealing shall be of reinforced rubber to metal in one length to be joined at
site and shall definitely not involve inflation or other similar forms of relative
movement of elements in the seals or seats. It shall be possible to adjust the
sealing contact without dismantling the valve.
c) BY PASS VALVE AND PIPING:
One by pass valve of suitable diameter shall be provided directly on the
upstream pipe along with a guard valve. The by pass valve which is required
for balancing the pressure across the BF valve shall be designed for vibration
and noise free operations and shall have stainless steel or bronze parts (those
coming in contact with water), thus preventing corrosion.
Metal sealing shall be provided to have leak proof seal when the valve is
closed. The By-pass valve shall be electrically operated with the provision of
manual operation. All wearing parts of the Bypass valve shall be renewable
and of bronze or stainless steel.
A by-pass steel pipe of suitable diameter and length joining upstream to down
stream of valve with necessary flanges, fasteners and packings shall be
provided.
d) DISCHARGE PIPE/OUTLET PIPE
The delivery pipe shall be of suitable diameter (nominal inside diameter)
considering the permissible velocity limits and shall conform to IS-3589 and of
Page 32

mild steel fabricated construction using required thickness plates (IS 2062).
The pipeline shall be complete with required specials (Viz. manholes, bends,
connections etc., as per requirement) fabricated and erected by the
contractor. Sufficient No. of manholes & air valves shall be provided by the
bidder along the raising main at locations to be decided after award of
contract.
Pipes shall be provided with stiffener rings at regular intervals of every 3

meters to retain the shape of pipes after fabrication. Pipes shall also be
provided with anchor rods, thermal expansion joints, etc., by the bidder as per
the requirement.
Low hydrogen electrodes conforming to AWS-E7018 class only shall be used
during fabrication/erection.
Hydraulic testing shall be conducted.
During erection, line and level shall be ensured by the contractor. The bidder
shall indicate the location of supports anchor blocks, thrust block required to
hold the pipes in position and accordingly include the supply & erection of
clamps and anchoring bolts, nuts in the scope.
2.19.3 OPERATING MECHANISM
The operating mechanism to open and close the valve and the bypass valve shall
be capable of being controlled from the control panel of the Pump house and also
from the valve chamber. The operating mechanism shall be such that the speed
retards as the valve approaches the end of each operation. Necessary dampers
shall be provided to regulate the speed of operation and to arrest the travel of the
valve exactly at the fully closed or open positions controlled by the necessary pilot
valve operated distributing valve as well as diaphragm so as to allow for an easy
adjustment of the closing time compatible with the upstream allowable pressure
rise.
The valve shall be operated by means of oil operated servomotor attached to the
door of the valve through a lever. The oil to the servomotor shall be supplied
under pressure by means of an oil pump. After balancing the pressure on the
upstream and downstream sides of valve by means of bypass, the oil pump shall
be put into operation. By means of the distributing valve, oil under pressure shall
be supplied to the lower side of the piston of the servomotor to bring about the
opening stroke. At the end of opening stroke, an electric contact shall cut off the
supply to the oil pump-motor. In case the piston of the servomotor descends due
to any leakage, an electric contact shall automatically start the oil pump motor
after a movement of 5% (approx.) of valve door in the closing direction. It shall
also be possible to open the Valve by manually operated pump in case of failure
of electric supply to the oil pump motor.
The closing shall be affected as under:
(a) Normal closing
(b) Emergency closing
(c) For normal closing, the oil pressure shall be admitted by means of a
distributing valve to the upper side of the piston of the servomotor to bring
about the closing stroke. At the end of closing stroke an electric contact shall
cut off supply to the oil pump motor.
Page 33

(d) For emergency closing, the oil pressure in the cylinder shall be released
through a solenoid operated valve and due to the action of hydraulic torque
and torque acting due to the counter weight, the valve disc shall close. The
movement of the disc shall be retarded by the servomotor which functions as
dash pot thus giving total security to the installation. The valve shall be
designed to close against the maximum velocity attained by pump .The
operation of the valve may be carried out using the pressure oil system
contemplated for opening and closing of guide vanes. However, preferably
the bidder should provide a separate hydraulic power pack for operation
of the valves.
(e) Hydraulic power pack: The hydraulic power pack system shall consist of 1
main and 1 standby electrically driven high pressure oil pump of vane type.
The pump shall have sufficient capacity to supply the entire pressure oil
requirement of the BF Valve servomotor etc. The pump shall be of continuous
duty, self primed under the maximum oil pressure. Necessary sump tank,
control valves, non-return valves, pressure switches etc., shall be supplied.
The sump tank shall be welded steel construction, and of sufficient capacity to
hold all the oil in valve servomotor system. The interior of the sump tank
shall be sand blasted and painted with two coats of suitable best quality oil
resistant paint. The sump tank shall be totally enclosed complete with
inspection lid and provided with duplex strainers, which could be cleaned with
ease when the valve is in service. It shall also be provided with oil level
gauge, breather and suitable tapping required for connecting the filter set for
circulation of oil. A hand operated stand-by pump of adequate capacity for
manual operation of the valve shall be provided. Oil pipes shall be of
seamless, heavy gauge and of suitable wall thickness. The electric motors
shall be of continuous duty directly coupled to the pump and it shall be TEFC
with Class B insulation suitable for operation on 415 10% volts, 3 phases,
and 50 +3% /-5% Hz AC supply. The motors shall be provided with starters
with protection equipment. The starting equipment shall incorporate a device
so as to start the motor and permit it to reach full speed before the pump is
connected to the pressure system and to unload the pump before the motor is
disconnected from the power supply.
2.19.4
Control and Electrical Equipments:

The Contractor shall supply all the control equipments such as solenoid
operated distributing valve, control and check valves (arranged for local and
remote operation) and they shall be suitably mounted. The electrical control
panel shall consist of contactors, operating switches, indicating lamps etc.
The panel proposed for this and to be mounted for remote operation in the
control room of the Pump house shall match in colour and size with the other
control panels in the control room. Sufficient number of limit and auxiliary
switches shall be provided on the valve operating mechanism in order to
energise the following signaling alarm and trip circuits. i) Indication of Valve
Open and Close and In transit.
a. Indication of bypass valve Open and Close.
Page 34

b. Indication and alarm for valve Out of Control when oil leakage is
excessive and the valve disc moves by more than 5 deg. from the open
position in the closing direction.
c. Indication and alarm for valve Over velocity trip when it acts to close the
Valve.
d. Any abnormal condition.
The limit switches shall be hermetically sealed and shall be of reputed make.
All indications and alarm shall be provided on the control cubicles to be
installed near the valve and at control room. The control devices, indicating
and alarm devices, starters for motors etc. shall be mounted on the control
cubicles.
2.19.5
PAINTING:
The water passage shall be shot or sand blasted and painted with two coats
of zinc rich epoxy primer and three coats of epoxy paints before dispatch.
Each coat of primer shall be of thickness not less than 40 microns and that of
epoxy not less than 100 microns. The outside shall be provided with suitable
paints.
3.
STATIC EXCITATION SYSTEM
A)
STATIC EXCITAION EQUIPMENT AND AUTOMATIC VOLTAGE REGULATOR

SCOPE:
This section covers the technical specification for providing microprocessor based
excitation system with thyristor control for Pump motors.
3.01
1
2
3
4
5
6
7
8
DESCRIPTION OF THE EXCITATION SYSTEM

Microprocessor based excitation system with thyristor control shall be provided to
suit the motor characteristics for each unit. The AC power required for the
excitation shall be tapped from the motor terminal, stepped down by means of
rectifier transformers and rectified by fully controlled thyristor bridges and then fed
to the motor field thereby controlling the motor voltage input. Any change in the
motor terminal voltage shall be sensed by an error detector and cause the voltage
regulator to advance or retard the firing angle of the thyristors thereby controlling
the field excitation of the motor. The excitation system for each unit shall consist of
the following:
Dry type excitation transformer
A Set of thyristor converters of suitable numbers such that even in case of ONE
bridge failure, the remaining bridges shall cater to the maximum continuous and
ceiling current requirements.
Arrangement for initial excitation start up
Field breaker and field discharge and suppression equipments
Automatic voltage regulator with auto and manual channels with all standard
limiter functions.
Features for motor dry out with the stator terminals short circuited.
Static energy meter in the primary circuit of excitation transformer for
measurement of kW, KVAR, Max demand etc.
Interfacing equipments for data communication.
Page 35
3.02
EXCITATION TRANSFORMER
The excitation transformer shall be three phase dry cast resin coil type
transformer connected to motor terminals by segregated phase Bus ducts. The
transformer shall be designed and manufactured in accordance with relevant
latest standard and shall be housed in a cubicle.
The transformer shall be sized such that it supplies rated excitation current at
rated voltage continuously and shall be capable of supplying ceiling current at the
ceiling excitation for a short period. The rated field current and field voltage shall
suit the requirement of the Motor. The transformer shall be self cooled indoor
enclosed dry type. Since the high voltage winding is connected directly to the
motor terminals, full design consideration shall be given to the frequency increase
rate, voltage build up rate, motor fault level and insulation co-ordination. The high
voltage and low voltage windings shall be of copper conductors Surge
transmission from the high voltage side to the low voltage side shall be prevented
by suitable means. Full rated capacity taps on the high voltage winding shall be
provided to accommodate the complete range of operation. The transformer shall
have taps of +5%, +2.5%, 2.5% and 5% on HV side.
A set of thermistors shall be embedded and used for providing transformer
temperature high alarm/ trips. The temperature surveillance unit suitable for these
thermistors shall be provided in the AVR panels.
The 11 kV terminations of the transformers shall be connected to the bus duct in
an appropriate manner. The low voltage terminals shall be suitable for terminating
copper cable of adequate size and run per phase to be approved by the owner.
The transformer shall be housed in a cubicle with IP-20 protection.
The transformer shall be completely assembled at the factory and shall be
subjected to standard type and routine tests. All routine and commissioning
tests/checks shall be carried out at site also. The transformer shall be provided
with necessary protections.
The bidder shall furnish calculations justifying the rating and ratio of the
transformer selected shall be furnished in the bid and the same is subject to the
approval of the Owner.
3.03
THYRISTOR CONVERTOR
The thyristor bridges shall be housed in one or more cubicles. Number of bridges
shall be such that in case one bridge fails during operation, the remaining bridges
shall have adequate capacity to meet the rated continuous output of the excitation
system. Fans mounted in the cubicle shall cool the thyristor bridges. Adequate
protection and monitoring is to be provided for the thyristors and cooling fans.
Each thyristor bridge shall comprise of six thyristors working as a six pulse fully
controlled bridge. Thyristors shall be so designed such that their junction
temperature rise is well within its specified rating. By changing the firing angle of
the thyristors variable output shall be obtained. Each bridge shall be controlled by
one final pulse stage.
The thyristors shall be provided with fast acting semiconductor fuses in series to
protect in case of over current. The fuses shall have micro switches for monitoring
purpose. The coordination of thyristors and semiconductor fuses shall be properly
done with calculations.
Page 36

An RC network shall be provided across each thyristor for protection against over
voltages. An airflow monitor relay to monitor the airflow shall be provided. The
thyristor shall be of silicon controlled type and shall have a PIV rating of not less
than four times the maximum RMS voltage of the input. During de excitation
thyristors shall be driven to invertor mode before tripping the field breaker. The
rated continuous output of the excitation system shall suit the rated continuous
input to the Motor rotor. Means shall be provided to equalize the reverse voltage.
Voltage spike protection shall be provided. It shall be possible to isolate any
Thyristorbridge while unit is in operation for any required replacement for which
Isolators on both AC & DC side shall be provided.
3.04
FIELD FLASHING
Necessary arrangement for initial building up of voltage shall be made by using
supply from start up equipment.
As soon as the motor is synchronized the excitation requirement shall be met by
the supply tapped from the bus duly isolating the initial start up supply.
3.05
FIELD BREAKER
A direct current circuit breaker shall be provided in the field circuit for ensuring
definite disconnection from the supply source and subsequent discharge of
energy in the field circuit in the event of a fault or disturbance.
The field breaker shall be suitable for providing protection by isolating the D.C
source from the field in the event of severe internal fault or three-phase short
circuit on motor terminals or a short circuit on the slip rings. The magnetic field
energy in such a case shall be dissipated through a field discharge resistor, which
shall get connected across the field during such operation.
The discharge resistor shall be such that the rapid de-excitation takes place and
the voltage developed across the discharge resistance following the 3 phase fault
current is less than the insulation level of the field winding.
The circuit breaker shall be electrically operated by means of control switches
provided in the panel. The control voltage for the breaker shall be the station
battery voltage. Anti pumping feature for the breaker shall be provided.
The trip coil of breaker shall be supervised by a relay and shall give an alarm in
case of failure of trip coil.
The field breaker shall have polarity change over links for equal abrasion of
brushes. Necessary shunts for field current measurement and rotor temperature
indicator cum recorder shall be provided. Sufficient nos. of auxiliary NO and NC
contacts for indication and interlocking shall be provided.
3.06
AUTOMATIC DIGITAL VOLTAGE REGULATOR

The voltage regulator shall be of the continuously acting type, responsive to the
voltage of all the three phases.
The voltage regulator shall automatically actuate the controlled rectifiers and shall
be capable of performing the following functions:
a) Maintain the average 3 phase motor voltage within +/- 0.5% without hunting
when operating under steady load conditions for any change of load or
excitation within operating range of motors
b) The voltage regulator shall restore the motor terminal voltage to a value not
Page 37

more than 5% above the voltage being held before load rejection following
any load rejection up to 115% of the rated load and shall maintain the voltage
within this limit throughout the period of the motor over speed.
c) Under steady state conditions, for any over speed up to 150% of normal,
maintain motor voltage within plus or minus 5 percent of the value that the
voltage regulators were holding before over speed. Also under steady state
conditions for an over speed between 150 percent and maximum permissible
over speed, maintain motor voltage within plus or minus 10% of the value, the
voltage regulator was holding before over speed.
d) Permit continuous stable operation of the motor under the control of voltage
regulators, while meeting the line charging requirements.
The AVR shall be designed with highly stable elements so that variation in
ambient temperature does not cause any drift or change in the output level.
The AVR shall consist of the following:
1
Voltage and current measuring and digitizing of signals.
Central processing unit.
Digital firing and control modules
Manual control with follow up facility for bump less transfer from auto to
manual mode & vice versa.
Pulse amplifier and final pulse stage
Rotor temperature measurement
Micro terminal
Monitoring
1.
Voltage & Current Measuring & Digitizing Of Signals

The electrical measured values such as motor voltage, motor current
etc. shall be fed to these modules from PTs & CTs. Here the values have
to be converted to filtered standard values.
These signals shall be rectified wherever necessary filtered and
converted to pulse signal for active and reactive measurement. These
signals have to be digitized using analog digital converters.
The AVR shall also have built in frequency dependent circuit, so that
when the motor frequency lies outside a certain frequency range either
during run up or after trip, the pulse shall be given from internal pulse
motor. Further when the machine is running below a particular frequency
the regulated voltage should be proportionally reduced with frequency.
The circuit shall be made to respond proportionally to voltage above a
particular frequency. The frequency shall be settable between 40 and 60
HZ.
2.
CENTRAL PROCESSING UNIT

The central processing unit shall accept the digitized input signals,
compare with the set values and parameters and shall calculate on
output variable corresponding to field voltage.
3.
DIGITAL FIRING AND CONTROL MODULES
Page 38

These modules shall convert the digital values received from the central
processing unit to a gate pulse train. These pulses shall be synchronized
to the AC input voltage of the thyristor converter.
4.
MANUAL CHANNEL
A separate manual control channel operating as a field current regulator
is to be provided. The control output shall be converted into a standard
value and then fed to digital firing and pulse generation module where
gate pulse trains are produced. These gate pulse trains shall be in
synchronism with the input supply of thyristor converter.
To ensure bump less transfer from automatic to manual control and vice
versa the position of pulses in both channels should be identical. A pulse
comparison unit to detect any difference in the position of the pulses and
to adjust the reference to eliminate any difference shall be provided. A
balance voltmeter shall be provided to ascertain bump less transfer.
A change over between auto to manual channel and vice versa shall be
effected by blocking or releasing the pulses of the corresponding inters
mediate pulse stage.
5.
PULSE AMPLIFIER & PULSE FINAL STAGE

Output pulses from the digital firing modules (auto & manual) shall be
amplified in intermediate pulse stage. Output of intermediate pulse stage
shall be paralleled and fed to pulse final stage. There shall be separate
pulse final stage for each converter. The output of the same shall be fed
to gate circuit of thyristor via pulse transformer to provide galvanic
isolation between power circuit and control circuit.
A pulse supervision unit shall detect spurious pulses or loss of pulse on
the bus bar and transfer control from AUTOMATIC channel to MANUAL
channel.
Each thyristor bridge shall have its own final pulse stage. Pulses shall be
blocked to respective bridges in case of
a.
Failure of one or more thyristor fuses
b.
Failure of power supply of the final stage
c.
Failure of convertor cooling fan
d.
Opening of input / output isolators
ROTOR TEMERATURE MEASUREMENT

Rotor temperature measurement shall be done through microprocessor,
the standard signals of field current and field voltage being obtained
using transducers and fed to processing unit for rotor temperature
measurement. The measurement shall take into account the brush drop
to calculate the rotor temperature. The output shall be connected to
recorder and also to the remote System.
MICRO TERMINAL/ MAN MACHINE INTERFACE

It shall be possible to read the data/ parameters fed to the
microprocessor using the micro terminal. Further the plant dependant
Page 39

parameters shall be made accessible to the purchaser. This shall work
like tool in trouble shooting by verifying the level of signal flow.
8.
MONITORING
It shall be possible to monitor the following.
3.07
a.
Actual value of Motor and field currents/voltages.
b.
Program sequence checks
c..
A/D & D/A converters Digital input and output modules Pulse output
checks for short circuits Output voltages of power supply modules.
VOLTAGE REGULATOR FEATURES

The voltage regulator shall also be provided with the following features:
a)
CONTROL OF MOTOR VOLTAGE

Motor voltage reference value shall be set by giving logic signals.
Limitations of motor voltage shall be keyboard configurable. DVR has to
give processed signal to firing circuit to maintain the motor voltage at the
set value. Reference value of the motor voltage can be set by: a. Adjusting
the voltage set point in auto channel. b. Adjusting the internal reference
value in manual channel for soft start. c. Adjusting the field current in
manual channel.
b)
LOAD ANGLE LIMITER (MINIMUM EXCITATION LIMIT)

An adjustable minimum excitation limit device shall be excited from
potential and current transformers and shall automatically limit the
decrease in synchronous motor excitation below that value which may
result in pull out of the motor when operating under any specified operating
conditions. The characteristics of the minimum excitation limiter shall
closely match the motor capability curves.
c)
ROTOR CURRENT LIMITER

An adjustable maximum excitation limit function shall automatically limit the
excitation of the motor to safe value with the excitation under control of the
regulator. The device shall have an adjustable time delay features to permit
short time operation (subject to thermal limitation) with ceiling excitation.
d)
STATOR CURRENT LIMITER

An adjustable max stator current limit function shall automatically limit
motor stator current to its rated value.
e)
LIMITATION OF VOLTS/HERTZ
This function shall prevent over fluxing of the motor r transformer.
f)
POWER SYSTEM STABILISER

Slip stabilization for damping the oscillations and improving the dynamic
stability shall be provided. It shall be possible to cut in or cutout this
feature.
Page 40
g)
SOFT START
Facility for smooth build up of motor voltage to prevent overshoots of the
machine terminal voltage during excitation build up shall be provided.
h)
LINE DROP COMPENSATION

Provision shall be made for inclusion of transformer and line drop
compensation function. It shall be adjustable over a range of 0 to 15%.
i)
BLOCKING OF PULSES IN DC SHORT CIRCUIT

The field current shall be maintained such that when it reaches a certain
adjustable threshold value, the pulses shall be blocked to avoid failure of
thyristors and fuses, flashover at slip ring etc., in case of slip ring short
circuit.
j)
CONDUCTION MONITORING
Conduction monitoring of thyristors shall be provided to monitor the
conduction status of thyristors.
k)
TEST FACILITY
A switch for selecting TEST & SERVICE shall be provided. On selection to
test it shall be possible to test output pulses by using station AC supply.
Separate transformer to simulate synchronizing pulses, to check airflow
monitors etc., shall be provided for this purpose
3.08
CAPABILITY
With rated AC supply voltage, the excitation system shall be capable of delivering
continuously, within rated temperature rise, required value of field current required
by the motor.
3.09
CEILING VOLTAGE
The exciter ceiling voltage shall be 2.0 times the excitation voltage required for
rated field current of the motor at full load and rated terminal voltage.
With positive field current flowing, the exciter shall be capable of providing an
adjustable maximum negative ceiling voltage which is not less than 70 percent of
the corresponding positive ceiling voltage for forcing the field current down to
zero.
3.10
OVER VOLTAGE
The excitation system shall be capable of withstanding or be adequately protected
against over voltages, which may be induced into the field during abnormal
system conditions, or by opening the field breaker.
The voltage of the excitation system shall be capable of withstanding an impulse
wave (1.2 x 50 micro sec) voltage having a crest value of 75 kV applied at the
H.V. terminals of the excitation transformer.
All components of the excitation equipment shall be capable of withstanding these
over voltages, without damage including all necessary isolating, protective &
regulating devices in equipment.
3.11
POWER SUPPLY TO REGULATOR

Redundant power supply shall be provided. Suitable AC/ DC and DC/ DC
Page 41
converters shall be used.

The excitation system shall be complete including its power supply transformer
connected to the motor terminals, circuit breaker and all necessary devices for
indication, protection, alarm and control of the equipment.
3.12
PT FUSE FAILURE DETECTION

A trip to manual control shall be initiated by the detection of failure of any of the
AVR PT fuses or loss of pre-set signal.
3.13
PROTECTION
Thyristors shall be provided with fast acting semiconductor fuses of trip indicating
type to protect the devices against short circuits.
An over voltage protection to protect the insulation of the field winding and the
static excitation equipment from induced over voltages in the field. Suitable
equipment shall be provided for over voltage protection under all conditions of
regulator in or out of operation or mal-operation. The protective circuitry shall be
responsive only to the exciter terminal voltage and its operation shall be separate
from and in addition to the operation of the maximum excitation limiter and its
associated controls. The equipment shall have an adjustable time delay feature
and a means for adjusting the operation voltage level so as to permit operation
that does not interfere with the normal regulator functions. If an exciter output over
voltage condition persists for a sufficient time, such conditions shall initiate the
following action: To operate motor lockout relay and trip main and field breakers.
To provide annunciation.
An over current relay shall be provided to protect the excitation transformer. It
shall initiate an auto to manual changeover command as a first stage and a trip
command to the field breaker as a second stage if the current fails to reduce even
after auto to manual changeover. Additionally, it shall trip the field breaker on
instantaneous over current. The transformer shall also be protected against high
winding temp with alarm and trip contacts, operated by thermistors embedded in
the excitation transformer.
Rotor earth fault protection shall be provided to give an alarm on reduction of rotor
insulation below a set value as first stage. The sensitivity shall be independent of
fault location, the excitation voltage value, its ripples and total capacitance to
earth of the complete rotor circuit.
A second stage rotor earth fault shall also be provided with necessary accessories
to trip the unit. Details of IR value of Rotor Earth fault stage-I and Rotor Earth fault
stage-II shall be furnished in the bid.
3.14
The following protections shall also be built in the system

1
Delay in field flashing to Trip the field breaker
Manual channel failure when manual mode selected to trip motor Master trip
relay.
DC short circuit to trip motor master trip relay
Rotor temperature monitoring disturbed to initiate an alarm
Page 42

The final pulse to the bridge shall be blocked on following conditions
1. Thyristor fuse fail

2
Loss of cooling.
AC/DC isolators open
4. Power supply pulse final stage fails.
3.15
3.16
Control shall change over from auto to manual on following

1
Auto channel failure.
Power supply to auto channel fail
AVR PT fuses fail (motor voltage actual value failure)
CURRENT TRANSFORMERS
One set of current transformers for O/ C relay in the primary side of the excitation
transformer shall be provided to trip the unit. One set of CTS shall also be
provided for energy meter in the primary circuit of SEE transformer to measure the
kW, kVA etc.
3.17
CONTROL, INDICATION AND ANNUNCIATION
3.18
CONTROLS AND INDICATIONS

The following controls and indications shall be provided by illuminated push
buttons
1
2
3
4
5
6
3.19
Voltage raise/ lower in manual with max & min position indication.
Voltage raise/ lower in auto with max and min position indication.
Field breaker close/ open
Auto/ Manual channel ON
Local/ Remote selection
Provision shall be made for taking analog/ digital signals to the remote system for
remote operations/ graphic display.
ANNUNCIATIONS
The following annunciations shall be provided with provision to take it to remote
Either as an individual or as a group alarm.
Thyristor bridge failure
Auto channel failure
Protective changeover to manual
Regulator power supply fail
Field flashing delayed
Field breaker trip coil faulty
Limiters in action
Thyristor fuse failure
Page 43
3.20
Thyristor cooling fan failure
Excitation transformer temperature high
Excitation transformer temperature very high
Excitation transformer over current delayed/ instantaneous.
Rotor over voltage
DC short circuit
Parameters change
Fan supply change over
Power supply to final stage failure
AVR in test
AC/DC isolators open
Motor voltage actual value failure (in Auto mode)
Field current actual value failure (in Manual mode)
Channel-1 pulse failure
Rotor earth fault
Manual channel in operation.
Rotor temperature monitoring disturbed.
Any other annunciation relevant to the system offered
Conduction failure Bidders shall indicate the annunciation provided for the
equipment offered in the bid. There shall be provision for resetting the local
panel alarm indications from remote.
REMOTE CONTROL & METERING

The following indications control and metering shall be provided in unit sequencer
panel for remote control. Field breaker close/ open with indications Auto / Manual
channel ON indication Auto / Manual change over switch with balance meter
Voltage raise / Lower in manual Voltage raise / Lower in auto Field current Field
voltage
3.21
MICRO TERMINAL FOR MAN MACHINE INTERFACE

Each regulator shall be provided with a terminal for local control and display. It
shall be possible to obtain display of measured values, set values and binary
status signals through key pad of the terminal. Changing of set values of Limiters
and controller shall also be possible from this terminal. If all these are not possible
in MMI terminal and if separate PC based tool is required the above shall be
supplied without additional cost.
3.22
TRANSFORMER FOR HEAT RUN

A suitable transformer for conducting OCC and SCC tests shall be supplied
separately.
3.23
SPARES
The necessary spares shall be supplied.
3.24
TESTS TO BE CONDUCTED AT WORKS

TESTS ON EXCITATION TRANSFORMER
Page 44
Checking of dimensions & GA
Measurement of winding resistance HV & LV
Ratio tests
Polarity & vector group tests IR measurement & HV tests
a. HV 35 kV for one minute

b
LV 3 KV for one minute
c. Induced over voltage tests as per relevant standards. Measurement of no load

loss & full load loss &impedance volts Tests on CTs & temperature detectors,
thermistors mounted on transformer Tests on CTs & temperature detectors,
thermistors mounted on transformer Partial discharge test & temperature rise test
on transformer.
TESTS ON AVR, FIELD BREAKER & THYRISTOR CUBICLES
1
Dimensional checks as per approved GA & mechanical assembly & mounting of

all components
Checking of wiring
All functional checks as per approved schematics & functional checks of

regulation Limiters etc.
Operation of field circuit breaker at +10 % & - 15 % control voltage &

measurement of closing & opening times
IR & HV tests
a. DC / AC bus bars - 3 KV for one minute

b. 415 V AC circuit - 2.5 KV for one minute
c. 220 V DC, PT & CT circuits 1.5 KV for one minute
d. All other control voltage circuits 0.5 KV for one minute
6
7
Heat run test of thyristor cubicles by passing rated current & measurement of
temperature at heat sinks & joints
Light load test on thyristor bridges.
DRAWINGS AND DATA
The bidder shall furnish the following along with the bid.
General arrangement drawings of SEE panels, Excitation Transformer
Transformer kVA & voltage ratio calculations
Thyristor rating calculations
A brief write up of SEE & Transformers Following drawings and literatures

shall be submitted after award of contract.
Detailed general arrangement drawings & foundation details of all panels,

transformers etc.
Schematic drawings of SEE
Page 45

Inter panel wiring details, internal wiring details, external cable connection
details etc.
Detailed drawing of each module
Signal flow & logic diagrams
10
Operating and maintenance instruction manual.
11
Test reports.
12
Scheme drawing of protective relay with write-up.
13
Catalogue of sub-supplied items along with write-up and address.

PUMPS STARTING EQUIPMENT
For starting of pumps the bidder shall quote either Static frequency converter
(SFC) system . Starting equipment offered shall be suitable to start the pumpmotor smoothly and without in rush current. The motor shall be soft started and
reach 90% of rated speed with in 5 Minutes. The bidder shall include the
necessary transformer, H.T. Switchgear, and all the control equipment in their
scope of supply.
The starting equipment offered shall be of proven design and shall be robust and
can withstand No. of starts in a day. The bidder shall quote 2 sets of starting
equipment 2 SFC . All the control equipment for selection of the pumps to be
started, and all interlock, indication, and alarm and annunciation circuits shall be
included in the scope supply. Drawings for the arrangement of starting isolators to
be furnished by the bidder .
All the protection and control circuits of starting equipment shall be incorporated in
the system. The system shall be suitable to start one pump at a time either from
local panel or from remote control panel/ control desk/ panel in the Control Room.
The Power Circuit Panels (11 KV System) shall be designed so that it can with
stand fault system fault currents during starting of pump. The starting equipment
shall be housed in a sheet steel cubicles of thickness not less than 14 gauge and
painted with anti corrosion resistive paint the colour of the final paint will finalized
with the successful bidder. The high voltage equipment of the starting equipment
shall be type tested. The manufacturer shall conduct all the routine tests as per
IEC standards on the equipment offered.
3.25 List of Recommended makes of major items of Plant and Services.

The following manufacturers are recommended for manufacturing of the item
given below. Where more than one manufacturer is listed, the Contractor is free to
choose between them. The Contractor is free to submit proposals for
manufacturers for additional items from time to time and the same shall be
effective after approval by the Chief Engineer.
The bidders may substitute alternative brand names provided that it demonstrates to the
employers satisfaction that the product of recommended make is not available and
substitution is inevitable and the proposed alternative makes are substantially equivalent
or superior to the one recommended hereunder.
Item / Component
Recommended makes
Page 46
High Head, high discharge Pumps

Pump motors
Power Transformers
Sluice Valves / Scour Valves
Non-return / Check Valve
Kinetic Air Valve
Butterfly Valve
Valve Actuators
Single faced Sluice Gates
Water Hammer Control
Dismantling / Expansion joints
Electro-magnetic Flow meters
Ultrasonic Type Level Measurement
Device
Float & Board Type Level
Measuring
system
Programmable Logic Controllers (PLC)
HT Switch Gear
Vacuum Circuit Breaker (VCB)
Air Circuit Breaker (ACB)
Moulded Case Circuit Breaker
(MCCB)
Soft starters
Relay and Contactors
Cables
EOT crane
Panel Enclosures and Consoles
Switch fuse Disconnector
Multi-Function Energy Meters
Capacitor bank
Cable Termination kit
Battery
Battery Charger
Tacho Meter on line
Pressure switch
Flow switch
Pressure gauge
Pressure Transmitter
Pressure Reducing Valves
Engineering cum Operator work Station
Local Supervisory Station
HMI Software
Alarm Annunciator
Uninterruptible Power Supply
Lightening Protection Unit

Jyoti / Kirloskar / Xylem/WILO
JYOTI/KIRLOSKAR/BHEL/ABB
ABB / Crompton / Emco / Siemens
Kirloskar / IVC / VAG
Kirloskar / IVC / VAG / L&T (Audco)
Auma / Rotork / Limitork
Sure seal
AnupEngg. / LoneStar / Vedanta / Precise
Emerson / Krohne Marshall / Yokogawa
Endress+Hauser / Krohne Marshall /
HycontrolUK.
Nivo (Toshniwal), Endress + Hauser, Pune
Techtrol
Rockwell (Allen Bradly) / Siemens /
Honeywell
Alstom / Jyoti / Crompton / Siemens
Siemens / Schneider M.G. / Jyoti / L & T
Siemens / Alstom / Jyoti / ABB
Siemens / Alstom / Jyoti / ABB / L&T
Tropodur / Finolex / Asian / Gloster /
Incab / Universal / Polycab
Hitech / Indef / Hiking / Ambika
Rittal / President / Cutler Hammer
L & T, FN Type, Siemens 3 KL Type, GEPC
Enercon, L & T, SOCOMEC
Crompton Greaves, Khatau Junker, Malde,
L &T
Raychem, Denson, M-Seal
HBL NIFE, Exide, Amco
Chaabi Electrical, Masstech
Kana Electric, Proton, Jay Shree Electronics
Indfoss, Switzer,Tag Process Instruments
Switzer, General Instrument,ForbesMarshall
WAREE, WIKA, AN Instruments, Guru, Hitek
Emerson, Foxbro, Druck, Endress Hauser,
ABB, Honeywell Automation
IVC or equivalent
IBM, Compaq, Dell
IBM, Compaq, Dell
Wincc, Rs View, Monitorpro, Intellution,
Indusoft
Minilec, Peacon, ICA, APLAB
HI-Real, Pulse, Tata Libert, APC, APLAB
MH Inst, Crompton Greaves, MTL, Pepper
Page 47
Instruments & Control Cables

Receiver Indicator/Digital panel meter
Intercom system
Conductivity level switch
Printer
Multifunction power monitor
Temperature Scanner
Analog Signal Multiplier
Portable vibration measuring equipment
Portable sound measuring equipment
Air conditioning
Furniture
Anti Vacuum valves

&fuchs, Rittmeyer, Cirprotec
Delton, Asian, Servel, TCL, Thermopad
Masibus, Yokogawa, Lectrotek, NISHKO,
SaiTech, MTL INSTS
Betel, Samsung, Tata, Panasonic, Matrix
Pune techtrol, SBEM, Krohne Marshall, E+H,
NIVO
EPSON, HP, CANNON, WIPRO
MASIBUS, L&T, ENERCON, SOCOMECH,
SECURE, DAE
SaiTech, Masibus, Nishko, Lectrotek
MASIBUS, Sai Tech, MTL INSTS, NISHKO
Shrenk Every, IRD, STM Instrument, TIME
CENTER, MECORD, CYNGET
Voltas, Samsung, Carrier, Hitachi
Godrej, Ergo, Featherlite
IVC or equivalent
Note(1)
In addition to above other reputed vendors may also be permitted with the approval
of Chief Engineer provided the same confirm to the relevant IS standards.
(2)
It should be certified by the above vendors that the spares of all the above makes
should be easily available in India for regular maintenance.
Page 48
SECTION - VII
Part-A Pipe Lines
Part-B Appurtenance works
Part-C Instrumentation,
Automation and Local
SCADA System
Page 49
VOLUME-III
Section-VII
PART-A PIPE LINES
The pipelines to be used in different parts of this Project such as Rising Mains, Gravity mains,
piped Main canals and Disnet shall be as mentioned in design criteria. All pipes should IS
marked only.
The pipeline shall be divided into sections by valves to avoid the necessity of emptying the
whole pipeline in case of repair (in compliance with Clause No.6.16.14 of the CPHEEO
manual). Each section being provided with an air valve and scouring facilities. The need for
scour should be particularly borne in mind when layout of the pipeline and siting of the valves
is finalized, as they cannot always be arranged in the best position due to likely difficulty in
disposing of the discharge. They are necessary for scouring the mains and hence should be in
proportion to the size of the main.
1.
Manufacture and supply of M. S. Pipes : The complete design for rising mains, gravity
main and surge analysis should be weighted by Indian Institute of Science Bangalore or any
of the IIT.
The thickness of MS/ DI Pipes in Rising mains shall be considered only as per the
following table (Ref IS 3589)

As per Clause 11.1 table 5 diameter of thickness of pipes
Outer Diameter
Thickness
In MM
168.30
219.10
273
323.9
355.6
400.6
457
508
610
711.0
813
914
1016
1067
1118
1219
1422
1626
1829
2032
2235
2540
In MM
2.6
2.6
3.6
4
4
4
4
5
5.8
6.3
7.1
8.0
8.8
8.8
8.8
10
12.5
14.2
14.2
16
17.5
20.0
Page 50
For M.S. pipes in Gravity mains , pipe thicknesses shall be as specified below in the table :
S.N
MS pipe
O inner dia
.
(mm)
1
2600
2
2500
3
2400
4
2300
5
2200
6
2100
7
2000
8
1900
9
1800
10
1700
11
1600
12
1500
13
1400
14
1300
15
1200
16
1100
17
1000
18
900
19
800
20
700
21
600
22
500
23
400
Minimum
Thickness
required
(mm)
13.0
13.0
13.0
12.0
12.0
12.0
11.0
11.0
10.0
10.0
9.0
9.0
8.0
8.0
7.0
6.0
5.0
5.0
4.0
4.0
3.0
3.0
3.0
For Gravity Mains the thickness of MS pipes shall be calculated as per the design
requirements and allowances stated in IS:5822 and in AWWA (American Water Works
Association) Manual M11- For steel pipes. In no case the final thickness arrived can be less
than as mentioned in above table.
Note :- 1. The thickness for intermediate diameter pipe not provided in IS

code
shall be interpolated
between the immediately lower & higher
category.
2. The thickness provided shall also be subject to upward revision in
surge analysis and as per site conditions requirement. No downward
revision is permissible. No negative tolerance will be permissible.
Page 51
1.1.
Applicable standards / codes

Following standards shall be referred for manufacture of M. S. pipes using Structural
Steel Sheets. In all cases, latest revision of the standards / codes shall be referred to.
If requirements of this specifications conflict with the requirements of the standards /
codes, this specification shall govern.
IS: 3589:
IS 1916 :
IS 5822 :
IS: 4853 :
Seamless / electrically welded steel pipes for water, gas,

Sewage - specification.
Steel cylinder pipe with concrete lining and coating
Laying of electrically welded steel pipes for water supply
Recommended practice for Radiographic inspection of fusion
welded butt joints in steel pipes.
IS: 4260 :
IS: 3600 :
(Part-1)
IS: 4711 :
IS: 1894 :
Recommended practice for ultrasonic butt weld in ferric steel.

Methods of testing fusion welded joints and weld mains in steel:
part 1 cruciform fillet weld tensile test
Sampling of pipe for various tests and criteria for conformity.
Methods of tensile testing of steel tubes.
IS: 10748 :
Hot - Rolled Steel Strip for Welded Tubes and Pipes Specifications
Dimensions for Steel Plates, Sheets, Strips and Flats for
General Engineer-in-Charge Purpose
IS: 1730 :
1.2.
Grade of steel
The steel used for manufacture of the pipes (HR coils) shall confirm to IS: 2062, gradeB or IS: 10748, grade - 3 or equivalent ISO. The dimension of HR coils shall conform
IS: 2062.The quality of steel, chemical composition and tensile strength of the steel
plates shall be as specified in IS: 3589 for steel of grade Fe 410. Positive tolerance
as per IS: 3589 shall be allowed for plate thickness, but no negative tolerance
shall be allowed.
Page 52
1.3.
Electrodes
The electrodes used for welding of steel plates shall confirm to IS: 814
1.4.
Certificate for Steel Plates

Steel plates should confirmed to IS: 1730, Dimensions for Steel Plates, Sheets, Strips
and Flats for General Engineer-in-Charge Purpose. The test certificate for the plates
shall be issued by Plate Manufacturer.
1.5.
Standard Length of pipes

The MS pipes shall be manufactured in lengths of 10 to 13m with beveled ends.
Length of each pipe shall be measured at diametrically opposite four places and
average of the four measured lengths shall be considered for measurements of pipe
length.
1.6.
Welding process
The pipes shall be manufactured by shop welding from steel plates, butt welded
spirally or longitudinally by automatic submerged arc welding process using at least
two runs, one of which shall be on the inner side of the pipes. Welding shall be so done that there
will be through fusion and complete penetration and shall be free from cracks, oxides, and slag inclusion
and gas pockets.
Longitudinally welded pipes shall have circumferential weld at not less than 1.8 m centre
to centre. Longitudinal weld shall be staggered. Minimum distance between spiral welds
should be 1.5 m.
1.7.
Deviation in Length
Finished pipe length shall not deviate from straightness by more than 0.2 percent of
the total length.
1.8.
Radiographic / Ultrasonic test

Three percent of all seams of pipes, welded in the fabrication shop, shall be radio
graphed at the end of pipe (as per IS: 4853) to render visible inspection of any internal
defects such as blow holes, slag, inclusion of cracks. If any defects are detected, the
metal at the location shall be chipped out and re-welded. In addition to the
radiography of the joints, 100 percent testing by ultrasonic equipment (as per IS: 4260)
shall also be done for welding tests. Any defects found out shall be rectified free of
cost. Welds found deficient in quality shall be removed by chipping or melting and
remade as per specifications. Chipping or cutting the weld shall not extend to the base
metal.
1.9.
Hydraulic Test at Works

Each pipe shall be hydraulically tested at manufacturers works before applying any
coating / lining.
1.10.
Allowable tolerance
Allowable tolerance for out side diameter shall be 0.75% of the specified diameter.
Allowable tolerance for ovality shall not be more than 1% of the specified diameter.
Negative tolerance for plate thickness shall not be allowed.
Page 53
1.11.
Sampling and testing

Sampling and conformity criteria for various tests shall be as given in IS: 4711. The test
samples shall be cut from pipes in the final condition of supply. Tests for tensile
strength, percentage elongation, guided bend test, shall be carried out and the test
values shall be in conformity with those specified in IS: 4711.
1.12.
Inspection
The pipes ready in the manufacturers work yard shall be inspected and tested before
dispatch, by the employer and or inspecting agency appointed by the employer. All the
tests including hydraulic test shall be carried out on specified number of samples from
each lot as specified in IS: 4711, in presence of the inspecting agency. The internal
cement mortar lining shall be applied to the pipes only after the inspecting agency is
satisfied regarding the test results, which shall be in conformity with the limits
specified in IS: 4711. The contractor shall produce the test certificate issued by the
inspecting agency charges for such inspection shall be born by the turn key agency.
2.0
Cement mortar coating (guniting) for external surface of MS

pipes
2.1
General
The outside surface of the MS pipes and bends shall be provided with reinforced
cement mortar coating for 30 mm thickness, 1:3 proportions, applied by mechanical /
pneumatic placement.
2.2
Material
Reinforcement
The reinforcement shall consist of BRC fabric of size 100 mm x 100 mm. x 3 mm.
Reinforcement shall be free of oil, grease and other contaminants that may reduce the
adherence between the coating and reinforcement. The BRC fabric shall be placed in
the middle third of the coating. Mortar cover blocks shall be provided to place the BRC
fabric properly. Splicing for fabric reinforcement, if required, shall have minimum 100
mm overlap.
2.3
Cement
Portland cement shall confirm to IS 269 / IS 8041 / IS 1489 and IS 8112.
2.4
Sand
Sand shall consist of inert materials having hard, strong, durable uncoated grains
confirming to the requirements of IS 2116.
2.5
Water
The water used for guniting shall be clean, colour less, and free from injurious quantities
of organic matter, alkali and salt. The maximum water cement ratio shall not exceed
0.45:1.
2.6
Cement mortar
The mortar applied by mechanical or pneumatic process shall consist 3 parts of sand
and 1 part of cement by weight. The water in the mixture shall be carefully controlled so
that the mortar will not run, sag or segregate. The soluble chloride-ion (Cl) content of the
cement mortar mix shall not exceed 0.15 percent, expressed as a percentage of cement
weight. Rebound not exceeding one fourth of the total mix weight may be used as
replacement material for fine aggregate only. Rebound not used within 1 hour shall be
discarded.
2.7
Surface preparation
Page 54
The outer surface shall be cleaned for oil grease etc. The outer coating of red oxide
shall be removed by sand blasting. The dust shall be removed by compressed air or
vacuum cleaner before placement of reinforcement. The BRC fabric reinforcement shall
then be placed with required cover on the pipe surface.
2.8
Application
The pipe shall be supported on wooden logs at the ends to keep bottom clearance and
to facilitate easy rotation while applying the coating. The mortar coating shall be applied
in one or more continuous applications for achieving required thickness. If applied in
more than one course, the interval between the first and last course shall not be more
than 2 hours. The mortar shall be projected at high velocity against the exterior surfaces
of the pipe with a pressure of 2.1 to 2.8 kg / cm 2 to produce a hard, tight adhering
coating of specified thickness. The coating shall not be applied on ends of pipes for 100
mm length. Ends of coating shall be uniform and square to the longitudinal axis of the
pipe. The rebound material unused shall be disposed off within a lead of 50m.
2.9
Placement temperature
The temperature of the cement mortar mix shall not be less than 4 0 C, nor shall the
surface temperature of the MS pipe be greater than 350 C at the time of placement.
2.10
Curing
After the initial set of the cement mortar coating has taken place, the mortar coating
shall be cured by the moist curing method. The coating shall be kept continuously moist
by intermittent or continuous spraying of water for a period of at least 7 days.
2.11
Defective coating
If any sand pockets or porous spots occur, they shall be completely cut out and replaced
by mechanical / pneumatic placement or hand application of mortar in proportion of 2
parts of sand and 1 part of cement, by weight.
2.12
Coating cracks
Care shall be taken to minimise the occurrence of cracks in the mortar coating.
However, hairline cracks need not be repaired. The cracks, if developed, shall be
repaired by brushing or wiping of neat cement in to the cracks, or painting of the cracks
with epoxy coating or a combination of these methods shall be adopted.
3.0
Transportation of pipes for laying

Handling of the mortar coated pipes while transporting those from guniting yard, for
laying and jointing purpose, shall be done very carefully to avoid any damage or
development of cracks to the mortar coating. Any damaged portion shall be cutout and
replaced. The pipes shall be laid in the trenches as early as possible after the curing
period is over to avoid hair cracks in the coating due to temperature variations. The
execution shall be programmed in such a way that the coated pipes are laid in the
trenches within a period of maximum 1 month after cutting period is over.
4.0
Coating for welded joint portion

After the welding and testing of the welded joints of MS pipeline, the BRC fabric
reinforcement shall be provided over the joint. Cement mortar used for the joints shall be
composed of one part of cement to not more than two parts of sand, by weight,
thoroughly mixed with water to the consistency of thick cream. Sand shall be graded
confirming to the requirements of ASTM C33, except that 100% shall pass a US
standard sieve number 16.
Page 55
Outside field joints shall be coated with cement mortar, retained by suitable waterimpermeable bands or diapers to bridge the joint and retain the cement mortar without
leakage. Before filling, the cement mortar space shall be flushed with water so that the
surface of the joint to be in contact with the cement mortar will be moistened when the
cement mortar is poured. The joint shall be filled with cement mortar by pouring from
one side only until the cement mortar reaches at least the pipe spring line on the
opposite side, and shall be rodded with a wire or other flexible rod, or vibrated so that
the cement mortar completely fills the joint recess by moving down one side of the pipe,
around the bottom of the pipe, and up the opposite side. Pouring and rodding the
cement mortar shall be continued to allow completion of the filling of the entire joint
recess in one operation. Care shall be taken to leave no unfilled space. The exposed
portion of the grout at the top of the pipe shall be coated with a sealing compound or
covered with burlap or moist earth for curing
3 LPE Coating for external surface of MS pipes

In case, the contractor provides 3 LPE coating on outer surface of pipes,
the specifications for that should be as per Annexure 1 attached at
page no 126 to 153 of this volume.
Page 56
Bansujara Major Irrigation Project
5.0
Testing
5.1
Adsorption test
Water adsorption tests shall be performed on samples of cured cement mortar coating
taken from each working shift. The samples shall have been cured in the same manner
as the pipe. A test value shall consist of the average of a minimum of three samples
taken on the same day from the same work shift. The test method shall be in
accordance with ASTM C497, method A. The average adsorption value for any ten
consecutive tests from a working shift shall not exceed 10% and no individual sample
shall have an adsorption value exceeding 12%.
Tests for each working shift shall be performed on a daily basis until conformance to the
adsorption requirements has been established by 10 consecutive test values not
exceeding 10%, at which time testing may be performed on a weekly basis for each
working shift. Daily testing shall be resumed for each working shift whenever an
adsorption test result exceeds 10%. Daily testing shall be maintained until conformance
to the adsorption requirements is reestablished by 10 consecutive test values not
exceeding 10 percent.
The contractor shall maintain the record of the adsorption tests and shall submit the
same to the Engineer-in-Charge weekly.
5.2
Inspection
The tests performed shall be inspected by the Engineer-in-Charge. If any sample fails to
meet the requirements, the contractor shall be notified immediately. Material affected by
the test r4esults shall be set aside pending final disposition
5.3
Rejection
Material and pipe that are noticed to be defective or that do not confirm to the
requirements will be subject to rejection at any time prior to final acceptance of

the pipe. Rejected material and pipe shall be removed from the work site within a
week after rejection without any liability to the WRD/Govt.
6.0
Internal Epoxy coating to MS pipes and specials
6.1
General
Epoxy coating is proposed for internal surface in all conditions and for external surface
of the MS pipes laid above ground on pedestals and outer surface of tees, manholes,
covers and eccentric reducers.
6.2
Material
The coating shall have one coat of two-part, chemically cured inhibitive Epoxy
primer and two coats of a different two-part, chemically cured, solvent free, and
spray applied epoxy paint. The coating system shall meet the performance
requirements of relevant IS code or AWWA C-210 standard.
.
6.3
Surface preparation:
6.4
Cleaning
Prior to abrasive blast cleaning, the external surface shall be cleaned to remove oil,
grease or other foreign matter. Only approved solvents that do not leave a residue shall
be used for cleaning.
Page 57
6.5
Abrasive blast cleaning

The surface shall be abrasive blast cleaned to achieve a white metal surface. Prior to
blast cleaning, any sharp protuberances, surface laminations, weld spatter, etc shall be
removed by through cleaning and grinding. The abrasive used should be capable of
producing a minimum profile of 50-75 microns corresponding to medium in accordance
with BS: 7079 part C4.
7.0
7.1
Application of Epoxy coating:

Atmospheric conditions
Prepared surfaces must be completely cleaned of dust and dirt by brush or vacuum
cleaner and shall be thoroughly dry. Coating shall not be applied in the following
atmospheric conditions.
Relative humidity exceeding 85%
When the surface to be coated is less than 30C above the due point
The surface temperature is less than 70C or greater than 500C.
7.2
Successive coats
After application of the first coat, the next coat shall be applied within the time limits,
surface conditions, and temperature recommended by the manufacturer.
7.3
Coating thickness
Final thickness of the coating shall not be less than 400 micron DFT. The coating shall
be applied leaving 15 cm at the edge of pipes / specials for welding of the joint. Coating
on this portion shall be applied after welding the joint.
7.4
Preheating
The temperature of mixed coating and that of the pipe at the time of application shall not
be lower than 100C. Preheating of the coating material, the use of inline heaters to heat
the coating material; or heating of the pipe, fittings or specials may be used to facilitate
the application. Heating shall confirm to the recommendations of the coating material
manufacturer.
7.5
Touch up and repair procedure

The finished coating shall be inspected for damage or reduced thickness. Any such
areas shall be repaired by thoroughly degreasing the surface and abrading using 180
grade abrasive papers, the abraded areas shall extend from the edge of the damage for
5075 mm on to surrounding sound coating. The prepared surface can then be recoated.
7.6
Final curing
Sufficient curing period shall be allowed after application of the coating as per
standards for the coating to gain required strength. The epoxy applied pipes;
specials shall be stored for curing in accordance with the durations given in the
following Table.
Ambient Temperature, (deg C)
Minimum number of 1
days storage
45 40 35
1
2
4
30 25
5
7
20 15 10 7*
11 17 22
*Minimum possible cure temperature

7.7
Electrical inspection for continuity

After curing, the coating shall be tested for holidays according to the procedures and
using the voltage settings. Any holidays indicated by the detector shall be got repaired.
Page 58
7.8
Coating of joints after welding

The joint portion shall be cleaned thoroughly as stated above and coated in required
coats for same thickness i.e. 400 micron DFT.
8.
Excavation for Pipe Line Trenches
8.1.
Excavation for Pipe Line Trenches

The excavation in hard rock will have to be carried out either by controlled blasting or
chiseling, wedging or by mechanical means and the tendered rate is supposed to cover
all other means.
8.2.
Site Clearance
The pipe line alignment shall be cleared of all bushes, shrubs, roots, grass, weeds and if
required trees, coming in the alignment of pipe line in the trench width portion. The rates
for excavation shall cover all such site clearance work and no extra payment will be
allowed on this account.
8.3.
Alignment marking
After the work site is cleared as above, pipe line alignment with required trench width
shall be marked on the ground with apex points, curves etc, as shown on the drawings or
as directed by the Engineer-in-Charge in charge for the stretch where the work is to be
started. The contractor shall provide all labour, survey instruments, and materials such
as strings, pegs, nails, bamboos, stones, mortar, concrete etc. required for setting out
and establishment of bench marks. The contractor shall be responsible for the
maintenance of bench marks and other marks and stakes as long as they are required
for the work in the opinion of the Engineer-in-Charge.
8.4.
Working survey
Working survey of the pipeline alignment shall be carried out by the contractor
before start of the excavation work. The contractor shall provide all the
instruments such as leveling instruments, steel tape, ranging rods, strings, pegs
etc. for carrying out the survey. Based on the working survey, the alignments, Lsection (depth of laying), grade, and location of specials, valves and chambers
shall be finalized and got approved from the competent authority. The gradient
and alignment shall be such that minimum horizontal and vertical bends shall be
required.
8.5
Use of Machinery:
All excavations shall be carried out by mechanical equipments / machinery unless, in
the opinion of the Engineer-in-Charge, the work involved and time schedule permit
manual excavation.
8.6
Trench Width and Depth:

All buried pipelines shall be minimum 1.2 meter below ground level.
The trench width for respective pipe diameters permissible as required under respective
IS code for Pipeline laying and installation.
The trench width shall be constant through out the trench depth, which will provide a
clearance of about 0.30 m on either side of the pipe line.
The contractor may, for the facility of work or similar other reasons, excavate and also
backfill later, if so approved by the Engineer-in-Charges, at his own cost, outside the
allowable trench width specified above. Should any excavation be taken below the
specified trench bottom, contractor shall fill it up to required level, at his own cost, with
the same material available at the trench bottom including watering and compaction.
Page 59
The excavation shall be taken down to such depths as shown in drawings. Excavation
for extra depth equal to the thickness of proposed pipe bedding shall be done below
pipe soffit level for providing bedding below pipe line. The trench bottom shall be
excavated to proper grade as shown on drawings. The contractor shall provide site rails
and leveling instruments required for checking the grade during excavation, bottom
bedding and pipe laying Projections in rock excavation shall be removed by chipping.
The contractor shall carryout extra excavation at the pipeline joints to be welded, as
required (minimum 0.6 m deep and 0.9 m lengthwise, all around the pipe), for facilitating
proper
welding
of
the
bottom
joint
from
out
side.
The work of trench excavation should be commensurate with laying and jointing of the
pipe line. It should not be dug in advance for a length greater than 500 m ahead of work
of laying and jointing of pipeline unless otherwise permitted by the Engineer-in-Charge.
The minimum cover on pipe is to be maintained 1 meter. However the cover on pipe
may be modified to suite gradients and site conditions as per direction of Engineer-inCharge.
8.7.
Barricading and Guarding:

To protect persons from injury and to avoid damage to property, adequate barricades,
construction signs, red lanterns and guards as required shall be placed and maintained
during the progress of work, till filling of the trenches after pipes are laid and jointed. The
lighting, barricading, guarding of the trenches and the maintenance of watchman shall
be done by the contractor at his cost.
All precautions shall be taken during excavation and laying operation to guard against
possible damage to any existing structures, under ground cables, pipe lines of water,
gas, sewage etc. Any damage done to such properties will have to be repaired / rectified
by the contractor at his cost. The Contractor has to ensure the following:
safety protections as mentioned above have to be incorporated in the work process
hindrances to the public have to be minimized
the trench must not be eroded before the pipes are laid
the trench must not be filled with water when the pipes are laid
the trench must not be refilled before laying of the pipes
The bed for the laying of the pipes has to be prepared according to the L-Section
immediately before laying of the pipes.
8.8.
Reuse of surface material

All surface materials, which in the opinion of the Engineer-in-Charge, are suitable for
reuse in restoring the surface shall be kept separate from the general excavation
material, as directed by the Engineer-in-Charge.
8.9.
Stacking of excavated material

All excavated materials shall be stacked in such a manner that it does not endanger the
work and avoids obstructing foot paths and roads. Hydrants under pressure, surface
boxes, fire and other utility controls shall be left unobstructed and accessible until the
work is completed. Gutters shall be kept clean or other necessary provisions made for
street drainage and natural water courses shall not be obstructed. All the excavated
material shall be the property of the Employer and shall be stacked or disposed off as
directed by the Engineer-in-Charge.
Page 60
8.10.
Maintenance of traffic
The work of excavation and pipe laying shall be carried in such a manner that it causes
the least interruption to traffic and the road / street may be closed in such a manner that
it causes the least interruption to the traffic. Where it is necessary for traffic to cross
open trenches, suitable bridging arrangement shall be provided. When the street is
closed for traffic, suitable signs indicating that street is closed shall be placed and
necessary detour signs for proper maintenance of traffic shall be provided.
8.11.
Structure protection
Temporary support, adequate protection and maintenance of all underground and
surface structures, drains, sewers and other obstructions encountered in the progress of
work shall be furnished under the direction of the Engineer-in-Charge. The structures
which have been disturbed shall be restored upon completion of work.
8.12.
Protection of property
Trees, shrubbery fences, poles and all other property shall be protected unless their
removal is allowed by the Engineer-in-Charge. When it is necessary to cut roots and
tree branches, such cutting shall be done under the supervision and direction of the
Engineer-in-Charge.
8.13.
Avoidance of existing services

As far as possible, the pipeline shall be laid below existing services, such as water and
gas pipes, cables, cable ducts and drains but not below sewers. Excavation of the
trenches shall be carried out to the required depth accordingly. If it is unavoidable, the
pipeline shall be suitably protected and lesser trench depth in such cases can be
allowed. A minimum clearance of 150 mm shall be provided between the pipeline and
such other services. When thrust or auger boring is proposed for laying pipeline across
roads, railway or other utilities, larger clearance as required shall be provided. Adequate
arrangements shall be made to protect and support the other services during excavation
and pipe laying operations. The work shall be so carried out as not to obstruct access to
the other services for inspection, repair and replacement. When such utilities are met
with during excavation, the authority concerned shall be intimated and arrangements
made to support the utilities in consultation with them.
8.14.
Bailing out of Water

During the excavation if subsoil water is met with, contractor shall provide necessary
equipment and labour for dewatering the trenches. If pumping out subsoil water is found
necessary, contractor shall provide sufficient number of pumps for the same. The
tendered rate shall cover all costs for bailing out of water including hire charges of
pumps, cost of diesel and labour etc and hence, no extra payment shall be allowed.
8.15.
Disposal of loose boulders etc

All loose boulders, semi detached rocks, (along with earthy stuff which might move
therewith), not directly in the excavation but close to the area to be excavated, as to be
liable, in the opinion of the Engineer-in-Charge, to fall or other wise endanger the
workman equipments, or the work etc, shall be stripped off and removed away form the
area of the excavation. The method used shall be such as not to shatter or render
unstable or unsafe the portion which was originally sound and safe. The tendered rate
is supposed to cover this job and no extra payment will be allowed on this account.
8.16. Disposal of Excavated Material
All the excavated surplus material shall be disposed off on muck area with due
consultation of Engineer in Charge.
Page 61
9.
Moorum / Sand Bedding below Pipeline
In case of hard rock and black cotton soil, before lowering of the MS pipes in
trenches, a layer of selected moorum, shall be provided below the MS pipe line
to act as bedding. The bedding shall be compacted properly including
required watering and the thickness of well compacted layer shall not be less
than 150 mm. The bedding shall be provided for full trench width with proper
grade as shown on drawings.
10.
Refilling the trenches
10.1. Use of selected excavated material

Filling of excavated material in trenches shall be commenced as soon as the joints of
pipes and specials have been tested and passed. The backfilling material shall be
properly consolidated by watering and ramming, taking due care that no damage is
caused to the pipes and the outer coating.
Selected surplus spoils from excavated material shall be used as backfill. Fill material
shall be free from clods, salts, sulphate, organic or other foreign material. All clods of
earth shall be broken or removed. Where excavated material is mostly rock, the
boulders shall be broken into pieces not larger than 150 mm size, mixed with properly
graded fine material consisting of murum or earth to fill up the voids and the mixture
used for filling.
10.2. Back Filling
For the purpose of back-filling, the depth of the trench shall be considered as divided in
to the following three zones from the bottom of the trench to its top:
Zone A:
From the bottom of the pipe (top
of bedding) to the level of the
centre line of the pipe
Zone B:
From the level of the centre line of
the pipe to a level 300 mm above
the top of the pipe
Back-filling by hand with selected approved material

available from excavation, placed in layers of 150 mm
and compacted by tamping. The back-filling material shall
be deposited in the trench for its full width on each side of
the pipe, specials and appurtenances simultaneously.
Special care shall be taken to avoid damage of the pipe
and the coating or moving of the pipe.
Back-filling and compaction shall be done by hand or

approved mechanical methods in layers of 150 mm;
special care shall be taken to avoid damage of the pipe
and the coating or moving of the pipe.
Zone C:
From a level 300 mm above the
top of pipe
Back-filling shall be done by mechanical methods in 15

cm compacted layers and carried to the level necessary
or the temporary restoration of road and path surfaces. If
any hard core surface for construction of road along the
pipe trench, is ordered by Engineer in Charge, the same
shall be done. Such level as will leave the requisite space
for the top soil, road surface etc. to be reinstated as
directed by the Engineer-in-Charge. In case of
agricultural or waste land and after approval by the
Engineer-in-Charge in Charge, back-filling may be made
in thicker layers up to 200 - 300 mm above the initial
ground level.
Page 62
10.3. All excavations shall be backfilled to the level of the original ground surfaces unless
otherwise shown on the drawings or ordered by the Engineer-in-Charge in Charge, and
in accordance with the requirements of the specification. The material used for backfill,
the amount thereof, and the manner of depositing and compacting shall be subject to the
approval of the Engineer-in-Charge in Charge, but the Contractor will be held responsible
for any displacement of pipe or other structures, any damage to their surfaces, or any
instability of pipes and structures caused by improper depositing of backfill materials.
The back filled layers shall be wetted and compacted to a density of not less than 90
percent of the maximum dry density at optimum moisture content of the surrounding
material. Any deficiency in the quantity of material for backfilling the trenches
shall be supplied by the Contractor at his expense.
The Contractor shall at his own expense make good any settlement of the trench backfill
occurring after backfilling and until the expiry of the defects liability period.
On completion of pressure and leakage tests exposed joints shall be covered with
approved selected backfill placed above the top of the pipe and joints in accordance
with the requirements of the above specifications. The Contractor shall not use
backfilling for disposal as refuse or unsuitable soil.
10.4.
Fillings of the trench excavated in rock

In case of excavation of trenches in rock, the filling up to a level of 30 cm above the top
of the pipe shall be done with fine materials, such as soft soil, murrum etc. The filling up
of the level of the centre line of the pipe shall be done by hand compaction in layers not
exceeding 15 cm, whereas the filing above the centre line of the pipe shall be done by
hand compaction or mechanical means in layers not exceeding 15 cm. The filling from a
level of 30 cm above the top of the pipe to the top of the trench shall be done by
mechanical methods with broken rock filing of size not exceeding 15 cm mixed with fine
material as available to fill up the voids.
10.5.
Consolidation
The consolidation of the filled material shall be done to attain not less than 90 percent of
the maximum dry density. The density of the filled and compacted material shall be
tested regularly and record maintained accordingly.
11.
Lowering, laying and jointing of MS pipes
11.1.
Standards
Except as otherwise specified in this technical specification, the Indian Standards and
Codes of Practice in their latest version, National Building code, PWD specification of
the state of Madhya Pradesh and Manual of water supply of GOI shall be adhered to for
the, handling, laying, installation, and site testing of all material and works.
11.2
Tools and equipment

The contractor has to provide all the tools and equipment required for the timely,
efficient and professional implementation of the work as specified in the various
sections of the contract and as specified by the instructions of manufacturers of the
pipes and other material to be handled under this contract. On demand he shall
provide to the Engineer-in-Charge a detailed list of tools and equipment available. If in
the opinion of the Engineer-in-Charge the progress or the quality of the work cannot be
guaranteed by the available quantity and type of tools and equipment the contractor
has to provide additional ones to the satisfaction of the Engineer-in-Charge. The
Contractor will always have a leveling instrument on site.
11.3
Handling, transportation of pipes and specials

The Contractor has to transport the pipes and other materials from manufacturer or site
store yard / guniting yard to the site of laying as indicated by the Engineer-in-Charge in
Charge. Pipes should be handled with care to avoid damage to the surface and the
Page 63
socket and spigot ends, deformation or bending. Pipes shall not be dragged along the
ground or the loading bed of a vehicle. Pipes shall be transported on flat bed
vehicles/trailers. The bed shall be smooth and free from any sharp objects. The pipes
shall rest uniformly on the vehicle bed in their entire length during transportation. Pipes
shall be loaded and unloaded by suitable mechanical means without causing any
damage to the stacked pipes.
The transportation and handling of pipes shall be made as per IS 12288 and IS 5822.
Handling instructions of the manufacturers of the pipes shall be followed. All precautions
set out shall be taken to prevent damage to the protective coating, damage of the
jointing surfaces or the ends of the pipes.
Whatever method and means of transportation is used, it is essential that the pipes are
carefully placed and firmly secured against uncontrolled movement during transportation
to the satisfaction of Engineer-in-Charge in charge.
Cranes or chain shall be used for loading and un-loading of heavy pipes. However, for
pipes up to 400 mm nominal bore, skid timbers and ropes may be used. Where using
crane hooks at sockets and spigot ends, hooks shall be broad and protected by rubber
or similar material, in order to avoid damage to pipe ends and lining / coating. Damage
to lining / coating must be repaired before pipe laying according to the specifications
mentioned elsewhere and as per instructions of the Engineer-in-Charge in charge.
Pipes shall not be thrown directly on the ground.
When using mechanical handling equipment, it is necessary to employ sufficient
personnel to carry out the operation efficiently with safety. The pipes should be lifted
smoothly without any jerking motion and pipe movement shall be controlled by the use
of guide ropes in order to prevent damage caused by pipes bumping together or
against surrounding objects.
11.4
Rolling or dragging pipes along the ground or over other pipes already stacked shall be
avoided.
Stringing of pipes along the alignment
The pipes shall be laid out properly along the proposed alignment in a manner that they
do not create any significant hindrance to the public and that they are not damaged.
Stringing of the pipes end to end along the working width should be done in such a
manner that the least interference is caused in the land crossed. Gaps should be left at
intervals to permit the passing of equipment across the working area. Pipes shall be laid
out that they remain safe where placed and that no damage can occur to the pipes and
the coating until incorporated in the pipeline. If necessary, pipes shall be wedged to
prevent accidental movement. Precautions shall be taken to prevent excessive soil, mud
etc. entering the pipe.
Generally, the pipes shall be laid within four weeks from the date of their dispatch from
the manufacturer / store or from out coating yard.
11.5
Laying and jointing of pipes- following Specifications are detailed herein for
laying and jointing
11.5.1. Laying of pipes below ground - guniting as per IS specifications

11.5.1.1. General
After the trench is made ready with bedding, and after the jointing pits are excavated at
the joint position, the gunited and lined pipes shall be lowered in the trenches.
Page 64
The MS pipe ends shall be cleaned with special care to ensure that they are free from
dirt and unwarranted projections. The whole of the pipes shall be placed in position
singly and shall be laid true to profile and direction of slope indicated on longitudinal
sections. The pipes shall be laid without deflection in a straight alignment between
bends and between high and low points. The alignment and levels shall be checked by
the contractor with theodolite.
Before pipes are jointed they shall be thoroughly cleaned of all earth lumps, stones, or
any other objects that may have entered the interior of the pipes.
Pipes and the related specials shall be laid according to the instructions of the
manufacturers and using the tools recommended by them.
Cutting of pipes shall be reduced to a minimum required to conform to the drawings.
Cutting has to be made with suitable tools and according to the recommendations of the
manufacturer without damage to the external coating and internal lining. The spigot end
has to be beveled again at the same angle as the original beveled end. While
assembling the pipes the ends shall be brought close enough to leave a uniform gap not
exceeding 3 mm. Marginal cutting shall be done if found necessary, for which no extra
payment shall be admissible. There shall be no lateral displacement between pipe faces
to be jointed. After the pipes are properly assembled and checked for the correct line
and level, tack welding for the pipe joint shall be done. Final welding of the joint from
inside and outside shall be done thereafter.
11.5.1.2. Straps
Whenever the pipe laying work proceeds from two ends and if gap remained between
two faces is less than 30 cm, such gap shall be bridged by providing a strap. Strap shall
also be provided during fixing of expansion joint for above ground pipeline. Such strap
shall be fabricated on site by cutting a piece from the pipe. This piece shall be split
longitudinally and stepped over the gap. A minimum overlap of 8 cm shall be provided
on both the pipe ends to be connected. The strap shall be welded with pipe ends with
required number of fillet wells from inside and outside. The gap between ends of the
strap shall be butt welded longitudinally.
11.5.1.3. Distance piece
Distance piece shall be provided when the gap between pipe faces to be jointed is more
than 30 cm. Distance pieces shall be cut from pipe pieces for required length either on
site or in factory. Payment shall be as per the laying and jointing of pipeline item.
All specials like bends, tees etc. and appurtenances like sluice or butterfly valves etc.
shall be laid in synchronization with the pipes. The Contractor has to ensure that the
specials and accessories are ready in time to be installed together with the pipes.
At the end of each working day and whenever work is interrupted for any period of time,
the free ends of laid pipes shall be protected against the entry of dirt or other foreign
matter by means of approved plugs or end caps.
When pipe laying is not in progress, the open ends of installed pipe shall be closed by
approved means to prevent entrance of trench water and dirt into the line. No pipe shall
be laid in wet trench conditions that preclude proper bedding, or when, in the opinion of
the Engineer-in-Charge, the trench conditions or the weather are unsuitable for proper
installation. The pipe line laid should be absolutely straight unless planned otherwise.
The accuracy of alignment should be tested before starting refilling with the help of
stretching a string between two ends of the straight stretch of pipes to rectify possible
small klinks in laying.
Page 65
11.5.2. Laying of pipes above ground - in forest area only
11.5.2.1 General
Above ground pipe line shall have epoxy coating on inner and outer surfaces.
Laying of pipeline shall be started only after sufficient number of chairs / pedestals have
been casted as per design which shelled not be less than 0.6 m in width to required
level and have achieved their final strength including fixing of the bearing plates and
roller bearings.
The contractor shall lay the pipeline to the exact line and level as shown on the
drawings, or as directed by the Engineer-in-Charge.
11.5.2.2 Laying procedure
The pipe laying shall start from the successive fixity points towards expansion joint, if
proposed in that stretch. Depending upon the distance between the successive chairs,
and the length of the pipes fabricated, two pieces may be welded on site before laying
so that after laying the pipe rests on next chair and overhangs for at least half the length
of pipe.
Normally not more than one pipe shall be aligned, tacked and kept in position on the
chairs at a time. During assembly, the pipes shall be additionally supported on adequate
wooden sleepers or scaffolding as necessary, kept between the chairs / pedestals.
While assembling the pipes, the ends shall be brought to leave a uniform gap not
exceeding 3 mm. The ends shall be tack welded to align the pipe properly.
Full welding of the circumferential joint shall be done only after the Engineer-in-Charge
has checked the correctness of the alignment and level. Further laying of pipes shall not
be undertaken unless full welding of the circumferential joints of the piped laid earlier is
completed. Expansion joint shall be fixed at the location shown on drawing or as
directed by the Engineer-in-Charge.
11.6. Welding the joints
11.6.1. General
Before aligning, assembling and welding, the pipe faces shall be cleaned by scrapping
with wire brushes or by any other approved method.
Welding of pipes in field shall confirm to IS: 816 (code of practice for use of metal arc
welding for general construction in mild steel). Electrodes used for welding shall comply
with IS: 814. In case of variation, specifications hereunder shall have precedence.
Welders shall be qualified and well experienced and shall be approved by the Engineerin-Charge. Contractor shall remove such of the welders from the job whose work is not
satisfactory.
The contractor shall keep record of the welding for each circumferential joint. It shall
contain the name of the welder, date of completion of the welding runs internal as well
as external.
11.6.2. Gouging and chipping
MS pipes to be jointed are large in diameter and hence the joints shall be welded with
two numbers of runs from inside and a sealing run from outside. External sealing run
shall be done only after internal welding is completed. Before starting the external
welding, the weld material in the joint shall be cleaned by chipping out loose scales.
Page 66
Gauging shall be done before rectification of any defective welding wherever necessary
and as directed by Engineer-in-Charge.
Gauging and chipping shall not be paid separately and the rate for welding shall be
deemed to include the cost of gauging and chipping.
11.6.3. Electrodes
Welding electrodes shall confirm to IS: 814. The contractor shall use electrodes of
Advani and Premier or equivalent depending on thickness of the plates to be welded
and the type of joint. The contractor shall use standard current and AC voltage required
for the machine as per manufacturers directions.
11.6.4. Type of joints
The circumferential joints of the pipes shall have butt welded with required number of
runs externally and internally.
All the fillet welds / lap welds shall have throat thickness not less than 0.7 times the
thickness of the pipe to be welded.
11.7. Testing of welded joints
Welded joints shall be tested in accordance with the procedure laid down in IS: 3600,
Method of testing fusion welded joints and weld metals in steel.
At least one test specimen shall be taken out for testing for every 50 field joints. Test
pieces shall be taken out from the places pointed out by the Engineer-in-Charge. These
shall be machined and tested as early as possible.
The shape of the test pieces removed for testing shall be such that it shall give the
specimen of the required dimensions with the weld in the middle of the specimen. It
must ensure good butt weld.
11.7.1. Tensile test
The test specimen taken perpendicularly across the weld shall be shaped in accordance
with IS: 3600 (part 3). The tension test specimen shall be machined. The protruding
welded portion from inside as well as outside shall be removed by machining before the
specimen is tested. The specimen shall be tested in tension in accordance with IS: 1608
If the specimen shows defective machining or develops flaws not associated with
welding, it shall be discarded and another specimen substituted. The welded joint shall
show strength not less than the minimum tensile strength for the plate in accordance
with IS: 226.
11.7.2. Bend test
Bend test specimen shall also be prepared in the same fashion as the tensile test
specimen. The specimen shall be bent cold 1800 around a pin that has a diameter equal
to 4 time the plate thickness, without developing cracks. For this test, face
representing inside of the pipe shall be placed next to the pin.
11.7.3. Tree-panned plugs
Tree-panned plugs shall be taken out from any welded portion as pointed out by the
Engineer-in-Charge. These plugs shall not show any defects in welding such as
inclusion of slag, blow holes, cavities, etc. The plug shall be 12 mm in diameter and
shall be taken out by means of suitable electrically operated machine. Such holes in the
pipe shall either be filled back by inserting a steel stud and welding around or threading
the hole and providing suitable GI plug. This test shall be done if considered necessary
by the Engineer-in-Charge.
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11.7.4. Non-destructive tests

Non-destructive testing of the completed weld shall be carried out on pipelines by
radiographic method as specified under IS: 4853 or ultrasonic method as per IS: 4260.
Non-destructive test for every 50 joints shall be carried out.
11.8.
Procedure on failure of test specimen

If the test specimen fails in either tensile or bent test or in both, two additional test
specimens shall be taken out from the section and shall be tested again for both the
tests. If any one of them fails, extensive gouging and repairing shall be carried out for
the welded joints in that section to the full satisfaction of the Engineer-in-Charge in
charge. However, if both the samples give satisfactory results, the joint from which the
original sample was taken and had failed, shall be repaired at contractors cost.
Welder who has done the welding of the joint that has failed shall be solely held
responsible for bad workmanship and failure. Since all other factors like electrodes,
current, arc voltage, etc are already controlled; negligence on the part of the welder only
is responsible for such failure. For first such failure, the welder shall be warned and if
the failure is repeated, he shall be removed from the job.
11.9
Anchoring of the pipeline:

Reinforced concrete thrust blocks shall be provided at each bend, tee, taper, end piece
to prevent undue movements of the pipeline under pressure. They shall be constructed
as per design done by ENGINEER-IN-CHARGE considering the highest pressure
during operation or testing of the pipes, the safe bearing pressure of the surrounding
soil and the friction coefficient of the soil.
11.10 Hydraulically operated butterfly valve should be fixed rising main / gravity main at an
interval of 3 km.
12
SPECIFICATION FOR DI PIPELINES
12.1
Material
The pipes will be Ductile Iron Pipes for Water and Sewage confirming to the IS: 8329.
The pipes used will be either with push on joints (Rubber Gasket Joints) or Flanged
joints. The class of pipe to be used shall be of the class K-7.
The pipes shall be coated with bitumen as per Appendix C and have factory provided
cement mortar lining in the inside as per the provisions of Appendix B of the IS 8329.
The pipes will be supplied in standard length of 5.50 and 6.00 meters length with suitably
rounded or chamfered ends. Each pipe of the push on joint variety will also be supplied
with a rubber EPDM gasket. The Engineer will approve any change in the stipulated
lengths. The gaskets will confirm to the IS: 5382.
The manufacturer of the pipes shall also supply the gaskets. The manufacturer of the
pipes should preferably manufacture them. In case they are not, it will be the
responsibility of the manufacturer of the pipes to have them manufactured from a suitable
manufacturer under its own supervision and have it tested at his/sub-Contractors
premises as per the contract. The pipe manufacturer will however be responsible for the
compatibility and quality of the products.
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The flanged joints will confirm to the Clause 6.2 of IS 8329. The pipe supply will also
include one rubber gasket for each flange.
12.2
Inspection and Testing
The pipes will be subjected to following tests for acceptance:
Visual and dimensional check as per Clause 13 and 15 of IS 8329

Mechanical Test as per Clause 10 of IS 8329
Hydrostatic Test as per Clause 11 of IS 8329
The test reports for the rubber gaskets shall be as per acceptance tests of the IS
5832 and will be in accordance to Clause 3.8
The sampling shall be as per the provisions of the IS 8329.
12.3
Marking
All pipes will be marked as per Clause 18 of IS 8329 and show as below:
Manufacturers name/stamp
Nominal diameter
Class reference
A white ring line showing length of insertion at spigot end
12.4 Packing and Transport

The pipes should be preferably transported by road from the factory and stored as per the
manufacturer Specifications to protect damage.
12.5
Specials for Ductile Iron Pipes

General
This section covers the general requirements for Ductile Iron (DI) fittings suitable for Tyton
joints to be used with Ductile Iron pipes with flanged and Tyton jointing system.
Page 69
Types of Specials
The following types of DI fittings shall be manufactured and tested in accordance with IS:
9523 or BS 4772.
Flanged socket
Flanged spigot
Double socket bends (90, 45 22 /12, 11 )
Double socket branch flanged tee
All socket tee
Double socket taper
All flanged tee
All flanged taper
Supply
All the DI fittings shall be supplied with one rubber ring for each socket. The rubber ring
shall conform to IS: 12820 and IS: 5382 as described in the preceding chapter. Flanged
fittings shall be supplied with one rubber gasket per flange and the required number of
nuts and bolts.
12.6
Lubricant for Ductile Iron Pipes and Specials

General
This section covers the requirements for lubricant for the assembly of Ductile Iron pipes
and specials suitable for Tyton push-in rubber ring joints.
Specification
The lubricant has to have the following characteristics:
Must have a paste like consistency and be ready for use

Has to adhere to wet and dry surfaces of DI pipes and rubber rings
To be applied in hot and cold weather; ambient temperature 0 50C, temperature of
exposed pipes up to 70C
Must be non toxic
Must be water soluble
Must not affect the properties of the drinking water carried in the pipes
Must not have an objectionable odour
Has to inhibit bacterial growth
Must not be harmful to the skin
Must have a shelf live not less than 2 years.
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Acceptance
12.7
They shall be conducted in line with the provisions of the IS 9523
Packing
All the DI fittings shall be properly packed with jute cloth. Rubber rings shall be packed in
polyethylene bags. Rubber rings in PE bags and nuts, bolts, etc. shall be supplied in
separate jute bags.
The manufacturer of the pipes shall also supply the fittings. The manufacturer of the pipes
should preferably manufacture them. In case they are not, it will be the responsibility of the
manufacturer of the pipes to have them manufactured from a suitable manufacturer under its
own supervision and have it tested at his/sub Contractors premises as per the contract. The
pipe manufacturer will however be responsible for the compatibility and quality of the
products.
12.8
Laying and jointing of pipes

General
The pipes will be cleaned in the whole length with special care of the spigot and sockets
on the inside/ outside to ensure that they are free from dirt unwarranted projections. The
whole of the pipes shall be placed in position singly and shall be laid true to profile and
direction of slope indicated on longitudinal sections. The pipes shall be laid without
deflection in a straight alignment between bends and between high and low points.
Vertical and horizontal deflections between individual pipes need the approval of the
Engineer. In no case the deflection shall be more than 75% of those recommended by
the manufacturer.
Before pipes are jointed they shall be thoroughly cleaned of all earth lumps, stones or
any other objects that may have entered the interior of the pipes, particularly the spigot
end and the socket including the groove for the rubber ring.
Pipes and the related specials shall be laid according to the instructions of the
manufacturers and using the tools recommended by them.
Cutting of pipes shall be reduced to a minimum required to conform to the drawings.
Cutting has to be made with suitable tools and according to the recommendations of the
manufacturer. The spigot end has to be chamfered again at the same angle as the
original chamfered end. Cutting shall be perpendicular to the centre line of the pipe. In
case of ductile iron pipes the cut and chamfered end shall be painted with two coats of
epoxy paint. If there is no mark for the insertion depth on the spigot ends of the (cut) pipe
it shall be marked again according to the instructions of the manufacturer.
Before pipes are jointed they shall be thoroughly cleaned of all earth lumps, stones, or
any other objects that may have entered the interior of the pipes, particularly the spigot
end and the socket including the groove for the rubber ring. End caps are removed only
just before laying and jointing.
All specials like bends, tees etc. and appurtenances like sluice or butterfly valves etc.
shall be laid in synchronization with the pipes. The Contractor has to ensure that the
specials and accessories are ready in time to be installed together with the pipes.
Page 71
At the end of each working day and whenever work is interrupted for any period of time,
the free ends of laid pipes shall be protected against the entry of dirt or other foreign
matter by means of approved plugs or end caps.
When pipe laying is not in progress, the open ends of installed pipe shall be closed by
approved means to prevent entrance of trench water and dirt into the line.
No pipe shall be laid in wet trench conditions that preclude proper bedding or when, in
the opinion of the Engineer, the trench conditions or the weather are unsuitable for proper
installation.
The pipeline laid shall be absolutely straight unless planned otherwise. The accuracy of
alignment should be tested before starting refilling with the help of stretching a string
between two ends of the straight stretch of pipes to rectify possible small kinks in laying.
Pipes shall be lowered into be trench with tackle suitable for the weight of pipes. For
smaller sizes, up to 200 mm nominal bore; the pipe may be lowered by the use of ropes
but for heavier pipes suitable mechanical equipment have to be used.
All construction debris shall be cleared from the inside of the pipe either before or just
after a joint is made. This is done by passing a pull-through in the pipe, or by hand,
depending on the size of the pipe. All persons should vacate any section of trench into
which the pipe is being lowered.
On gradients of 1:15 or steeper, precautions should be taken to ensure that the spigot of
the pipe being laid does not move into or out of the socket during the jointing operations.
As soon as the joint assembly has been completed, the pipe shall be held firmly in
position while the trench is back filled over the barrel of the pipe.
The designed anchorage shall be provided to resist the thrusts developed by internal
pressure at bends, tees, etc.
Where a pipeline crosses a watercourse, the design and method of construction should
take into account the characteristics of the watercourse to ascertain the nature of bed,
scour levels, maximum velocities, high flood levels, seasonal variation, etc. which affect
the design and laying of pipeline. The pipe shall be laid accordingly with adequate
protection.
The assembly of the pipes shall be made as recommended by the pipe manufacturer and
using the suitable tools.
The socket and spigot ends of the pipes shall be brushed and cleaned. The chamfered
surface and the end of the spigot end have to be coated with a suitable lubricant
recommended by the manufacturer of the pipes. Oil, petroleum bound oils, grease or
other material, which may damage the rubber gasket, shall not be used as lubricant. The
rubber gasket shall be inserted into the cleaned groove of the socket. It has to be
checked for correct positioning.
The two pipes shall be aligned properly in the trench and the spigot end shall be pushed
axially into the socket either manually or with a suitable tool specially designed for the
assembly of pipes and as recommended by the manufacturer. The spigot has to be
inserted up to the insertion mark on the pipe spigot. After insertion, the correct position of
the socket has to be tested with a feeler blade.
Deflection of the pipes if any shall be made only after they have fully been
assembled. The deflection shall not exceed 75% of the values indicated by the pipe
manufacturer.
Page 72
12.9
Dismantling Joints
Double-flanged Dismantling joints shall be fabricated from MS sheets in such a manner
that valves can be dismantled without stress to the joints. Dismantling joints shall be
suitable for installation with all valves of diameters of more than 250 mm. These shall be
for working pressures of 7 kg/cm2 to 25 kg/cm2 and shall be completely leak proof with
proper gasket arrangement. Flange dimensions shall conform to IS 1538 (part I to XXII).
Flanged specials shall be supplied with required nuts, bolts and rubber gaskets. The
nuts and bolts shall be of best quality carbon steel, machined on the shank and electrogalvanized. Rubber gasket shall be as per IS 5382. Dimensions and drilling of flat
gasket will be as per IS 1538, suitable for making flanged joint. The dismantling pieces
shall provide minimum clearance of + 25MM (total distance 50 mm). The dismantling
joint shall be internally and externally coated with hot applied (dip) bituminous paint.
13.
Field Hydraulic testing of the pipelines
13.1
Sectional tests
After laying and jointing the pipeline shall be tested for tightness of barrels and joints,
and stability of thrust blocks in sections approved by the Engineer-in-Charge in Charge.
The length of the sections depends on the topographical conditions. Preferably the
pipeline stretches to be tested shall be between two chambers (air valve, scour valve,
bifurcation, other chamber).At the beginning, the Contractor shall test stretches not
exceeding 1 km. After successful organization and execution of tests the length may be
extended to more than 1 km after approval of the Engineer-in-Charge in Charge. The
hydraulic testing shall have to be commenced immediately after laying and jointing of 1
km reach is completed.
The water required for testing shall be arranged by the contractor himself. The
Contractor shall fill the pipe and compensate the leakage during testing. The Contractor
shall provide and maintain all requisite facilities, instruments, etc. for the field testing of
the pipelines. The testing of the pipelines generally consists in three phases:
preparation, pre-test/saturation and test, immediately following the pre-test. Generally,
the following steps are required which shall be monitored and recorded in a test
protocol.
Complete setting of the thrust blocks.

partial backfilling and compaction to hold the pipes in position while leaving the
joints exposed for leakage control
opening of all intermediate valves (if any)
fixing the end pieces for tests and after temporarily anchoring them against the soil
(not against the preceding pipe stretch)
at the lower end with a precision pressure gauge and the connection to the
reciprocating pump for establishing the test pressure
at the higher end with a valve for air outlet
If the pressure gauge cannot be installed at the lowest point of the pipeline, an
allowance in the test pressure to be read at the position of the gauge has to be
made accordingly
Slowly filling the pipe from the lowest point(s).
the water for this purpose shall be reasonably clear and free of solids and
suspended matter
Complete removal of air through air valves along the line.
Closing all air valves and scour valves.
Slowly raising the pressure to the test pressure while inspecting the thrust blocks
Page 73
and the temporary anchoring.
Keeping the pipeline under pressure for the duration of the pre-test / saturation of
the lining by adding make-up water to maintain the pressure at the desired test
level. Make up water to be arranged by Contractor himself at his own cost.
Start the test by maintaining the test pressure at the desired level by adding more
make-up water; record the water added carefully and the pressure in intervals of
15 minutes at the beginning and 30 minutes at the end of the test period.
The pipeline stretch will pass the test if the water added during the test period is not
exceeding the admissible limits. No section of the pipe work shall be accepted by the
Engineer-in-Charge in Charge until all requirements of the test have been obtained.
13.1.1. Hydraulic test for MS pipes
13.1.1.1. Field test pressure
The sections of MS Raw Water Pumping main shall be tested for the pressures as
worked out in detailed designed.
13.1.1.2. Test requirement
The quantity of water added in order to re-establish the test pressure should not exceed
0.1 liter per mm of pipe diameter per km of pipeline per day for each 30 m head of
pressure applied.
All pressure testing at site should be carried out hydrostatically. The pipes shall be
accepted to have passed the pressure test satisfactorily, if the quantity of water required
to restore the test pressure does not exceed the amount calculated as above.
13.2.
Failure to pass the test

All pipes or joints which are proved to be in any way defective shall be replaced or
remade and re-tested as often as may be necessary until a satisfactory test shall have
been obtained. Any work which fails or is proved by test to be unsatisfactory in any way
shall be redone by the Contractor.
13.3.
Back filling
Water used for testing should not be carelessly disposed off on land which would
ultimately find its way to trenches
On completion of a satisfactory test any temporary anchor blocks shall be broken out
and stop ends removed. Backfilling of the pipeline shall be completed.
13.4.
Flushing and disinfecting of pipelines

After testing and commissioning the contractor shall flush the pipes with a velocity not
less than 1 m/s or as approved by the Engineer-in-Charge in Charge. Disinfection of
drinking water pipelines should be done by Contractor.
14.
15.
DELETED
DELETED
16A. Specification for other type of pipes or for those which do not have IS
standards shall be governed as provided under the Design Criteria under Volume-I .
Page 74
16.
PARTICULAR SPECIFICATION
1.0
SUPPLY OF MS PIPES AND DI PIPES, SPECIALS, VALVES, LAYING AND JOINTING

OF PIPELINES.
1.1
General
1.1.1
Standards
Except as otherwise specified elsewhere in this tender document, the Indian/International

Standards and Codes of Practice in their latest version shall be adhered to for the design
manufacturing, inspection, factory testing, packing, handling and transportation of product
wherever applicable. Should any product be offered conforming to other standards, the
equipment or products shall be equal to or superior to those specified and the documentary
confirmation shall be submitted for the prior approval of the Engineer.
This specification requires a reference to the following standard specifications:
IS: 8329
Centrifugally cast (spun) ductile iron pressure pipes for water, gas and sewage.
IS: 9523
Specification for DI fittings for pressure pipes for water, gas, and sewage
IS: 12288
Code of Practice for use and laying of ductile iron pipes
IS: 12820
Dimensional requirements for rubber gaskets for mechanical joints and push on
joint for use with cast iron pies and fittings for carrying water, gas and sewage.
IS: 1387
General requirements for the supply of metallurgical material
IS: 210
Grey Iron casting
IS: 1363
Hexagon head bolts, screws and nuts of product grade A and B (Part 1-5)
IS: 14846
Sluice valve for water works purposes
IS: 318
Leaded tin bronze ingots and casting
IS: 7181
Horizontally cast iron double-flanged pipes for water, gas and sewage
IS: 5382
Rubber sealing rings for gas mains, water mains and sewers
IS: 3624
Pressure and vacuum gauges
IS: 341
Black Japan, types A, B, and C
IS: 9862
ready mixed paint, brushing, bituminous, and black, lead free, acid, alkali, water
and chlorine resisting.
IS: 1239
Mild Steel tubes, tubular and other wrought steel fittings
IS: 554
Dimensions for pipe threads where pressure tight joints are required on the
threads
IS: 778
Specifications for copper alloy gate, globe and check valves for water works
purposes.
IS: 2062
IS: 808
Specification for steel for general structural purposes

Specification for dimensions for hot rolled steel beam, column, channel and
angle sections
IS: 814
Specification for covered Electrodes for manual metal arc welding of carbon
and carbon manganese steel.
Acceptance tests for wire flux combination for submerged arc welding.
IS: 3613
Page 75
IS: 7280
IS: 1367
IS: 2016
IS: 2074
IS: 102
IS: 1786
IS: 432
(Part-I)
IS: 432
(Part-II)
IS: 269
IS: 8041
IS: 383
IS: 12330
IS: 456
IS: 800
IS: 816
IS: 4353
IS: 817
IS: 1182
IS: 2595
IS: 3658
IS: 5334
IS: 3600
IS: 4853
IS: 3589
IS 5822
IS: 6631
IS: 7343
IS: 2598
IS: 5822
BS EN 499
AWS:A-5.1
AWS:A-5.17
Specification for bare wire electrodes for submerged arc welding of structural
steel
Technical supply conditions for threaded steel fasteners
Specification for plain washers.
Specification for ready mixed paint air drying, red oxide zinc chrome and
priming
Ready mixed paint, brushing, red lead, non-setting, Priming.
Specification for high strength deformed steel bars and wires for concrete
reinforcement.
Specification for mild steel & medium tensile steel bars and hard drawn steel
wire for concrete reinforcement: Mild steel and medium tensile steel bars
Specification for mild steel and medium tensile steel bars and hard drawn
steel wire for concrete reinforcement: Hard drawn steel wire
Specification for 33 grade ordinary Portland cement
Specification for rapid hardening Portland cement.
Specification for coarse and fine aggregates from natural sources for concrete
Specification for sulphate resisting Portland cement
Code of practice for plain and reinforced concrete
Code of practice for general construction in steel
Code of practice for use of metal arc welding for general construction in mild
steel
Recommendation for submerged arc welding of mild steel & low allow steels
Code of practice for training and testing of metal arc welders.
Recommended practice for radiographic examination of fusion- welded butt
joints in steel plates.
Code of practice for radiographic testing.
Code of practice for liquid penetrant flaw detection.
Code of practice for magnetic particle flaw detection of welds.
Code of procedure for testing of fusion welded joints and weld metal in steel
Recommended practice for radiographic examination of fusion welded
circumferential joints in steel pipes.
Specification for seamless or electrically welded steel pipes for water gas and
sewage (168.3 to 2032mm outside diameter).
Laying of electrically welded steel pipes for water supply.
Steel pipes for hydraulic purposes
Code of practice for ultrasonic testing of ferrous welded pipes and tubular
products.
Safety code for industrial radiographic practice
Code of practice for laying of welded steel pipes for water supply
Welding Consumables. Covered Electrodes for Manual Metal Arc Welding of
Non Allow and Fine Grain Steel Classification
Specification for Mild steel Covered Arc Welding Electrodes
Specification for Bare Mild Steel Electrodes and Fluxes for Submerged Arc
Welding
Guide for Radiographic Testing
Guide for Magnetic Particle Examination
Test Method for Liquid Penetrant Examination
Code for SW pipes
ASTM E 94
ASTM E 709
ASTM E 165
IS: 5504 &
IS: 3589
IS: 10748
Requirement for Weldable Hot Rolled Carbon Steel Strip in Coils
BS: 4772
Specification for DI fittings
CPHEEO
Manual on Water Supply and Treatment, II edition, Ministry of Urban
Development, New Delhi May 1999
Page 76
17. Deleted
18.
18.1
Supply, laying and jointing of High Density Polyethylene (HDPE) Pipes and
fittings.
Scope
This specification covers the requirements for successfully designing,
manufacturing, supplying, laying, jointing and testing at works and site of High
Density Polyethylene Pipes used for water supply. Use of HDPE Pipes shall be
Pressure class of minimum PN 6 or above.
18.2
Applicable Codes
The manufacturing, testing, supplying, laying, jointing and testing at work sites of
HDPE pipes shall comply with all currently applicable statutes, regulations,
standards and Codes. In particular, the following standards, unless otherwise
specified herein, shall be referred. In all cases the latest revision of the Codes
shall be referred to. If requirements of this Specification conflict with the
requirements of the standards / Codes, this Specification shall govern.
Others Codes not specifically mentioned here but pertaining to the use of HDPE
pipes form part of these Specifications.
IS 4984
High Density Polyethylene Pipes for Water Supply
IS 5382
IS 4905
IS 7328
IS 7634
IS 9845
Rubber sealing rings for gas mains, water mains and sewers.
Methods for random sampling
High density polyethylene materials for moulding and extrusion
Laying & Jointing of Polyethylene (PE) Pipes
Method of analysis for the determination of specific and/or overall
migration of constituents of plastics material and articles intended
to come into contact with foodstuffs
Positive list of constituents of polyethylene in contact with food
stuffs, pharmaceuticals and drinking water.
Polyethylene for its safe use in contact with foodstuff,
Pharmaceuticals and drinking water.
IS 10141
IS 10146
Page 77
Designation
18.3 Pipes shall be designated as per IS 4984, according to the grade of material,
followed by pressure rating and nominal diameter, for example, PE 100 PN 10
DN 200 indicates a pipe pertaining to material grade 100 having a pressure
rating 1.0 MPa and outside nominal diameter 200 mm.
All IS specifications shall apply to HDPE pipes and they shall be tested by
CIPET for the standards required for HDPE pipes
18.4
Colour
The color of the pipe shall be black.
18.5
Materials
The material used for the manufacturer of pipes should not constitute toxicity
hazard, should not support microbial growth, should not give rise to unpleasant
taste or odour, cloudiness or discoloration of water. Pipe manufacturers shall
obtain a certificate to this effect from the manufacturers of raw material by any
internationally reputed organization as per the satisfaction of the Engineer-inCharge in charge.
18.6
Raw Material
Raw material used to manufacture the HDPE pipes shall be 100% virgin PE 100,
compounded or Natural black PE resin confirming to IS: 4984, IS: 7328 and ISO:
4427. For this a certification has to be given by the resin manufacturer as per
clause 3.2.3 of IS: 4984. The resin proposed to be used for manufacturing of the
pipes should also comply with the following norms as per ISO 9080
(b) The resin should have been certified by an independent laboratory of
international repute for having passed 10,000 hour long term hydrostatic strength
(LTHS) test extrapolated to 50 years to show that the resin has a minimum MRS
of over 10MPa. Internal certificate of any resin manufacturer will not be
acceptable.
(c) Certificate from reputed organization OR Raw material supplier for having
passed the full scale rapid crack propagation test as per ISO 13478. High density
Polyethylene (HDPE) used for the manufacture of pipes shall conform to
designation PEEWA-50-T-003 of IS 7328. HDPE conforming to designation
PEEWA-50- T-003 of IS 7328 may also be used with the exception that melt flow
rate (MFR) shall not exceed 1.10 g/10 min. In addition the material shall also
conform to clause 5.6.2 of IS 7328.
(a)
(d) The specified base density shall be between 940 kg/ m and 958 kg/ m (both
inclusive) when determined at 27C according to procedure prescribed in IS 7328
The value of the density shall also not differ from the nominal value by more than
3 kg/ m as per 5.2.1.1 of IS 7328. The MFR of the material shall be between
0.20 and 1.10 (both inclusive) when tested at 190C with nominal load of 5 kgf as
determined by method prescribed in IS 2530. The MFR of the material shall also
be within 20 percent of the value declared by the manufacturer.
(e) The resin shall be compounded with carbon black. The carbon black content in
the material shall be within 2.5 0.5% and the dispersion of carbon black shall be
satisfactory when tested as per IS 2530.
Page 78
18.7
Anti-oxidant
The percentage of anti-oxidant used shall not be more than 0.3 percent by mass
of finished resin. The anti-oxidant used shall be physiologically harm less and
shall be selected from the list given in IS 10141
18.8
Reworked Material
No addition of Reworked/ Recycled Material from the manufacturers own rework
material resulting from the manufacture of pipes is permissible and the vendor is
required to use only 100% virgin resin compound.
18.9
Maximum Ovality of Pipe

The outside diameter of pipes, tolerance on the same and ovality of pipe shall be
as given in table 2 of IS 4984. Ovality shall be measured as the difference
between maximum outside diameter and minimum outside diameter measured at
the same cross section of the pipe, at 300 mm away from the cut end. For pipes
to be coiled the ovality shall be measured prior to coiling. For coiled pipes,
however, re-rounding of pipes shall be carried out prior to the measurement of
ovality.
18.10 Detectability
HDPE Pipes should be detectable when buried underground, by providing a
copper wire of 1.20mm +/- 0.2 mm , co-extruded along the entire length of pipe.
18.11 Length of Straight Pipe
The length of straight pipe used shall be more than 6 m or as agreed by
Engineer-in-Charge in charge. Short lengths of 3 meter (minimum) up to a
maximum of 10% of the total supply may be permitted.
18.12 Coiling
The pipes supplied in coils shall be coiled on drums of minimum diameter of 25
times the nominal diameter of the pipe ensuring that kinking of pipe is prevented.
Pipe beyond 110mm dia shall be supplied in straight length not less than 6m.
18.13 Workmanship / Appearance
Pipes shall be free from all defect including indentations, delaminating, bubbles,
pinholes, cracks, pits, blisters, foreign inclusions that due to their nature degree
or extent detrimentally affect the strength and serviceability of the pipe. The pipe
shall be as uniform as commercially practicable in colour opacity, density and
other physical properties as per relevant IS Code or equivalent International
Code. The inside surface of each pipe shall be free of scouring, cavities, bulges,
dents, ridges and other defects that result in a variation of inside diameter from
that obtained on adjacent unaffected portions of the surface. The pipe ends shall
be cut clearly and square to the axis of the pipe. IS 4984:1995 will be followed for
visual appearance.
Page 79
18.14 Handling, Transportation Storage and Lowering of pipes

During handling, transportation, storage and lowering, all sections shall be
handled by such means and in such a manner that no distortion or damage is
done to the section or to the pipes as a whole.
The following procedures should be followed so as to eliminate potential damage
to pipes and fittings and to maintain maximum safety during unloading, lifting and
lowering.
Pipes must not be stored or transported where they are exposed to heat
sources likely to exceed 60oC.
Pipes shall be stored such that they are not in contact with direct sunlight,
lubricating or hydraulic oils, petrol, solvents and other aggressive materials.
Scores or scratches to a depth of greater than 10% or more of wall thickness
are not permissible; any pipes having such defects should be strictly rejected.
PE pipes should not be subjected to rough handling during loading and
unloading operations. Rollers shall be used to move, drag the pipes across any
surface.
Only polyester webbing slings should be used to lift heavy PE (>315mm) pipes
by crane. Under no circumstances, chains, wire ropes and hooks are used on
PE pipes.
Pipes shall not be dropped to avoid impact or bump. If any time during handling
or during installation, any damage, such as gouge, crack or fracture occurs, the
pipe shall be repaired if so permitted by the competent authority before
installation.
During coiling care should be taken to maintain the coil diameter at or above the
specified minimum to prevent kinks. Coiling shall be done when the pipe attains
the ambient temperature from the extruder. In uncoiling or recoiling care should
be taken that sharp objects do not scour the pipe.
When releasing coils, it must be remembered that the coil is under tension and
must be released in a controlled manner. The end of the coil should be retained
at all times, then the straps released steadily, one at a time. If the coil has bands
at different layers of the coil, then they should be released sequentially starting
from the outer layers. The amount of the energy locked up in the coil will depend
on the size of the pipe, the SDR of the pipe, and the size of the coil.
Straight lengths should be stored on horizontal racks giving continuous support
to prevent the pipe taking on a permanent set
Bare coils shall be wrapped with hessian cloth for long distance (> 300Kms)
transportation. The truck used for transportation of the PE pipes shall be
exclusively used of PE pipes only with no other material loaded especially no
metallic, glass and wooden items. The truck shall not have sharp edges that can
damage the Pipe.
Pipes manufactured at factory are to be carried to the site of work directly or
stacked suitably and neatly along the alignment/road side/elsewhere near by the
work site or as directed by the Engineer-in-Charge.
Damages during transit, handling, storage will be to the Contractors account
and replacement for such pipes has to be made by the Contractor without any
extra cost as directed by the Engineer-in-Charge.
Page 80
18.15 Lowering, Laying of Pipes

Each pipe shall be thoroughly checked for any damages before laying and only
the pipes which are approved by the Engineer-in-Charge shall be laid.
While installing the pipes in trenches, the bed of the trench should be level and
free from sharp edged stones. In most cases, the bedding is not required, as
long as the sharp and protruding stones are removed, by sieving the dug earth,
before using the same a backfill material. While laying in rocky areas suitable
bed of sand or gravel should be provided. The fill to about 10 to 15 cm above
the pipe should be fine sand or screened excavated material. Where hard rock
is met with, bed concrete M15, 15 cm or 20cm thick sand bed as approved by
the Engineer-in-Charge may be provided
As PE pipes are flexible, long lengths of fusion-jointed pipes having joints made
above ground can be rolled or snaked into narrow trenches. Such trenches can
be excavated by narrow buckets.
During the pipe laying of continuous fusion jointed systems, due care and
allowance should be made for the movements likely to occur due to the thermal
expansion/contraction of the material. This effect is most pronounced at end
connections to fixed positions (such as valves etc) and at branch connections.
Care should be taken in fixing by finishing the connections at a time the length
of the pipe is minimal (lower temperature times of the day.)
For summer time installations with two fixed connection points, a slightly longer
length of PE pipe may be required to compensate for contraction of the pipe in
the cooler trench bottom.
The final tie-in connections should be deferred until the thermal stability of the
pipeline is achieved.
The flexibility of polyethylene pipes allows the pipe to be cold bend. The fusion
jointed PE pipe is also flexible as the plain Pipe. Thus the total system enables
directional changes within the trench without recourse to the provision of special
bends or anchor blocks. However, the pipe should not be cold bend to a radius
less than 25 times the OD of the pipe.
The Installation of flanged fittings such as connections to sluice/air/gate valves

and hydrant tees etc., requires the use of stub ends (collars/flange adaptors
complete with backing rings and gaskets. Care should be taken when tightening
these flanges to provide even and balance torque.
Provision should be made at all heavy fittings installation points for supports
(such as anchoring of the flange in the soil) for the flange joint to avoid the
transfer of valve wheel turning torque on to the PE flange joint.
PE pipe is lighter than water. Hence care should be taken for normal
installations where there could be a possibility of flooding of the trench thus the
trench shall be kept free of water till the jointing has been properly done
Page 81
When flooded, some soils may lose cohesiveness, which may allow the PE pipe
to float out of the ground. Several design checks are necessary to see if
groundwater flotation may be a concern. Obviously, if the pipeline typically runs
full or nearly full of liquid, or if groundwater is always below the pipe, flotation
may not be a significant concern.
However, weights by way of concrete blocks (anchors) are to be provided so

that the PE pipe does not float when suddenly the trench is flooded and the soil
surrounding the pipe is washed away. Thus site conditions study is necessary to
ensure the avoidance of flotation.
Pipe embedment backfill shall be stone-free excavated material placed and

compacted to the 95% maximum dry density.
18.16 Jointing of Pipes

The pipe shall have Electro-fusion jointing system that shall provide for fluid
tightness for the intended service conditions.
18.17 Bedding, Backfilling and Compaction
18.17.1 Bedding
In case of sandy strata no separate bedding is required. However the bottom
face / trench bed where pipe shall be placed shall be compacted to provide a
minimum compaction corresponding to 95% of maximum dry density. The pipe
bedding should be placed so as to give complete contact between the bottom of
the trench and the pipe. The minimum cover over buried pipe should be 1 m.
18.17.2 Back Filling
Backfilling should be placed in layers not exceeding 15cm thickness per layer,
and should be compacted to a minimum of 95% maximum dry density. The
refilling should be done on both sides of pipe together & height difference in
earth fill on each side should not be more to cause lateral movement of pipe.
Most coarse grained soil is acceptable. This may comprise of gravel or sand.
However silty sand, clayey sand, silty and clayey gravel shall not be used unless
proposed to be used in conjunction with gravel or clean sand.
It is very important that the pipe zone backfill material does not wash away or
migrate in to the native soil. Likewise, potential migration of the native soil in to
the pipe zone backfill must also be prevented.
Heavy earth moving equipment used for backfilling should not be brought until
the minimum cover over the pipe is 90 cm in the case of wide tracked bulldozers
or 120 cm in the case of wheeled roaders or roller compactors.
18.17.3 Compaction
Vibratory methods should be used for compaction. Compaction within distances
of 15 cm to 45 cm from the pipe should be usually done with hand tempers. The
backfill material should be compacted not less than 95% of maximum dry
density.
18.18 Thrust Block
RCC thrust block should be suitably designed & provided at bends and at places
of reduction in cross section to take care of trust
Page 82
18.19 Fittings & Specials

All HDPE fittings/ specials shall be of minimum PN 6 or above Pressure class,
fabricated in accordance with IS: 8360 (Part I & III). PE Injection moulded fittings
shall be as per IS: 8008 (Part I to IX). All fittings/specials shall be fabricated or
moulded at factory only. No fabrication or moulding will be allowed at site, unless
specifically permitted by the Engineer-in-Charge. Fittings will be welded on to the
pipes or other fittings by use of Electro- fusion process. Recommended makes
for PE / PP fittings / specials are Georg-Fischer, Glynwed, Astore, Magnum and
GPS.
18.20 Bends
HDPE bends shall be plain square ended conforming to IS: 8360 Part I & III
Specifications. Bends shall be moulded.
18.21 Tees
HDPE Tees shall be plain square ended conforming to IS: 8360 Part I & II
Specifications. Tees may be equal tees or reduced take off tees. Tees shall be
moulded.
18.22 Reducers
HDPE Reducers shall be plain square ended conforming to IS: 8008 Part I & VII
Specifications. Reducer must be moulded.
18.23 Flanged HDPE Pipe Ends
HDPE Stub ends shall be square ended conforming to IS: 8008 Part I & VI
Specifications. Stub ends will be welded on the pipe. Flange will be of slip on
flange type as described below.
18.24 Slip-On Flanges
Slip-on flanges shall be metallic flanges covered by epoxy coating or plastic
powder coating. Slip-on-flanges shall be conforming to standard mating relevant
flange of valves, pipes etc. Nominal pressure rating of flanges will be PN10.
18.25 Welding Procedure (not applicable up to 4.35)
Jointing between HDPE pipes and specials shall be done as per the latest IS:
7634 part II. Method of jointing between the pipes to pipes and pipes to specials
shall be with Electro-fusion welding using automatic or semi automatic,
hydraulically operated, superior quality Electro-fusion machines which will ensure
good quality fusion welding of HDPE pipes.
18.26 Hhydraulic Testing
Pipes shall be given different hydraulic tests for ensuring quality of manufacture
as per clause 16.9.5.6.2 of Standard Specification.
18.27 Site Fabrication of PE Fittings
Two or more PE specials coming at one place (like PE Tee, Reducer, Flanged
end etc.,) shall be jointed at contractors workshop and transported to the site of
works for final installation with proposed PE pipelines. In no case, jointing of
three or more welds in one place, at site will be allowed.
18.28 Raining
The Contractor shall provide on-site training on PE pipe laying, jointing, testing
and maintenance etc., to the personnel authorized by EMPLOYER.
18.29 Manuals
Technical Manual on PE pipes including precautions to be taken during operation
Page 83
of the pipeline.
18.30 Flanges
All flanges employed in the project must be compatible whatever material used.
18.31 Marking
All pipes shall be marked at maximum interval of 1 m.
The marking shall indicate at least the following information.
Manufacturers name & / or trade mark.
The dimensions (nominal outside diameter X nominal wall thickness)
The outside diameter tolerance (A or B)
The designation of pipes material (PE 100, PE 80 etc)
The nominal pressure (PN)
The production period (date or code)
The number of the International standard.
The word Water shall also be included.
18.32 Packing & Transport
The pipes should be preferably transported by road from the factory and stored
as per the manufacturer specifications to protect damage.
1)
2)
3)
4)
5)
6)
7)
18.33 Summary of quality Tests :

1.
2.
3.
4.
5.
6.
7.
8.
9.
Quality Mark
Material
: Pipe: IS 4984
: As per IS 4984. However only virgin resin is allowed,
Reworked material is not allowed.
Grade of Material
: PE 100 as per IS 4984 (Certificate from raw material
Manufacturer is required).
Pressure Rating : Minimum PN 4 or above as per requirement.
Colour
: as per IS 4984
Dimensions of Pipe :
Diameter
: The nominal diameter (outside)
Wall thickness : As per IS 4984.
Length
:
i. For diameter 90 mm and 110 mm
: 100 meter
ii. For diameter more than 110 mm : minimum 6 meter.
(Tolerance as per IS 4984)
Visual Appearance : as per IS 4984.
Test and sampling : as per IS 4984.
Special Test
: Notch hydraulic Test for the HDPE pipe made from PE-100
grade raw material as per ASTM 1474 OR ISO 13479 at manufacturers
laboratory or independent laboratory and should pass the Hydraulic test as per
IS:4984:1995 for a minimum 165 Hours. The test reports shall not be more than
three months old.
Pipe shall convey water under variable temperature conditions ranging from 4
degree centigrade to 45 degree centigrade.
10. Jointing of pipes (pipe end):

More than 110 mm diameter: Electro-fusion (Heat Fusion Process)
11. Quality Assurance :
Quality Assurance Plan shall be got approved from the employer before
production start.
Page 84
Note: All remaining parameters / specifications are as per respective IS.
VOLUME- III
Section-VII B
PART-B
APPURTENANCES
AND
MISCELLANEOUS ITEMS
Page 85
VOLUME- III
Section-VII - B
PART-B APPURTENANCES AND MISCELLANEOUS ITEMS
1. Double Flanged Valves
1.1.
1.1.1
Sluice Valves
General
The sluice valves shall confirm to IS: 14846. Double flanged short body, Gland less
(stem sealing rings) type Sluice valves with appropriate pressure rating.
The material to be supplied under this sub-section shall include, but not be limited to,
the following: All necessary fittings including bolts, nuts, gaskets, backing rings, counter
flanges, jointing material, strainers etc. shall be supplied as required. The entire Gland
less (stem sealing rings) sluice valve shall be provided with ball thrust bearing and spur
gear arrangement.
1.1.2
Scope
The Gland less (stem sealing rings) sluice valves shall be with non rising stem type. The
valves will be used for water supply on line installations in upright positions, with double
flange, and cap or hand wheel for manual operation. The valves shall be suitable for
continuous use at their PN rating within the temperature range of -100 C to 650 C.
1.1.3
Nominal pressure and dimensions

The working pressure on the valves shall be appropriate to the working conditions and
approved by the Employer. The flanges and their dimensions of drilling shall be in
accordance with IS: 1538 (part-I to XXII).
1.1.4
Material
The makes given are acceptable makes however the material for different component
parts of sluice valve shall conform to the requirements given below:
No.
Component
Material
Ref. to IS
Grade / Designation
Body, bonnet, dome, stool

cover, wedge, stuffing box,
gland, thrust plate, hand
wheel and cap.
S. G. iron
1865
Gr.400/ 12
Stem
Stainless steel
6603
12Cr 13 04Cr 18Ni 10 04Cr

17Ni 12 MO 2
3.
Wedge, nut, shoe
Leaded tin
bronze
318
LTB-2
Body seat ring, wedge

facing ring and bushes
Leaded tin
bronze
318
LTB 2
Bolt
Carbon steel
1363 (Part 1)
Class 4.6
Nut
Carbon steel
1363 (Part 3)
Class 4
Gasket
EPDM Rubber
11855
Gland packing
Stem Sealing
Ring
5414
Nil
Page 86
Gear
Spheroidal
graphite iron
1865
10
Gear housing
S.G. iron
1865
11
Pinion
Wrought carbon
steel
1570 (Part 3)
and
pinion shaft
Gr 500 / 7
Gr.400/12
C55Mn75
1.1.5. Marking, testing and inspection

The standard marking and packing of the valves shall be done as per Clause 11 and 13of
IS: 14846. The direction of rotation for OPEN, CLOSE position shall be marked on the
hand wheel and on the bonnet of the valve.
Hydraulic testing of each sluice valve shall be done for close end test in accordance with
IS: 14846 Annex B, to the test pressure and test duration as specified in table 5 and 6 of
the IS.
All the valves shall be inspected for flaw detection test in accordance with IS: 14846,
clause 10.2.The design, construction material, manufacture, inspection, performance and
testing shall comply with all applicable Indian Standards and Codes. Nothing in the
specification will be construed to relieve the supplier of this responsibility.
1.1.6
Manufacturers Test certificate

The manufacturer shall provide a test certificate confirming that all the valves have been
tested in accordance with IS: 14846 and stating the pressures and medium used in the
test.
1.1.7. Inspection
The inspection and testing of the sample valves from a lot will be carried out by the
employer and or inspecting agency appointed by the employer, in the manufactures
workshop, before application of any paint. All the tests as required as per the IS: 14846
shall be carried out on samples from each lot (Number of samples from a lot shall be as
per the relevant IS for sampling and testing), in presence of the inspecting agency. The
valves shall be dispatched only after issue of the test certificate by the inspecting
agency for satisfactory performance of the tested valves. The inspection charges for
such tests shall be paid by the contractor to the inspecting agency.
1.1.8. Acceptable makes for the valves
Acceptable makes for the sluice valves shall be either, VAG, IVC or Kirloskar or other
reputed make as may be approved by Chief engineer.
1.1.9. Installation
The installation of the sluice valves shall be done at the locations shown on L-sections
of the pumping main as washout valves and isolating valves for air valves. The job
covers supply of the valves at work site with cost of all the required material and all
types of taxes and duties, cost of packing, loading, transportation, unloading, stacking
and installation at the specified location with cost of all jointing materials such as
nuts and bolts, EPDM rubber gaskets etc. The job also covers field hydraulic testing of
the valves after installation for the specified test pressure for the respective pipeline
section
1.2.
Butterfly valves
1.2.1. General
The Butterfly valves shall confirm to IS: 13095. Double flanged short body butterfly
valves of required nominal diameter and pressure rating shall be supplied. The material
to be supplied shall include, but not be limited to, that as shown in the table given below.
Page 87
All necessary fittings including bolts, nuts, gaskets, jointing material etc. shall be
supplied as required.
1.2.2. Scope
The butterfly valves shall be with disc and shaft and shall be designed to withstand the
maximum pressure differential across the valve in either direction of flow. The valves
shall have no visible leakage past the disc in closed position under test conditions. The
shaft may be of one piece design or in two pieces separately attached to the disc. The
valves will be used for water supply on line installations in upright positions with manual
operation. The valves shall be suitable for continuous use at their pressure rating within
the temperature range of -100C to 650C.
1.2.3. Nominal pressure and dimensions
approved by the Employer. The flanges and their dimensions of drilling shall be in
accordance with IS: 1538 (part-I to XXII).
1.2.4. Material
The makes given are acceptable makes however the material for different component
parts of butterfly valves shall conform to the requirements given below:
S.
No.
Component
Body
Disc
Shaft
Material
Grade
1865
Gr. 400/12
1865
Gr. 400/12
6603
Seating ring / Integral Nicol

Seal retaining Crominium
ring
Welding
Seat
EPDM Rubber
Shaft
seals
bearing Bronze
/
brass bearing with O rings
Internal
fastners
Stainless steel
External
bolting
Carbon
steel; tensile strength 390
Mpa
Sphrodal graphite
Iron. / Ductile Iron.
Sphrodal graphite
Iron. / Ductile Iron.
Stainless steel
Ref. to IS
Manufacturers
standard
Suitable for duty

-
Page 88
1.2.5
Operation
All valves shall be capable of being operated at a differential pressure across the disc
as marked on the valves. Leaver, worm gear / traveling nut type or any other suitable
type of operator can be used.
Manually operated valves shall be closed by turning hand wheel or leaver in a clockwise
direction when facing the hand wheel or leaver. The design of leaver when fitted shall
be such that the leaver may only be assembled to the valve so that it is parallel to the
direction of flow when the valve is open.
All traveling nut operators shall be provided with suitable stops to prevent movement of
the shaft beyond the limit corresponding to the fully closed position of the disc.
All gear / traveling nut operators shall be self locking type. All leaver operated valves
shall be capable of being locked at at-least three intermediate positions. The operating
hand wheels shall be marked CLOSE or SHUT to indicate the direction of closure.
The operator shall be provided with arrangement to indicate disc position.
1.2.6. Testing
All valves shall be hydraulically tested by the manufacturer before dispatch. The
pressure shall be applied without any significant hydraulic shock. Testing shall be
carried out before application of paint or other similar treatment.
1.2.6.1. Body test
The body ends shall be blanked. The valve disc shall be in slightly open position and the
pressure equivalent to 1.5 times the maximum permissible working pressure shall be
applied with water. The duration of test shall be 5 minutes for 1600 mm diameter valve.
1.2.6.2. Seat test
Seat test shall be carried in accordance with clause 17.3 of IS: 13095 for 3 minute
duration.
1.2.6.3. Disc strength test
The test shall be conducted with the body flanges in horizontal position. The test
pressure shall be 1.5 times the maximum permissible pressure. With disc in closed
position, hydro test pressure shall be applied to the lower face of the disc for duration as
per table 3 of the IS: 13095. There shall be no damage to the valve disc or any part of
the valve, or disc shall not be permanently deformed.
1.2.7. Manufacturers certificate
The manufacture shall provide a test certificate confirming that all the valves have been
tested in accordance with IS: 13095. The manufacturer shall also provide documentary
evidence of having manufactured and supplied BFV of similar design and specifications,
working satisfactorily for minimum 10 years in India, through Performance Certificate.
1.2.8. Inspection
The inspection and testing of the sample butterfly valves shall be carried out by the
workshop before application of any paint. All the tests as required as per the IS: 13095
shall be conducted in presence of the inspecting agency on the sample valves from the
lot (Number of valves to be tested from a lot shall be as per the relevant IS for sampling
and testing). The valves shall be dispatched only after issue of the test certificate by the
Page 89
inspecting agency for satisfactory performance of the tested valves. The inspection
charges for such tests shall be paid by the contractor to the inspecting agency.
1.2.9. Marking
Marking shall be cast integral on the body or on a plate securely attached to the body.
Marking shall be as specified under clause 21 of IS: 13095.
The design, construction material, manufacture, inspection, performance and testing
shall comply with all applicable Indian Standards and Codes. Nothing in the
1.2.10.
Acceptable makes for the valves

Acceptable makes for the double flanged butterfly valves shall be either, Fouress,
VAG or IVC or other reputed make as may be approved by the Chief Engineer.
1.2.11. Installation
The installation of the butterfly valves shall be done at the locations shown on Lsections of the pumping main as online valves. The job covers supply of the valves at
work site including all type of taxes and duties, cost of packing, loading, transportation,
unloading, stacking and installation at the specified location with cost of all jointing
materials such as nuts and bolts, EPDM rubber gaskets etc. The job covers field
hydraulic testing of the valve after installation for the specified test pressure for the
respective pipeline section.
1.3. Kinetic Air valves
1.3.1. General
Kinetic air valves are required with pressure rating appropriate for the working
conditions and approved by the Employer, confirming to IS: 14845.
1.3.2. Scope and general design features
The air valves shall be capable of exhausting air from pipeline automatically when being
filled. Air shall be released at sufficiently higher rate so that there shall be no restriction
for the inflow rate. Similarly, the valves shall be capable of ventilating pipeline
automatically when being emptied. The air inflow rate should be sufficiently high to
avoid development of vacuum in the pipeline.
The design shall be such that, higher the rate of flow the greater the resultant down
thrust, keeping the ball 'glued' to its seat until the last drop of air is expelled from the
pipe system.
Each air valve shall be provided with an isolating sluice valve with flanged end
connection. The possible air velocity (inflow and outflow) must be at least 10 m/s.
1.3.3. Construction features
The flow of air should be as unobstructed as possible. The low pressure orifice shall be
in the same axis as the main discharge / incoming air flow and must have a diameter
sufficiently large. The valve body shall be designed in such a way that the turbulent air
at the time of filling of pipeline shall not circulate and cause the ball to be caught in the
discharging air stream and blowing the valve shut permanently. The cone angle of the
low pressure (large orifice) chamber shall be such that even at a critical velocity of air
escaping at 344 m / sec the total impact force on the vulcanite covered ball is less than
the suction force on the annular area between the ball and cone. The annulus around
the low pressure vulcanite covered ball is to be generously proportioned for discharge of
air under various differential pressures. Normal range of cone angle is 450 to 600.
The orifice shall be carefully profiled to allow the requisite flow of air under varying
differential pressures. It shall be in molded synthetic rubber such that even after
extended contact the, vulcanite covered ball does not stick to it, when the line pressure
becomes zero.
Page 90
The high pressure chamber having small orifice shall be so designed that the orifice is
effectively sealed in working condition. The orifice shall be profiled in such a manner
that the rubber covered ball is not damaged even after extended contact. There should
be machined guide in the chamber which ensures that the ball travels vertically and
makes contact with the nipple and seals off the orifice without fail. The orifice size shall
Not be less than 2.5 mm and tapering to 10 mm suitable to release accumulated air
within the pipeline. High pressure orifice may be fitted from bottom side of the cover.
1.3.4. Material
The makes given are acceptable makes however the material for different components
parts of the air valve shall conform to the requirements given below:
No.
Component
Material
Reference
No.
to IS Grade
designation
Body, cover, valve disc, S. G. iron / Ductile 1865

stuffing
box, valve iron
guide,
cowl, gland,
Low Pressure seat ring and Natural rubber

face ring
High pressure orifice
Leaded
bronze
Bolts
Carbon steel
1363
Class 4, 6
Nuts
Carbon steel
1363
Class 4
Gasket
Rubber
638
Type B
Float
Stainless steel
Float guide
Leaded
bronze
of
Gr.400/ 12
11855
tin 318
tin 318
LTB-2
LTB-2
1.3.5. Floats
Minimum float diameters for kinetic air valves shall be as indicated in table 3 of IS
14845. The inner core of the floats shall be made from stainless steel having sufficient
bearing strength and equivalent specific gravity.
1.3.6. Testing
Testing of all the air valves shall be carried out in the suppliers work shop as per
IS:14845.
Following tests shall be carried for each valve.
Function and performance test as per clause 12.4.1
Page 91
High pressure orifice test as per clause 12.4.2
Low pressure orifice test as per clause 12.4.3
Body test as per clause 12.4.4
The performance of the valve for the above mentioned tests shall be as specified under
clause 12.1, 12.2 and 12.3 of IS 14845.
1.3.7. Manufacturers Test certificate
The manufacturer shall provide a test certificate confirming that all the air valves have
been tested in accordance with the relevant standards and performance of the test
results observed.
1.3.8. Inspection
The inspection and testing of the sample air valves shall be carried out by the employer
and or inspecting agency appointed by the employer, in the manufactures workshop
before application of any paint. All the tests as required as per IS 14845 shall be
conducted in presence of the inspecting agency on the sample valves from the lot
(Number of valves to be tested from a lot shall be as per the relevant IS for sampling
and testing). The valves shall be dispatched only after issue of the test certificate by the
inspecting agency for satisfactory performance of the tested valves. The inspection
charges for such tests shall be paid by the contractor to the inspecting agency.
1.3.9. Marking
Each valve shall be permanently marked with a plate securely fixed to the body with the
information as specified under clause 15.1 of IS 14845.
1.3.10. Acceptable makes for the valves
Acceptable makes for the kinetic double orifice air valves shall be either, VAG, IVC or
Kirloskar or other reputed make as may be approved by the chief engineer.
1.3.11. Installation
The installation of the air valves shall be done with isolating sluice valve. The job covers
supply of the valves at the work site including all taxes and duties, cost of packing,
loading, transportation, unloading, stacking and installation at the specified location with
cost of all jointing materials such as nuts and bolts, EPDM rubber gaskets etc. The job
covers field hydraulic testing of the valves after installation for the specified test
pressure for the respective pipeline section
1.4
NON RETURN VALVES
1.4.1
General
Non-return valves generally conforming to IS 5312 Part I & II (Single or Multi Door Type)
shall be provided on delivery side of a l l pumps. The valves shall be suitable for
continuous use at their pressure rating within the temperature up to 60 0C and shall be
conforming to following specifications and requirements.
Page 92
1.4.2
1.4.3
Design
The non-return valve shall be swing check reflux valve type with S in gl e or
multiple doors.
The valve shall be suitable for mounting on a horizontal pipeline and flow direction
shall be clearly embossed on the valve body.
Valves shall possess inbuilt high speed closing and non-slam characteristics
achieved by suitable disposition of weight on door and the hydraulic passage.
Valves of multi-door type shall be additionally provided with a supporting foot.
All faces and seat rings shall be riveted to the machined surface in the Casting. The
door shall be integral with the hinge and shall have a flat seating face. Minimum two
(2) nos. suspension lugs shall be cast integrally on the diaphragm plate and shall be
of adequate strength.
Bypass of appropriate diameter with sluice valve of appropriate size and pressure
class as per relevant applicable code shall be provided.
No spring loaded/ spring return action or external dampening arrangement will be

acceptable. All the Non-return valves shall be from the same manufacturer.
Material
The material for different component parts of Multi-door Non return valves shall conform
to the requirements given below:
Component
Body / Door
Material of construction
Ductile Iron GGG 40 / IS 1865 Gr. 500/7 to IS 1865 OR
(& Diaphragm)
Stub pin
Seat & Face rings
Cast steel grade B conforming to IS 1030

SS AISI 410
Soft seated up to 300 mm.
Rivets
Fasteners
Painting
350 mm and above: Gun metal : IS 318 Gr. LTB 2

Soft annealed brass
Carbon steel
Liquid epoxy coating of DFT 300 microns with proper
Blast cleaning to near white - SA 2 Grade and 2 coats
Flange Drilling
1.4.4
of epoxy based primer coating, prior to final coating.

IS 1538 Table 4 & 6/ BS En 1092 2
Nominal pressure
approved by the Employer.
1.4.5
Marking
All valves shall be marked to show the following information permanently.
Manufacturers name or trade mark.
PN rating
Valve size
Direction of flow
Page 93
1.4.6
Factory Tests
The following tests shall be conducted on the valves at manufactures works before
painting. The tests shall be generally as per IS 5312 Part 2.
Body Test
Body of each valve shall be hydrostatically pressure tested at 1.5 times its rated
working pressure. The test fluid shall be water. Duration of test shall be 2 minutes.
There shall be no leakage or permanent distortion of any component under the test.
Seat Test
Each valve shall be tested for seat test by applying hydrostatic test pressure equal to
its rated working pressure, on outlet side. Duration of test shall be 2 minutes. During
the test, there shall be no leakage of water through the seats.
1.4.7
Manufacturers certificate
The manufacture shall provide a test certificate confirming that all the valves have been
tested in accordance with above specifications and relevant IS 5312 Part II. The
manufacturer shall also provide documentary evidence of having manufactured and
supplied Non-return Valve of similar size and design, working satisfactorily for minimum 5
years in India, through Performance Certificate.
1.4.8

Acceptable makes for the double flanged butterfly valves shall be either, Kirloskar, VAG
or IVC or other reputed make as may be approved by the chief engineer.
1.4.9
Installation
The job covers supply of the Non-return valves at the work site including all taxes and
duties, cost of packing, loading, transportation, unloading, stacking and installation at the
specified location with cost of all jointing materials such as nuts and bolts, EPDM rubber
gaskets etc. The job covers field hydraulic testing of the valves after installation for the
specified test pressure for the respective pipeline section.
1.5
Anti Vacuum Valve:
1.5.1 Scope:
The Anti vacuum valve will be installed to prevent the formation of vacuum in large
diameter (having of 1000 mm. and above) water mains to prevent line collapse under
such conditions of flow as may result, for example, from too rapid a closure of an
upstream head gate or shut down valve, a down stream burst or ordinary emptying or
recharging of a pipeline.
1.5.2 Design features:
Design of the anti vacuum valve shall automatically allow induction of large volumes of
air to prevent vacuum formation; and also provide an automatic means of ventilating a
line when it is being emptied of water, and of exhausting air when it is being recharged.
It should be suitable to react automatically, sensitively, and positively even after long
periods of inactivity, to changes of pressure within a pipe, and whenever necessary,
permit air to flow in at a sufficiently high velocity, and at low enough induction pressure, to
safeguard the line against collapse.
Cowled Inlet Type of the anti - vacuum valve should have an annular cowl shrouding the
orifice, providing protection to the orifice and the seating. It should be suitable for air to
flow through the ports provided around the periphery of the body assembly. Such
Page 94
application is confined to situations where no damage is likely to occur surrounding

structures from sudden intakes of air.
1.5.3
Operation :
About Operation, the valve element should be in the form of the disk which is sensitively
balanced by a counterpoising mechanism. The disk guide pin should be attached to a
crosshead, to which is fitted at either end a cranked lever that should rock about an
intermediate pivot pin and should be applicable to carry an adjustable counterweight on
its outer arm. The parts should so arranged that by adjusting the position of the
counterweights, the valve must be balanced at any desired points on its working travel.
Thus, when swinging freely the valve may be balanced at a partially opened position in
which case, if it is closed by hand, it self-opens to the pre determined point of equilibrium,
and vice- versa. Also attached to the crosshead should be an oil dashpot which should
give free opening, in a downward direction, but offer resistance to closing, in an upward
direction, and avoid all possibility of oscillation of the suspended.
In action, therefore, the valve should not remain at either extremity of its travel unless it is
acted upon by some external force. During normal operation, the disk should be held
shut by the water pressure in the pipe. If the pressure on the underside of the disk falls
below that of the atmosphere, the valve should immediately open to admit air and break
vacuum. With very small vacuum, say 1 inch of mercury or about psi below
atmosphere, should open fully and offer a wide passage for free flow of air. On the
cessation of air inflow, the valve must return to a position of slightly open, which is
sufficient for the escape of air during refilling of the line. When the rising water makes
contact with the underside of the disk, closure is completed: only a very small water
pressure should be required to close the valve, consequently, the quantity of water overflowing through the orifice during final closure will be negligible.
1.5.4 Manufacturers Test certificate

The manufacturer shall provide a test certificate confirming that all the Anti vacuum
valves have been tested in accordance with the relevant standards and performance of
the test results observed.
1.5.5
Inspection
The inspection and testing of the sample Anti vacuum valves shall be carried out by the
workshop before application of any paint. The valves shall be dispatched only after
issue of the test certificate by the inspecting agency for satisfactory performance of the
tested valves. The inspection charges for such tests shall be paid by the contractor to
the inspecting agency.
1.5.6
Marking
Each valve shall be permanently marked with a plate securely fixed to the body with the
information as specified under relevant standards.
1.5.7
Page 95
Acceptable makes for the Anti vacuum valves shall be either, Fouress, VAG or IVC or
other reputed make as may be approved by the chief engineer.
1.5.8
Installation
The job covers supply of the Anti vacuum valves at the work site including all taxes and
duties, cost of packing, loading, transportation, unloading, stacking and installation at
the specified location with cost of all jointing materials such as nuts and bolts, EPDM
rubber gaskets etc. The job covers field hydraulic testing of the valves after installation
for the specified test pressure for the respective pipeline section.
1.6
PAINTING SPECIFICATION FOR VALVES :

Final coating on internal and external surface of the Valve shall be carried out after
satisfactory testing, prior to dispatch.
Before inspection : Each valve shall be cleaned and surface shall be prepared by Sand
blasting to SA 2 Grade Near white blast cleaning, and suitably protected by applying
one coat of two component high build polyamide cured re-coatable zinc phosphate epoxy
primer.
After inspection : One coat of two component high build polyamide crude re-coatable
epoxy coating shall be applied to achieve DFT 150 micron, followed by one coat of two
component aliphatic polyurethane finish to achieve DFT 80 micron.
2.
Manufacture, supply and installation of MS Expansion joints and Cover box
2.1.
Expansion joints
2.1.1. Requirement
Expansion joints are necessary on the MS pipeline laid above ground to accommodate
expansion and contraction of the MS line due to temperature variations, so that the
expansion or contraction is not cumulative over several lengths. These joints permit
linear movement of the pipe relative to the packing provided in the joint. Fabricated steel
Bellow-type expansion joints, as per the EJMA standards, shall be provided and
installed at the locations shown on longitudinal section of the pipeline.
Normally, on plain ground, the centre to centre distance of the expansion joints shall not
be more than 300m. When the length of above ground pipeline is less than 300 m but
more than 100 m, one expansion joint at the centre shall be provided. The pipe line shall
be anchored firmly with concrete anchor blocks between two expansion joints, so that
the expansion or contraction between two anchor blocks is accommodated by the
expansion joint provided between the blocks. Supports / saddles shall be placed on
each side of the expansion joint at about one meter distance from the centre of the joint
to avoid unequal deflection of the pipe on either side of the joint.
The item covers providing and packing, transportation to work site and fixing wherever
required on the pipeline with hydraulic testing along with the pipeline section.
2.1.2
Acceptable makes
Page 96
Acceptable makes for the Bellow-type expansion joints shall be either, Vedanta / Anup
Engg. / Lone Star / Precise Engg or other reputed make as may be approved by the chief
engineer.
2.1.3
MATERIAL OF CONSTRUCTION
BELLOWS MATERIAL
SA 240 GR. 304
CENTRE SPOOL / WELDENDS
IS 2062 GR. B
INTERNAL SLEEVE
SA 240 GR. 304
LIMIT RODS / NUTS & CHECK NUTS
IS 1367
FLANGES
IS 2062 ( AS PER IS 1538/ IS 6392)
2.2.
MS cover for expansion joints
2.2.1. Requirement
Circular MS covers as shown on drawing shall be fabricated and fixed on the expansion
joint for protecting the joint from possible damages. The item covers the cost of plates
and material required, nut bolts, all taxes and duties, providing and applying two coats
of epoxy paint in addition to one primer coat, transportation and fixing charges etc
complete
3.
Manufacture, supply. and installation of MS dismantling joint

Bellow type Dismantling joint shall be provided for each online sluice valves, butterfly
valve and washout valve to facilitate removal of the valve for repairs whenever required.
The joints shall be fabricated as per EJMA standard .The item covers cost of Bellow
type Dismantling joint, including all taxes and duties and cost of coating, packing,
transportation, cost of jointing including required material such as nut bolts, rubber
packing, labour cost etc complete with hydraulic testing to required pressure.
3.1 Material
LLOWS MATERIAL
SA 240 GR. 304
CENTRE SPOOL / WELDENDS
IS 2062 GR. B
INTERNAL SLEEVE
SA 240 GR. 304
LIMIT RODS / NUTS & CHECK NUTS
IS 1367
FLANGES
IS 2062 ( AS PER IS 1538/ IS

6392)
3.2
Acceptable makes
Page 97
Acceptable makes for the Bellow-type Dismantling joints shall be either, Vedanta / Anup
Engg. / Lone Star / Precise Engg or other reputed make as may be approved by the chief
engineer.
4.
Supply and fixing of roller bearings
4.1.
Requirement
Steel roller bearings shall be provided and fixed on the bearing plates fixed on concrete
pedestals for above ground pipeline, as shown on drawing. The bearing boxes shall be
firmly fixed to the bearing plate. Number of bearings and rollers, size of rollers etc shall
depend on the pressure and thrust on the pipeline and shall be as directed by the Chief
Engineer.
5.
Surge Control System For Pumping Main shall be as approved after surge analysis
from expert of IISc or IIT.
5.1
Accepted Control System
5.1.1
Following types of control systems are

pressures in the pumping mains.
a)
Zero Velocity Valves and
b)
Air Cushion Valves (only for pumping main).
c)
Bladder vessel
d)
5.2
acceptable
for control of water hammer
As may recommended by the expert from IISc or IIT for surge analysis.
Surge Control System Requirements
5.2.1. The requirements given are tentative. The contractor, after award of contract, must carry
out the surge analysis based on the Longitudinal section, Pump and Motor characteristics
of the selected pumps by the contractor. Surge analysis along with the selected system.
5.2.2. During detailed engineering following information must be submitted based on the Surge
Control System selected by the contractor. For design of surge control system limits will
be adhered to (The surge pressures will be estimated after all working pumps at
designed discharge, trip simultaneously) as may be approved after the surge analysis
report from the expert.
5.3
Specification of Surge Control Devices- As approved by Chief Engineer after
getting report of Expert from IISc or IIT.
6.0
Flow measurement devices: As approved by Chief Engineer
6.7
Scoure Valve /Silt Ejector

These valves are to be provided at regular interval at suitable location nearby local /
natural drainage in the rising main / distribution network
6.8
Duel plate check valve. As approved by Chief Engineer
Page 98
VOLUME-III
SECTION VII
PART C
INSTRUMENTATION,
AUTOMATION
AND
LOCAL SCADA SYSTEM
Page 99
VOLUME-III
SECTION - VII
PART C
INSTRUMENTATION, AUTOMATION AND LOCAL SCADA SYSTEM
1.
Object
The objectives of providing Instrumentation, Automation and Local SCADA for each pumping
station and the entire irrigation system network in general are as follows.
2.
Hydraulic parameters monitoring and control.

Electrical Energy monitoring.
Equipment monitoring i.e. pump, motors etc.
Emergency response for stopping pumping station.
Optimisation of pumping system.
Monitoring and measurements in Distribution network up to 2.5 ha chak
Pumping system efficiency monitoring.
Minimization of human errors.
Aid to man power.
Logging, reporting, preventive maintenance, safety etc.
In case of sabotage/pilferage/ leakage in any distribution network the SCADA
should be able to automatically shut down the valve one level above.
General Requirement Of Instrumentation system
The entire Instrumentation system is required to Receive & store the information from
the following systems and takes desired computerized actions including alarm and
automatic actions. The design details and standards of the SCADA system shall be such
as may be approved by the C.E. (BODHI) WRD.
The Scada system includes automation and pressure control up to 20 ha chak
outlet and only on /off control at 2.5 ha chak outlet, with operational details. He will be
required to show in concept as to how will he achieve 25 m residual head at each of the
20 ha chak and 20 meter head at 2.5 ha chak and automation.
Electrical System:
A)
THE FOLLOWING DATA SHALL BE DISPLAYED ON PANEL MOUNTED GRAPHICAL USER

INTERFACE (GUI) AT EACH LOCATION, PUMPING STATION AS WELL AS THE SAME SHALL BE
DISPLAYED AT THE MASTER CONTROL ROOM.
a)
Power consumption (kWH), and power factor of system, auxiliary transformers and
all HT motors
a)
Status of breakers
b)
Status of all HT motors and all LT motors (on/off/Trip / Local / remote) & all
parameters.
Page 100
c)
Winding temperatures and bearing temperature of HT motors
d)
Any modification required in Electrical MCC to facilitate for SCADA System.
e)Water level in balancing reservoir corresponding to maximum and minimum level

permitted and the OPENING/CLOSING of sluice gate with the discharge released
at Bansujara reservoir sluice .
B)
MECHANICAL EQUIPMENT THE FOLLOWING DATA SHALL BE

DISPLAYED ON PANEL MOUNTED GRAPHICAL USER INTERFACE
(GUI) AT EACH LOCATION, PUMPING STATION AS WELL AS THE
SAME SHALL BE DISPLAYED AT THE MASTER CONTROL ROOM.
a)
Status of all pumps, dewatering pumps and pumps used for circulation/cooling
pumps and all discharges.
b)
Status (open/close/Local/Remote) of all Butterfly, on individual pumps (delivery &

Suction), manifold pipe, etc.
c)
Temperature of HT motor/ pump Thrust /shaft Bearing
C)
INSTRUMENTATION EQUIPMENTS
THE FOLLOWING
DATA SHALL BE DISPLAYED ON PANEL MOUNTED GRAPHICAL
USER INTERFACE (GUI) AT EACH LOCATION, PUMPING STATION
AS WELL AS THE SAME SHALL BE DISPLAYED AT MASTER
CONTROL ROOM.
A)
FLOW DATA (INSTANTANEOUS FLOW RATES AND TOTAL FLOW) FROM THE PUMP HOUSE
(THROUGH FLOW METER INSTALLED ON DISCHARGE HEADER MAIN), INLET CHANNEL OF
RESERVOIRS / PUMP HOUSE, DISTRIBUTION LINE UP TO 2.5 HA CHAK, ETC.
B)
LEVEL OF WATER IN THE SUMP OF JACK WELL & INTAKE,
C)
PRESSURES AT DELIVERY OF EACH MAIN PUMP
D)
FLOW SWITCH AT INLET COOLING WATER LINE/ LUBRICATING WATER LINE
E)
DIFFERENTIAL PRESSURE SWITCH ACROSS THE PRESSURE

DISCHARGE OF LUBRICATING WATER PUMPS.
f)
Portable vibration meter
FILTERS
AT
THE
g) Portable Sound level meter

h) Portable Speed meter
D)
SCADA FOR DISNET NETWORK:
THESE SHALL BE
DISPLAYED AT MASTER CONTROL ROOM.
Introduction
Page 101
Automation System for Outlet Management System (OMS) will be able to control and
monitor the OPEN/CLOSE outlet as well as discharge upto 2.5 ha chak. Automation
consists of remote control room, Wireless Radio Communication Infrastructure,
Distribution Points and field outlets known also as Field Controller Units (FCU). Based on
crop water requirement, control centre will decide the quantity of water requirement at
each outlet management system (OMS). Accordingly outlet valve OPEN/CLOSE
schedule will be sent to individual FCUs. FCU will issue command to OPEN/CLOSE
outlet valve. Same time FCU will read the water flow/volume pulses and transmit to
control centre at regular interval.
The Scada system include automation and pressure control up to 20 ha chak outlet and
only on /off control at 2.5 ha chak outlet, with operational details. Tenderer will be
required to show in concept as to how will he achieve 25 m residual head at each of the
20 ha chak and 20 meter head at 2.5 ha chak.
Remote control centre server will also poll the data from FCU at regular interval. Also
server will check the heart bit (communication healthiness) of each FCU. If FCU is failed
to communicate to central server then will be reported on central screen as an alert
message.
Valve operating time schedule and total volume and flow will be recorded in the central
room server for historical trending and reporting.
The Outlet Management System at 20 ha chak shall be suitably supplemented with
adequate capacity solar powered electric facility with three days of backup power
capacity.
Automation System to control and monitor the

OPENING/CLOSING of sluice gate at Bansujara reservoir sluice from the master control room
and shall be integrated to the complete operation of the scheme.
E
SCADA for Sluice gate operation :
Page 102
VOLUME - III
SECTION - VIII
STEEL & IRON WORK
Page 103
Volume III
Section - VIII
Steel & Iron Works

The relevant specification for irrigation projects (November 1991) volume-II of
E in-C
Water Resources Department M.P. Bhopal shall be strictly followed for carrying out Steel
works for rising main/gravity main/main pipe canal along with distribution network
complete, including Steel works for construction of pump houses, various structures,
buildings, roads and transmission line etc.
(updated) / MPPKVVCL specifications and "manual on water supply in treatment"
publish by Central Public Health and Environmental Engineering Organization
(CPHEEO) shall also be followed for the above work and as directed by Engineer Incharge.
Page 104
SECTION - IX
ROAD WORKS
Page 105
VOLUME-III
Section - IX : Road Works
The Specifications of relevant Indian standard code (updated) / IRC specifications

(updated) /M.O.S.T. specifications (updated)/ MPPKVVCL specifications and "manual on
water supply in treatment" published by Central Public Health and Environmental
Engineering Organization (CPHEEO) shall also be followed for the above work and as
directed by Engineer In-charge.
Page 106
Volume III
SECTION X
TRANSMISSION LINES
&
SWITCH YARD
INSTALLATION OF SUITABLE ELECTRIC POWER LINE AND

SWITCH YARD FROM SUB STATION OF MPPKVVCL TO PUMP
HOUSES / PUMPING STATIONS SITE ARE TO BE DONE AS
PER
SPECIFICATION
&
NORMS
OF
CONCERNED
ELECTRICAL AUTHORITIES.
Page 107
SECTION XI
SPECIFICATION
FOR
BUILDING WORKS
Page 108
Volume-III
Section-XI
Specification for Building Works
The relevant specification for irrigation projects (November 1991) volume-I, II, III & V of
out Buildings construction works.
In addition to above the relevant Indian standard code (updated) shall also be followed
for the above work and as directed by Engineer In-charge.
Page 109
SECTION XII
Quality Control Guidelines
Page 110
Quality Control Guidelines
The relevant Quality Control Manual for irrigation projects (June 1995) volume-I & II of
out earth works, concrete works, buildings works, road works & tunnels etc.
shall also be followed for the above work and as directed by Engineer In-charge.
The quality control guidelines for pipe/pump/motors shall be followed as mentioned in
respective section.
Page 111
Volume-III
SECTION XIII
Design & Drawing Parameter
Page 112
Section-XIII
Design & Drawing Parameter
The information mention in check list given below should be submitted while
submitting the alignment for approval.
CHECK LIST FOR APPROVAL OF ALIGNMENT AND DESIGN.
1.0
The following details shall be submitted.

(i)
The full village map (in tracing cloth) of all the villages within command of the canal.
(ii)
Contour with 0.50 M interval
(iii)
Ridge marked with red dotted line
(iv)
Valleys marked with blue arrows
(v)
Out of command area by red line
(vi)
The boundary of chak should be marked in bold red letter, encircled by red circle with
chak number.
(vii)
Alignment of the piped canal with Km / radius along the curves
(viii)
Position of Measuring devices
(ix)
Position of Regulators.
(x)
Position of Road Crossings
(xi)
Position of Railway crossing
(xii)
Position of outlets with irrigated design area in Ha.
(xiii)
Position of permanent B.M. and their values at every 5 Km.
(xiv)
Position of permanent pillars at every tangent point.
(xv)
Catchment area survey plan (up to 2.50 Sq.Km.) of all Cross drainage works extent of
Topographical surveys, scales, contour interval, etc.
(xvi)
Certified tracing of catchment area from 1:50,000 topo sheets 1:15000 command
area sheets of all Cross Drainage works whose catchment area is more than 2.50 Sq.
Km.
For the above details the survey should be carried out as per section-II
2.
L-Section & Plan.
2.1
Complete survey plan and L-section shall be submitted in 1 cm. : 1m. (V) scale showing
position of Measuring devices, Regulators with its Hydraulic data, Road, Hydraulic grade
Page 113
line/ gas pipe line, Railway Crossings, drainage crossings Out lets with irrigated area in
Ha., and discharge in cumecs, etc. including head losses in main and disnet pipe line.
2.2
On each sheet of the L section/plan the following certificates shall be recorded.

(i)
Certified that the strata shown in the trial pits are correct (By S.D.O., Executive
Engineer and contractor).
3.
(ii)
Certified that there are no religious places like Tombs, Graveyards etc. along the
canal alignment (By S.D.O. & Executive Engineer &contractor) .
(iii)
Certified that I have walked over the alignment & Found it most suitable &
recommend for approval (By E.E. & S.E. and as the case may be)
(iv)
Reference of bench mark/GTS bench mark should be shown.

CUT OFF AND DESIGN STATEMENT FOR DIFFERENT OFF TAKES.
The cut off and design statement shall be submitted with following consideration.
3.1 Cut off and design statement along with capacity factors for each pipe line.
3.2 The cut off is to be started from the tail of pipe line.
3.3 The pipe line would be divided in to reaches in which the discharge does not
significantly vary.
3.4 The section would be designed for the discharge required at the upper end of the
reach.
4
OUTLETS: 4.1 Outlets shall be provided as per standard design. The exit pressure at outlet
shall be such that farmer of extreme field in a chak shall receive designed
discharge.
4.2 As for as possible no direct outlet should be provided from the Rising main.
4.3 The levels of the outlet shall be kept at suitable location to serve maximum areas.
4.4 The multiple Outlets shall be designed to serve all the users in that particular
chak.
MEASURINGS DEVICES
Measuring devices shall be provided at suitable locations.
ROAD CROSSINGS
Where Rising main, gravity main, main piped canal ,distribution network are crossing
national highway, State highway, district road, other district road, village road or any other
road the required structure shall provided as per norms and specifications of the
concerned department and approval of design and drawing shall be obtained from the
concerned authorities by the contractor.
Page 114
CROSS DRAINAGE WORKS

Wherever the alignment of the pipe line crosses the natural drainage, valleys, the
provision shall be made to take the drains safely across the pipe line /
RAILWAY & GAS PIPE LINE CROSSING

Whenever any pipe line alignment crosses a railway line, gas pipe line the crossing
structure shall have to be provided as per design drawing of concern department.
CONSTRUCTION PLANNING
The construction of pump houses, pipe line system including inline structures for
rising main, gravity main, main piped canal along with distributories & minors shall be
executed simultaneously from head to tail to develop irrigation facilities in the
command area of a major chunk.
10
DETAIL ESTIMATE
The detailed estimates should be submitted by agency for each work after details survey,
drawing & design for approval.
11
BASIS OF DESIGNS
The deign shall be as per the provisions laid down in design criteria Vol-I. The
relevant IS code ,manuals,IRC code and technical circulars etc shall be followed
for design of pipe lines, pump, motors, Pump houses Tunnels and inline
structures etc. wherever applicable.
12.
Duty at 0.6 to 1.2 hectare chak outlet is 0.35 Littre / sec / Ha.
13.
Automatic Control at the chak outlets to regulate designed flow with flow
meter.
14.
In case of pipeline crossing nalla suitable encasing should be provided
Page 115
Volume-III
SECTION XIV
Reference information
(Departmental Conceptual plan)
Page 116
BANSUJARA LEFT BANK PRESSURIZED IRRIGATION PROJECT-
TEHSIL WISE/DISTRICT WISE DETAILS OF COMMAND AREA

Total Geographical Area Canal Wise/Tehsil Wise
Geograp
hical
area
S.N
o Canal
Tehsil
under
comma
nd
Net
C.C.
A.
in Ha.
in Ha.
1.
Piped
canal
Baldevgarh,Kharg
93402
75000
93402 Ha
75000H
apur, Palera &

Jatara
Grand
Total
a.
Total Geographical Area District Wise

District
Tehsil
Tikamgarh
Baldevgarh,Kharg
Area in
Ha.
C.C.A. In Ha.
93402
75000
93402 Ha.
75000 Ha.
apur, Palera &

Jatara
Grand Total
Page 117
INDEX MAP OF BANSUJARA LEFT BANK PRESSURIZED
IRRIGATION PROJECT-
Page 118
SCHEMATIC DIAGRAM OF GRAVITY MAIN AND PRESSURE MAINS FOR

BANSUJARA LEFT BANK PRESSURIZED IRRIGATION PROJECT
Bansujara Dam
B-1
Pressure main
Dia 2.2 m
GCA- 18942 ha.
CCA 15893 ha.
21.0
Km
Near Kudila Village

MDDL 300M
BALANCING RESERVOIR AT RD 30900 M 0F LEFT BANK

CCA-MAIN CANAL
PUMP HOUSE
B-2
Gravity main
18 Km
Dia 1.5 m
(Varies)
34.0 Km
Dia 2.6 m
(varies)
B-3/R -1
Length 16 KM
Dia. 1.5 m
GCA 14975 ha.
CCA 12564 ha.
B-3
B-4
Gravity main
Pressure
main
B-3/L -1 for
GCA 8231 ha.
CCA 6906 ha
Length 12.0 Km
Dia. 1.1m
12.0 Km
Dia
Dia1.5
1.5m
m (varies)
B- 2
B-3
B- 4
GCA: 14737
ha
CCA: 12365ha
Avg. Level:
244 M
GCA: 26814 ha
CCA: 19131 ha
GCA: 9703ha
CCA: 8141 ha
Avg. Level:
284 M
Avg. Level:
237 M
Page 119
Power Requirement for Mains B-4 ( CCA 8141ha.)

S.No.
1
2
3
4
Particulars
CCA
Duty
Discharge
Average CCA Level
A1
8141
0.35
2.85
284
Unit
Ha
lit./sec/hr
Cumecs
M
5
6
MDDL of Balancing reservoir

Velocity
300
1.6
M
m/s
Dia
1.50
8
9
Length
Static Head
12
-16
Km
M
10
11
Frictional Loss
Command area loss
5.997
3.60
M
M
12
Provision for exit gradient and filter
25.00
18.54
617
M
KW
617
KW
0.075
KW
losses
13
14
Design Head
Power Requirement
15
Total Power Requirement

Power per ha for sample size 8141 Ha
Page 120

Pipe Design for sample size of 8141 Ha.
Duty
0.35Lps /Ha
Sr.
No.
Pipe Dia
Qty (In
Meters)
RISING MAIN
1
1500 mm dia
737
Pipe
1400 mm dia
1474
Pipe
1300 mm dia
1474
Pipe
1200 mm dia
737
Pipe
1100 mm dia
1474
Pipe
1000 mm dia
737
pipe
900 mm dia
737
Pipe
900 mm dia
737
Pipe
DISTRIBUTORY
9
800 mm dia
737
10
Pipe
700 mm dia
737
11
pipe
600 mm dia
737
12
pipe
400 mm dia
737
Page 121
pipe
Total
11055 M
Design for chak size of 500 ha.

@ 0.35 Lps /Ha
Sl.No.
Pipe Dia
Qty (In Mtrs)
400 mm dia pipe
522
355mm dia Pipe
415
315mm dia Pipe
538
280mm dia Pipe
403
250 mm dia Pipe
581
6
7
225 mm dia pipe

200mm dia Pipe
187
301
180mm dia Pipe
545
125 mm dia Pipe
609
10
110 mm dia pipe
570
11
75mm dia Pipe
200
TOTAL
4871 M
Page 122
Pipe Quantities for 20 to 2.5 Ha

Sl.No.
Pipe Dia
Qty (In Mtrs)
63mm dia Pipe
626
Total
626 M
Page 123
DISNET PLANNING FOR 500 Ha. chak to 20 ha chak
500 Ha (ICA) Zone

Disributory
Inlet to 500Ha Zone
20
Ha
20
Ha
20
Ha
20
Ha
20
Ha
20
Ha
20
Ha
20
Ha
20
Ha
400m
20
Ha
500m
Design Flow 0.35 lps / Ha

Flow at 500Ha inlet 0.35 X 500 = 175 lps
Flow / 20Ha Chak = 7.0 lps
Page 124
DISNET PLANNING FOR 20 Ha. chak to 2.5 ha chak
LAYOUT OF A 20hA CHAK

Out let @ 2.5Ha
.
8
5
2.5Ha
.
8
5
2.5Ha
.
8
5
2.5Ha
.
8
5
2.5Ha
2.5Ha
.
8
5
2.5Ha
.
8
5
2.5Ha
.
8
5
2.5Ha
.
8
5
200m
Entry to
20Ha Chak
125m
OMS every 20Ha

Flow 0.35 x 20 =7.0 lps
Outlet every 2.5Ha 0.875 lps
All Valve Open
Page 125
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Page 153

Tender Specifications - Bansujara Madhya Pradesh

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Ban Sujara Major Project

Government of Madhya Pradesh

BANSUJARA MAJOR PROJECT

Supplying of water by constructing Balancing reservoir/Distribution chamber at RD

GOVERNMENT OF MADHYA PRADESH

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

Local SCADA System

Section XI V Reference Information

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

nearest technical parameters as may be used in IS code for similar items.

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

Survey and Preparatory Work

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

EXCAVATION AND EARTH WORK

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

excavation for construction of pump

houses, various structures, buildings, roads and transmission line etc.

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

PUMPS AND MOTORS

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

IS 1710 - Vertical turbine pump for clear cold, fresh water

IS 5120 - Technical requirements for roto-dynamic special purpose pumps

1.3 Design Requirement:

Ban Sujara Major Project

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

The total length of column

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

1.12 Discharge Head & Motor Stool:

The power shall be transmitted from motor to vertical shafting

Ban Sujara Major Project

WATER RESOURCES DEPARTMENT

Ban Sujara Major Project

1.15 Water Lubrication Tank and Other Accessories:

Overflow lead to sump

Drain valve lead o sump

Float valve in the tank for control of overflow.

: C.I. I.S. 210 Gr. FG 200

b) Discharge head, Bell mouth

and motor stool

: High grade carbon steel/ stainless

: heavy duty fabricated

: Stainless steel AISI 410/416

: Stainless steel AISI 410/416