CONSTRUCTION AND COMMISSIONING OF LIME SLURRY HOLDING

TANK SYSTEM WITH ANCILIARIES AT CHOA CHU KANG

WATERWORKS

TECHNICAL SPECIFICATIONS

1. GENERAL

This tender calls for the construction, supply, installation and commissioning of a lime
saturator slurry desludging, conveyance, storage, transfer and draining system. The
system shall comprise of 1 nos of lime slurry holding tank, complete with desludging
and transfer pump sets, motorised valves, level sensors, mixers, couplings, pipeworks,
cables, local control panels, programmable logic controllers and miscellaneous civil
works at Choa Chu Kang Waterworks (CCKWW).

2. SCOPE OF WORK
The scope of works in this tender includes but shall not be limited to;
a) Construct, supply, install, testing and commissioning of lime slurry holding tank
with proposed capacity of at least 400m3

b) Modification of existing 2 nos of lime mixing tanks pipeline configuration to link

up with the new lime slurry holding tank system.

c) Supply, install, testing and commissioning of 2 nos of mechanical mixers for new
lime slurry holding tank.

d) Supply, install, testing and commissioning of 3 nos of new pump sets c/w motorised
valves and pipeworks, supports, Motor Control Centres (MCC), cables, electrical
works, instrumentation and SCADA works, to convey lime slurry from existing two
lime saturators to the new lime slurry holding tank and 2 existing lime mixing tanks.

e) Supply, install, testing and commissioning of 3 nos of new pump sets c/w 2 nos of
mixers, 2 nos of sump pump sets, motorised valves and pipeworks, supports, Motor
Control Centres (MCC), cables, electrical works, instrumentation and SCADA
works, to convey lime slurry from existing new lime slurry holding tank to the two
existing lime mixing tanks.

f) Modification of existing Chemical LV switchboard for electrical supply to new

MCCs c/w new MCCBs, overcurrent and earth fault protection etc.

g) Supply, delivery, installation and commissioning of 1 set of adequately sized XLPE,

armoured cables from existing Chemical LV switchboard to new motor control
centre (MCC) at lime saturator area

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h) Supply, delivery, installation and commissioning of 1 set of adequately sized XLPE,
armoured cables from existing Chemical LV switchboard to new motor control
centre (MCC) at new lime holding tank area

i) Supply, delivery, installation and commissioning of new distribution board (DB)

for small power and lightings at lime saturator and new holding tank areas. Lighting
installation shall be in accordance of SS 531.

j) Supply, delivery, installation and commissioning of necessary cable ladders and

trays, trunking, conduits, ducts, multi cable transit, supports for new plant

k) Supply, delivery, installation and commissioning of power and control cables

necessary for the commissioning of new plant

l) Supply, delivery, installation and commissioning of complete earthing system in

accordance of SS 551:2009 and lightning system in accordance of SS 555

m) Replacement, supply, delivery, installation and commissioning of the existing Lime

System from a standalone to a redundant system. This shall include provision of the
SCADA graphics for the existing Lime System and new processors on the Ignition
SCADA. Contractor shall replace all existing PLC cards. PLC cards for existing
and new processors shall be conformal coated.

n) Supply, delivery, installation and commissioning of 2 nos of Radar Level Sensors.

o) Supply, delivery, installation and commissioning of siren and beacon system for
new treatment process units.

p) Supply, delivery and installation of compatible Fibre Optic cables (OM3, 1GB) to
link the Lime PLC to the upgraded PLC backbone network. This shall include
provision of compatible network switches to link the Lime PLC to both Plant
Automation Network Fibre backbone.

q) Supply, delivery, installation and commissioning of two (2) RIO panels for the
works to act as the process interface between the field instruments and existing
Lime PLCs. This shall include provision of a ring network between the two (2) RIO
panels and the Lime PLC.

3. CONTROL PHILOSOPHY

3.1 Lime Saturator Pump Set

a) Three (3) progressive cavity pumps, one for each lime saturator and one for
common standby shall be installed at ground level below the lime saturators to
convey the lime slurry to the new lime slurry holding tank as shown in Appendix x
in the particular specification.

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b) The existing lime saturator has a holding capacity of 750 m3. The Contractor shall
size the progressive cavity pump to transfer the 400 m3 of lime slurry from lime
saturator based on the space available around the lime saturators. The minimum
capacity of each progressive cavity pump shall not be less than 20 m3/hr. However,
if space constraint is an issue, tenderers shall counter proposed suitable capacity
pump for the Superintending Officer (S.O.)’s considerations.

c) The suction of the progressive cavity pumps shall be tee off from the existing drain
pipe between the existing sluice valve and butterfly valve. The nominal diameter of
the suction and discharge pipes shall not be less than 150 mm and 100 mm
respectively.

d) The tenderer shall size the duty head of the progressive cavity pumps to transfer the
lime slurry from the lime saturator to the new lime slurry holding tank based on the
proposed pipe route as shown in Appendix 2.

e) The existing lime saturator sluice drain valve shall be replaced with motorised knife
gate valve. The existing drain pipe and motorised isolating butterfly valve for each
lime saturator shall also be replaced with the same size and rating.

f) Two discharge lines to the new holding tank shall be provided, one duty and the
other for standby. The discharge line from the lime saturator to the new lime holding
tank shall be laid in covered trenches as specified.

3.2 Lime Holding Tank Pump Set

a) Three (3) lime transfer pumps, one for each lime slurry holding tank and one for
common standby, shall be supplied and installed. The lime transfer pump shall
convey the lime slurry from the lime slurry holding tank to the existing lime mixing
tank nearby as shown in Appendix 1. The capacity of each progressive cavity pump
shall not be less than 10 m3/hr. However, if space constraint is an issue, tenderers
shall counter proposed suitable capacity pump sets for the S.O.’s considerations.

b) The transfer process shall be fully automatic with fully motorised valves and
protection sensors such as level and flow control, timer, etc.

c) The transfer pumps and pipe gallery at the lime holding tank area shall be installed
within bund walls with 2 sump pumps to contain leakage. The 2 sump pumps
discharge line shall be laid to the nearest drain trench. The pump shall be well type,
SS 304, IP68 with Hmax of 12m and Hmin of 2m.

d) Flushing line shall be provided to flush the pump after every transfer as shown in
Appendix x. Separate flushing line shall be provided for each pump. This shall be
fully automatic with motorised valves and protection sensors such as level and flow
control, timer, etc.

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3.3 Pump Operation

a) The lime saturator pumps shall be programmed to desludge daily, i.e. convey the
lime slurry from the lime saturator to the lime holding tank, at interval between 4
to 6 hrs and for a duration of 1 to 2 minutes followed by the flushing after every
transfer. The desludging interval, duration of pump operation and flushing will be
finalised after the award of tender. The flushing interval and duration of pumping
shall be adjustable. The Contractor shall design and propose the sequence of the
motorised valve operation to the S.O. for his approval.

b) The lime saturator pump shall also be programmed to drain out each lime saturator
once every 6 months. It shall be operator initiated and the PLC programme shall be
manually override to allow this function.

c. The operation of the lime holding tank pumps shall be operator initiated to run and
stop. The pump shall also trip if the high level of the lime mixing tank is reached to
prevent overflow.

4. DETAILED DESCRIPTION OF WORK

4.1 CIVIL & STRUCTURAL WORKS

(a) The scope of works under this contract for the Civil & Structural Works shall
include the detailed construction and testing of all civil and structural works
associated with the entire Works. The works shall include but not limited to:

(i) Site setting up, site clearing, preparation and excavation works including
all temporary access provisions, site establishment, site investigation and
site survey works;

(ii) All temporary works including supply, install and their removal upon
completion of the Works;

(iii) Construction of earthworks, involving the general excavation and earth

control measures, backfilling with compaction to the required building and
roadwork levels and removal of the excavated spoil off the Site to approved
dumping grounds;

(iv) Lining all surfaces of concrete structures, tank, sumps, etc. that are in
contact with the lime solution, with approved lining material to protect
them from being corroded. All coating specification and application details
and necessary certification that it is approved for contact with potable
water shall be provided to the Board Application of all coatings shall be by

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 a fully qualified and certified applicator, approved by the coating/lining
manufacturer;

(v) Construction of access roads if required;

(vi) Cable detection and diversion of the existing power and signal cable across
the proposed sites;

(vii) Protection to the underground pipes in all areas of the site that shall be
subjected to excavation, including the bypass pipe across the green field
beside the dual-media filters, during the construction Works.

(viii) All external works interfacing with existing infrastructures within

CCKWW including sewerage discharge point, drainage discharge point,
services diversion if any etc.;

(ix) Concrete works associated to all interfaces with the existing structures for
process, electrical, mechanical, building services and instrumentation
connections and tie-ins;

(x) Miscellaneous concrete works associated with the installation of all

Mechanical and Process Equipment, related to the process, including
plinths, pump pedestals, instrument vaults and tank pads;

(xi) Fabrication and erection of all pipe supports;

(xii) All necessary test including hydrostatic testing of all structures including
RC flat roof and pipelines;

(xiii) All civil and structural computations shall be in full compliance with the
respective latest standards and codes of practice (including any
amendments) in force at the time of tendering. All civil and structural
computations shall comply with Euro codes BS EN 206-1, SS544.

(xiv) Concrete structures and structural elements shall only be constructed using
the concrete for that type of structure.

(xv) To ensure a consistent colour of structural concrete throughout the works,

the constituent materials, cement combination, mix proportions and
grading, particularly of the sand shall be maintained constant and from a
single consistent source for all above-ground concrete structures. For the
avoidance of doubt, the Contractor shall select a concrete mix prior to
commencement of the works and shall use only this mix for all above-
ground concrete structures incorporated into the works.

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 (xvi) The Contractor shall submit proposals for his chosen concrete mixes and
chosen supplier to the BOARD for approval.

(xvii) Only steel or modular timber panelled formwork shall be used for the
construction of above-ground surfaces.

(xviii) For the purpose of concrete repair and crack injection, a Single-
component Diphenylmethane Diisocyanate (MDI) based, water-activated,
hydrophobic type polyurethane injection resin shall be used.

(xix) The Contractor shall submit his repair proposals for the S.O and board’s
approval. The Contractor shall be responsible for any leaks in the water
retaining structures.

4.2 CONSTRUCTION REQUIREMENT FOR FRP TANK

4.2.1 New Lime Holding Tank

a) The Contractor shall design, construct, deliver, install, test & commission of lime
holding tank complete with pipe works to form an efficient functional system.

b) The lime holding tank shall meet, but not limited to, the following design
parameters:
Type: Circular/Rectangular shape enclosed tank (to be
proposed by the contractor for SO approval based on the design study of the
space available beside existing lime mixing tanks)
Quantity: 1
Material: FRP
Effective capacity: minimum 400 cubic meters (to design to hold the volume
of lime transferred from one saturator).
c) Useable capacity shall be measured 1 meter from the top of tank. The lime holding
tank shall be designed to withstand the hydrostatic head resulting from the tank
being surcharged to 150mm above the top of the tank.
d) FRP Tank shall be seated flat cement plinth.
e) FRP tank shall be able to hold effective capacity 400Cu.m. and 1 meter allowance
space is above effective capacity.
f) FRP Tank can be built in parts but no metal supporting structure internally.
g) FRP Tank shall be self-supported for tank weight & Lime-water weight. No metal
Intersection allowed within tank. No metal supporting structure allowed within the

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 tank. All necessary metal support to be on external of tank to be covered with fibre-
glass protect for corrosion.
h) Material of tank shall be fully fibre-glass. For any connection required EPDM
Gasket & SS304 B/N/2W to be used.
i) Tank Base shall be designed for side drain for sludge & water discharge.
j) FRP Tank shall be designed for full drain of water during maintenance time.
k) FRP tank shall be with tank mechanical property & Professional Engineer
Endorsement.
l) FRP tank top shall be designed for 2 person load (150kg/m2).
m) FRP tank shall be provided with ladder, cage & Handrail. Material of the ladder,
cage & Handrail would be galvanized.
n) FRP tank internal to be designed for sludge stirring to prevent any stagnant sludge.
o) FRP tank top to be allowed for 2 mixers.
p) 2 Inlet, 2 drain c/w socket for suction cap, 2 manhole dia. 1m, 1 level gauge, 3
pump out & 2 spare connection.
q) FRP tank to be compatible with calcium carbonate to prevent corrosion. FRP tank
design to be self-supported of design of water to be 1.6 kg/m3.

r) The contractor shall carry out soil investigation prior to the design and preparation
of the foundation. The cost of soil investigation shall be included in the tender price.
The price of additional piling shall be deemed inclusive in the tender price if
required. No claim of extra cost will be entertained.

s) Besides the openings required for mechanical mixers, the lime holding tank shall
be complete with:
i. Drain pipe with isolation valve (DN100 as per drawing, PN10, Material:
Stainless Steel 304, Cobalt-alloy-coated ball or hardened materials type)
ii. Vertical Mixers with galvanised supports
iii. Suction pipe for the transfer pumps (DN100 as per drawing, PN10,
Material: Stainless Steel 304)
iv. Pipeline with valves, fittings, adaptors, supports, brackets, flexible
coupling, hose coupling, etc. The hose coupling must be compatible
with the coupling of the vacuum tanker with the size of approximately
63.5mm (2.5”) hoses
All the external auxiliary equipment’s (accessories) required to complete the
lime holding tank should be designed and submitted for the S.O. approval before
finalising the drawing for construction.

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t) The contractor shall provide an external stainless steel (Grade 304) working access
platform and staircase complete with railing and toe board. The steps are to be
coated with non-slip material.

u) The lime holding tank and transfer pumps to be located in a containment bund with
a sump for the sump pumps. The bund shall be sized to contain the content of one
lime slurry holding tank. A level switch high (44‐LSH‐5300) is located within the
sump of the containment bund to indicate that the sump is full. This is an alarm only
and does not inhibit any other process.

v) Additional reinforcement shall be provided as necessary to support the required

accessories and human loads.

w) A galvanised metal roof shall be provided for the transfer pumps.

x) Design drawings and calculations shall be submitted. Drawings shall include a

design details of the entire tank indicating the thickness, reinforcement and
materials of construction.

y) All drawing and calculation shall be certified by a Qualified Person

z) All construction waste shall be removed and disposed offsite. The cost of the
disposal shall be included in the tender price.

aa) The contractor shall perform a detailed study on the lay-out for the drainage pipeline
and other pipelines and propose the available route such that the existing live plant
shall not be affected during construction. The proposal shall be submitted for the
Board approval.

bb) All concrete supports to the pipework shall be GEN3 designated concrete mix in
accordance with BS EN 206-1 and SS 544-2, with a maximum 20mm aggregate
size and S3 slump class. The design shall be approved by PE.

cc) All pipe trenches and backfill shall be in accordance with the proposed design
drawings.

dd) Where pipework is diverted and the existing pipe does not interfere with the works,
it may be left in place with the ends of the pipes sealed.

ee) The Contractor shall produce updated services drawings for use on site. The
Contractor shall submit the updated service drawings to the Board. The services
drawings shall be updated regularly to reflect the latest details/changes on the route;
location; position and depth, etc., of the services based on the results of the trial
trenches, cable detection; as-built details of diverted services, etc. The Contractor
shall ensure the correctness and accuracy of the updated services drawings. Any

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 cost or time implication arising from damage to the existing services as a result of
error(s) in the drawings shall be entirely borne by the Contractor.
4.2.2 REFERENCE STANDARDS FOR FRP

We will be following the National Bureau of Standards, Standard PS 15-69; Custom

contact Moulded Reinforced Polyester Chemical Resistant Process Equipment

a) Barcol Hardness : ASTM D-2583

b) Tensile Strength, psi : ASTM D-638
c) Tensile Modulus, psi x 10 : ASTM D-638
d) Tensile Elongation, % : ASTM D-638
e) Flexural Strength, psi : ASTM D-790
f) Flexural Modulus, psi x 10 : ASTM D-790
g) Heat Distortion Temperature, ºC : ASTM D-648
h) All Flanges : ASTM D-3299

4.2.3 MATERIAL SPECIFICATIONS FOR FRP

Standard: PS 15-69
Resin Type: Isophthalic Resin / Vinyl Ester Resin
Corrosion Barrier: Chopped Strand Mat 450gm/m²
Reinforcing Material: Woven Roving 600gm/m²
Surfacing Material: Surface Gel-coat / Veil
4.2.4 DATA & TECHNICAL SPECIFICATION FOR FRP
a) Design Code : Manufacturer Standard FRP PS 15-69
b) Design Pressure : Atmospheric
c) Design Temperature: 60°C
d) Dimension : Dia.10m x 6mHt
e) Tank Thickness : + 12 to 22 mm
f) Material : Isophthalic Resin / VE Resin
g)Reinforcement : Generally E-glass chopped strand mat
450gm/m², Woven Roving 800gm/m²
h) Corrosion Barrier : Surfacing veil is usually C Glass
g) Connecting Structure: EPSM Gasket & SS304 B/N/2W
h) Handrail, Ladder & Cage: Galvanized steel

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 New Lime Holding Tank Layout Drawing

4.2.4 Existing Lime Mixing Tank

The contractor shall design and modify the existing 2 nos of lime mixing tank
with a discharge line from the New Lime Holding Tank transfer pumps and a
level sensor for the new tank.
The drain line from the existing lime mixing tank to be re directed to the sump
of the new lime holding tank.

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4.2.5 Pipe Service Trenches
a) The Contractor shall carry out a survey of the pipe trench route and submit
the finalised pipe trench routes to the BOARD for approval. The Contractor
shall carry out design of crossings of existing trenches, cables, pipes, road
and any other buried services and submit the proposal for S.O’s approval.
The Contractor shall size the required pumping and conveyance systems
based on the final pipe routings. The cost shall be included in the tender
price.

b) The trenches shall be sized with due consideration for ease of accessibility
and maintainability. Trenches shall have a minimum internal width of at
least 500mm.

c) Pipe trenches shall be supplied complete with covers. Unless otherwise

stated, covers for trenches on roads shall be precast concrete sections,
designed for vehicular traffic. Covers for trenches on grass, and non - traffic
verges shall be reinforced aluminium chequered plates.

d) All pipe trenches shall be sloped to the nearest drain points. The Contractor
shall provide drain points at the lowest section of the pipe trench to the
nearest surface drains. All drain pipes shall be complete with isolation
valves. The drainage point shall be linked up to the existing silo pits at the
existing lime mixing tanks for disposal.

5. MECHANICAL WORKS

5.1 Progressive cavity Pumps

5.1.1 General

a) Pumps shall be designed to handle and process thick slurry lime sludge and shall be
of Progressive Cavity Pumps or equivalent. The pumps shall be of Block-Design
and space saving and short in length in its design.

b) Pump and drive are connected through a lantern and a plug-in shaft connection so
that rotating unit can be removed as one part.

c) Pump needs to be complete with pressure gauge (suction and discharge), Pressure
Release Valve (PRV), NRV, etc. Any overflow from the PRV should be diverted
to drain pit.

d) Operating speed of the pump shall not be more 300 rpm.

e) Pump shall be designed and constructed to operate up to maximum of 12 bar

pressure.

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5.1.2 Details of the Pumps

a) The Contractor shall supply three (3), viz two (2) duty and one (1) standby, lime
transfer pumps from Lime Saturator Tank to New Lime Holding Tank. The
Contractor shall size the duty requirements of the transfer pumps.

b) The Contractor shall supply three (3), viz two (2) duty and one (1) standby, lime
transfer pumps from New Holding Tank to existing Lime Mixing Tank

5.1.3 Casing Parts

a) Casing parts made of Grey Cast Iron GG25.

b) Pressure gauge connection shall be available on the pressure branch casing body.

c) Suction casing shall be provided with cleanout ports on both sides of the pump
casing.

d) In addition, drain plugs shall be provided on the pump suction casing.

5.1.4 Rotating Parts

a) Plug-in shaft and coupling rod with impellers shall be made of 1.4404/AISI
316L.

b) Mechanical seal shall be made of Single Acting Mechanical seal of silicon

carbide vs silicon carbide faces with FPM-Viton Elastomers and 1.4571 spring
and metal parts complete with flushing connection.

c) Rotor shall be made of 1.4404/AISI 316L Ductile Chromium Coating to

minimum of 250 micron.

d) Stator shall be made of NBR- Perbunan

5.1.5 Coupling Rod Fitted with Impeller

a) Coupling rod complete with Impellers shall be provided and the

impeller shall be welded onto coupling rod.

b) The impeller serves for mixing of the lime sludge and to prevent
sedimentation during the process of conveying.

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5.1.6 Plug in Shaft

Shaft mechanical seal replacement shall be conducted without dismantling of the

drive (gear motor) suction casing and the pressure branch casing or any part of the
pipework’s and has to be guaranteed and demonstrated during the plant
commissioning.

5.1.7 Rotor
Rotor shall be designed for quick and easy removal by removing the two
(2) halves of the Stator without dismantling any part of the pipe works or
any parts of the drive or suction casing or pressure branch

5.1.8 Universal Joints

a) Universal joints designed shall be of pin joints with exchangeable,
wear resistant bolts and bushes.

b) Universal joint with lifetime lubrication has to be encapsulated via

universal joint sleeves in a gas- and leak-proof designed.

c) Universal joint on the rotor end shall be additionally equipped with a

universal joint sleeve protection made of NBR-Perbunan.

5.1.9 Stator

a) Only stators with DE vulcanized sealing bonds are admissible.

b) Stators design shall be such that it is design and constructed in two (2) halves
with four metal adjustable segments and integrated re-tensioning devices
allowing quick and easy pump maintenance.

c) This could be either to change the stator or assist in the removal of debris or
foreign material or matter.

d) Changing of the stators without dismantling any of the pipe work or any part of
the drive and pressure branch must be guaranteed.

e) Re-tensioning of the stator halves must be guaranteed due to inevitable wear

during such time that it is required to be performed.

f) Stator shall be of NBR

5.1.10 Dry Running Protection Device

a) The pumps shall be supplied and fitted, in factory from the same
pump manufacturer, with Thermal Dry-Running Protection

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 Device of PT100 conducted via temperature measuring
embedded in the stator.

b) The enclosure of the Integrated Thermal Dry Running Protection

Device shall be of IP67 complete with SS1.4404 / SS316L
connection head and sensor sleeve.

c) The temperature of the working surface of the stator is constantly

monitored via a temperature sensor integrated in the stator and
switches off the drive motor of the pump via a contact if a pre-set,
non-adjustable limit value (60ºC) is reached.

5.1.11 Motors

a) IE3 Motor shall be used

b) PTC Thermistors on each winding phase. Space Heaters ( 230V,

1Ph, 50Hz ) shall be provided.

5.1.12 Factory Acceptance Test (FAT) of Pump

Pump shall be tested in accordance to VDMA 24 284 and the FAT Certificates
shall be submitted for approval prior shipment from factory.

5.1.13 Camp Water for Flushing all the 6 nos of Lime Slurry Transfer Pumps

The contractor should Tee off from the nearest existing camp water line.
Contractor to supply, install camp water pipelines complete with manual
isolating as well as motorised valves, supports to facilitate the flushing
requirement after each transfer of the lime slurry pumps.

6.2 Mixers

6.2.1 General

a) Chemical mixing shall use either hydraulic or mechanical energy and shall
provide uniform mixing of the chemical in the main flow of water at all times
over the entire range of chemical doses applied and flows through the works. A
high degree of local turbulence is considered necessary for satisfactory mixing.
The electrical power or head loss requirements to achieve efficient mixing shall
be optimized to ensure minimum energy consumption at each mixing location.

b) Mixing energy shall be defined either by the ‘mean velocity gradient’, G, in the
expression water power (W) per unit flow (m³/s) is equal to the product of the

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 viscosity (Pa-s), mean residence time (s) and square of the velocity gradient (s-
1) or any other method approved by the BOARD

6.2.2 Mechanical Mixers

a) Mechanical mixers shall be of the mixed flow type with the concentration of the
additive chemical in the exit flow being the same as that in the lime holding tank.
The lime holding tank shall be equipped with a mixer of the top-entry three bladed
axial flow type to achieve process homogeneity in a shorter blend time for chemical
mixing, unless otherwise specified.

b) Mixer drive units shall be suitable for 24 hours continuous operation. Each drive
unit shall consist of either vertical or foot-mounted electric motor and a gear reducer
with a flexible coupling provided between the motor and the gear reducer. Unless
otherwise specified the motor shall be fixed speed. Lifting lugs shall be provided to
permit lifting the complete mixer and drive unit. Gearing shall be helical or spiral
bevel and shall be totally enclosed. The output shaft shall be either enclosed in a
drywell which provides positive leak proof sealing or above the liquid level for
vertical tank mounted motor. The mixer shaft shall be rigidly coupled to the output
shaft.

c) The coupling to the mixer shaft shall be readily accessible so that the gearbox may
be easily removed and replaced without entry of personnel into the mixing chamber
or shutdown of the stream flow.

d) Gear reducer and motor bearings shall be oil or grease lubricated, antifriction type.
All points where oil leakage may occur shall be suitably trapped to prevent oil
contamination of water. The bearings life shall have a minimum -10 rating of
100,000 hours.

e) For mixer that are mounted on structural steel beam or channel supports with
chequered plate access platform complete with hand railing. The opening in the
platform shall be large enough to permit the removal of the mixer and the shaft after
the removal of the impeller.

f) The impeller diameter and tip speed shall be of a design to provide efficient mixing
of the applied chemicals. The rotational speed of the mixer shall not be greater than
80 percent of the critical speed of the shaft. Mixers shall not be provided with
bottom steady bearings. The height of the impeller above the floor of the tank shall
be as recommended by the manufacturer, subject to the approval by the S.O.
Provision shall be made in the design of the shaft except hollow shaft, to allow
vertical adjustment of the impeller from the recommended position in order to
optimise performance.

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g) Vertical shafting of the impeller shall be designed and supported to eliminate shaft
whip and vibration. The shaft diameter shall be equal or greater than the diameter
of the output shaft of the gear reduction unit. The mixer shaft, impeller assemblies,
and couplings shall be constructed from stainless steel type 316. Carbon steel or
equivalent material coupling is acceptable if the coupling is not in contact with the
liquid.

h) Mixer shall be suitable for installation in lime holding tank

i) The location of the lime feed point with respect to the mixer shall be submitted for
SO approval.

6.2.3 Pipe- Works, Valves and Fittings (Progressive cavity Pumps)

a) The suction and discharge pipes, isolating valves and pipe fittings shall be
constructed of stainless steel grade 304 and of a schedule for pipe threads.
The nominal size of the discharge pipes and pipe fittings shall be equal to the
discharge outlet port size of the lime transfer pumps before the common
discharge line.

b) All the pumps discharge will be connected to one common discharge line.

c) A standby common discharge line shall be provided for duty and standby.

d) Isolation valves for both suction and discharge of the pumps shall be stainless
steel grade 304, cobalt-alloy-coated ball or hardened materials type ball type,
DN150, motorised type with manual override and shall be the type suitable
for used with slurry lime.

e) The isolation valves shall be operated remotely from existing SCADA system
at the Control Room.

f) The run/stop/trip signals of the valves shall be linked and monitored at

SCADA.

g) All the Progressive cavity pumps shall be inter–connected with pipes and
isolation valves so that,

i Pumping can be diverted should there be any pump failure.

ii One standby pump for both saturator and new lime holding tank.

6.2.4 Pipe- Works, Valves and Fittings (New Lime Slurry Holding Tank)

a) Material for the pipeline shall be constructed of stainless steel grade 304.

b) Suitable valves for lime slurry shall be used.

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 c) The valves shall be selected such that, the system can be operated remotely
from existing SCADA system.

6.2.5 Drawings and O&M Manuals

a) Contractor shall submit proposed drawings showing the location of

progressive cavity pumps, new holding tank and all associated piping and
valves layouts to the satisfaction of the SO before commencement work.

b) Final drawings consisting of 2 sets of A1 and 2 sets of A3 shall be submitted

with PE endorsement. Price quoted shall include this.

c) Supply 4 sets of Operation & Maintenance Manuals and As-Built Drawings

in A3 size, including 1 set in soft copy.

6.2.6 Motorised Isolation Valves

a) Each suction pipe shall be installed from the outlet port of the existing
tanks or pipeline to the transfer pump. Contractor shall also provide
motorised isolation valves on the suction pipes. Each discharge pipe shall
be installed from the outlet port of the transfer pump to the common
discharge manifold pipe or to the discharge pipeline. Each discharge pipe
shall be isolated by a motorised discharge valve.

b) All motorised valves with manual override shall be installed for isolation
purpose for each of the transfer pumps, where applicable.

c) Auto flushing shall be automated and programmed into the PLC/SCADA.

A manual override operation shall also be provided. Drain outlets shall be
provided along the pipes with automated valves to aid in flushing.

7. ELECTRICAL WORKS

7.1 Submission by Contractor

a) The submissions by the contractor in accordance with the specifications

shall include but not limited to the following:

Drawings:

i Electrical network single-line drawings (SLDs) with details of the relay

settings to give correct discrimination to the electrical network
protection system.
ii MCC single line diagrams and schematic diagrams

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 iii Control circuit diagrams
iv Panel front layout, panel sections
v Layout of electrical components within each (front/rear) compartment
vi Equipment general arrangement
vii Equipment installations and cable termination details
viii Lightning Protection System Layout
ix Earthing Schematics
x Cable route drawings
xi Drawings detailing the arrangement of cable trays/ladders and their
supports
xii Modification of main SLD to incorporate the changes
xiii Distribution box SLD
xiv Lighting works with lux simulation and calculations

b) All other drawings necessary for the complete understanding of the

operation, maintenance and extension of the electrical system including any
required information for the Employer to dismantle, repair, maintain,
modify or extend the plant shall also be provided.

c) All electrical work/installation, particularly those affecting safety, operation

and maintenance of the electrical equipment, including sizing of conductors,
selection and setting of protection devices, layout of components within
switchboards and control panels etc shall be designed and endorsed by a
certified Licensed Electrical Worker (LEW), of appropriate grade,
appointed by the Contractor. Approval shall be obtained from the Board
prior to any change in LEW.

d) Equipment Sizing and Cable Schedules

Calculation on motor sizing, cable sizing, fuse, MCB and MCCB

sizing, power factor correction capacitor sizing, etc.

e) Certificates

i Manufactures work test certificates

ii Installed equipment performance test certificates

f) Manufacture Installation & Site Tests/Commissioning Instruction Manuals

and Data Sheets

i Composite manual of all manufacturers catalogues and data sheets

for all equipment provided.
ii Manufactures instruction sheets for correct installation, operation,
site testing and commissioning of each equipment.

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 iii Document necessary to understand the principle of operation,
mechanism, correct installation, testing and commissioning of a non-
standard package/system/subsystem
iv Any documentation on materials which may be harmful to human
health or the environment.

g) Operation and Maintenance Manuals

i Operation and maintenance manuals as stated on the specifications.

ii Voltage drop and fault discrimination study

7.2 Scope of Electrical Works

The scope of the electrical works shall include but not limited to

a) Modification of existing Chemical LV switchboard for electrical supply to

new motor control centres (MCCs) c/w new MCCBs, overcurrent and earth
leakage protection etc.

b) Supply, delivery, installation and commissioning (SDIC) of 1 set of

adequately sized XLPE, armoured cables from existing Chemical LV
switchboard to new MCC at lime saturator area

c) SDIC of 1 set of adequately sized XLPE, armoured cables from existing

Chemical LV switchboard to new motor control centre (MCC) at new lime
holding tank area

d) SDIC of new MCC for transfer pumps and mixers at lime saturator area c/w
direct on-line (DOL) or star-delta starters, overcurrent, earth leakage, motor
protection selector switches, pushbuttons, indication lamps, anti-
condensation heaters, surge arrester, current transformers, ammeters, hours
run meters and kilowatt hour meters etc for each transfer pumpset and mixer.
Each pumpset and mixer shall have both local and remote control for
operation. The new MCC shall be of stainless steel construction, double
enclosure for outdoor use. The new MCC shall be installed on a concrete
plinth of minimum 100mm height. A shelter shall be installed to protect the
MCC from direct rain and sun.

e) SDIC of new MCC for transfer pumps and mixers at new lime holding tank
area c/w direct on-line (DOL) or star-delta starters, overcurrent, earth
leakage, motor protection selector switches, pushbuttons, indication lamps,
anti-condensation heaters, surge arrester, current transformers, ammeters,
hours run meters and kilowatt hour meters etc for each transfer pumpset and
mixer. Each pumpset and mixer shall have both local and remote control for
operation. The new MCC shall be of stainless steel construction, double

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 enclosure for outdoor use. The new MCC shall be installed on a concrete
plinth of minimum 100mm height. A shelter shall be installed to protect the
MCC from direct rain and sun.

f) SDIC of 3 nos motors at lime saturator area c/w 1 set of adequately sized
cables each. IE3 motors shall be used. Motors shall be of IP55 and designed
for continuous rating.

g) SDIC of 3 nos motors at new holding tank area c/w 1 set of adequately sized
cables each. IE3 motors shall be used. Motors shall be of IP55 and designed
for continuous rating.

h) SDIC of new distribution board (DB), be fitted with RCCB to comply with
regulations, for small power and lightings at lime saturator area. Lighting
installation shall be in accordance of SS 531.

i) SDIC of new distribution board (DB), be fitted with RCCB to comply with
regulations, for small power and lightings at new holding tank area. Lighting
installation shall be in accordance of SS 531. Light fittings shall be of LED
type.

j) SDIC of necessary cable ladders and trays, trunking, conduits, ducts, multi
cable transit, supports for new plant

k) SDIC of power and control cables necessary for the commissioning of new
plant

l) SDIC of complete earthing system in accordance of SS 551:2009

m) SDIC of complete lightning system in accordance of SS 555.

n) All works carried out shall be in accordance to CP5 or any Singapore or

international standards with the endorsement of Contractor’s LEW.

o) 1 set of visual & audio alarm shall be supplied and installed at site. Mounting
location of the siren and beacon shall be decided by the S.O.

p) The siren and beacon shall be triggered when the level exceeded the pre-set
level settings. The status of the siren shall be linked and monitored at
SCADA.

q) When the level meter reaches reach pre-set high or high-high level, the
siren and beacon will be activated.

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8. INSTRUMENTS WORKS
8.1 Scope of Work

a) The Contractor shall modify the existing SCADA system to be on the new
Ignition SCADA system, integrating the existing and new treatment process
units. These shall include but not limited to the system diagnostic pages,
trends, alarms etc.

b) All PLC controllers, backplanes, switches, auxiliaries and PLC cards are to
be replaced and integrated into the existing plant network.

c) All PLC cards shall be conformal coated and compatible with the existing
PLC network. Existing PLC program shall be compatible with Schneider
Unity 11.0 or license for the PLC shall be provided for maintenance.

d) The ICA Works shall include, but not be limited to, the following items:
(i) Modification of existing Supervisory Control and Data Acquisition
(SCADA) control system using Ignition. Process automation shall
be achieved primarily through the Lime PLC.

(ii) The Contractor shall provide two (2) RIO panels of SS316/306 with
thickness 1.5mm, sufficient ventilation and lighting. The Contractor
shall install a Fibre Optic Ring topology network linking the existing
RIO Panel with the two new RIO panels. This shall include fibre
optic patch panel, cable routing and excavation of the road if
necessary to form the Ring.

(iii)The Contractor shall modify the existing Lime PLC logic and
configuration to accommodate the new processors and replacement
of new PLC cards.

(iv) The Contractor shall provide fuses, signal isolators and surge
protectors as per existing Choa Chu Kang Plant Design for the RIO
panels.

(v) Instruments (inclusive of remote transmitters) mounted outside

instrument panels shall have weatherproof and dust‐proof cases.
Instrument cases shall be of corrosion‐resistant material or finish.

(vi) The Contractor shall supply, deliver, install, test and commission all
instrumentation necessary for the correct, efficient and safe
operation of the process.

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 (vii) Field instrumentation selection shall be based on field proven
devices for the particular process application and will be
microprocessor based where possible.

(viii) Unless otherwise specified all functions shall be transmitted

electrically and all analogue signal transmission systems shall be in
accordance with BS 5863 Part 1, being isolated 4 to 20 mA dc. The
motor control voltage shall be 230V 50 Hz and analog signals will
be 4 – 20mA.

e) Radar Level Transmitters

(i) A local display of the measured values, in metres, shall be an integral
part of the transmitter. It shall be able to display, as a minimum, the
following two groups of information:
i. Level readings
ii. Status of the transceiver including the transceiver’s current
operating mode and alarms.

(ii) Remote display of the level readings shall be provided at the bottom
of the tank for easy reading.

(iii)The measuring distance shall be user programmable.

(iv) The radar level transmitter shall operate on a 2-wire, 4-20mA loop
powered current loop with a voltage of 20 to 36 Vd.c.

(v) The output current shall be linearly proportional to either liquid level
or free air space.

(vi) The current shall be able to drive a load impedance of 500 ohms
maximum. It shall be optically isolated within the 4 to 20mAd.c.
signal range.

(vii) There shall be no loading effect on the output signals when

external lightning surge arrestors are connected.

(viii) The configuration and calibration of the transmitter shall be

programmable via its detachable programming module or using
HART handheld communicator. All configurations shall be retained
during power failure, with no battery required.

(ix) The electronic housing / enclosure shall be designed to meet IP65 or

better with separate openings for sensor cables, supply cables and
signal cables.

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 (x) The ambient operating temperature shall be 0 to 80°C at a relative
humidity from 0 to 100 %.

(xi) The antenna (sensor) shall be suitable for flange or bracket mounting
as required.

(xii) The associated transmitter shall be mounted in an enclosure. It

shall be programmable with an integral programming keyboard,
have a digital display, and shall provide an isolated 4 to 20mA dc
output signal. The transmitter shall contain signal processing
facilities so as to eliminate the effects of standing echoes from tank
features, moving echoes from mixers and other such problems.

(xiii) The design and application of radar level meters shall take into
account the vessel or channel construction, the material, size, shape,
environment, process fluid or material, the presence of foam,
granules, size etc. The sensing element shall be mounted off‐centre.

(xiv) Radar level transmitters shall comply with local

telecommunications and radiofrequency regulations.

(xv) The Radar level meter reading shall be linked and monitored at
SCADA. The operator shall be able to set LL/L/H/HH alarm settings
in SCADA.

(xvi) The accuracy of the transmitter shall be better than ±3mm of the
measured value with a resolution that is within ±1mm

(xvii) The price quoted shall include everything deemed necessary for
the successful completion of work.

a) All the transfer pumps shall be remotely monitor and control from the SCADA
system
d) The Contractor shall test and commission the whole system to the
satisfaction of the Board. The price quoted shall include everything deemed
necessary for the successful completion of work.

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