Bendung Karian Banten

DESIGN OF KOMERING PUMPING STATIONS
1. General
1.1 Introduction
The purpose of the “Komering Pumping Stations” is to provide irrigation water from the
Komering main Canal to the highland by the both sides of the canal. Base on topographic
survey, the existing rain fed on the left bank and right bank are 410 ha, and 195 ha
respectively. After reconnaissance of the sites, and the discussion with the project Officials,
two pumping stations will be established on both bank at the station 1 + 190 of the man
canal.
The left bank station, or pumping station No. 1 will provide water to the Wayanda Secondary
Canal (410 ha), while the right bank station (pumping station No. 2) with provide water to
the Joyo Muliyo Secondary Canal. The later two canal network will be established in the
meanwhile.
1.2 Pump Operation Study
The operation rules to be proposed for the Komering Pumping Stations was studied and
established assuming that these pumping stations will be operated by the Project O & M staff
while the electric power will be provided by the generators of the Perjaya Weir through a
transmission system.
The operation is divided into three cases normal condition of q100, normal condition of Q70,
and flood condition (assumed Q 125), controlling the up stream channel stage below elev. +
78.72 in order to avoid overflow in the forebay. The start of pump is adopted as the water
level of Q70 : + 77.80 For the further operation of pumps, it is necessary to modify the rules
as practice data become available.
1.3 Proposed Operation Rules
1. Daily Operation Hour
Maximum daily pump operation is defined 18 hrs per day with considering maintenance
requitment. The maximum daily hours might be adopted in May during land preparation
period of the dry season paddy (DSP) crop. Gradually the daily operation hours will be
shortened in the months of crop growing stage in DSP or in wet season paddy (WSP).
Actually, the pump will be operated during November to March (for WSP) and April to
August (for DSP). The pump will be stooped during maintenance period (September to
Oktober).
2. Numbers of Pump in each station
Two pump will be equipped in each station. One is for duty while the other is off-duty
alternately.
3. Joint Operation with Perjaya Weir
Generally, the electric power produced by the generators of Perjaya Weir is to lift all the
gates related to the weir during flood stage. Therefore, pump operation is used the idle
time of weir operation. By this mechanics, the generators of the weir will be fully
utilized. Thus, during flood, the pumps will not be operated. A control gate will be
equipped for this purpose.
2. Structure Design
The “ Design Criteria for the Komering Pumping Stations” , attached as Appendix A of this
report, was prepared and provided the basic data and analysis methods applied in the
structural design of pumping station, including pump house, inlet channel, surge chamber,
etc.
3. Hydraulic Design
3.1 Basic Conditions
The operation of the pumps will be based on the water levels (WL), at suction and
discharge sides. The concerned WL are briefly below :
1. Suction Side
At Komering main Canal
Q125 + 78.72 Said HWL = +78.70
Q170 + 77.80 NWL = +77.80
Q50 + 77.39 LWL = +77.40
2. Discharge Side
At Wayanda Secondary Canal
Q125 + 84.43 Said at surge chamber HWL = +78.70
Q70 + 84.14 NWL = +77.80
Q50 + 84.06 LWL = +77.40

At Joyo Muliyo Secondary Canal
Q125 + 84.37 Said at surge chamber HWL = +85.10
Q70 + 84.18 NWL = +84.20
Q50 + 84.09 LWL = +83.80
LLWL = +83.20
The canal hydraulic properties of Komering Main Canal, Wayanda Secondary Canal. Joyo
Muliyo Secondary Canal and inlet box at left and right bank, are given in Table 1.1
3.2 Design Conditions of Pumps
Description Unit Pump Sta. 1 Pump Sta. 2

m³/sec 0.83
Pump Unit capacity m³/mm 50.13 26.40
Actual head m 6.40 6.40
Head Loss m 1.20 1.40
Total Head m 7.60 7.80
3.3 Specification of Equipment
Description Pump Sta. 1 Pump Sta.2

1. Pump
Type Mixed flow, vertical shaft Mixed flow, vertical shaft
2. Discharge Valves
Type Butterfly Butterfly
No. of valve 8 2
Size 700 mm 500 mm
3. Discharge Valves
Type Flap Flap
No. of valve 1 1
Size 900 mm 700 mm
4. Power of Prime
Mover 98.1 KW 54.4 KW
5. Over head Traveling
Crane (electric) 8 Ton 5 Ton
3.4 Inlet Conducts
Description Unit Pump Sta. 1 Pump Sta. 2
Width m 2.0 1.4
Height m 2.0 1.4
Length m 20.0 20.0
Conduct Bottom m 76.3 76.7
Fore bay Bottom m 74.80 75.2
3.5 Dimension of Surge Chamber
Description Left Bank Right Bank

Top Elev. +86.10 +86.10
Free board (m) 1.00 1.00

HWL +85.10 +85.10
NWL +84.20 +84.20
LWL +83.80 +83.80
LLWL +83.20 +83.40
Elbow of outlet +83.80 +83.80
Center of Flap Valve Elev. 82.20 82.50
Bottom Elev. 81.10 81.60
B x W x H (m) 5.0 x 5.0 x 5.0 4.5 x 4.5 x 4.5
Dead Volume (m³) 5 x 5 x 2.7 = 67.5 4.5 x 4.5 x 2.2 = 44.6

Hydraulic Computation of Pumping Station No.2
1. Hydraulic Characters of Canals
A. At Komering Main Canal

Q100 = 80.38 m3/sec
h = 2.81 m
V = 1.01 m/sec
n = 0.015
i = 0.000075
hv1 = 0.52
Water level = + 78.03 m
Bottom elev = 75.22 m
Q70 = 2.28 m
V = 0.9 m/sec
hvz = 0.041 m
Water level = 77.50 m
B. At Intake Conduct
Dirnension of Box Conduct ( B x H) = 4 x 1.4 m
h = 1.4 x 0.8 = 1.12 m
A = 1.568 m2, p = 3.64 m
R=A/P = 0.431 m, R2/3 = 0.57
n = 0.014
Q1 = 0.440 m3/sec = 26.4 m3/min
V = Q/A = 0.281 m/sec
Hv2 = 0.004 m, L = 16 m
head loss hl1 = ( n x v/R2/3) x L = 0.00076
i = ( n x v/R2/3) = 0.000048
C. At Pump Bore
D = 500 mm
A = (n x DZ)/4 = 0.19635 m2
V=Q/A = 2.24 m/sec
hv4 = 0.256 w
n = 0.012
Length = 16 m
2 bents with angle = 450, R = 0.75 m
Butterfly value (no return value) one
Flap value (no return valvu) one
2. Head Losses at Intake Conduct and Trash Rake

A. At Entrance
Hl2 = 0.5 x hv3 = 0.5 x 0.004 = 0.002 m
B. At Slots of Stoplog and Sliding Gates
h13 = 0.15 x hv3 x 3 = 0.0018 m
C. At Trash Rake
Angle of Trash Rake = 60°
rake thickness t = 8 mm, spacing b = 52 mm
head loss = β x sinθ x (t/b)4/3 x hv2 .
β = 1.6, sinθ = 0.866, hv2 = 0.041 m
head loss = 1.6 x 0.866 x 0.08244 x 0.041 = 0.00468 m
added losses due to clogging of garbage
hl4= 0.00468 x 3 = 0.014 m
hl1+ hl2 + lit3 + hl4 = 0.01856 m, said 0.02 m
3. Head Losses at Pump Bore

A. At Entrance
Hl5 = 0.2 x hv = 0.2 x 0.256 = 0.0512 m
B. At Strught Pipe
L = 4.1 + 0.9 + 0.9 + 0.9+ 2 + 3.2 + 5 = 16.8 m, said 17 m
from Darcy formula
hl6 = λ x L/D x hv
λ = 1.5 x (0.02 + 0.0005/0.5) = 0.03115
hl6 = 0.0315 x 1710.5 x 0.256 = 0.2742 m
C Friction Loss through Pipe

h17 = 0.35 x hv = O35 x 0.256 = 0.0896 m
D. Fit Butteifly Value

Hl8 = 0.4 x 0.256 = 0.1024 m
E. At 2 Bents Angle = 45°, R = 0.75 m

R/D = 0.75/0.5 = 1.5 from figure in the code.
F = 0.125 hl9 = 0.125 x 0.256 x 2 = 0.064m
F.At Flap value

Hl10 = 1 x 0.256 = 0.256 m
G. At Outlet
Hl11 = 1 x 0.256 = 0.256 m
H. Summation
Hl5 + hl6 + ..... + hl11 = 1.093 m
Total head losses = 1.093 + 0.02 = 1.113 m, said 1.2 m
4. Settlement = 0.2 m
5. Total Head of Pump
Ha = Ho - Hi
Ht=Ha+H1+S
Where = Ha = Actual head (m)
Ho = Discharge water level
Hi = Suction water level
Ht = Total head (m)
HI = Head loss (m)
S = Settlement
A. Suction Water Level(Hi)

Water level at Q70 is adopted as Hi, thus
Hi = 77.50 m
B. Discharge Water Level (Ho)

Water level at beginning of Wayanda Secondary Canal is adopted as Ho. thus
Ho = 84.20 m
Mean while :
Hight Water Level (HWL) = 78.03 m
Planned Water Level = 77.50 m
I.ov, Water Level (LWL) = 77.00 m
Bottom of Sump = 75.00 m
C. Ha = 84.2 - 77.5 = 6.7 m

D. Ht = Ha + HI +S
= 6.7 + l.2 + 0.2 = 8.1 m
6. Pump Type
Vertical shaft with mixed flow is adopted
7. Power of Prime Mover

P = 0.222 x r x Q x H/(np x ng x nb) x (1+α) PS
P = 0.163 x r x Q x H/(np x ng x nb) x (l+α) KW
W'here :
P = Power of prime mover in unit of PS (Horse Power) and
in unit of KW (Kilowatt)
r = Specific gravity of water r w 1.0 kgf/1 for clean water
Q = Pump capacity = 50.1 m3/min
H = Total head = 7.9 m
np = Pump efficiency, np = 0.77
ng = Transmission efficiency of reduction gear, ng = 0.96
nh = Transmission efficiently of fluid coupling, nh = 0.96
α = Allowance, α = 0.15
P = 0.222 x 26.4 x 8.1/(0.77 x 0.96 x 0.96) x (1+0.15)=77 PS
P = 0.163 x 26.4 x 8.1/(0.77 x 0.96 x 0.96) x (1 + 0.15) = 56.5 KW
.
.. = Power of prime mover = 57 KW
8. Design Criteria
A. Selection of Pump Bore D
D = 90 x Q1/2 = 90 x 26. 41/2 = 462 mm
said D = 500 mm
B. Power Resources
The power for pumping station will be provided by the Diesel Engine Generator from the
Perjaya Weir.
C. Daily Operation Hours

Peak daily operation hours is adopted 18 lms. Proposed dails operation hours arC slm0VI n
in the following table.
Wet season paddy Dry season paddy
Nov Dec Jan Feb Mar Apr Ma Jun Jul Aug
5 15 15 14 1s 9 18 16 17 12
D. Allowable Velocity
Pump bore = 3.00 m/sec
Intake conduct= 0.30 m/sec
frash rake = 0.60 in/sec
Hydraulic Computation of Pumping Station No.l
(Alternative II)

Q100 = 80.38 m3/sec
h = 2.81 m
V = 1.01 m/sec
n = 0.015
i = 0.000075
hv1 = 0.52
Q70 = 2.28 m
V = 0.9 m/sec
hvz = 0.041 m
Dimension of Box Conduct ( B x H) = 20 x 2.0 m
h = 2.0 x 0.8 = 1.6 m
A = 3.2 m2, p = 5.2 m
R=A/P = 0.615 m, R2/3 = 0.7235
n = 0.014
Q1 = 0.835 m3/sec = 50.1 m3/min
V = Q/A = 0.261 m/sec
Hv3 = 0.00347 m, L = 16 m
head loss hl1 = ( n x v/R2/3) x L = 0.00041 m
i = ( n x v/R2/3) = 0.000026
C. At Pump Bore
D = 700 mm
A = (n x DZ)/4 = 0.38485 m2
V=Q/A = 2.17 m/sec
hv4 = 0.24 w
n = 0.012
Length = 16 m
2. Bents with angle = 450, R = 1.05 m

A. At Entrance
Hl2 = 0.5 x hv3 = 0.5 x 0.00347 = 0.00174 m
h13 = 0.15 x hv3 x 3 = 0.0016 m
C. At Trash Rake
β = 1.6, sinθ = 0.866, hv2 = 0.041 m
head loss = 1.6 x 0.866 x 0.08244 x 0.041 = 0.00468 m
hl4= 0.00468 x 3 = 0.014 m

A. At Entrance
Hl5 = 0.2 x hv = 0.2 x 0.24 = 0.048 m
B. At Strught Pipe
L = 4.1 + 0.9 + 0.9 + 0.9+ 2 + 3.2 + 5 = 16.8 m, said 17 m
from Darcy formula
hl6 = λ x L/D x hv
λ = 1.5 x (0.02 + 0.0005/0.7) = 0.031
hl6 = 0.031 x 17/0.7 x 0.24 = 0.181 m
h17 = 0.35 x hv = O35 x 0.24 = 0.084 m

Hl8 = 0.4 x 0.24 = 0.096 m

F = 0.125 hl9 = 0.125 x 0.24 x 2 = 0.06 m
F.At Flap value

Hl10 = 1 x 0.24 = 0.24 m
G. At Outlet
Hl11 = 1 x 0.24 = 0.24 m
H. Summation
Hl5 + hl6 + ..... + hl11 = 0.949 m
Ha = Ho - Hi
Ht=Ha+H1+S
Ht = Total head (m)
HI = Head loss (m)
S = Settlement

Hi = 77.50 m
Ho = 84.20 m
Mean while :
C. Ha = 84.2 - 77.5 = 6.7 m

D. Ht = Ha + HI +S
= 6.7 + l.0 + 0.2 = 7.9 m
6. Pump Type

Where :
P = 0.222 x 26.4 x 8.1/(0.77 x 0.96 x 0.96) x (1+0.15)= 139 PS
P = 0.163 x 26.4 x 8.1/(0.77 x 0.96 x 0.96) x (1 + 0.15) = 102 KW
.
8. Design Criteria
D = 90 x Q1/2 = 90 x 50.11/2 = 637 mm
said D = 700 mm
B. Power Resources
Perjaya Weir.

Peak daily operation hours is adopted 18 lms. Proposed dails operation hours arC slm0VI
n in the following table.
5 15 15 14 13 9 18 16 17 12
Intake conduct = 0.30 m/sec
Hydraulic Computation of Pumping Station No.1
(Alternative I)

Q100 = 80.38 m3/sec
h = 2.81 m
V = 1.01 m/sec
n = 0.015
i = 0.000075
hv1 = 0.52
Q70 = 56.3 m
V = 0.9 m/sec
Hv2 = 0.041 m
Dimension of Box Conduct ( B x H) = 2.25 x 1.5 m
h = 1.5 x 0.8 = 1.2 m
A = 2.7 m2, p = 4.65 m
R=A/P = 0.58 m, R2/3 = 0.696
N = 0.014
Q1 = 0.835 m3/sec = 50.1 m3/min
V = Q/A = 0.309 m/sec
Hv3 = 0.00388 m, L = 16 m
head loss hl1= ( n x v/R2/3) x L = 0.00062 m
i = ( n x v/R2/3) = 0.000039
C. At Pump Bore
D = 700 mm
A = (n x D2)/4 = 0.38485 m2
V=Q/A = 2.17 m/sec
hv4 = 0.24 w
n = 0.012
Length = 16 m
Bents with angle = 450, R = 1.05 m

A. At Entrance
Hl2 = 0.5 x hv3 = 0.5 x 0.00488 = 0.00244 m
h13 = 0.15 x hv3 x 3 = 0.0022 m
C. At Trash Rake
β = 1.6, sinθ = 0.866, hv2 = 0.041 m
head loss = 1.6 x 0.866 x 0.08244 x 0.041 = 0.00468 m
hl4= 0.00468 x 3 = 0.014 m

A. At Entrance
Hl5 = 0.2 x hv = 0.2 x 0.24 = 0.048 m
B. At Strught Pipe
L = 4.1 + 0.9 + 0.9 + 0.9+ 2 + 3.2 + 5 = 16.8 m, said 17 m
from Darcy formula
hl6 = λ x L/D x hv
λ = 1.5 x (0.02 + 0.0005/0.7) = 0.031
hl6 = 0.031 x 17/0.7 x 0.24 = 0.181 m

h17 = 0.35 x hv = 0.35 x 0.24 = 0.084 m

Hl8 = 0.4 x 0.24 = 0.096 m

F = 0.125 hl9 = 0.125 x 0.24 x 2 = 0.06 m
F.At Flap value

Hl10 = 1 x 0.24 = 0.24 m
G. At Outlet
Hl11 = 1 x 0.24 = 0.24 m
H. Summation
Hl5 + hl6 + ..... + hl11 = 0.949 m
Ha = Ho - Hi
Ht = Ha + H1 + S
Ht = Total head (m)
HI = Head loss (m)
S = Settlement
Hi = 77.50 m

Ho = 84.20 m
Mean while :
C. Ha = 84.2 - 77.5 = 6.7 m

D. Ht = Ha + HI +S
= 6.7 + l.0 + 0.2 = 7.9 m
6. Pump Type

Where :
P = 0.222 x 26.4 x 8.1/(0.77 x 0.96 x 0.96) x (1+0.15)= 139 PS
P = 0.163 x 26.4 x 8.1/(0.77 x 0.96 x 0.96) x (1 + 0.15) = 102 KW
.
8. Design Criteria
D = 90 x Q1/2 = 90 x 50.11/2 = 637 mm
said D = 700 mm
B. Power Resources
Perjaya Weir.

Peak daily operation hours is adopted 18 lms. Proposed dails operation hours arC slm0VI n
in the following table.

5 15 15 14 13 9 18 16 17 12
Intake conduct= 0.30 m/sec
4. IRRIGATION PUMPS AND APPURTENANSCES
4.1 GENRAL
4.1.1 Scope of Work
The work under this Section includes the design, manufacture, fabrication, supply, shop
tests, finishing, painting, packing for export, insuring, shipment, inland transportation
from port Indonesia to the site, installation and field tests etc. of the mechanical and
Electrical Equipment to be installed in the Komering Pumping Stations in accordance with
the detailed specification contained in the following Clauses and the Contract Drawings.
The Contract Drawings show the required type of the equipment and governing
dimensions and are not intended to define the details of the equipment to be furnished nor
do they exclude any modifications needed.
Except as many otherwise specified in the contract, the following provisions shall be
applied to all parts of the Equipment.
4.1.2 Extent of Supply
The supply mainly includes the following equipment and their necessary accessories :
1) Irrigation Pumps
2) Discharge Pipe, Loose Flange and Expansion Joints
3) Valves
4) Speed Reduction Gears
5) Overhead Traveling Cranes
6) Housing and Dewatering Pump equipment
7) Electrical Equipment
4.1.3 Standards and Regulations
The Design material, manufacture, fabrication, workmanship, test and performance of all
equipment shall conform to the latest edition the following standards or to equivalent
applicable standards of :
1) AGMA - American Gear manufacturers Association

2) AISI - American Iron and Steel Institute
3) AISC - American Institute of Steel Construction
4) ANSI - American national Standard Institute
5) ASME - American Society of Mechanical Engineers
6) ASTM - American Society for Testing Materials
7) AWS - American Welding Society
8) AWWA - American Water Woks Association
9) CMAA - American Water Woks Association
10) HI - Standards of Hydraulic Institute, USA
11) BS - British Standard
12) DIN - Deutsche Industrie Nomen
13) JEM - Japanese Electrical Manufacture’s Association
14) JIS - Japanese Industrial Standards
15) ICEA - Insulated Cable Engineers Association
16) IEEE - Institute of Electrical Electronic Engineers, USA
17) NEC - National Electrical Code, USA
18) NEMA - National Electrical Manufacturer’s Association,
U.S.A
19) SII - Standard Industri Indonesia
If the Contractor desire for any reason to deviate from the above –mentioned standards, he
shall submit a statement of the exact nature of deviation and the certified English language
copies of such standards which he proposes to use to the Engineers to approval.
4.1.4 Materials and Workmanship
1) General
All materials incorporated in the Equipment shall be new and of first class commercial
quality , free from defects and imperfections, and where shown, of the classifications
and grades designated, material not specifically designated herein shall be suitable for
the purpose intended and shall, as far as practicable, comply with the latest
specifications of ASTM or any other approved equipment standard.
All workmanship shall be of the highest class throughout to ensure smooth and
vibration free operation under all possible operating conditions, and the design
dimension materials of all parts shall be such that the stresses to which they may be
subjected shall not render them liable to distortion, undue wear, or damage under the
most server conditions encountered in service.
All parts shall conform to the dimensions show on and shall be built in accordance
with approve drawings. All joints, datum surfaces, and mating components shall be
machined and all casting shall be spot faced or nuts. All machined finishes shall be
shown on the contractor’s drawings.
In all machine parts such as screws, bolt, studs, nuts, and thread for pipes etc, the unit
of measurement should be in metric system.
2) Material Inspection and Testing
Material, parts and assemblies thereof , entering into the works shall be tested, unless
otherwise directed, according to the best and most up to date practice for the particular
type and class of work. When the manufacture desires to use stock material not
manufactured specifically for the equipment furnished, satisfactory evidence that such
material conforms to the requirements stated herein shall be submitted for the
engineer’s approval, in which case tests on these materials ma be waived. Certified
mill test reports of plates and sections will be acceptable. In addition to the mechanical
test required by the specifications before incorporating them in to the work and any
defective material shall be rejected.
For each castings specimen shall be tested and certificate to this effect shall be
furnished by the manufacturer to the engineer showing the conformity of the materials
specified.
The ultimate strength, limit of elasticity, harness, etc, will be determined from such
test pieces. The contractor shall furnish, free of charge, all such test pieces out of
machined to the size, shapes and dimensions. The testing of the specimens shall be
carried out by the contractor at his own expense.
Each two copies of all test reports shall be mailed simultaneously to the employer and
engineer. The contractor shall also supply to the engineer certified test reports giving
the chemical analyses and physical properties of materials used.
3) Shop Assembly
All items of equipments shall be assembled in the shop prior to shipment and test shall
be performed by the Contractor. All test should simulated normal operating conditions
as closely as possible.
All dismantled parts shall be properly match marked and doweled to ensure correct
assembly in the filed.
4) Castings
All Casting shall be dense, sound and true to pattern, of workmanlike finished of
uniform quality and condition, free from blowholes, porosity, hard spots, shrinkage
defects , cracks or other injurious defects, and shall be satisfactory cleaned for their
intended purpose.
Castings shall not be repaired, plugged , or welded without permission of the engineer.
Such permission will be given only when the defects are small and do not adversely
affect the strength \, use, or machine ability of the castings. Excessive segregation of
impurities or alloys at critical points in the casting will be a cause for its rejection.
Surfaces which do not under group machining and are exposed in the final installation
shall be dressed to provide a satisfactory appearance so that they will not require
surface smoothing at the site prior to painting.
a) Iron Castings
Iron casting shall be in accordance with ASTM A48 Class 30 or Equivalent.
b) Steel Castings
Steel Castings Shall be fully annealed and shall be in accordance whit ASTM A148,
A148M Grade 15-125 or ASTM A27 Grade 70-36 or equivalent.
c) Bronze Castings
Bronze castings shall be in accordance with ASTM B584 or equivalent.
d) Phosphor Bronze Castings
Phosphor bronze casting shall be in accordance with JIS H 5113, PBC 2 or

equivalent.
Minor defects or imperfections that will not ultimately impair the strength or
serviceability of the castings, may be repaired by welding in accordance with
accepted commercial casting repair practice without securing approval. No repairs
of major defects shall be made to castings without approval of the engineer.
5) Forgings
Forgings shall be accordance with ASTM A 668 or equivalent. The forgings shall be
free from all defects affecting their strength and durability, including scams, pipes,
flaws, cracks scales, fins, porosity, hard spots, excessive non-metallic inclusions and
segregation,
6) Mild Steel Plate and Bars
a) Structural steel and flat bars shall be in accordance with ASTM A242, A242M,
A36, A36M or equivalent.
b) Steel bolt, nuts and washers shall be in accordance with ASTM A307 or
equivalent.
c) Corrosion-resisting steel and bars shall be in accordance with ASTM A240 Type
304 and 410.
7) Machine Work
a) General
All tolerance, allowance and gauges for metal fits between plain cylindrical parts
shall conform to ANSI Standard B4.1 or other approved equivalent standards for the
class of fit as shown or otherwise required. Finished contact or bearing surface shall
be polished and all surface shall be finished with sufficient smoothness and
accuracy to ensure proper operation when assembled. Parts entering any machine
shall be carefully and accurately machined. All drilled holes for bolts shall
accurately located and drilled from templates.
b) Finished Surfaces
Surface finished shall be indicated on the Contractor’s drawings and shall be in
accordance with ANSI Standard B46.1 or equivalent. Compliance with specified
surface will be determined by sense or fell and by visual inspection of the work
compared to standard roughness specimens, in accordance with the provisions of the
above stated standard.
c) Unfinished Surfaces
So far as is practicable, all work shall be arranged to secure proper matching of

adjoining unfinished surfaces. When there is a large discrepancy between adjoining
unfinished surfaces, they shall be chipped and ground smooth or machine to secure
proper alignment. Unfinished surfaces shall be true to the lines and dimensions
shown on the drawings and shall be chipped or ground free of all projections and
rough spots. Depressions or holes not affecting the strength or usefulness of the
parts may be filled in an approved manner.
d) Keys and Keyways
Keys and keyways shall conform to the requirement of approved standards, unless
otherwise specified or required.
e) Pins and Pin Holes
Pin holes shall be bored to gauge, smooth and straight, and right angles to the axis
of the member. The boring shall be done after the member is securely fastened in
position. Pins shall be of hardened and ground steel and positively held in position.
Wheels or rollers for use in gate shall be mounted on removable pins and have self-
lubricating bushing and brass washers.
f) Lubrication
Before assembly, all bearing and journal surface’s grease and oil grooves shall be
carefully cleaned and lubricated with approved oil and grease. After assembly, each
lubricating system shall be cleaned with clean rags, and greased with an approved
lubricant before assembly, solvent shall not be used on the self-lubricating bearings.
The specification of all approved lubricants will be mentioned in the operating and
maintenance instructions.
g) Balancing
All revolving parts shall be truly balance both statically and dynamically so that
when running at normal speeds and at any load up to the maximum, there shall
operate with the least possible amount of noise.
8) Welding
All welding shall done either manually by the shielded metallic are process or
automatically by the shielded arc or submerged arc method.
The Contractor shall submit a welding procedure for approval of the engineer. Weld
sizes and types shall be shown an all Contractor’s drawings where welding is required.
Plates to be joined by welding shall be accurately cut to size and rolled by pressure to
the proper curvature which shall be continuous from the edge. Plattening the curvature
along the edges with correction by blows will not be allowed. The dimensions and
shape of the edges to be joined shall be such as to allow through fusion and complete
penetration and edges of plates shall be property formed to accommodate the various
welding conditions. The surface of the plates for a distance of 25 mm from the edge to
be welded shall be thoroughly cleaned of all rust, grease and scale, to bring metal.
The technique of welding employed, the appearance and quality of welds mad and the
methods used in correcting defective work, shall conform to the American Welding
Society (AWS) standard D.I.I or other approved equivalent standard.
All welders and welding operators assigned to the works shall have passed a
qualification test, within the preceding six months, for welders and welding operators,
in accordance with ASMF. Section IX or equivalent. The Contractor shall submit to the
Engineer with three certified copies of report of the results of physical tests of
specimens welded in the qualification tests. All costs of qualification test shall be
borne by the Contractor.
The welding Electrodes shall be low hydrogen, suitable for the electric current
characteristic base materials and welding position. The electrodes, fluxes and wire
shall be free from moisture by baking to ensure that the welds will not have excessive
porosity.
Stainless type weld metal, where used in the water passages for protection against
pitting, shall be chromium nickel steel. The type, chemical composition and JIS or
approved standard number of welding rods used for this purpose shall meet with the
approval of the Engineer.
9) Piping
a) General
Steel pipe shall be used for water lines. All necessary studs, bolts, screws, nuts,
washers, gaskets, packing, supports, etc. required in connection with the field
assembly of the piping systems shall be of approved material and of a type that has
been proved satisfactory for the service to which they will be subjected. Where pipe
is embedded in concrete, it shall be carefully set to the required lines and grades and
securely braced and held so that no movement shall occur during concrete
placement which will not deteriorate., weaken or cause damage to the pipe. The
Contractor shall schedule and arrange his Work of installing pipes and pipe supports
in co-operation with the Employer.
b) Hangers and Supports
The Contractor shall supply and install all pipe hangers, brackets and supports
requires for the support of the piping including the drilling and caulking for
expansion anchors and any work incidental to the setting of such embedded anchors
or inserts in concrete.
Unless otherwise specified pipe support, shall be spaced at 2.1 m maximum Vertical
runs shall be supported by means of pipe clamps or collars. Hangers and supports
shall be painted.
c) Embedded insert for Supporting Pipe and Electrical Conduit
The contractor shall design his support system for his equipment and shall define
the location of all required embedded inserts. This system of insert shall be supplied
and installed by the contractor. The Contractor shall design and install the support
system to distribute concentrated loads to the concrete and shall install the clamping
bar used for distributing the load, with the support. The insert shall be left clean and
ready for use.
d) Installation and Workmanship
Piping shall be installed in the locations elevation and to lines in accordance with
the approval drawings. All lines shall be sloped to allow drainage to the low point.
Where a branch cannot be drained through fixture, a drain, valve shall be provided
in an accessible location. All piping shall be fitted and assembled to introduce the
minimum of stressing to the pipe and the fitting and the assembly shall conform to
the best piping practice. The Engineer shall be the sole judge of the standard of
workmanship. All pipe shall be supported and installed to avoid pockets that will not
drain completely. All piping to be embedded shall be tested and approved by the
Engineer prior to being embedded.
Sleeves or check-nuts shall provided where pipe passes through a wall, floor or
beam. The space around the pipe shall be filled with concrete.
All surface of the pipe which come in contact with concrete shall be cleaned prior to
placing the concrete in order to secure a satisfactory bond. Pipe union shall be fitted
where necessary to facilitate installation or maintenance of equipment.
e) Test of Piping Systems
The contractor shall test of pipe lines as directed by the Engineer and shall supply of
labour , material, pumps, plugs, gauges, etc. required to make the complete test.
Lines shall be tested in convenient sections. In the case of failure due to faulty
workmanship on the part of the Contractor, material failure or leaks. Be shall repair
all damage and leaks. replace the faulty material and retest the piping at his own
cost until satisfactory results are obtained. Results of all such test shall be submitted
to the Engineer for approval.
Before testing all anchor blocks, thrust support, and hangers shall be in place. If
piping in tested in sections, temporary and caps shall be fitted to the Engineer for
approval.
Before testing, all anchor blocks, thrust supports, and hangers shall be in place. If
piping is tested in sections, temporary and caps shall be fitted to the approval of the
Engineer. Each section shall be slowly filled with the test medium, care being taken
to expel all air from the piping if liquid in used.
If a drop in pressure occurs, leaks shall be repaired and the pipe line retested until
acceptable.
10) Hydraulic Pressure Tests
All pressure vessels, cooling coils and piping shall be pressure tested and shall meet
the following requirements :
a) Parts subject to water pressure ;
1.5 times the maximum design pressure for 10 minutes.
b) Parts subject to air pressure :
1.5 times the maximum design pressure for 10 minutes.
c) All others parts :
Twice the maximum working pressure but not less than 5 kgf cm² for 10 minutes.
All pressure is gauge pressure. All leaks and evidence or excessive of permanent
detection shall be repaired to the fullest satisfaction and the test repeated until the
test results are satisfactory. Results of all such tests shall be submitted to engineer
for approval.
4.1.5 Change of Material and Equipment
The Contractor shall not make any change to the equipment or in the materials to be
incorporated in the Equipment that specification without the written approval of the
Engineer. Such changes or alterations shall in no way be detrimental to the interests of the
Employer and shall not results in any increase to the Contract Price.
4.1.6 Design and Working Stress
The design, dimension and materials of all parts shall be such that they will not suffer
damage under the most adverse conditions nor results in deflections and vibrations which
might adversely affect the operation of the equipment. Mechanisms shall be so and shall
also pay attention both to the optimum material selection and to construction in order to
ensure their long reliable service life and efficient operation by removing the much
amount of garbage, etc.
All parts which will have to be dismantled or which might have to be dismantled, for
purposes of servicing or replacement shall be fastened with non corrosible fasteners. The
type, material and size of all fasters shall be selected to safely withstand the maximum
superimposed direct, alternating, kinetic, thermal loads and all loads induced by workmen
when installing or removing the fasteners during the life of the Equipment.
All parts which will have to be dismantled or which might have to be dismantled, for
purposes of servicing or replacement shall be fastened with non-corrosible fasteners. The
type, material and size of all fasteners shall be selected to safely withstand the maximum
superimposed direct, alternating, kinetic and thermal loads and all loads induced by
workmen when installing or removing the fasteners during the life of the Equipment.
The design shall be such that the installation, replacement and general maintenance may
be undertaken with the minimum of time and expense. The tolerance used for dimensions
and finished shall be selected with due consideration to the particular properties and
functions of the parts and the corresponding accuracy required to obtain proper operation
and tight sealing.
Wherever possible, all similar parts, including spare parts shall me made to gauge and
interchangeable. Such parts shall be of the same materials and workmanship and shall be
constructed to such tolerances as to enable substitutions or replacement from spare pars to
be made easily and quickly.
Suitable structural steel bases or frames shall be provided where necessary to transmit to
the concrete foundations all loads imposed by the various parts of the equipment. Such
bases or frame shall be supplied complete with suitable anchor bolts and shall be so
proportioned that the bearing loads imposed in the concrete foundations will not exceed
50 kg/cm²
All equipment shall be designed to minimize the risk of fire and consequential damage, to
prevent ingress of vermin, dust and dirt and accidental contact with electrically energized
or moving parts. The equipment shall be capable of continuous operation with minimum
attention and maintenance in the exceptionally server conditions likely to occur in site
climate.
4.1.7 Protection Cleaning and Panting
The following surface shall not be painted :
1) Surface to be buried in concrete

2) Part made of stainless steel, bronze or brass
3) Surface in rolling or sliding contact
4) Surface such as gear teeth
5) Wire ropes
All machined parts or bearing surface shall be cleaned and protected from corrosion
before leaving the manufacture’s shop by the application of an approved rust preventive
compound or a peelable plastic film. Where the letter is impracticable, such parts shall be
heavily covered with high melting point grease or other approved materials. Before
commencement of erection, such parts shall be cleaned with solvent and lapped or
polished bright the Contractor shall supply the materials necessary for each cleaning.
All parts, other than machined parts, which will be exposed after erection shall be
thoroughly cleaned and given alt least three coats of best quality approved primer an at
least two coats of best quality approved finish paint before leaving the manufacturer’s
shop. The Contractor will perform to the equipment touching up on the site after erection,
excepts such apparatus as panels and instruments which will be finish painted under
approved procedures before shipment. The Contractor shall supply paint materials and
necessary tools, which are used at the Site, with the Equipment.
Primer be shall applied to surfaces prepared in accordance with the paint manufacture’s
instructions. The surface shall be wiped clean immediately prior to applying the pain. The
primer and finish coats of paint shall be applied using the methods and equipment
recommended by the manufacturer. The pain system selected shall have a proven life
expectancy of not less than five years in the atmosphere prevailing at this Project.
The internal surface of all pipes shall be cleaned out by approved methods before
installation and prior to commissioning to ensure freedom from dirt, rust, scale, welding
slag, etc. All exposed shall be colour coded for indentification after erection is completed.
The code system shall approved by the Engineer.
The final colour of all equipment shall be approved by the engineer but the Contractor
shall propose a colour scheme for the equipment and shall submit colour chips or paint
samples. A colour chip shall be included with approved colour schedule, for each type of
finish to be applied at the Site.
4.1.8 Labels and Plates
All equipment shall have metal labels or nameplates permanently attached them on their
most visible side after being installed. The lettering shall be engraved or stamped into
them and shall be in Indonesian language. The Contractor shall submit for the Engineer’s
approval the data to be placed on the plates.
4.1.9 Packing and marking
All items of the equipment shall be packed or bundled in such manner that enabling them
to withstand without any damage the roughest possible handling during transportation to
the Site. The packing shall be weatherproof for prolonged outdoor storage in the tropics.
Vermin and insects should not be able to enter bacteria and fungi should not be able to
grow. Fragile units such as pressure indicators, electromagnetic, valves, etc. Shall be
packed separately. Mixing two or more different or identical items into one package is not
acceptable. The contractor shall be entirely responsible for ensuring that the packing is
suitable for transportation by sea and on land, and shall bear full responsibility for any loss
or damage due to faulty packing.
Each crate packing or bundle shall be labeled or marked on its most visible sides the
followings ;
- Port of embarkation
- Port of destination /Legal address of consignee
- Contract designation
- Catalog name number

- Dimension and weight of package
- Notice for transport such as lifting eyes, center of gravity etc.
- Other particular such as fragile signs etc.
Each separately packed items shall accompanied by a packing list enclosed in waterproof
envelope, three copies of which shall be sent to the Engineer Prior to dispatch. The
contents of the package shall relate exactly its accompanying package lists.
After unpacking all packing materials shall be removed from the Ste by the Contractor at
the earlist opportunity and disposed of the satisfaction of the Engineer.
4.1.10 Delivery
No part of the equipment shall be delivery to the site until approval by the Engineer for
such delivery has been obtained. Such approval will be issued to the Contractor’s request
accompanied with the applicable manufacture’s factory as prescribed in the Clause 36(5)
of Special Condition’s of Contract. Upon Shipment of each package or crate there copies
of the shipping list and package lists shall be attached to the Bill of Lading and additional
copy shall be attached to the package or crate shipped.
The equipment shall be delivery with the complete assembly as far possible to ensure that
installation or erection may be easily undertaken with the minimum of time and costs.
4.1.11 Test
1) Test at the manufacture’s Factory
Test at the manufacturer’s Factory shall be carried out in accordance with relevant
clauses specified in the Contract and Specifications. The results all test shall verity that
the guarantees and technical particulars given in the aforesaid documents have been
fulfilled. After each major equipment has been tested and adjusted if required, ti the
satisfaction of the Engineer will issue a certificate to this effects, and authorize the
delivery to the Site of the equipment.
2) Tests the Site
a) Preliminary Test
During and after the installation /erection of each equipment, the Contractor shall
perform the following preliminary test to establish the accuracy of the assembly, to
be in sound, condition to operate under load and to prove the adequacy of the
materials and workmanship. All test and test procedures shall be approved by the
Engineer.
 Insulation tests and draying out of equipment, if required

 Ground continuity tests
 Circuit continuity test
 Testing and setting up of all relays and other protective equipment
 Hydrostatic test on all piping, cooling coils and pressure thanks
 Operation test of auxiliary equipment
 Pump reduction gear and motor shaft alignment and measurement of impeller
vane clearance
 Operation of the pump and motor, to check bearing operations, running
clearances
 High voltage test
 Any additional test required by the Engineer to ensure the safety of the
equipment when operated.
b) Test on Completion
After the ancillary and control equipment has been installed, tested and approved
and each pump unit is fully installed, adjusted and successfully completed its
mechanical run, the Contractor shall conduct operation test in the Engineer’s
presence to demonstrate that the entire work is properly installed. Is free from
objectionable leakage and is correctly adjusted to operate as specified. The test on
completion shall be carried out in such procedures pursuant to the relevant
Condition of Contract.
The Contractor shall make all final adjustment to the control and detection device.
The Contractor Shall be responsible for the operation of the unit during the test on
completion.
The pump operation test shall be made when water level in suction pondage is
situated at above to the stop water level. All the test shall be carried out by the
Contractor at his responsibility and coast including necessary testing equipment
and instrument. The final results off all test carried out by the Contractor shall be
subject to acceptance by the Engineer. Unless otherwise specified or directed, the
contractor shall submit to the Engineer 5 copies of test or inspection report . After
all equipment have been tested and finally adjusted to the satisfaction of the
Engineer , the Engineer will issue a Provisional Completion Certificate.
c) Commissioning (Test Run)
After completion of the works, Contractor shall operate and maintain whole Plant
at his cost (including power charge in case of PLN power is supplied or diesel
engine generator operating cost case of PLN power is not supplied) with
attendance of the employer’s employee during the Maintenance Period as provided
in the Contract. Detailed records of equipment operation and instrument readings
shall be submitted to the engineer periodically for his inspection. The Engineer
shall be at any time during the period have the right to inspect the Contractor’s
operation and to order any additional test to be carried out by and at the coast of
the Contractor.
Upon Expire of the Maintenance period, or extended time thereto as provided in

the Contract, and upon the Engineer’s certificate to the effect that the Equipment
has been test run to the satisfaction of the Engineer, the Employer will issue the
takeover Certificate.
3) Engineer’s Service
Coast the Engineer’s (or his representative’s) service for test specified in this Clause
shall not be include in the Contract Price. However, one man for 10 days for tests at
the Manufactures Factory and three men for total of 30 man-day for test at the Site is
estimated.
4.1.12 Training of Local Staff
The Contractor shall provide the training service by qualified instructors who are fully
skilled in operation and maintenance of machine, controlling equipment and the other
equipment supplied under the Contract for the employer’s employees who will
subsequently be responsible for the operation and maintenance of the Plant to the object
that the level of proficiency of the employer’s employee will be reached and the Plant can
be operated and maintained in a technically and economically viable manner.
The training will consists of :
 During manufacturing and shop testing. Two Employer’s personnel will witness
fabrication and shop testing at the manufacture’s premises for 30 days.
 During the erection or installation at the site, at least 3 months.
 During the commissioning period at least 3 months.
The test schedule for such training shall be submitted to the Employer and the Engineer
for perusal and approval, and the training shall be performed to the satisfaction of the
Employer and the Engineer. Training at the Site shall be conducted in Indonesian language
for which the Contractor may provide interpreters if the need arises.
The coast of training services shall be included in the Contract Price. Furthermore,
expenses for the witness such as air fare for round trips, accommodation, daily
transportation, per diem and incidental fees for two Employer’s personnel shall also be
included in the Contract Price.
4.1.13 Spare Parts
Attendant spare parts shall be furnished by the Contractor together with the respective
Equipment, which includes but not limited to consumable such as grease, rags, oil, etc.
throw-away-after-use items such as packing, filters, etc,; early lost or damaged parts such
as nuts, bolts, etc,: and statically important and irreparable parts. The number and volumes
of the spare parts to be furnished shall be sufficient for one year running of the plant after
Taking-over by the Employer of the Plant.
Any spare part supplied shall be packed or treated in such manner as to be suitable for
storing in the climate at the Site for a period of not less than two year, and each parts shall
be clearly marked with its description and purpose on the outside of the packing.
Spare parts so provided must be delivered into such store as may be nominated by the
Employer and delivery will not be deemed to be complete until the package have been
opened by the Contractor, their contents checked by the employer and the articles re
protected and repacked.
The coast for furnishing of spare parts shall be included in the unit or lump sum price of
the equipment it pertains.
4.1.14 Tools
A complete set of all necessary tools other than the Contractor’s equipment be supplied by
the contractor to enable any dismantling, reassembling or testing to carried out on any part
of the Equipment whether of an electrical, mechanical or any other nature during the life
of the equipment and shall be subject to approval by the Engineer. The cost for supply
tools of this Clause shall be quoted in the Bill of Quantities.
Further, the following maintenance tools shall be supplied separately and additionally.
Two pcs : Chain wrenches (Nominal pipe capacity : 75 – 45 mm and 10 – 45 mm each
Two pcs : Pipe wrench (Pipe capacity : 10 -50 mm)
Two pcs : MCCB 325 AF/250 AT, 3 Phase, 4 poles
Four pcs : MCCB 200 AF/160 AT, 3 Phase, 4 poles
Two pcs : MCCB 160 AF/125 AT, 3 Phase, 4 poles
Four pcs : MCCB 43 AF/35 AT, 3 Phase, 4 poles
One pc : Master maintenance set snap-on tools (Snap-on Tools Model 5351 A –GS-B
or equivalent).
Two pcs : Magnetic base holder (Snap-on tools Models CM-233 or equivalent).
One Pcs : Dial calipers (snap-on Tools Model CM -210 or equivalent).
4.1.15 Payment
(1) All equipment specified in this Section will be paid for at the unit or lump sum prices
tendered there for respectively in the Bill of Quantities, which price shall include the
costs of all labour, materials, equipment, tools and incidental for design, manufacture,
ocean and local transportation, erection or installation, and test of the equipment, and
furnishing of accessories and spare parts all as required by the Specification and the
Drawings and directed by the Engineer. The price shall also include duties, taxes,
insurance’s overhead and all other necessary expenses connected herewith.
(2) All payment of the Equipment shall be incorporated into the statement of monthly
payment stipulated in Clause 60(5) in the General Conditions of Contract, and will be
made in the manner prescribed below, provided that the payment shall be subject to the
deduction of payment of the advance payment as stipulated in Clause 60(5) the
General Conditions of Contract.
(a). Advance payment : 20% of the Contract Price will be paid as and advance
payment in compliance with the provision in the Conditions of Contract.
(b) Delivery of Equipment to site : 70% of each amount priced in the Hill of Quantities
will be paid to the Contractor upon arrival of each equipment at the Site against
submission of Inspection Certificate and Authorization of Delivery.
(c) Installation : up to 90°% of each amount priced in the bill of Quantities will be paid
to the Contractor upon completion of installation Equipment and after passed the
final test on completion.
(d) Commissioning : on expire of commissioning period as required in the Contract,

final payment will be made up to Whole value of the Contract.
(3) The payment for the other items related to Mechanical and Electrical Equipment will
be made in the following manner :
(a) Cost of training of local staff the site during the installation and commissioning
period will be paid for lump sum price tendered therefore in the Bill of Quantities
upon the expire of said 3 months training course during commission period or on
the issuance of the Employer’s Take-over Certificate whichever comes earlier.
(b) Cost of Tools provided by the Contractor as prescribed in Clause 4.1.14 will be
paid for in lump sum price tendered therefore n the Bill of Quantities upon the
delivery to the Site and acceptance by the Employer of said tools.
4.2 IRRIGATION PUMPS
4.2.1 General
This clause cover the main requirement of the design, manufacture, test before shipment,
furnish, delivery, erection and test at the Site of Four Irrigation Pumps, each complete with
all equipment and necessary accessories and facilities for their satisfactory and efficient
operation.
The complete detail of the various parts of the equipment are not specified in the
Specifications. The Contractor shall furnish the Equipment complete with all accessories
to meet in all respect the requirement of the Employer with regard to performance,
reliability and satisfactory operation, but subject the Engineer’s approval.
The arrangement of the pump is shown on the respective Contact Drawings. The pumping
stations shall be used for lifting of irrigation water form the Komering Primary Canal to
the Way Anda and Joyo Mulyo Secondary Canals during November to August for daily
operation around 18 hours.
4.2.2 Design Condition.

II Pump Station I Pump Station
 3
Design Discharge per set, m /s 0.835 0.440
 Number of Drainage Pumps, Sets 2 2
 Design Total Head. M 7.40 7.60
 Total Head Variation, m 1-3 1-3
 Bore Diameter (Approx), mm 700 500
 Guaranteed Efficiency (Min.) 79 7
vertical vertical
 Pump type : shaft
mixed flow mixed flow
 Pump type : flow
electric, squirrel Induction
 Primer mover cage, motor
 Power to be provided from Perjaya weir Perjaya weir authority
authority
4.2.3 Techincal Requirements
The irrigation pump shall be one-floor type, vertical shaft, single stage, mixed flow
pumps and each shall be connected with a vertical shaft induction motor through a
reduction gear.
The irrigation pump shall be capable of satisfactory operations under full range of total
head without any cavitation, pitting, excessive noise and vibration.
The pump shall be designed and installed at the pimping station as shown on the relevant
Contract Drawings. The tenderer shall check the completeness and adequateness if the
layout of the intake basin and discharge structure, and shall state the dimensional data
wish to match with his design requirement.
The pump speed may be varied to match with the manufacturer’s optimized design, but
shall not be greater than that recommended by the Hydraulic Institute curve “ Upper
Limits of Specific Speed”, base in the recommended submergence of the pump impeller.
The pump shall be design and constructed with robust construction having adequate
stiffness and shall be proved to have smooth running under the specified operation range
with high hydraulic efficiencies.
All component shall be made of suitable material and finished in the best known modern
practice for services intended. The Tenderer shall list the materials with the adequate JIS,
ASTM or SII specification for which he recommend to use for the specified equipment.
If the Tenderer wants to use the materials other than materials as specified, he shall
indicate the deviations and give explanations.
The hydraulic trust and the weight rotating parts of the pump shall be supported bye the
thrust bearing furnished with the reduction gear. The weight of the reduction gear and
motor and the thrust load acted in t he trust bearing of the reduction gear shall be
supported at the motor floor, and the weight of the pump and water in the pump casing
shall be supported the pump floor.
4.2.4 Construction
Corrosion allowance of 2 mm shall be added to the surface of the pump parts exposed in
irrigation water. Adequate provision shall be made for convenient handling of the all
parts during assembly or disassembly of the pumps.
(1). Suction Bell, Casing and Diffuser Casing
The suction bell, casing and diffuser casing shall be made of gray iron casting
conforming with ASTM A48 class 30.
The suction bell shall have a flared and uniformly enlarged design to minimize the
hydraulic entrance losses .
The casing facing to the impeller shall be well machined and finished as practicable
to minimize the leakage loss between impeller casing and impeller, and to obtain high
pump efficiency.
The casing shall be flanged and machined and shall be able to be separated for
maintenance purpose.
(2). Column Pipe and Discharge Elbow
The column pipe and discharge elbow shall be made of gray iron casting conforming
with ASTM A48 class 30.
The column pipe shall be assembled between the diffuser casing and discharge elbow.
The column pipe and discharge elbow shall have smooth inner surfaces so as to allow
effective discharge with a minimum head loss.
The column pipe shall be assembled between the diffuser casing and structural steel
or iron casting rugged enough to support weight of complete unit as well as dynamic
loading and hydraulic thrust. Lifting and support lugs shall also be provided ofr field
installation and future maintenance of the column pipe and discharge elbow.
The discharge elbow shall be designed to withstand all structure loading, and be
provided with adequate curve sections for discharging the water form the column
pipe to the horizontal outlet. A manhole with watertight corner shall be provided for
convenient access to the interior of discharge elbow.
(3). Impeller.
The impeller shall be of the mixed-flow type and shall be mad of stainless steel
casting conforming with ASTM A148 Grade 150-125, or shall be made of gray iron
casting conforming with ASTM A48 class 30, or all Bronze.
The impeller shall be designed ti withstand the specified actual head, and shall be
free form noise, cavitation and vibration. The impeller shall be statically and
dynamically balanced by accurate machining and finished to minimize losses arising
form hydraulic impulse and to prevent from vibration during operation. An optimum
clearance shall be provided between of the impeller and the casing liner so as ti
minimize the efficiency loss of the pump and minimize the occurrence of cavitation.
All the matching surfaces shall be machined and highly finished to a smooth surface.
Appropriate sealing devices shall be provided such that no water mud and sand will
entrap into the setting part between impeller vanes and impeller hub.
(4) Shaft
The shaft shall be made of stainless steel conforming with ASTM A2,40, Type 304.
The shaft shall be accurately machined for precision shafting, and shall have
sufficient strength to transmit the required power. In particular consideration on the
critical speed; the design shall be taken with ample safety allowance.
(5) Shaft Coupling
The coupling between the shaft of the reduction gear and the pump shaft shall be of
flexible type which mainly consists of hub, spacer and flexible element. Adjustment
shall be made at this coupling to obtain the correct axial alignment of the impeller in
the casing.
(6) Submerged Guide Bearings
Submerged guide bearing shall be provided to support radial load of the pump shaft.
The bearing shall be located just below the stuffing box and in the casing. The
bearing shall be of ceramic type or well practice-proven type with appropriate
construction and subject to approval by the Engineer.
(7) Stuffing Box
Gland seal shall be provided at the stuffing box. The gland seal shall be of
waterless type with ceramic floating seal or of well practice-proven type with
appropriate construction and subject to approval by the Engineer.
(8) Bolts and Nuts
All bolts and nuts of pump being in contact with the canal water should be stainless
steel conforming to ASTM A276. Type 31G.
4.2.5 Control System

(1) Description of Pump Operation
Each pump shall be operated in the motor room, and shall be able to be individually
operated on the local control panel. A changeover switch for the individual
operation shall be turn of selector switch in the motor room.
(2) Operating individual for Irrigation Pump
Starting individual
(a) Confirming the water level conditions

(b) Opening the discharge valve
(c) Confirming the starting conditions
(d) Starting the irrigation pump Starting conditions for the irrigation pumps shall be
interlocked.
Stopping individual
(a) Stopping the irrigation pump

(b) Closing the discharge valve
Protection and Alarm
The Contractor shall provide all necessary facilities in the control system for
stopping the operating pumps and giving alarms and indications to the operator on
the occurrence of each of the following-conditions :
(a) Excessive temperature rise in thrust bearing of 'reduction gear

(b) Trouble of startup
(c) Extremely low water level at suction side
(d) Fault of control power source
(e) Extremely low voltage of electric power
(f) Overload of irrigation pump motor
(g) Extremelv low pressure of lubricating oil for reduction gear
(h) Other items deemed necessary by the Contractor.
The Contractor shall also provide all necessary facilities in the control panel for
giving alarms and 'indications to the operator on the occurrence of each of the
following conditions :
(a) Excessive temperature rise of lubricating oil for reduction gear

(b) Over torque of discharge butterfly valve
(c) Emergency stop (only bell alarm)
(d) Other items deemed necessary by the Contractor.
(3) Alarm System

The Contractor shall provide the alarm systems for water level of pump suction pit and
discharge surge chamber. The lead switch type level switches protected by the guard
pipe shall be installed in the suction inlet and surge chamber. The alarm shall be
performed in combination with the conditions for irrigation pump and water levels.
The audible alarm shall be given by a buzzer at the motor room. Detail of alarm
systems shall be directed by the Engineer.
4.2.6 Accessories
The following accessories shall be provided by the Contractor for each pump.
(1) One complete set of coupling bolts and nuts

(2) One complete set of anchor bolts; nuts and liners
(3) One complete set of compound gauges
(4) One set of air vent valve including necessary pipes
(5) Special tools
(6) Spare parts for one year operation
(7) Other necessary accessories
4.2.7 Documentation Required with Tender
The Tenderer shall submit the following documentation together with the tender:
(1) Pump performance curve : total head. Efficiency, NPSII(R), power input versus
irrigation pump capacity.
(2) Outline, sectional drawings with material list for irrigation pump.
4.2.8 Test
(1) Tests at the Manufacturer's Shop,
Before delivery from the manufacturer’s shop, all pumps shall be assembled.
inspected and tested by the Contractor to prove the satisfactory functions. The test
includes dimensional check, material test, static and dynamic test of impeller,
performance test, painting and packing inspection. If any defect or improper
operations are discovered, they shall be corrected.
The performances test of a11 irrigation pumps shall be carried out in the presence
of the Engineer in accordance with the applicable provisions of the latest JIS
B8301 "Testing Methods for Centrifugal Pumps; Mixed flow Pumps and Axial
Flow Pumps" or equivalent. Measurements shall be taken on not less than five
different discharges including the discharge quantity at the rated total head.
The pumps shall. be rejected for any of the following reasons.
(a) The shaft power at one point or more in the measuring scope exceeds the specified
motor rate output.
(b) Discharge which corresponds to the rated total head is smaller than the specified
values.
(c) The pump efficiency which corresponds to the rated total head is smaller than the
specified value.
(2) Installation and Test at the Site
The contactor shall take out the pump form it’s packing and shall inspect the pump for
damage. The Contractor shall repair or replace any damaged portion of the pump
subject to approval of the Engineer.
The liner for each pump base plate shall be installed on the concrete foundation. The
base plate shall be assembled and installed on the liner. The base plate level shall be
aligned and adjusted to keep the pump vertical. After preliminary alignment, the
anchor bolts shall be grouted. The base plate shall be tightened and the grouted with a
non-shrink grout by the Contractor after secondary alignment.
The Contractor shall test all materials, apparatus, equipment and works before the
completion date. Before any test is made, the Contractor shall check the work
materials. Apparatus and equipment for proper connections and adjustment and place
in satisfactory operation condition.
After the installation has been completed and pumps have been operated fir a sufficient
period to make all desirable corrections and adjustment, each pumping unit and
associated equipment shall be tested to prove that the operation is satisfactory.
The test on Completion shall be done in accordance with the requirement of the clause
4.1.11.
System shall be tested as deemed necessary by the engineer, to prove that the facilities
meet the operational requirement.
Any part showing defective performance during the test shall be repaired or replaced
by and at the costs of the Contractor to the satisfaction of the Engineer.
4.3 DISCHARGE PIPES LOOSE FLANGES AND EXPANSION JOINTS
4.3.1 General
The Contactor shall provide the necessary discharge pipe form each pump to be discharge
side with a loose flange. The pipes shall be designed to minimize the hydraulic losses and
for water to flow smoothly. The loose flange with tension blots shall be provided for easy
assembling and disassembling of the pump and the pipe.
For each discharge pipe of the irrigation pump and expansion joint shall be provided
between the pump house and surge chamber.
4.3.2 Discharge Pipes.
The design condition of the discharge pipes be as follows :
Design pressure : 2 kgf/cm2

Corrosion allowance : 2 mm
Size : 700 mm to 900 mm dia and 500 mm to 700 mm dia
Flange rating : JIS B22102 kgf/cm2
Each discharge pipe shall consist of a pipe proper a magnifying pipe, see rings and other
necessary component. Each pipe shall be connected with a flange. The pipes shall be
made of mild steel conforming with ASTM A242.
The following accessories shall be provided by the Contractor for each pipe :
(1). Bolts and nuts

(2). Gasket.
(3). Other necessary accessories.
Before delivery from the manufacturer’s shop the pipe shall be assembled to check the
satisfactory manufacturing. The tests shall include material test, dimensional check,
painting and packing inspection. If any defect is discovered. Is shall be repaired.
4.3.3 Loose Flange
Each loose flange shall consist of a loose flange proper a short pipe. Tension bolts and
nuts.
The loose flanges proper shall be made of mild steel conforming with ASTM A242. short
pipes shall be design in accordance with the design requirement of discharge pipes.
4.3.4 Expansion Joints
The design condition of the expansion joint shall be as follows :

Settlement : 200 mm
Diameter : 700 and 500 mm
Flange rating : JIS B2210 2 kgf/cm2
The expansions joint shall be rubber type.

4.3 VALVES
4.4.1 General
This Clause covers the design, manufacture, test before shipment, erection and tests at the
Site of :
Four discharge valves

Two non-return valves
The complete detail of the various parts of the equipment are not specified in the
Specifications. The Contractor shall furnish the equipment to meet in all respects the
requirements of the Employer in regard to performance reliability and satisfactory
operation, but shall be subject to the Engineer’s approval.
The arrangement of the valves are shown on the Contract Drawings.
4.4.2 Discharge Valves
Each irrigation pump shall be provided with an electrically operated butterfly valve in its
discharge pipe. The valves shall be of flanged type and be complete with actuating
Mechanism, bolts nuts, gaskets, lifting lugs and supporting foot.
The butterfly valves shall be of water-tight construction and shall conform to the
following, and shall be installed in horizontal position.
Size : 700mm and 500mm diameter

Maximum differential pressure : 1 kgf/cm2
Maximum flow through valve : As determined from the pump characteristics
Flange rating : JIS B 2210 2 kgf/cm2
The materials of construction of the valve shall be as follows.
Body : Gray iron casting conforming with ASTM A48 class 30

Disc : Gray iron casting conforming with ASTM A48 class 30
Shaft : Stainless steel conforming with ASTM A240 Type 410
The valve shall be connected with the pipe by means of flange connection
Provision for manual operation and the interlock device shall be provided. Each butterfly
valve shall have two limit switches to actuate at full open and full closed positions. Torque
switches for the butterfly valve shall also be provided by the Contractor.
4.4.3 Non-Return Valves
The Contractor shall provide a non-return valve at the end of each discharge pipe of
irrigation pump. The non-return valve shall be used for preventing back-flow of the water
from the surge chamber to the pump.
The design conditions of the valves shall be as follows :
Type : Flap valve

Size : 900 and 700mm diameter
Corrosion allowance : 2 mm
The valve shall consist of a valve case, two sets of flaps, spindle and other necessary
components. The flap shall be inclined 15 degrees from the vertical axis to smoothly seat
it self at the valve case. The valve shall be connected with the discharge pipe by means of
a flange connection. The valve case shall be made of either cast iron of mild steel, the flap
of mild steel, and the spindle of stainless steel.
Before delivery from the manufacturer’s shop, the valve shall be assembled and tested to
prove the satisfactory functions. The tests shall include dimensional check, material test,
leakage test, painting and packing inspection. If any defect or improper operations are
discovered, they shall be corrected.
After the installation has been completed, the valves shall be tested to prove that the
function is satisfactory with the pumping equipment.
4.4.4 Tests
Before delivery from the manufacturer’s shop, the valves shall be assembled and tested to
prove the satisfactory functions. The tests shall include dimensional check, material test,
leakage test, painting, and packing inspection. If any defect or improper operations are
discovered, it shall be corrected.
After the installation has been completed, the valves shall be tested to prove that the
function is satisfactory with the pumping equipment.
4.5 SPEED REDUCTION GEARS
4.5.1 General
The reduction gear shall be of vertical, planetary, air-cooled type and be sufficient for
transmission of the power from the motor to the pump. The reduction gear shall be
designed to provide efficient, smooth and reasonably quiet-running drive under operation
conditions of the irrigation pump.
4.5.2 Design Conditions
Rated transmission power : Same as rated output of motor

Input speed : Depend on manufacturer
Output speed : Depend on manufacturer
Guaranteed transmission efficiency : Depend on manufacturer

Service factor : Depend on manufacturer
4.5.3 Construction
The reduction gear shall consist of the power input shaft, sun gear, planetary gears,
internal gear, power-output shaft and other necessary components.
The hydraulic thrust and the weight of rotating parts of the pump shall be supported by the
thrust bearing of the reduction gear.
All gears shall be hardened, precision ground or cut and shall have no defect on the
surface. The rotating direction of the power input shaft shall be same as that of the power
output shaft. The materials of the sun and planetary gears, the internal gear and the shafts
shall be of nickel chromium steels, chromium molybdenum steels and carbon steel
castings, respectively, or approved materials. The reduction gear shall be for 25,000 hours
operation.
The gears, the inside coupling and the bearings shall be lubricated by a lubricating unit
which shall be provided to each reduction gear and shall consist of an oil cooler, an oil
circulation pump provided in the reduction gear, an oil supply pump driven by a separate
motor and other necessary components.
An air-cooled oil cooler shall be provided and be mounted on the side of the gearbox unit.
The cooler consists of a radiator and motor-driven fan. The radiator shall be able to
withstand the maximum pressure of lubricating oil.
4.5.4 Accessories
The following accessories shall be provided by the Contractor for each reduction gear.
One set of air-cooled oil cooler

One set of pressure gauge
One set of strainer
One set of electrically-driven priming oil pump
One set of oil circulation pump integral in the reduction gear
4.5.5 Tests
(1) Test at manufacture’s Shop
Before delivery from the manufacture’s shop, the reduction gear shall be assembled
and performed to prove satisfactory functions. The operation test shall be made with
a pump and motor assembled as an operating unit to simulate load conditions, and be
chcckcd on the lubrication systcm, lcal:agc, noisc, vibration and bcaring tcmpcraturc
rise. The tests shall include material test, dimensional check, painting and packing
inspection. If any defect or improper operations are discovered, they shall be
corrected.
(2) Tests at the Site
After the installation has been completed, the reduction gears shall be tested under Y
field conditions to prove that the operation is satisfactory with the pumping equipment.
If any unsatisfactory performance is observed, the whole system shall be replaced by
and al the costs of the Contractor. Repair or replacement of part or parts will not be
accepted.
4.6 OVERHEAD TRAVELLING CRANE
4.6.1 General
One set of low speed overhead traveling crane shall be provided in the pumping house as
shown on the Contract Drawings. The crane shall be electrically operated and be complete
with crane girders, hoists, shafts, gears, complete control equipment, motors, limit
switches, current collector, trolley electrification, brakes; hoisting ropes; blocks and
hooks, and necessarv components for proper and efficient operation of the crane. Crane
rails, stoppers and their fittings shall be also provided.
The crane shall be in accordance with the following conditions :
Hoisting capacih : 8 ton and 5 tan for P. S. No. 1 and 2

Span : Approx. 9 m
Lifting height : Approx. 7 m
Traveling length : Approx. 9.2 m
Hoisting speed : Approx. 2.5 mimin
Traveling speed : Approx. 20 m%min
Trolley traveling : Approx. 10 mimin
4.6.3 Construction
The crane shall be designed such that all movement will take place smoothly and
positively. No slipping or creeping of the load shall occur at any times. The crane shall be
designed for continuoush, repeated cycles upto one hour total duration, and shall be
capable of traveling with the full load suspended in any position of the pumping
equipment provided in the pump house. Special care shall be taken to guard against oil or
grease dripping from the crane.
The crane Structure shall be of steel and all-welded construction. The crane girder shall
consist of two main girders connected together at each end. All crane motors shall be
capable of being controlled from the operating floor level by means of pendant push
button switch.
The circuits shall be so arranged that when any push button is released the corresponding
motor shall stop and the brake applied.
The travel mechanism of the crane girder shall be mounted on the crane girder assembly.
The wheels will be driven directly the motors installed at both ands through the oil bath
type gear box. For the wheel bearings, anti-friction bearings will be used to permit access
to the travel mechanism for inspection and maintenance.
The trolley frame shall be of fabricated steel contraction. Wherever possible, trolley steel-
work shall be arranged to support checkered plate walkways for convenient and safe
access to all equipment on the trolley. The trolley traverse drive unit shall incorporate a
motor driving enclosed gear reducer through flexible coupling to cross shaft which shall
be mounted on ball or roller bearings. Four steel trolley wheels shall be double-flanged
and shall be fitted with ball or roller bearings on fixed axels. Two of the wheels shall be
matched as driving wheels.
Sparing set magnetic brake, mounted on the motor and shaft shall be applied for the travel
mechanism of the crane girder and the traverse mechanism of the trolley.
The hoist drums shall be fitted with bronze bushing and shall operate on fixed shafts and
shall be mounted in such a way that a drum and shaft can be readily removed together. The
hoist drums shall be steel or cast iron and shall be accurately machined grooving to
accommodate the hosting ropes.
All gears other than final drivers, shall be enclosed in gearboxes with automatic
circulation, grease, gun, or in the case of the final drive gears and hoist ropes, by direct
manual application, of heavy bodied grease. All load warning and instruction notice,
necessary for the crane, shall be provided by the Contractor.
The Contractor shall provide, on the crane adequately rated single phase transformer,
suitable for continuous operation for the supply of power to the control circuits, lighting
and power outlet, etc.
The electrical power supply to the crane shall be by means of three phase copper collector
wires supported by brackets, attached to the buildings.
A cable carrier system shall be employed for the current collection for trolley traversing.
All motor shall be of AC, totally enclosed, squirrel cage type 25 % ED rating.
4.6.4 Accessories
The following accessories shall be provided by the Contractor for the crane :
1. One lot of trolley wires, insulators and brackets

2. Lubricating oil, grease, machine oil with 50 % spare
3. Working light
4. Signal horn
5. Other necessary accessories
4.6.5 Tests
The crane shall be completely assembled at the manufacture’s shop and the following tests
shall be carried out :
1. Inspection for fabrication and appearance
2. Dimensional inspection
3. Test for each drive mechanism
As for test of the traveling device, the girder shall be assembled temporarily on the
ground, and idle running test shall be performed.
Any defect observed during the test shall be repaired by the Contractor.
After the complete assembly at the Site the crane shall pass an operation test including
brake system test. These test shall demonstrate that performance have been met and that
the entire equipment meet the Contract requirements and that it is properly installed and
adjusted to operate correctly and safely.
4.6.6 Lettering
On the visible sides of the girders the rated load of the crane shall be painted as large as
possible in black capital letters against a light background as MAX ……………TON.
4.7 Lettering
4.7.1 General
Station pump equipment such as such as housing pumps, dewatering pumps, water supply
pipe, drainage pipe, etc. shall be provided in the pump house. The housing pump shall be
installed in the deep well nearby the pump house for supply of clean water. The
dewatering pumps and pipe shall be used for drainage of the sump pit to the outside of the
pumping house.
The station drainage pump equipment shall be designed for two station pumps in
accordance with the following conditions :
Housing Pumps
Nos. of pumps : Two sets, each station one set

Type of pump : centrifugal pump
Rated discharge per unit : approx 30 liter/mm
Rated design head : 10 m or more
Liquid handled : well water
Dewatering pumps
Nos. of pumps : Two sets, each station one set

Type of pump : Portable Submersible type
Rated discharge per unit : 0.5 m³/min
Rated design head : 10 m or more
Water proof cable length
(min) : 15 m
Liquid handled : Canal water
Flexible tube : 30 m
4.7.3 Contraction
The housing pump and dewatering pumps shall be provided with

effective lubricating system. The impeller and casing shall he
made. of cast iron or bronze. The design and construction of the
motor shall be made to prevent the entry of external water, foreign
material or contamination Into the motor under operating
conditions. The cables, shall be water proof and be supplied to
adequate length.
A check valve shall be provided at the outlet side of the housing

pump to prevent adverse water flow when the pump stops. T he
check valve shall be swing type. The valve body shall be made of
PVC and the sealing surface of the valve shall be accurately
machined for complete unit and function of the slop valve. The
valve body shall be made of PVC and the contact surface of the seal
parts shall he accurately machined for sufficient water seal when
the valve closes. Flanges shall be provided for the valves connected
to the piping.
The pumps shall be completely assembled at the manufacturer's

shop and tested to prove the capacity of them before shipment.
After installation at the Site, the operation test for the drainage
pump equipment shall be carried out.
Tests on completion shall be made for the station pump equivalent

to the main pumping equipment.
A piping system, connected to the housing pump and the relevant

valves should be provided by the Contractor.
One set of flexible tube of 30 m long shall also be provided by the

Contractor for each dewatering pump draining the water of suction
chamber of main pump to the drainage System of the house.
4.8 ELECTRICAL EQUIPMENT
4.8.1 General
1) Electrical Equipment to be Provide
(a) All electrical equipment required for the power supply, and
operation and controls of irrigation humps and overhead
traveling crane shall be supplied and installed. The available
power source will be 380 Volt, 3-phase, 50 Hertz, 4 wire
system.
(b)Irrigation pump motors Shall 17G directly coupled to

reduction gear of the pump unit to drive the pumps for
pumping Komering primary canal water. The motor shall meet
the ranges of pumping rates and the capacity and speed shall
be coordinated with the requirement of the pump to be
driven. 'I-he motor shall be reduction voltage started by
soft-starter.
(c) To sets of step up and step down transformer. 200 KVA. 20 KV.
380/220 volts; 3 phase, 4 wire, will be used to low voltage
switch gear for power.
(d)The existing Perjaya weir diesel engine generator units are

rated 600 kW, 3 phase, 3800/200 Volt, 50 Hz, with starting
system for supply the station power and lighting.
(e) Sufficiently high voltage and. low voltage power/control

cables shall be supplied and installed for connection of the
equipment to form an operational system. The cable trays and
conduits shall, be supplied and 'installed to run the cables.
(f) The Tenderer must include in his offer all the specified spare
parts and recommend other spare parts if necessary.
(g)The Tenderer must include in his offer all tools necessary for
the maintenance operation of the pumping station.
(2) Standards
All electrical equipment and accessories shall be in accordance

with the latest issue of the standards listed in Clause 3.1.3.(15) -
(18) and the following :
Peraturan Umum Instalasi

Listrik (PUIL) Regulation or
Standard of PLN
Other regulations related to work safety.
(3) Shop Drawings
The Contractor shall prepare the following shop drawings in

large scales far approval of the Engineer showing all necessary
details of equipment and installation :
(a) All equipment and installation details, including foundations

(b) All distribution, control panels and boxes with complete electrical wiring diagram
(c) All conduit runs and wises, pull boxes and location
(d) Other shop drawings as required by the Engineer
If departures from the Drawing are necessary and required by the Contractor details of
departures and the reasons therefore shall be submitted with the drawings for
Engineer's approval.
(4) Data and Samples
The Contractor shall submit for approval a complete set of data and information such
as catalogues, diagrams, performance curves, charts, layout drawings and other data
published by the manufacturer to demonstrate conformance to the Specifications and
Drawings of the installed equipment.
The Contractor shall submit samples of conduit, cables, cabling devices, and of any
other items as may be required by the Engineer.
4.8.2 Power System Information
(1) 20 KV system
20 KV lines shall be of 35 mm2, alluminium air cable, The ratings for 20 KV system
are as follows :
Nominal Voltage : 20 KV
Nominal frequency : 50 HZ
No of phases :3
No of wires :4
Material : Alluminium A = 35 mm2
(2) 380/220 V system
Four sets of the existing diesel engine generators, total rated 600 KV 380/220 volts, 3
phase, 4 wire, 50 H7 from the Perjaya Weir will supply power to these pumping station
operations.
Two sets of step up & step down transformer, 1.200 KV, 20 KV – 380/220 volts, 3
phase, 4 wire, 50 HZ will be used law voltage. switch-gear far power, lighting, small
appliance and sockets uses. The ratings are as follmos :
Nominal voltage : 380 V

Rated voltage : 40 V
Nominal frequency : 50 Hz
No of phases :3
No of wires :4
Maximum Fault Level : 50 KA for 1 sec,
Neutral : Solidly earthed to grounding network.
4.8.3 Step up and Step down Transformer
(1) Rating
This Clause specifies the requirement for transformer 200 KV A, 3 phase, oil
immersed naturally cooled, sealed type, with horizontal ducts of primary and
secondary on the opposite side, suitable for installed outdoor at an ambient
temperature of 40 C. Transformer rating shall be as follows :
Number of units : 2 sets

Rated capacity : 200 KVA
Rated frequency : 50 Hz
Rated primary voltage : 20,000 V
Rated secondary voltage : 380 V
(2) Construction
(a) Winding
The transformcr winding shall be of coppcr, fully insulatcd for continuous working
at specified service voltage and the bracing of the windings shall be such that no
mechanical movement of the coil is possible as a result of the dead short circuit on
any side of the transformer. The transformer shall withstand, without injury the
dead short circuit, for a duration of at least two seconds.
(b) Corc
The core shall be of cold rolled, oriented grain silicon steel of low hysteresir loss
and high permeability. The cores, framework, clamping arrangement and general
structure of transformers shall be of robust design capable of withstanding any
shocks to which transformers may be subjected. All reasonable care shall be taken
in the design and construction of transformers to rcducc noisc and vibration to a
minimum.
(c) No Load Tap Changer
The no load tap changing switches shall be located inside the tank under oil and
rigidly attached to the core structure. A hand hole shall be provided for the tap
changing switches.
(d) Tank
The tank of the transformer shall be made of mild steel plate with external cooling
provisions. The tank shall be fight sealed and shall be sufficiently rigid to resist the
internal pressure variation. The tank cover -,hall be provided with lifting eyebolts.
(e) Oil
The transformer shall be supplied with a sufficient quantity of oil suitable in all
respects for continuous service. The oil shall be of approved grade and comply
with National or International Standards.
(f) Skid Base

The transformer shall be provided with skid base; and necessary devices for
setting, and appropriate devices for locking on the foundation.
(3) Accessories
The following accessories shall be furnished with the transformer.
(a) Compound gauge

(b) Drain valve and filter valve
(c) Dial type indicating thermometer to measure the top oil temperature with alarm
contacts suitable for 110 V A. C
(d) Magnetic oil lcvcl gaugc
(e) Pressure relief valve
(f) Nameplate with diagram
(g) Lifting lugs
(h) Oil drain with valve
(i) Grounding lugs for case grounding
(j) Hand hole for tap changer.
(4 ) Test
(a) The manufacturer shall supply the results of the following routine lest reports or
appropriate test certificates
- Winding resistance
- Ratio, polarity and phase relation - Impedance
- Load losses
- No load current
- No load losses
- Insulation resistance and power factor test or tan test
- Induced over voltaQe withstand
- Scparatc sourcc voltage withstand
- Temperature rise test
- Oil tests
(b) The Contractor shall at his own e>:pen%e make the following field tests. -
Winding resistance test
- Insulation test and power factor test or tantest.

- Voltage ratio test
- Vector group symbol test
- Transformer oil dielectric test.
4.8.4 Local Panel and Other Instrument
(1) Local Control Panel
(a) The local control panel shall be metal enclosed, self-standing, outdoor or indoor
use, complete with circuit breaker illuminated push-button, control/selector
switches, indicating lamps, ammeters, annunciatars, test blocks, terminal miring
and other miscellaneous device as per requirements.
(b) The surface steel plates shall be not less than 2.3 mm thick, with angler or channel
edges bent to 7.C) mm radius, seam welded at corners, and ground smooth. Panels
shall be bolted at the bottom to suitable steel channel sills which with necessary
framing will hold the structure rigidly together to form a self-supporting dead-front
type of structure.
(c) Outside panels shall not drilled or welded for attaching wires or switchboard
devices. Vertical edges of panels shall be so formed and bolted together that no
gaps exposed to view will pass a 0.8 mm filler gauge.
(2) Starter unit
(a) Each starter unit shall consist of a moldcd case circuit breaker, overload relays and
other auxiliary and pilot devices, and a magnetic contractor, all mounted in an
individual box unit. The unit assembly shall be so constructed that it can be easily
removed from its compartment after disconnecting the wires to the terminal block
and pullino open a switch-jaw type or similar approved type of disconnecting
device from the Lusbar connection. Removal of a unit assembly shall be
practicable without access to the rear of the. vertical section, and without
disturbing any other unit in the motor contn,1 center assembly. Vvrhere control
push-buttons. indicating lamps, control and selector switches and similar control
devices are associated with the unit, they shall he ulnimter1 on the compartment
door and arcersi ble from the front of the motor control center without opening the
compartment door. The door shall be fitted with a suitable gasket to exclude dust
when the door is closed. The ratings of the breakers and contractors shall be
according to the actual capacity of motor.
(b) Magnetic contractors shall he 3-pole, AC 3 duty insulated for 600 k-olts AC, The
rated operational current shall be not less than the full-load current of the motor
specified on the Drawings. The corresponding rated thermal current and the rated
operational power with the starter mounted in the control center shall be checked
with the final ratings of the circuit.
(c) Each contractor shall be provided with low voltage protection and 3-cliemcrit
thermal overload relays with external manual reset. Thennal overload relays shall
be sensitive to phase failure. Time current characteristics shall be supplied by the
Manufacturer on 28 mm x 56 mm logarithmic decades. These curves shall have a
tolerance not exceeding ± 10%.
(d) The rated operational voltage for the magnetic contractors shall be in accordance
with the drawings and/or the control sequence diagrams.
(e) Each contractor shall be provided with auxiliary contacts as required for operation
control circuits. Two circuit-opening and two circuit-closing auxiliary contact shall
be provided on each contractor at the least. Each contractor shall be wired at the
factory to the unit circuit breaker and to the individual unit terminal blocks.
(f) The soft starter shall be used for irrigation pump starting. The soft starter shall
consist of solid-state controller, fast-acting SCR fi.aes, low voltage protection,
triple pole motor protection unit incorporating three phase over current and single
phase and earth leakage protection, isolation contractor, main (by-pass) contractor
and circuit breaker, all mounted in an individual enclosure. Each phase is provided
with two antiparallel connected thyristors which conduct current during portions of
or during the entire half cycle. One during the positive half cycle and the other
during the negative half cycle. The soft starter shall provides a smooth start
simultaneously as the starting current is limited. The magnitude of the starting
current is directly dependent on the static torque requirement during a start and on
the masses which are to be accelerated.
The soft starter shall incorporate with power factor correction capacitors to
improve the power factor to be not less than 0.95. These must be installed ahead of
the isolation contractor with perfect magnetic contractor's control to prevent
damage to the SCRs in the soft starter and automatic open the capacitors after
irrigation pump being stopped completely.
The soft starter is used only for soft starting the motor. Then the starter has been
brought up to normal operating conditions. the soft starter is by-passed by a main
contractor. The motor is switch over to mains and soft starter is disconnected
The soft starter shall have the current-limiting function If the current-limiting
function is used, the starting current can be maximized to a preset value (2.5 times
the rated current). The voltage and current ratings shall he in accordance with the
rated voltage and current of' the motor.
(3) Molded Case Circuit Breaker (MCCB)
(a) Molded case circuit breakers shall be rated 380 volts and shall have continuous
current ratings and interrupting current rating as required by their application.
(b) Except for the terminals and toggle, the entire current carrying and operating
mechanism of circuit breakers shall be contained within s molded case. The
operating mechanism shall be arranged so that it will be trip-free i.e. impossible to
hold the circuit breaker contact, closed by means of the, toggle, tinder overloaded
conditions.
(c) The circuit breakers shall have an inverse current time characteristic in which the
time delay on tripping shall be inversely proportional to the magnitude of the load
current up to approximately seven times full load current ratina. On heavy over-
loads or short circuits the breaker shall trip instantaneously.
(d) The operating toggle shall he labeled or marked to indicate whether the, contacts of
the breaker are in the open or closed position. When a breaker trips and
opens its contacts the toggle shall remain at the "Tripped" position.
(e) Triple pole circuit breakers shall be interlocked internally so that an overload on
any one phase shall trip all three phases of the breaker simultaneously.
(4) Name Plates
Each circuit or equipment shall be provided with an engraved name plate approved by
the Engineer. Card holders will not be accepted. Name plates shall be made of
laminated plastic sheet or of anodized aluminum, approximately 3 mm thick, engraved
to provide white. letters on a black background. The name plates shall be 'fastened to
the panels in proper positions with black finished round-head screws. Equipment of
the removable type shall be provided with name plates mounted on the removable
equipment at locations visible when the equipment is in place. The Contractor will be
permitted to supply and attach to each switchgear cubicle and equipment a name plate
or trademark. A drawing or illustration showing the proposed trademark or name plate,
its size and location shall be submitted for approval. An additional blank circuit
identification card shall be provided on each circuit near the name plate for further
identifications insertion.
(5) Test
After finislung installation, operational test shall be carried out to check all required
functions are performing satisfactorily.
4.8.5 Cables
(1) General
(a) The power cable, control cable. wire and communication cable shall be in
accordance with IPC A (Insulated power cable association) standard,
(b) Conductor for cables and wires shall be of annealed copper stranded wire in
accordance with ASTM standards (American Society for Testing, Material). The
stranded wire shall be semi-compressed.
(c) Conductor for communication cable shall be of annealed copper, solid, tincoated
wire in accordance with ASTM and IPCA standards.
(2) 20 KV Power Cahlc
(a) The 20 KV power cable sltall be of four wires, open air line, Aluminum cable 35
mm2; as shown on the Contract drawing.
(3) 600 v Power and Control Cables, and Control Wires
(a) The cables for 380 V power shall be YV(insulated, PVC sheathed, copper
-stranded power cable for C-,00 V service.
(b) Insulation for 380 V power cables, control and communication cables shall be
polyvinyl-chloride according to the thickness specified in IPCA-NEMA
standards. Maximum operating temperature of conductor shall be GO C in dry or
wet location. Maximum overload and short-circuit temperature of conductor shall
be 85 C'. and 150 C. respectively.
(c) The average thickness of insulation measured at a section shall be not less than
spccificd values in the II'CA-NEMA. The minimum thicl:ncss shall bc not less
than 90% of the specified values.
(4) Markings
(a) Cable Markings
On the outer surface of the cables and wires, the name of manufacturer; or its
abbreviation, or trade mark, core & size, and the date of production shall be
printed with unfading ink.
(b) Drum Markings
On the appropriate side of the cable drum, the following markings shall be
printed.
Number of conductor, cable size and voltage classification Cross-sectional area

Cablc lcngth Drum weight Name of manufacturer or its abbreviation Date of
production
Position of beginning of cable Direction of drum rotation Contract number
(5) Cable Ducts
(a) Cable entry ducts iuto buildings shall be completely sealed after the uistallation of
the cables to prevent the ingress of water. Sealing shall be carried out using an
approved mastic compound or cold setting polyurethane compound. Care shall be
taken to ensure eood adhesion of the sealant to the wall of the duct and cable
sheaths.
(b) Cable ducts and holes through internal walls shall be completely filled with a fire
resisting material which is relatively easy to remove and has no delete:iou; effect
on the cable serving or sheath. Spare ducts shall be filled in a similar manner.
(c) Cable ducts through floors to individual plant items shall protrude 100 mm above
finished floor level to give protection against mechanical damage and the ingress
of water where floors are washed down.
(d) Holes through floors for main cable runs on tray will be provided with a tiled or
similar edging to provide protection as described above where floors are subject
to washing down. The holes shall be completely filled with a waterproof are
resisting material.
(e) Except with the express consent of the Engineer, cables shall not be run through-
wet wells. Where it is essential to run cables in these locations they shall be
enclosed in suitably sized watertight tubes constructed of P. V. C.
4.8.6 Installation
(1) Installation of Equipment
(a) Installation of all switch and control boards, switchgear, metering and
instrumentation units and other electrical equipment units shall comply with this
Clause.
(b) Where unitsvare specified as wall mounting, they may be fixed on the walls, and
other masonry, by means of approved non-ferrous bolts and nuts grouted into the
wall or expanding bolts or similar type of fastening approved by the Engineer
depending upon the weight of the switchgear. Wooden plugs are not acceptable.
(c) Where a unit is delivered in more than one section, the sections shall be joined
together to form an integral unit. Joints in between the units shall be flat in all
directions. The unit shall be installed with sides, front and back vertical and base
and top level.When the floor is uneven sides, not level, the base of the unit shall
be packed up until truly level before being grouted into position.
(d) Before energizing each unit shall be thoroughly cleaned. Any loose pieces of
packing material or other foreign bodies shall he removed.
(e) Units shall be so wired that the insulated cables do not come into contact with any
moving part of the unit.
(2) Installation of Conduit
(a) Steel conduit shall form a continuous. electrical enclosure throughout. Smooth
before hushed and couplings shall he used with plain boxes or alternatively
spouted boxes may be used. The ends of tubing shall be cleaned with a reamer.
(b) Conduit shall be adequately secured in chases and surface mounted conduit shall
be fixed with nylon or galvanized stand-off saddles providing a clearance, of not
less than 6 mm. The saddles shall be fixed with non-ferrous or stainless steel
screws in PVC: or metal plugs, and shall be provided at suitable intervals not
exceeding 1 m to fom a robust assembly.
(c) The drain holes 4 mm in dia. shall be provided at low paints of all runs to allow,
condensaie to escape

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DESIGN OF KOMERING PUMPING STATIONS

1.2 Pump Operation Study

1.3 Proposed Operation Rules

1. Daily Operation Hour

2. Numbers of Pump in each station

3.1 Basic Conditions

At Komering main Canal

Q125 + 78.72 Said HWL = +78.70

Q170 + 77.80 NWL = +77.80

Q50 + 77.39 LWL = +77.40

At Wayanda Secondary Canal

Q125 + 84.43 Said at surge chamber HWL = +78.70

Q70 + 84.14 NWL = +77.80

Q50 + 84.06 LWL = +77.40

Q125 + 84.37 Said at surge chamber HWL = +85.10

Q70 + 84.18 NWL = +84.20

Q50 + 84.09 LWL = +83.80

3.2 Design Conditions of Pumps

Description Unit Pump Sta. 1 Pump Sta. 2

Pump Unit capacity m³/mm 50.13 26.40

Actual head m 6.40 6.40

Head Loss m 1.20 1.40

Total Head m 7.60 7.80

3.3 Specification of Equipment

Description Pump Sta. 1 Pump Sta.2

Description Unit Pump Sta. 1 Pump Sta. 2

Width m 2.0 1.4

Height m 2.0 1.4

Length m 20.0 20.0

Conduct Bottom m 76.3 76.7

Fore bay Bottom m 74.80 75.2

3.5 Dimension of Surge Chamber

Description Left Bank Right Bank

Free board (m) 1.00 1.00

Elbow of outlet +83.80 +83.80

Center of Flap Valve Elev. 82.20 82.50

Bottom Elev. 81.10 81.60

B x W x H (m) 5.0 x 5.0 x 5.0 4.5 x 4.5 x 4.5

Dead Volume (m³) 5 x 5 x 2.7 = 67.5 4.5 x 4.5 x 2.2 = 44.6

1. Hydraulic Characters of Canals

A. At Komering Main Canal

2. Head Losses at Intake Conduct and Trash Rake

3. Head Losses at Pump Bore

C Friction Loss through Pipe

D. Fit Butteifly Value

E. At 2 Bents Angle = 45°, R = 0.75 m

F.At Flap value

A. Suction Water Level(Hi)

B. Discharge Water Level (Ho)

C. Ha = 84.2 - 77.5 = 6.7 m

7. Power of Prime Mover

C. Daily Operation Hours

1. Hydraulic Characters of Canals

A. At Komering Main Canal

2. Head Losses at Intake Conduct and Trash Rake

3. Head Losses at Pump Bore

D. Fit Butteifly Value

E. At 2 Bents Angle = 45°, R = 1.05 m

F.At Flap value

A. Suction Water Level(Hi)

C. Ha = 84.2 - 77.5 = 6.7 m

7. Power of Prime Mover